A benchmark 12kWp solar + 20kWh battery installation delivering 99.9% uptime and 90% diesel reduction at a 24×7 petrol pump in Haryana.
Solar PV Array (23 Panels)
Lithium-ion Battery with BMS
3-Phase Hybrid Inverter
System Uptime Achieved
Ezinore designed and implemented a customized fail-safe hybrid solar energy system at the Hansi Jio BP petrol pump, addressing the critical challenge of maintaining 24×7 uninterrupted operations in an area with unreliable grid infrastructure.
The system’s unique dual-path architecture ensures that even in the event of component failure, the petrol pump continues operations without interruption — essential for Jio BP’s brand commitment to reliability.
The Hansi site presented three unique challenges that required architectural innovation.
Industry-first parallel redundancy design for retail fuel infrastructure.
Instead of the conventional single-path design (Grid → Inverter → Load), we implemented a dual-path architecture with parallel redundancy:
Purpose-built components working together for maximum reliability.
12kWp capacity with 23 panels (11+12 configuration) for primary daytime power generation.
12kW, 3-Phase with MPPT for power conversion, grid-tie, and battery management.
20kWh Lithium-ion with CAN Bus BMS for nighttime backup and grid outage support.
30–40kVA with ±1% accuracy for grid voltage conditioning (300–480V input range).
Grid/DG selector for source selection between grid and diesel generator.
Output selector (Servo vs Inverter) for final power path redundancy.
The system operates on intelligent priority logic that maximizes solar utilization while ensuring backup readiness.
Solar powers load directly (45%), charges battery (35%), exports surplus (15%). 95% solar utilization on-site.
Battery discharges stored solar to power load. Handles peak evening demand spike at 19:00. No diesel required.
Minimal 5kW load. Battery provides 4+ hours autonomy. Grid fallback if battery <20% SOC. DG as last resort only.
Comprehensive protection ensuring zero-downtime operations.
Dual voltage stabilizers (Servo + Inverter AVR), dual power paths — either path can power 100% of site load independently.
Real-time monitoring of voltage, frequency, and waveform quality with <10ms fault detection and automatic transfer to healthy path.
Manual changeover switches for maintenance, bypass mode for emergency servicing — no single point of failure.
20kWh provides ride-through during transfer, prevents dispenser reset during switchover, and maintains server uptime during any transition.
Dramatic improvements across all operational parameters.
Up from 85% — a 14.9% improvement.
Down from >8% — 62% better harmonic performance.
Down from ±15% — 15x better regulation.
Down from 10–15 seconds — instantaneous switchover.
75% reduction in total energy costs with ₹7.08 Lakhs annual savings.
| Cost Category | Before (Monthly) | After (Monthly) | Savings |
|---|---|---|---|
| Diesel Cost | ₹45,000 | ₹5,000 | 89% |
| Grid Electricity | ₹25,000 | ₹12,000 | 52% |
| Maintenance | ₹8,000 | ₹5,000 | 37% |
| Carbon Credits | ₹0 | -₹3,000 | Benefit |
| TOTAL | ₹78,000 | ₹19,000 | 75% |
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90% reduction in diesel usage, eliminating fuel price volatility risk.
77.7 tonnes of CO₂ savings annually — equivalent to planting 3,500 trees.
From 102 to 24.3 tonnes CO₂/year
Of total consumption from solar
Eliminating local DG emissions & noise
Complete autonomy from grid
Setting a new standard for petrol pump energy infrastructure.
Enhancing business continuity, customer experience, and regulatory compliance.
Jio BP’s centralized billing and inventory systems get 99.9% uptime. 20kWh battery provides uninterruptible power during any transition — no transaction data loss or system reboots.
No fuel dispenser resets during power fluctuations. Consistent service during grid outages. Enhanced brand reputation for reliability.
Meets Petroleum Ministry mandatory backup power guidelines, environmental norms for DG emissions, fire safety (reduced diesel storage), and renewable purchase obligations.
The Hansi model is fully scalable and serves as the reference architecture for future Jio BP projects.
IoT-enabled remote monitoring with proactive maintenance scheduling.
Get a fail-safe hybrid solar solution custom-designed for your 24×7 operations.
Deploy Smart Hybrid SolutionsVisual highlights of the Hansi Jio BP hybrid solar installation.
