In the ever-evolving solar/renewable energy landscape, driven by the increasing demand for solar energy, reducing solar system downtime before and after commissioning, as well as effective power plant maintenance, is critical for ensuring optimal performance and return on investment. Webinar 27, featuring insights from Rylan Gordon of Sinovoltaics and Tori Clifford of HelioVolta, provided actionable strategies and innovative solutions to tackle these challenges. Want to watch the recording? Click here.
Here are the key takeaways to empower your solar projects.
Understanding Downtime in Solar Projects
Downtime in solar projects (or solar panel failure) can arise from manufacturing defects, poor installation practices, poor solar farm maintenance, and operational issues. Tackling these effectively requires a multi-faceted approach that combines advanced technology with robust field practices.
1. Manufacturing Quality Assurance
Rylan Gordon emphasized the importance of quality assurance during manufacturing. Sinovoltaics’ SELMA software, an industry-leading electroluminescence (EL) testing tool, is groundbreaking in the industry. Unlike traditional sampling methods, SELMA conducts 100% EL testing on solar modules during production, identifying defects in real-time and ensuring only top-quality modules are shipped. This not only mitigates risks but also prevents delays caused by defective shipments.
Key insights from Sinovoltaics' case study:
Figure 1: Scenario Model
In a batch of 31,774 modules being manufactured at a Tier 1 Manufacturer, SELMA identified 1,621 defects (5.10%), including 324 solder faults (19.9%). These defects were only identified due to the 100% inspection available only through SELMA testing. These defects were not identified during the Standard Sampling of the same order. Removing these broken panels before the order shipped to the project site prevented over 590 kWp of initial production loss in this 15 MW project.
2. Common Manufacturing Defects
Figure 2: What is solder fault?
One of the prevalent issues discussed was solder faults, which can lead to:
• Thermal events.
• A Short-circuiting
• Hotspots
• Reduced module power generation
By integrating real-time 100% defect detection into your project, you can eliminate these issues before modules leave the factory floor.
Field Practices: Preventing Downtime in Operations
Once modules are deployed, rigorous field practices, including PV maintenance, ensure long-term system reliability. Tori Clifford shared valuable insights based on HelioVolta’s extensive inspection data, derived from hundreds of site visits across various project types.
1. Critical Field Observations
Figure 3: Key Findings from the Field
Key findings from Helio Volta’s inspections:
72% of projects inspected had major or critical issues likely to cause downtime. Wiring and connector issues were the most common culprits but are also the most addressable through proper training.
2. The Role of SolarGrade Software
HelioVolta’s SolarGrade software supports inspections from construction to operation, enabling detailed geo-referenced documentation and risk severity assessment. This ensures minor issues are tracked and resolved before escalating into major failures.
Preventive Measures for Success
1. Comprehensive QA/QC Inspections
Conducting QA/QC (solar quality control) inspections at key construction milestones significantly reduces critical issues. For example, an example client’s project showed a robust QA/QC process reduced critical issues to just 2% compared to the industry’s average of 8%.
2. Training and Education
Investing in training for crews on proper wire management, terminations, and connector installation was highlighted as a cost-effective strategy to minimize future downtime.
3. Leveraging Field Data
Using inspection data to identify recurring issues with specific components or suppliers can guide targeted interventions, such as:
• Retorquing campaigns for inverters.
• Standardizing best practices across teams.
• A Collaborative Approach to Reliability.
By combining Sinovoltaics’ upstream QA capabilities with HelioVolta’s field insights, solar projects can achieve unparalleled transparency, reliability, and predictable energy production.
Key takeaways include:
• Proactive defect detection using SELMA ensures a robust start.
• Continuous monitoring and addressing minor issues early prevents costly downtimes.
• Advanced tools like SolarGrade empowers teams with actionable data and streamlined reporting.
Conclusion
Webinar 27 Best Practices for Reducing Solar Project Downtime Before and After Commissioning underscored that achieving minimal downtime in solar projects is possible with the right combination of technology, expertise, and proactive management. Whether through advanced manufacturing QA or field-based preventive practices like PV maintenance, these best practices can transform how solar projects are delivered and maintained. Interested in learning more? Contact Sinovoltaics & Contact HelioVolta and discover how minor preventative solar panel inspection costs can save you significant expenses by identifying defects early and ensuring optimal system performance.
