By Priyanka Gupta

Copyright india

With the world solar power capacity 452 GW increasing by record rates by 2025 as it is projected by the International Renewable Energy Agency (IRENA) report a systematic approach to cost estimation has become a key factor in the delivery of megaprojects. The sophistication of the contemporary energy infrastructure requires radically different approaches to planning in which accuracy in cost estimation is what defines not only budgets but competitive advantage.
The advantage that Bechtel had when they bided on the 495 MW Charger Solar project was an unlikely one; a cost estimation methodology that anticipated risks before they occurred. Hitesh Ananda a lead specialist at Bechtel one of the biggest U.S. based engineering and construction firms has come up with a method that transforms big ideas into solutions. His approach to data systematization database experience of implemented solar projects and real-time field adjustment has allowed the provision of one of the largest solar arrays in America and created a new industry standard currently implemented in LNG and combined-cycle industries.
This systematic approach to planning from initial estimates to final execution deserves detailed examination. How do standardized methodologies overcome the challenges of megaprojects? What tools transform risks into predictable outcomes?
How a Mega-Project Takes Shape
The transformation of ambition into megawatts begins with numbers. This process starts before ground-breaking with sophisticated modelling that accounts for regional climate patterns and sun path analyses. On major solar projects every detail matters. Often you must review estimates multiple times to account for all site changes. Its continuous work with the numbers the team and contractors Hitesh says. His team developed a risk-weighted contingency model that adjusts for supply chain volatility and regulatory uncertainties. Charger Solar became a testing ground for Anandas new methods in practice. Hitesh Ananda had previously developed standardized cost estimating methodologies to eliminate inconsistencies in indirect costs. The new approach integrated historical data field feedback and modular estimating templates. These templates include sustainability metrics allowing clients to track environmental ROI alongside financial returns. Over time these methods were refined and became standard across the company. To analyze quantity and cost trends data from two previous projects in Texas Oriana and Cutlass were used. We carefully studied them to understand where mistakes could happen Hitesh recalls.
When Numbers Meet the Field
One of Hitesh’s key improvements was integrating two systems: CES Cost Estimating System and HCSS – Heavy Construction Systems Specialists. CES provides structured cost estimating while HCSS delivers field-level productivity data. “By linking these systems we reduced manual input sped up estimate preparation and improved labor forecasting.” A major outcome of this integration was the creation of a comprehensive equipment catalogue. “It enabled equipment selection based on actual performance data from past projects.” This systematic approach optimized processes and strengthened collaboration between construction engineering and estimating teams. On other projects such as Rio Grande LNG Trains 4 & 5 the use of dynamic labor tracking models achieved a 10% reduction in labor costs. Hitesh notes: “If the numbers don’t match it can lead to delays or budget overruns. My work is to make sure that doesn’t happen.” These methods allowed for timely adjustments and more accurate resource planning.
From Experience to Winning Contracts
Charger Solar is not the only major project in Hiteshs portfolio. He also worked on Goldfinch Solar Lavender Solar and Sunfish 2 for Hecate Energy. Each project contributed to a growing knowledge base with validated data across different terrains and environments. Each assignment required adapting methods to new conditions: schedule changes or site-specific challenges. He used parametric models and scenario-based forecasting to quickly reprice estimates and adjust evaluations in real time without losing accuracy. These models incorporate machine learning algorithms that identify patterns across projects. Every project is unique but the principles remain the same precision transparency and team engagement Hitesh says. Moreover techniques refined on solar projects were successfully applied in LNG and other sectors. The methodologys adaptability has proven valuable in hybrid projects combining solar with storage technologies.
The Estimate as a Tool of Influence
For Hitesh an estimate is more than just numbers: It must help people make decisions not just sit on a shelf. In client interactions a phased approach is used starting with Class-5 estimates based on prior projects and then progressing to more detailed Class-2 estimates. He views the estimate as a strategic tool that aligns stakeholders and builds confidence. Anandas approach allows Bechtel to build trust with clients. This method ensures reliability throughout execution. An estimate not only controls budgets but also helps manage risks plan resources and set realistic expectations. Hiteshs contribution extends beyond individual projects his methods are referenced in ASPE guides. By combining analysis and experience Charger Solar transformed into one of the largest solar arrays in the U.S. market. What began with meticulous calculations has become the energy of the future.