Optimizing Utility-Scale Solar Designs for Efficiency, Sustainability, and Reliability

In utility-scale photovoltaic projects —150 MW or larger— electrical complexity increases exponentially: hundreds of circuits, long cable runs, multiple trench configurations, and strict regulatory requirements.

For Solar Bull, the challenge was not only to design a compliant installation but to do so in a way that is:

• Technically optimized
• Cost-efficient
• Sustainable in materials and civil works
• Reliable from day one of operation

Traditional methods based on spreadsheets and scattered tools made it difficult to evaluate the system as a whole and extended engineering cycles, especially for thermal studies and protection coordination. Solar Bull needed a solution that would allow them to model the plant as an integrated system and analyze its real-world behavior before construction.

With the implementation of ETAP, Solar Bull adopted a comprehensive electrical design approach based on a single plant model.

Through ETAP, the engineering team can:

• Model the complete network, including its interconnection with the external grid
• Perform power flow and short-circuit studies
• Coordinate protections in low and medium voltage systems
• Simulate grounding networks in compliance with IEEE standards
• Execute advanced thermal analyses of trenches and cable groupings

Trench thermal studies became a key element. ETAP enabled the simulation of different real-world conductor configurations, depths, and soil conditions, evaluating multiple scenarios in a matter of hours. This rapid iteration capability allowed the team to move from lengthy manual calculations to a dynamic and fully traceable simulation environment.

• Up to 40% reduction in engineering time
  Iterative studies that previously took weeks can now be validated in days.
• Optimization of trenches and civil works
  Thermal simulation enabled approximately a 10% reduction in civil works associated with cable routing.
• Significant cost savings
  In recent 150 MW projects, thermal and cabling optimization resulted in over €60,000 in direct savings.
• Reduced oversizing
  Accurate modeling prevents unnecessary use of conductors and materials.
• Improved sustainability
  Fewer trench meters, less copper, and reduced earthworks translate into a lower environmental impact.

“The adoption of ETAP lets us model the entire plant as a single system, validate designs in days instead of weeks, optimize trenches and cabling, and reduce costs and environmental impact. The result: faster engineering, more reliable installations, and greater overall efficiency.”

Adrián Espasa, Electrical Engineering Manager, Solar Bull

Impact on Execution and Reliability

Arriving on site with a validated electrical model allows you to:

• Reduce changes and rework in the field
• Improve coordination between engineering and construction
• Increase schedule predictability
• Ensure regulatory compliance from the start

In addition, simulation according to IEC and IEEE standards enhances electrical safety and builds confidence for developers, investors, and operators.

Thanks to ETAP, Solar Bull has strengthened the reliability of its electrical designs in large-scale photovoltaic plants, optimizing time, costs, and resources without compromising safety or performance.

The integration of an advanced simulation environment into its workflow has transformed electrical engineering into a key competitive advantage for meeting the challenges of the energy transition.

“Having a fully validated electrical model on site reduces rework, improves coordination, and ensures compliance from day one, giving investors and operators full confidence.”

Adrián Espasa, Electrical Engineering Manager, Solar Bull