HelioVolta has launched “PV Connectors: The State of the Field,” a brand new report that highlights the persistent dangers of low-cost PV system elements, particularly connectors, to photo voltaic investments. The white paper particulars observations from over 5 GW of impartial area inspections carried out by HelioVolta at tons of of utility and business photo voltaic initiatives in the USA.
For years, trade professionals have recognized that improperly made connectors introduce important security dangers to PV techniques. Since 2008, successive revisions to the Nationwide Electrical Code have aimed to cut back connector-related failures with new set up necessities. Practically 20 years later, little has modified: connector failures stay probably the most widespread threats to PV system security and reliability.
“It’s absurd that one of many least expensive elements in a PV system is chargeable for the trade’s most infamous failures,” mentioned David Penalva, CEO of HelioVolta. “We’re speaking a few greenback’s value of plastic and steel placing multimillion-dollar belongings — and other people — in danger. It’s unacceptable.”
The connector report analyzes area knowledge, presents connector failure and remediation case research and shares connector threat mitigation ways for asset house owners, O&M suppliers and EPC groups.
Key findings from HelioVolta’s area inspections embrace:
- 83% of initiatives inspected suffered from at the very least one connector-related difficulty.
- 45% of web sites had main connector points requiring pressing upkeep.
- 4.3% of initiatives confronted important connector failures requiring partial or complete system de-energization.
- The vast majority of points stemmed from preventable causes reminiscent of improper set up.
These numbers sign rising urgency for asset house owners and managers, who endure elevated downtime, important upkeep prices and legal responsibility publicity when connector points go unresolved. For instance, the price of connector failure and remediation equaled 58% of a business photo voltaic portfolio’s annual revenues and 19% for utility energy plant.
The report additionally presents a transparent path ahead. HelioVolta outlines threat discount methods, reminiscent of quantifying connector-based threat for various system configurations, connector varieties, and set up strategies through the design part. Implementing procurement specs to make sure cross-brand compatibility of factory-made connectors additional reduces threat. Recognizing that product availability is commonly restricted, HelioVolta delineates enhanced high quality management and O&M procedures for initiatives with higher-risk system configurations.
HelioVolta’s report notes that stopping connector failure additionally requires supporting EPC and O&M area groups with higher instruments, coaching and documentation strategies. Trainings should cowl correct set up strategies, measuring thermal anomalies (“scorching connectors”), and visible inspection tips. Lastly, conducting third-party inspections of connectors throughout building and all through the challenge lifecycle helps asset house owners guarantee the protection of their fleet over time.
“Correct connector set up is clearly vital, however assessing these elements at each preventive upkeep go to is simply as important,” mentioned Jesse Waters, CEO of Servist Power, an O&M supplier. “Since connector issues grow to be riskier as techniques function, discovering and fixing points earlier than catastrophe strikes is one of the best ways to keep away from high-cost remediation campaigns.”
The report concludes by highlighting improvements within the connector area, together with the rise of crimpless connectors, efforts to standardize connector terminology led by Sandia Nationwide Laboratories and an initiative to develop a common connector normal from Nationwide Renewable Power Laboratory (NREL).
Information merchandise from HelioVolta
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