One team from structure to monitoring
We design and fabricate the mounting structure in our own Lahore workshop, install and commission the plant, test it as it ages, and monitor it so you can see what it produces. One team does all of it, so the people who built your plant are the ones who answer when you call.
Quick answer
GFE runs a solar project in four steps. FERO designs and fabricates the mounting structure in Lahore, our crews install and commission the plant, the O&M team tests it with IV curve tracing and thermal imaging, and we monitor and control it. One team does all four, and each step is also sold on its own.
Reviewed by the GFE engineering team. Last updated .
Step 1: Structure design and fabrication
FERO structures are cut, bent, welded and galvanized in Lahore, designed for your roof or land and the wind at your site, and covered by a 10 year warranty.
FERO is the structure side of Green Fuel Energy. Each structure is specified from four inputs: what it sits on, how much wind it sees, how many modules it carries, and how people will reach it for cleaning. Laser CNC cutting, hydraulic press forming, bending, welding and punch lines all run in our Lahore workshop, so a member, a hole pattern or a bracket can change for a site without waiting on a supplier.
Galvanized iron structures are hot-dip galvanized to ASTM A123 at 90 microns after fabrication, so the zinc covers cut edges, holes and welds. Aluminium structures are anodized 6063 T5 with SS304 fasteners. The standard design wind speed is 35 m/s (about 126 km/h) and the standard tilt range is 10 to 45 degrees. Both are set per project.
What you receive
- A structure specified for your roof or soil, the wind at your site and the module layout
- Hot-dip galvanized iron at 90 microns, or anodized aluminium 6063 T5
- A 10 year warranty, galvanized iron and anodized aluminium alike
Step 2: Installation and commissioning
Our crews install the plant, commission it and connect it to the grid or the generator system.
Our crews build the foundations or roof mounting, run the DC and AC cabling, install the inverters and protection, and connect the plant at the switchboard to the grid or the generator system. The work follows IEC practice and is recorded with photographs.
GFE prepares the net metering or net billing file and follows it through with the DISCO (LESCO, FESCO, PESCO, HESCO, MEPCO and others). Before handover we test the strings, check the protection and run the plant under load.
What you receive
- A commissioning report comparing measured and expected performance
- The net metering or net billing application handled with your DISCO
- One year of monitoring and post-commissioning support
Step 3: O&M and testing
We trace IV curves and scan with thermal imaging to find weak strings early, then correct them.
A plant loses output slowly: dust on the modules, a loose connector, a weak string. The O&M programme runs on a fixed cadence of monthly visual inspections, quarterly electrical testing and an annual review. IV curve tracing finds underperforming strings and modules, and handheld and drone thermal imaging finds hotspots and faulty connections. Cleaning is scheduled to soiling, often 3 to 4 cycles a year on dusty industrial sites.
When a fault is confirmed, GFE gives you a recommendation or carries out the fix as a paid correction job. O&M is pay-as-you-go, an onboarding fee plus an annual fee, with no monitoring hardware to buy up front.
What you receive
- Monthly and annual performance reports, fault logs and maintenance records
- Performance Ratio tracked against the modelled figure
- IV curve and thermal imaging results for the strings tested
Step 4: Monitoring and control
We monitor the plant and control export and generator loading, so you see what you produce and what you save.
We connect the plant to online monitoring that records generation and flags anomalies as they appear. A zero export controller measures import and export at the grid connection point and adjusts generation in real time to hold export at zero, or at the limit in your DISCO agreement.
On sites with diesel generators, a PV DG controller keeps each generator above its minimum loading and prevents reverse power. Where a site needs backup power or peak shaving, a battery system joins the same control and monitoring.
What you receive
- A live view of generation, grid import and export, and generator output
- Export held at your agreed limit without the plant tripping offline
- Generators protected from reverse power and low loading
Automation and data monitoring for factories and businesses
The same monitoring skill reaches past the roof. With our partner NeoTAQ Systems we set up automation for factories and businesses, so you can see your energy use and daily operations in one place.
Monitoring does not stop at the solar plant. With our partner NeoTAQ Systems we set up automation for factories and businesses: data loggers and energy meters on existing machines and process equipment, gateways that convert between industrial protocols, and SCADA where operators need control as well as data.
Owners see energy use by machine or process line next to day to day operations, with alerts and daily, weekly or monthly reports, whether or not the site has solar.
Questions about working with one team
Who is my single point of contact?
GFE. One team covers the structure, installation, O&M and monitoring, so the engineers who built your plant are the ones who answer when you call.
Can I buy only one step?
Yes. FERO supplies structures to other contractors, O&M and testing can be contracted for plants GFE did not build, and monitoring, SCADA or PV DG control can be retrofitted to an existing plant.
Do you work with other EPCs?
Yes. FERO designs and fabricates structures for other EPC contractors. Send the site drawings, capacity and location, and FERO returns a design, a bill of quantities and fabrication drawings, then manufactures and delivers. GFE can also add O&M, monitoring or generator control to a plant another contractor built.
How do I see the plant after handover?
Online monitoring is set up at commissioning and shows generation and alarms as they happen. Every GFE project includes one year of monitoring and post-commissioning support. After that, an O&M contract keeps the monitoring running and adds monthly and annual performance reports.
Can you monitor a factory that has no solar?
Yes. With NeoTAQ Systems we fit data loggers and energy meters to existing machines, sensors and process equipment, and gateways convert between industrial protocols so everything reads into one system. You get energy use by machine or process line, alerts, and daily, weekly or monthly reports.
Who maintains the plant?
GFE's O&M team, on a pay-as-you-go contract with an onboarding fee and an annual fee. The programme covers monthly visual checks, quarterly electrical testing with IV curve tracing and thermal imaging, cleaning scheduled to soiling, and an annual review. Confirmed faults get a recommendation or a paid correction job, whichever you choose.
Your site assessment is free.
Your quote arrives in 48 hours.
Tell us your site location and monthly consumption. GFE's engineers will send a preliminary sizing and cost estimate within two business days.