Solutions for Solar/Photovoltaic High Volume Manufacturing Your Trusted Partner for MW- and GW-Scale Factories
Renewable Energy – Solar/PV: The Time is Now As the cost of electricity generated from photovoltaic modules approaches grid parity, the solar/photovoltaic (PV) industry is poised for explosive growth. Companies aggressively seek to establish market share through competitive technological and market advantages. In this dynamic time, cost reductions are being achieved through: • Improving conversion efficiency across different cell technologies • Increasing factory yield, uptime and throughput by optimizing manufacturing equipment, integrated lines and facility systems • Reducing operational costs • Reducing capital factory costs for equipment and plant • Improving operational efficiencies through large-scale factories • Applying stringent site selection processes and global manufacturing strategies
We Cover the Entire Solar PV Value Chain
Raw Material Processing
High Volume Manufacturing
Solar Power Generation
Deep Resources, Full Service Solutions CH2M HILL’s full-service solutions bring solar/PV projects from initial planning and design to final operation and production. Our engineering services cover the entire value chain from raw material processing to high volume manufacturing and solar power generation projects. With global-scale leadership we help our solar/PV clients meet today’s business objectives with the flexibility to capitalize on tomorrow’s growth. Our strength is the knowledge and experience of our employees, who have successfully delivered the world’s most complex and challenging solar/PV projects.
High Volume Manufacturing We help our customers achieve sustainable success by enabling them to offer cutting edge products manufactured with best-in-class Cost / Wp performance, in a robust and safe mass manufacturing environment.
Design-Bid-Build
Raw Material Processing
PV Manufacturing Venture Planning
Design & Construction Management (EPCM)
Design and Construction of PV Manufacturing Plants
Design-Build (EPC)
Operation & Maintenance
Manufacturing Integration, Technology, and Productivity Solutions
Solar Power Generation
High Volume Manufacturing
Maximizing the Return on Your Assets
PV Manufacturing Venture Multidisciplinary Coordination Planning
From economical building shells to major manufacturing complexes, CH2M HILL’s design-build approach helps solar/PV clients maximize the return on their assets. Our collaborative process recognizes each client’s unique needs and expectations, and identifies innovative solutions that deliver extraordinary value. Our integrated project delivery is structured to meet aggressive market-driven schedules, anywhere in the world.
The cornerstones for a successful PV manufacturing venture are thorough business and technology roadmap planning, combined with highest quality site selection processes. Our advanced planning and site selection experts have helped many solar/ PV companies successfully expand their business into new markets, technologies and geographies. Together with our expertise in permitting, estimating, programming and conceptual design, our planning services support mission critical project funding decisions and provide certainty in moving forward with business plans.
Design for Seamless Execution Meticulous planning and pragmatic, constructible design allow a seamless transition to efficient field execution, with a focus on safety, economical operation, environmental protection, and future expansion.
We organize our greatest resource — our people — in dedicated team spaces for every project. Multidisciplinary environments, including architects, engineers, technologists and planners, encourage formal and informal dialogue among team members, spark innovative ideas, and provide a holistic approach to project challenges.
Construction Management CH2M HILL has provided construction management (CM) services on more than 1,500 projects during the past five years, effectively managing construction services and resources to complete projects on schedule and budget. Our CM approach provides a single point of contact, representing the owner’s interests first and foremost.
Photo: Aleo Solar
CH2M HILL designs value into solar/PV manufacturing facilities to sustain each client’s economic advantage.
Master Design for LargeScale Manufacturing Complexes Clients seeking to scale up production facilities face unique challenges. A large-scale manufacturing complex must be evaluated for viability and value, positioned for minimum risk, designed for optimum performance, and constructed in the right location.
CH2M HILL helps meet these challenges with comprehensive planning and design services that include: • Feasibility, competitive, financial and risk analysis • Conceptual programming • Technology process consulting • Site/location evaluation and selection • Utility needs analysis • Transportation logistics planning • Environmental analysis • Permitting and licensing • Campus, site and facility master planning
Manufacturing Integration, Productivity and Technology Solutions With a thorough understanding of how material handling and tool layout support efficient operations and life cycle cost reduction, we lead the drive for cost efficiency in largescale manufacturing complexes. The resulting facilities are “fit for purpose,” with reduced cost-perwatt, robust and compliant process systems, and flexibility for future improvements.
Our dedicated industrial engineering group provides focused expertise and services that help improve the performance, output, and profit of solar/PV manufacturing operations, through: • Lower operating costs and lower cost-per-watt from the beginning • Optimized automation for greatest return on investment and best cycle time • Shorter learning curve at factory start-up • Faster “time to money” return on investment We capture these beneftis for our clients by applying proven services such as: • Static and dynamic layout modeling • Material handling simulations and solutions • Line automation and equipment integration • Factory start-up, ramp-up and decommissioning • MES solutions and design • Tool install / process equipment hook-up
Solar/PV High Volume Manufacturing Experience — from MW to GW For more than a decade, CH2M HILL has worked with developers of solar/PV products in all cell technologies. The majority of our customers require non-disclosure agreements; while we carefully guard proprietary information, we can say that our portfolio includes:
99Polysilicon projects,
ingot/wafer plants, cell manufacture, module, and thin-film projects 99Projects ranging from lab
scale to MW production facilities and GW “supersites” 99Greenfield and brownfield
99Solar/PV customers
ranging from start-ups to companies in the top 20 list of manufacturers 99Extensive experience with
all major technologies: c-Si, a-Si, CdTe, and CIGS 99Design-build, design-only,
and front end consulting work in Asia, Europe, and North America
(retrofit) experience We keep our customers on the leading edge with up-to-the-minute knowledge and best practices from across the spectrum of advanced technology. For example, we have incorporated aspects from semiconductor and flat panel display manufacturing (gas handling, balancing utility requirements for tool support, hazardous material safety) and combined this with our experience in general manufacturing of commodity products to improve solar/PV commercial scale production.
Best Knowledge
Startup Factory
Global Reach and Replication Strategies With offices worldwide and partnerships with many international design and construction professionals, CH2M HILL has program management capabilities to manage multiple projects in locations around the globe. We help clients achieve more consistent, less expensive, faster replication of factories.
Factory: Region A HVM Factory
Designed for International Deployment
HVM = high volume manufacturing
CH2M HILL clients also benefit from our long-standing relationships with major equipment suppliers, helping optimize information exchange, tool installation, and compliance with design requirements.
Factory: Region B Factory: Region C
Sustainable and Lean Design for Solar/PV Factories CH2M HILL builds sustainability and Lean design into a project from the beginning, considering full life-cycle value. With an in-depth understanding of PV business and technology, we consider an array of sustainable approaches to optimize cost and benefits over the lifetime of a factory, including LEED® design principles, factory life cycle analysis and carbon footprint assessments.
Resource evaluation Plant layout Energy estimates/ forecasting Permitting Environmental assessments Community outreach
To supplement our High Volume Manufacturing services, CH2M HILL provides a full value chain offering for solar power generation projects — all the services our clients need from a single source, aligned with the scope and the needs of the project.
Operations and Maintenance
Procurement
Planning Technology selection
Engineering Services for Solar Power Generation
Engineering
Long term manufacturer relationships
Construction
Source inspections Electrical
Logistics
Transmission and interconnection planning
Network of suppliers
Site civil and geotechnical Structural * Additional Services
Labor-union and merit shop Safety procedures to prepare for energization Materials management
Scada reporting frequency Panel cleaning breakeven analysis Meteorology and output forecasting Spare parts inventory, management and obsolescence planning
Warranty coordination Operator training
* CH2M HILL provides all engineering disciplines as required by individual project needs.
Meeting the Challenges of a Market in Growth & Transformation We tailor solar/PV solutions to meet the demanding requirements of a dynamic and fast-changing market.
Meeting Demand
Evolving Technologies
With deep resources and a broad range of services, we can mobilize a team to rapidly build facilities. We support the need for speed-tomarket to gain market share.
For 30 years, CH2M HILL has helped high technology clients scale up, commercialize, rapidly deploy and maintain their competitive advantage as leaders in evolving technology.
“Best in Class” on Cost/Wp
Energy Solutions
Our experience in site selection and our innovative approach to design, project execution and industrial engineering improve efficiencies throughout the manufacturing plant and reduce the cost of support systems and buildings.
In the past decade, the pace of reform and change in the electricity sector has rapidly increased. CH2M HILL offers expertise in power generation, renewable energies, solar farms, oil and gas, and energy services and operations.
Environmental Stewardship
Advanced Services
As a world leader in environmental engineering, CH2M HILL offers comprehensive expertise in environment protection, sustainability, cleanup, and reuse.
CH2M HILL offers specialized resources and capabilities including industrial engineering, front end planning, manufacturing integration, facilities management, and operations.
Understanding the Solar Value Chain CH2M HILL is active along the full solar value chain, from raw material processing to high volume manufacturing and solar power generation.
About CH2M HILL Headquartered near Denver, Colorado, employee-owned CH2M HILL is a global leader in full-service engineering, procurement, construction, and operations for public and private clients. With $6.3 billion in revenue and more than 23,000 employees worldwide, CH2M HILL delivers innovative, practical, sustainable solutions—helping clients develop and manage infrastructure and facilities that improve efficiency, safety, and quality of life. The firm has long been recognized as a most-admired company and leading employer, including being named by FORTUNE magazine as one of the 100 Best Companies to Work For (2009). Web Address: www.ch2m.com/solarpv Email: solarpv@ch2m.com CH2M HILL operates out of more than 200 offices worldwide. For a complete list of office locations in your area, please visit us at ch2mhill.com. Global Headquarters 9191 South Jamaica Street Englewood, CO 80112 USA Toll-free: 888.CH2M.HILL Tel: +1 303.771.0900 Fax: +1 720.286.9250
North America 2020 SW 4th Avenue Third Floor Portland, OR 97201 USA Tel: +1 503.235.5000 Fax: +1 503.736.2000
North Asia 22nd Floor, Tower B City Center 100 Zun Yi Road Shanghai, 200051 People’s Republic of China Tel: +86 21.6057.3000 Fax: +86 21.6057.3299
South Asia 150 Beach Road, 34th Floor Gateway West Singapore, 189720 Republic of Singapore Tel: +65 6391.0350 Fax: +65 6299.4379
Europe Optima Building, Level 1 North 58 Robertson Street Glasgow, G2 8DU Scotland, U.K. Tel: +44 (0) 141.204.2333 Fax: +44 (0) 141.204.2033
Mexico AV. Xola 535 Piso 23 Col. del Valle Del. Benito Juarez Mexico City, 03100 Mexico Tel: +52 55 5999 0400 Fax: +52 55 5999 0410
Brazil Vila Olimpia Rua do Rocio, 351 - conj. Suite 11, 12, 21, 22, 52, 61 e 62 Sao Paulo, 04552-000 Brazil Tel: +55-11 3040 0800 Fax +55-11 3040 0802
Argentina Azara 841, 1 Floor Ciudad Autonoma de Buenos Aires, 1267 Argentina Tel: +54 114 309 0201 Fax +54 114 303 3954
Middle East/North Africa Star Holding Building Ground Floor #2 Dubai Internet City PO Box 500554 Dubai, United Arab Emirates Tel: +971 4.427.7600 Fax: +971 4.427.7601
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