Power Assessment Report (SAMPLE)
Prepared for: Sample Plastics Ltd. (fictional), Gauteng, South Africa Prepared by: TF PowerProof engineering team Report no.: PA-SAMPLE-001 · Date: October 2026
This is a sample report for a fictional factory. Your own report is based on the data you send us. All figures are estimates for decision-making and are confirmed in the detailed proposal.
1. Summary
| Today | With the recommended system | |
|---|---|---|
| Outage hours affecting production | about 8 h per day | 0 h for critical loads |
| Diesel use | about 3,950 L per month | about 800 L per month (around 80% less) |
| Diesel cost (at USD 1.20/L) | about USD 4,740 per month | about USD 960 per month |
| Critical load backup without the generator | none | about 4.3 h at full critical load, longer with solar during the day |
Recommended system
120 kWp solar + 215 kWh lithium (LFP) battery + 100 kW hybrid inverter/PCS + energy management system (EMS), working with the existing 150 kVA diesel generator.
Suggested retail price range
included in your own report (not shown in this public sample). See section 6.
2. Your site and loads
| Item | Value (from customer data) |
|---|---|
| Industry | Plastic injection moulding |
| Working hours | Two shifts; main production 07:00–19:00 |
| Average load, daytime (07:00–19:00) | 70 kW |
| Average load, night (19:00–07:00) | 15 kW |
| Daily energy use | about 1,020 kWh |
| Peak load | about 120 kW |
| Critical loads (must never stop) | 45 kW: 2 moulding machines, chiller, air compressor, office and IT |
| Grid | Connected, frequent load shedding: about 8 h per day (about 5 h in the day, 3 h at night) |
| Existing generator | 150 kVA diesel, runs during every outage |
| Available area | 900 m² metal roof |
| Existing batteries | None |
Today: the generator supplies about 395 kWh per day during outages. At low and medium load it produces about 3.0 kWh per litre, so it burns about 132 L per day.
3. Recommended system
| Component | Specification | Why |
|---|---|---|
| Solar PV | 120 kWp on the metal roof (about 650 m²) | Produces about 550 kWh per day on average, all used on site |
| Battery | 215 kWh LFP, about 194 kWh usable | Covers night outages and bridges day outages; 6,000+ cycles |
| Hybrid inverter / PCS | 100 kW, seamless switchover | Critical loads do not see a power interruption when the grid fails |
| EMS | Automatic control of grid, solar, battery and generator | Starts the generator only when the battery reaches its lower limit |
| Generator | Existing 150 kVA, kept as backup | Covers long outages and cloudy days |
| Monitoring | Remote monitoring with alarms to your phone | You and our engineers see the system status at any time |
Critical loads are moved to a dedicated critical bus. Non-critical loads can be shed automatically during long outages.
4. Outage simulation
Scenario A: grid outage at 10:00, lasting 5 hours
The battery takes over immediately. Solar supplies most of the load during the day, and the battery covers the rest. The generator does not start. Battery state of charge falls from 95% to about 60%.
Scenario B: night outage at 22:00, lasting 3 hours
The battery supplies the 15 kW night load (about 45 kWh). The generator does not start. Battery state of charge falls from about 80% to about 60%.
Scenario C: long outage after a cloudy day
The battery reaches its lower limit after about 4 hours at full critical load. The EMS starts the generator, which supplies the loads and recharges the battery, then shuts down when the grid returns.
Result
in the simulated typical week, critical loads were never interrupted, and the generator ran about 11 hours instead of about 56 hours.
5. Lifetime cost (illustrative)
| Item | 10 years | 20 years |
|---|---|---|
| Diesel saved (at USD 1.20/L, no price increase) | about USD 450,000 | about USD 900,000 |
| Grid electricity saved (about 300 kWh per day at USD 0.13/kWh) | about USD 140,000 | about USD 270,000 |
| Battery replacement | none expected (LFP rated 6,000+ cycles) | one replacement around year 12–15: about USD 25,000 |
| Solar output after degradation | about 95% of year 1 | about 90% of year 1 |
| Maintenance | about USD 1,500 per year | about USD 1,500 per year |
| End-of-life handling | battery and panel disposal through a compliant channel: about USD 3,000 | — |
Compared with a lead-acid battery bank of similar usable capacity: lead-acid would typically need replacing every 3–5 years at this cycling rate, about 2–3 replacements in 10 years.
6. Reference equipment list and suggested retail price range
| Item | Option A | Option B |
|---|---|---|
| PV modules | Brand option A (model in your report) | Brand option B (model in your report) |
| Hybrid inverter / PCS | Brand option A (model in your report) | Brand option B (model in your report) |
| LFP battery cabinet | Brand option A (model in your report) | Brand option B (model in your report) |
| EMS and monitoring | Included | Included |
| Mounting, cables, protection | Included | Included |
Suggested retail price range
included in your own report, in USD, CIF to your port. Not shown in this public sample. Installation by a TF PowerProof Certified Partner in your area, quoted by the partner.
How we choose equipment
certification (IEC / UN38.3), warranty terms, after-sales support in your country, and fit with your loads.
7. Assumptions and next steps
Assumptions
- Load and outage figures as provided by the customer; not yet verified on site
- Solar yield 4.6 kWh/kWp/day, based on Global Solar Atlas data for Johannesburg
- Generator efficiency about 3.0 kWh/L at low and medium load
- Diesel price USD 1.20/L, no price increase
- Grid tariff USD 0.13/kWh average, no increase
Next steps
- Confirm loads and outage pattern (a short WhatsApp call, plus photos of the main switchboard)
- We prepare the detailed proposal, full simulation report and single-line diagram (included with your order)
- Final quote with trade terms
Your contact: your TF PowerProof project engineer, WhatsApp +86 151 9255 3850, sales@tfpowerproof.com
TF PowerProof is operated by TF EnergyTech (Qingdao) Co., Ltd.