Category: Blog

PV Wire Management Systems Explained

Posted on by bop-admin

When you’ve got thousands of feet of PV wire strung up for seemingly endless acres, keeping them organized and protected is crucial. 

The best wire management plan relies on understanding the terrain, project size, complexity, layout, and other factors. Depending on the project, solar EPCs have several wire management options, from open-air clips and ties to comprehensive conduits and trays. Regardless of the style, these systems organize and protect cables for the life of the solar system. 

The result? Cleaner, manageable layouts, more efficient repairs and replacements, and safer sites over the long term. 

S Clips 

S clips are a low-cost and effective solution to keep wires and cables in place. 

The clips are usually made from stainless steel, which is strong and resists corrosion, making them great for outdoor use. Other options include aluminum alloys or even UV-resistant plastics. 

Crews like S clips because they’re easy to install without tools, attaching to the back of the solar panel or onto the racking. They’re also reusable, allowing workers to remove and reattach clips during maintenance, repairs, or replacements. 

Multi-Faceted Fasteners 

The allure of S clips lies in their simplicity. 

They’re small enough to hide under panels and along racking and perform well across many environments and temperatures. Certain constructions also work in harsh areas, including in or near salt water. 

Unlike more expensive wire management systems, S clips don’t require other tools to install. This makes them easy for even inexperienced workers to use. Removal is almost as easy, requiring only a screwdriver to pop the clip off the panel or racking. 

Though the clips only hold a few wires in place, they do an excellent job of preventing sagging along the cable line. However, crews must be careful to avoid accidental nicks or scrapes caused by the clips. Normally, they’re coined or smoothed to prevent damage but could cause problems over time or during severe weather. 

Hanger Systems 

Like S clips, wire hanger systems hold wires in place, but do it on a larger scale. 

Made from galvanized steel and coated with PVC, hangers are extremely durable and weather-resistant. The PVC protects the underlying steel core against exposure and ensures wires stay damage-free. 

Unlike S clips, which can hold two or three wires, hangers can hold many safely – including large-gauge cables. They’re cost-effective, reusable, easy to install without tools, and can bend to fit nearly any configuration. Hangers also perform well across many environments, including challenging terrain. 

To install hangers, workers first need to install a messenger wire. Though it doesn’t carry current, the steel cable shoulders the weight of all the cables to reduce sagging. It also provides a steady, safe spot to mount hangers that isn’t part of the racking or the panel itself. Once the messenger wire is in place, workers bend the hanger into the shape they need and hang it. 

Cable Ties and Locks 

Most people are familiar with plastic or nylon zip ties used for DIY projects, but solar cable ties are much stronger. 

Made from high-quality, durable, and UV-resistant plastic, these one-time-use ties secure cables directly to the solar racking. They’re chemical, water, and sunlight resistant, and more rugged ties could work in colder temperatures. 

Keep in mind that not all cable ties are equal. Low-quality ties, like the nylon ones hiding in your junk drawer, will eventually become brittle, causing them to break. This is especially true in areas where snow and cold weather are a threat and regions with high UV exposure. 

Unlike S clips and hangers, cable ties are a one-and-done product. Crews must replace them every time they complete work. 

Cable Locks 

Cable locks use a tool-free locking mechanism to hold ties in place, with additional room for slack. 

Depending on the company and the style, cable locks can look or act differently, but the overall logic is the same. Most are easy to install and reusable, utilizing locks and tie lines to hold cables in place and prevent accidental removal. 

Despite the similar design to cable ties, cable locks will last for the life of the panels, generally 20 to 25 years. 

Cable and Wire Trays 

Sometimes, open-air solutions aren’t the best way to protect solar wires.  

In those situations, especially in harsh environments and areas where digging isn’t possible, wire and cable trays make all the difference. 

Unlike conduit, which requires digging and burying wires, cable trays are aboveground installations. Workers connect the tray pieces, lay the wire in, and move along. The cables are safe from physical damage, including scrapes, abrasions, crushing, and even pests like rodents. Beyond physical damage, trays protect cables from wind, snow, sun, and other weather-related issues. 

Solar developers can choose either metal or plastic trays, depending on how much flexibility and strength they need. But no matter what material installers select, the cables inside are safe and organized. Best yet, if wires need replacement, workers can quickly access the tray. 

Conduit 

For the ultimate utility-scale solar cable protection, conduit is king. 

To install conduit, workers dig trenches in the ground and lay metal or PVC tubing. Next, workers fish the PV wire through the conduit from the solar panel to the combiner box. The resulting installation offers stellar protection from crushing, abrasion, UV, temperature changes, chemicals, and pests for the wire’s usable lifespan. 

Conduit keeps wire safe and sound but is more expensive than other wire management methods and is slower than open-air methods. Conduit also doesn’t work for certain solar sites, including those with rough terrain or brownfield sites. 

Wire Management Boxes 

Protecting wire is vital, but connection points are equally important. 

Combiner boxes are a staple at commercial, industrial, and utility-scale solar installations. Depending on the layout, they can hold dozens of wires in place, alongside fuse assemblies, buses, and even system monitoring equipment. 

When installing wire management boxes, placement is important. Every installation is different, and boxes must be ready to address unique challenges. From paint color and box size to breather vent placement and mounting position, every decision impacts performance and lifespan. 

Many Options, One Mission 

No matter what solutions installers choose, the goal is always to prevent wire damage. 

Wire management systems do a lot to prevent damage, but they aren’t perfect. Accidents happen, nicks occur, and wires pinch, leading to potentially dangerous situations like arcs, faults, and other issues. 

Damaged wires don’t always immediately cause problems – nicks in a conductor’s insulation take time to develop. Leaks, corrosion, pinches, abrasions… they can all eventually create delays, lost profits, and put people at risk. 

Crews should trust monitoring systems to track trends and spot abnormalities but should perform scheduled inspections, too. Beyond looking for obvious damage, workers should be on the lookout for other issues, including: 

  • Sharp edges on clips, ties, locks, and other materials 
  • Signs of aging on wire management systems, including peeling coatings, insulation pulling away, chipping, or nicks 
  • Damage to PV wire conductors, such as pinching, abrasions, nicks, and other wear 

Most importantly, work with local code departments and follow NEC guidelines. Keeping an eye on the regulations will ensure that teams safely manage solar power wires and cables.

Dirty Jobs: Do Dust and Grime Lower Solar Panel Performance?

Posted on by bop-admin

How often do you look around your house and realize everything is a dusty mess. 

You clean, wipe, and feather dust everything, but keeping everything tidy is a never-ending battle. 

Well, take solace that you’re not alone. Solar farms around the world deal with the same problem with varying results. 

Efficiency Killers 

The average solar panel has an efficiency rate above 20%, though some prototypes can perform better. 

But no matter how efficient your panels are, dirt, grime, and other schmutz are a constant threat. It might not seem like it at first glance, but solar panels are constantly picking up debris called soiling. If not taken care of, those particles can cause headaches for utilities, communities, and companies. 

Luckily, soiling doesn’t have to be an energy-generation killer. With some planning, proactive work, and emerging panel cleaning technology, it’s possible to easily maintain efficiency. 

What Causes Dirty Solar Panels? 

As with anything left outside, dust, dirt, pollen, and debris collect on panels over time. 

When dirt, dust, and other particles fall onto solar panels, they obscure the cells, leading to lower efficiency. Unfortunately, this is a common problem for many solar installations, especially those in sunny, desert areas. 

Dirty panels may not seem concerning, but even a little dust and debris can hurt production. According to the National Renewable Energy Laboratory, soiling accounts for as much as 7% of annual energy lost in the United States. Unfortunately, in even dustier areas like the Middle East, losses can be as much as half. 

Although lost energy is an issue, let’s face it: money can be an even larger motivator. MIT experts suggest even a 1% reduction in power from a 150 MW solar project could cause $200,000 in lost revenue annually. As panels take on more soiling, losses can quickly mount, resulting in lower ROIs. 

Of course, soiling does more than impair solar power generation – it can be a headache. In many cases, a good rainstorm can wash away most dust, dirt, and other messes, but that’s if there’s regular rain. In areas where rain is rare, moisture can combine with dirt and grime to create a much harder-to-remove filth. 

Sometimes, it may make sense for workers to use a water jet to clean solar panels. This process uses pure water to wash away soiling – any impurities can leave water spots and deposits. Another option for solar sites is dry brushing. Brushing is generally less effective than water and may potentially scratch or damage panels. 

Not all Soiling is Dirt 

It might not cause the same issues as a thick layer of dust on a solar panel, but snow poses its own production risks. 

When snow lands on solar panels, it’s harder for sunlight to reach cells, limiting power generation. Beyond reducing power output, heavy snow can damage panels, racking systems, and sensitive tracking components. Workers must then replace expensive equipment, leading to further lost revenue. 

Unlike dirt and grime, snow is easier to deal with on a solar site. Workers can quickly remove snow with a soft bristle or foam brush, leaf blower, de-icing product, or heating system. Panels could also naturally clear themselves as snow and ice slide off the tilted panels. 

Melting snow and ice offers another benefit for solar sites, as the water may remove soiling. 

Powering Down: How Soiling Impacts Production 

When dust, bird droppings, dirt, snow, and other debris block solar panels, it can start a chain reaction impacting short- and long-term activity. 

But what types of problems can we expect, and when can we expect them? The answer isn’t always clear, but it depends on location, water resources, and cost. 

Reduced Power Generation 

We’ve covered this a little bit already, but when dust builds up on solar cells, it prevents them from collecting solar energy. 

Needless to say, a solar panel not collecting solar energy is a problem. Over time, more dust and grime build up on the panels, causing drastic production decreases. Even worse, soiling can cement onto the panels as dirt combines with resting liquids like dew or condensation. 

Soiling does more than impact initial energy output. Less generated power means less revenue, which hurts the bottom line and the project’s lifetime return on investment (ROI). 

Higher Maintenance Costs 

Dirty panels are more than a productivity killer – they can run up maintenance costs, too. 

If rain and melting snow can’t clean the panels naturally, crews might have to drive to the site and clean them. Unfortunately, cleaning solar panels isn’t as easy as hooking up a garden hose and getting to work.

NOTE: Never allow crews to clean panels using a pressure washer. High-pressure water can damage sensitive solar cells and panel seals, even from several feet away.

Utility-scale solar systems can cover hundreds of acres, requiring the services of a professional cleaning company. Depending on how they choose to clean, the company might need to bring in pure water – regular water can leave deposits on the panels. Cleaning crews also need specific cleaning tools to prevent scratches and other damage that could impact energy production. 

Another option could be to invest in a self-cleaning system. Although these systems increase upfront costs, they maximize efficiency over the installation’s lifespan. 

Shorter Panel Lifespans 

How often do we hear about the importance of changing our car’s oil to avoid catastrophic engine issues? 

The same “ounce of prevention” advice our uncles gave us years ago holds the same value when applied to solar systems. When soiling goes untreated, it puts the solar energy system at risk. 

Without regular cleaning, dirt and debris raises the operating temperature of the solar panel system, resulting in damage. If damage occurs, crews may need to repair or replace panels to regain lost efficiency. 

Worse yet, muck and grime could damage other parts and pieces in the solar system, including tracking components. These sensitive components are complex – anything preventing their movement will immediately impact performance and eventually cause them to break. 

Preventing Damage 

Despite the potential problems associated with soiling, keeping up with cleaning is sometimes surprisingly simple. 

Whether allowing nature to lend a hand or investing in top-notch tech, keeping panels clean isn’t always a battle. 

Let the Rain Help 

Sometimes, the easiest way to handle a dirty solar panel is to let nature take its course. 

Rain, wind, and snow do a good job of keeping solar panels clean, especially between scheduled cleanings. Depending on the panel’s angle and the environment, rain and snow might be enough to wash away dust, dirt, and other debris. However, flat panels may have difficulty self-cleaning because they lack tilt. 

In rainy or snowy regions, the weather can be an excellent way to maintain panel efficiency with little effort. During dry spells, dust and grime build up on the panels, but one or two rainstorms can quickly improve efficiency to near its maximum. 

Keep an Eye on Systems 

Problems are much easier to address early on than when left to grow. 

Monitoring systems attached to solar systems can detect power generation decreases using sensors, output metrics, or other tracking. Larger sites mean more sensors, especially on farms where conditions vary from one area to the next. 

Constant monitoring allows crews to investigate problems quickly and determine if they need to take action. 

Maintain a Regular Schedule 

Proper maintenance helps get the most out of every component throughout its lifespan. 

Just like changing a car’s oil regularly, set up a cleaning schedule for the solar site and follow it. Crews can clean panels in several ways but most commonly use water or soft brushes. 

Using pure water is the safest method for cleaning solar panels, but costly if it needs to be delivered by truck. Soft brushes or blower systems are a cheaper option but tend to be less effective. They also may risk scratching or damaging the thin film solar panels if done improperly. 

Beyond simple cleaning methods available today are developing technologies capable of cleaning solar panel surfaces without touching them. One solution uses electrostatic repulsion to magnetically remove dust from the panel’s surface, safely cleaning it without water. 

Join the Robot Revolution 

As our lives become more autonomous, robots and algorithms have taken on more of our daily work. 

Autonomous cleaning systems mounted onto the solar system can wipe dust from panels without humans. The process is successful in the Middle East, where sand and dust constantly threaten energy production. 

Solar companies have no shortage of automated cleaning systems, with dozens on the market today. Many operate on solar power, cleaning rows of panels without water. 

Keeping Up with a Constant Problem 

We can’t realistically protect solar panels from every bit of dust and debris. Luckily, we have plenty of tools to help us mitigate damage. 

It starts with finding optimal locations away from construction, agriculture, and trees. Later, it means investing in regular cleaning, using either water, brushing, or an automated system. Monitoring systems also play a role in reducing the threat of poor performance and lost productivity. 

The solar industry is booming, not only in the U.S. but around the world. As technology improves, other innovative solutions will soon come to market, keeping our panels clean and our future bright.

Installing PV Wire: Direct Burial, Hangers, or Conduit?

Posted on by bop-admin

PV wire doesn’t seem like a big deal, but moving generated power from solar panels to the electrical grid would be impossible without it. 

To the untrained eye, installing thousands of feet of wire seems like a pretty straightforward process. But maximizing its performance depends on several factors, including: 

  • Environmental Conditions  
  • Cost Considerations  
  • Ease of Installation  
  • Project Size

Depending on the situation, solar EPCs have a few installation options, including direct burial, conduit, and hangers. 

Direct Burial Installation 

When solar developers directly bury PV wires, they install them in trenches underneath the panel rows. 

Direct burial wire is designed for underground installation without a conduit. To ensure the wire is up to the task, it undergoes rigorous testing to earn a specific UL mark. In this case, the mark signifies the wire can withstand abrasions, crushing, moisture, chemicals, and other hazards. 

Solar companies like direct burial wire because it’s a low-cost and easy way to install electrical wiring. Workers only need to dig a trench along the panel aisle near the racking, place the wire, and cover it back up. But as easy as it is, direct burial wire isn’t appropriate for every application. 

The Good and the Bad of Direct Burial Wire 

Soft soil compositions with relatively few rocks are the best conditions for direct burial wire. Sandy soil is also a good option because it drains quickly. Drainage is vital for underground wire installations because moisture can damage wire insulation and jacketing over time. 

Direct burial wires also run the risk of damage from environmental hazards. Sharp rocks could nick wire insulation, allowing moisture to get in. Large rocks can crush the wire and its insulation, hurting performance. Even damage caused by rodents chewing on the wire can potentially create faults. 

Damage could lead to less electricity generated and create unsafe conditions. It also costs crews time, money, and long-term production since they must visit the site, dig up damaged wires, and repair or replace them. 

Underground Conduit Installation 

Conduit installation is similar to direct burial, but instead of putting the wires in the ground, they’re fished through metal or PVC tubes. 

The tubing provides an additional layer of protection on top of the wire’s standard thick insulation and works well in rocky, moist, or corrosive environments. Typically, conduit is used when crushing, abrasion, or other threats are an issue. Beyond soil, conduit protects the wire from rodents, temperature fluctuations, and accidental damage from digging. 

Unlike direct burial situations, workers can easily replace or repair wires if something goes wrong – without digging. Crews only need to pull the wire out, replace it, and fish it through the conduit pathway. 

Like any other electrical project, local regulations may dictate conduit use. Requirements could change from one municipality to the next. The National Electrical Code (NEC) also has specific standards, so keep them in mind. 

More Protection, Higher Costs 

Encasing wires in conduit offers better protection than insulation alone, but makes solar projects more expensive. 

Not only do you have to buy enough for the entire site, you need people to install it. This means digging trenches, burying the conduit, then pulling wires through the tubing to connect everything. And as utility- or community-scale solar sites get bigger, so do the associated costs and timelines. 

Conduit is also not as flexible as direct burial wire, making it harder to use on slopes and curves. Shovels or excavators could also accidentally puncture metal or PVC conduit, damaging the contained wire. 

Cable Hangers 

Hangers come in many shapes and sizes, using galvanized steel coated with thick PVC to safely hold PV wires in place from the solar panel to the combiner box. 

Unlike conduit, workers can easily bend hangers to fit whatever shape they need. And unlike direct burial and conduit solutions, hangers don’t require any digging. They connect directly to the racking underneath the solar panels and provide a cost-effective way to string PV wire quickly across difficult terrain. This makes them useful in areas where the ground isn’t suitable for digging, like brownfields. 

Depending on the number of wires carried along the pathway, messenger wires might be necessary. Unlike PV wire, messenger wires don’t carry any current – they provide strength and support to keep wires in position. 

Maintenance and repair work is also easier for operators because the wires live in the open air. Workers can find damaged wires, remove them from the hanger system, and replace them without additional equipment. 

PV Wire Hanger Considerations 

As with any electrical job, PV wire hangers fall under NEC guidelines. 

According to NEC Article 690.31 (C) (1) (b), “Exposed cables sized 8 AWG or smaller shall be supported and secured at intervals not to exceed 600 mm (24 inches) by cable ties, straps, hangers or similar fittings.” 

The rules are slightly different for wires bigger than 8 AWG, allowing hangers up to every 54 inches. For added support, messenger wires can help carry some of the weight. 

Depending on the location of the solar array, code enforcement could apply other rules. Contact your local codes department to avoid any potential issues. 

Above-ground wires also face several potential issues, including contact with people and vehicles and severe weather. Buried wires are typically hidden, but hanging wires don’t have the same type of protection. This leaves them open to damage from sun, wind, rain, snow, vandalism, and accidental contact. 

What Impacts Solar Wire Installation? 

No two installations are alike, but knowing what you’re getting into before putting shovels in the ground can make mistakes avoidable. 

Environment 

Soft soil without much moisture is well-suited for direct burial projects. If the soil is rocky, struggles with drainage, or risks contact with chemicals, conduit makes sense. If the land is rocky, too wet, or at a brownfield site, hangers are a safe, cost-effective choice. 

Cost 

Direct burial is a low-cost option but requires laborers to dig trenches. Hangers are also cost-effective but leave wire out in the elements and exposed to other dangers. 

Conduit is pricier and requires labor, time, and equipment. However, it offers solar systems the best protection from damage and exposure. 

Project Size 

Bigger sites mean more work and longer timelines. Worse yet, delays can occur if crews run into unexpected issues. 

Smaller community-scale solar energy projects take less time to wire compared to utility-scale solar projects. However, smaller sites may benefit from the added protection conduit offers without a massive hit to the bottom line. As sites become larger, costs increase dramatically, forcing project developers to limit expenses. 

Code Regulations 

Although the NEC is an excellent guidebook, follow local and state codes to avoid mistakes. 

Failing to do so could result in violations, leading to work delays, fines, or other problems. 

Know Your Surroundings 

As solar sites spring up across the United States in brownfields, farmland, and even on water, teams should carefully determine how to set up their arrays.

Whether it’s a utility company with a small solar farm in the rolling hills or a large-scale developer repurposing brownfields, having the right manufacturing partner makes a huge difference. 

Good partners understand community, industrial, and utility-scale installations and act as a guide. They can also field questions and offer insight throughout the blueprinting, development, and troubleshooting processes. 

Most importantly, companies can keep every solar job on time and within budget.

What Is Fixed Tilt, Single, or Double Axis Racking?

Posted on by bop-admin

Solar panel racking is a mundane yet vital part of any utility-scale solar installation. 

Harnessing solar energy is more than simply pointing panels at the sun. Despite looking like simple infrastructure, ground-mounted racking can vastly improve a solar operation’s overall performance. 

Racking systems allow operators to precisely angle panels to optimize generation and maximize results over the system’s lifespan. Luckily, solar EPCs have access to several types of racking systems to fit any budget, environment, or climate. 

Fixed Tilt Solar Racking 

True to its name, fixed tilt solar racking holds the solar panel at one tilt angle. 

Since the panels do not track the sun’s movement, installers must find the angle that maximizes sunlight absorption. This angle, called the azimuth, helps the panel collect as much sun as possible during peak hours. 

Azimuth angles use true north and the sun’s position to find the perfect direction to face the sun. To calculate the azimuth, developers can use the National Renewable Energy Laboratory’s Solar Position Algorithm to get results within 0.0003 degrees. 

Pros of Fixed Tilt Racking 

So, why do solar EPCs like using fixed-tilt systems for certain projects? It comes down to ease of installation and upkeep, durability, and application. 

Fixed tilt systems don’t have complex tracking systems, making them easy to install almost anywhere, ultimately saving time and labor costs. The system’s straightforward design also makes it useful across residential, community, and utility-scale projects. 

Fixed-tilt systems are more durable than other options. They need little maintenance over their usable lifespan and have a low risk of losing the sun’s position. The racking systems also do well in poor weather conditions, including where snow could be an issue. 

Finally, installers prefer fixed tilt systems when working with brownfields and other challenging landscapes. Brownfields are former industrial or commercial sites that may have environmental contaminants, making them unattractive for regular development. In cases like this, solar panel systems stationed in poured concrete hold up the panels without disturbing the ground too much. 

Concrete pads or blocks work in other challenging locations, too. Rolling hills make it hard for some tracking systems to work, but fixed-tilt systems don’t have similar problems. 

Cons of Fixed Tilt Racking 

Despite being cost-effective, durable, and easy to install, fixed tilt racking falls short in other ways. 

Because the racking system doesn’t move, solar panels don’t follow the sun through the sky. This limits the amount of sunlight the panels absorb, making them less efficient. 

Less efficiency also leads to another problem – less production. To offset the lack of production, developers may need to install more panels to achieve better results. The additional panels require space, leading to higher land costs and expenses. 

Shading can also cause issues for solar panels attached to fixed tilt racking because of their lack of movement. If a tree casts shade on a section of solar panels, their production plummets without a way to change direction. 

Single Axis Systems 

Unlike fixed-tilt mounting systems, single-axis ones follow the sun using tracking components. 

Because the system tracks the sun, panels collect more sunlight, leading to better solar power generation. Though they cost more than fixed-tilt options, their increased output means sites need fewer panels to produce the same power. 

To save money, developers can also install panels in long rows, using one drive system to control all the trackers at once. The cost is a little more burdensome in tight areas with shorter aisles because the installation requires more drives. 

Pros of Single-Axis Racking 

Single axis tracking setups are more expensive but prove their value by increasing long-term electricity generation. 

Moving, even in one lateral direction, makes a dramatic difference for most systems, including those in small spaces. Experts suggest single-axis setups are somewhere between 15-30% more efficient than fixed-tilt ones. This is because panels can keep pace with the sun all day. 

Furthermore, single-axis racking reduces impacts caused by shade. As the sun moves, the panels follow, as opposed to becoming trapped at a bad angle for hours on end. 

Cons of Single-Axis Racking 

When you introduce more complexity to a system, you increase the risk of something going wrong. 

While fixed tilt systems offer an easy-to-maintain, no-frills experience, single-axis systems need more maintenance. They also require space to allow the panels to safely move along their axis. When space is an issue, there may be less room for panels. 

Increasingly complex systems also come with higher price tags, as developers can expect to pay more for a single-axis system, compared to a fixed tilt one. Though the price may cause some cost-conscious developers to shy away, the added generating power helps soften the blow. 

Finally, it’s worth noting that single axis tracking systems don’t always perform well on difficult terrain. Whether it’s hilly areas, brownfields, or other tough conditions, setting up panels in one row is hard. As a result, solar EPCs must find creative ways to safely run these systems. 

Double (Dual) Axis Systems 

What’s better than a solar panel that follows the sun across the sky? How about a solar panel that tracks the sun’s elevation at the same time? 

Not only do double-axis trackers follow the sun east to west, but they can also move north to south, tracking elevation too. PV systems outfitted with dual-axis solar racking systems are up to 40% more efficient than standard fixed tilts. The result is a system capable of generating maximum electricity every day of the year. 

Pros of Double-Axis Racking 

One benefit of being incredibly efficient is that installations can often do more with less. 

When panels follow the sun better, farms need less space and fewer panels to achieve similar results. For developers, it means getting more power out of the same plot of land, reducing project costs. 

More importantly, double-axis tracker systems can negate issues caused by shade or clouds. When shade covers the panels, they can be repositioned, optimizing the situation and generating clean power. 

Cons of Double-Axis Racking 

Better technology often means higher costs. 

For some solar developers, the high upfront cost to install double-axis racking can be a tough pill to swallow. Unlike fixed-tilt trackers, these complex systems often require skilled workers to install, calibrate, and maintain them. 

Maintenance is critical to keeping a double-axis system running smoothly. If the trackers don’t work, they can’t follow the sun, hurting overall production and return on investment. However, with proper maintenance and care, the farm can “pay” developers back over time. 

Finally, it’s possible that even with proper maintenance, tracker components may wear out before the panels. Panels can go decades with only routine maintenance and cleaning, but moving parts tend to show wear and tear much sooner. 

Options for Every Installation 

Every installation is different, so developers and their teams should decide what racking is best for their situation. 

Budget-friendly options are easy to install and perform well across a variety of landscapes but are less efficient. Tracking systems dramatically increase energy generation but are more expensive and need more maintenance. 

No matter what, work alongside qualified companies and partners who understand your project’s needs and goals. Their experience and expertise can help you avoid pitfalls and navigate unexpected problems, making installations smoother and more productive.

From Coal Towns to Sunscapes: Renewables Reach Coal Country 

Posted on by bop-admin

Despite years of excitement about renewables, we’re not all that far removed from the days of King Coal. 

As recently as the early 2000s, coal was the driving force for American electricity generation. According to the Energy Information Administration (EIA), coal accounted for 2,016 billion kilowatt-hours (kwH) of electrical generation in 2007.  

Natural gas boomed soon after, eventually becoming the nation’s leading producer. 

Today, coal only accounts for about 675 billion kwH, leapfrogged by natural gas, nuclear energy, and even renewables. But nothing happens overnight; the writing has been on the wall for years.  

It also helps to keep everything in perspective. Yes, coal energy generation has fallen by two-thirds, but it still accounts for 16% of America’s energy portfolio. 

A Black, White, and Gray Issue 

Coal production capacity has fallen precipitously since the mid-2000s, decreasing by one-third from 2012 to 2022. 

Though use and consumption fell, coal is still a critical energy source. Data from the EIA determined that 91% of coal consumed went to electric power. 

As the country adopts more renewable energy, including solar, coal is slowly falling behind. Unfortunately, coal’s decline is also woven into several states’ economies and histories. 

How can emerging technology and energy generation support these states, and is a coal- 

free future possible? 

Coal Meets Its Match 

Since 2007, coal has seen its share of energy generation eaten up by cleaner, cheaper options. 

Natural gas is plentiful and cost-effective, leading energy generation plants to switch from coal. Though still a fossil fuel, natural gas is more efficient than coal. It also produces much less carbon dioxide during energy generation. 

Between 2011 and 2019, more than 120 coal-fired generation plants converted to other fuels. Of those, the vast majority became natural gas-powered. In states where natural gas is plentiful, like Texas, Florida, California, Pennsylvania, and Ohio, the decision felt immediate. By 2021, natural gas was the largest power generator in all five states. 

Meanwhile, states like Iowa, Kansas, and South Dakota also distanced themselves from coal, investing in wind power. By 2021, wind was the largest share of electricity power generated in those states. 

Weaning Off Coal 

Despite clean energy advancements and ambitious net-zero emission goals, some states still depend on coal to survive. 

West Virginia, Missouri, Wyoming, and Kentucky still rely heavily on coal. More than 70% of each state’s power comes from burning it, including more than 90% of West Virginia’s energy. Moreover, Wyoming, West Virginia, and Kentucky are several of the nation’s largest coal producers. 

Despite their reliance on coal, all three states have tried to adopt more renewable energy.  

For example, Wyoming established wind farms to take advantage of its windy conditions. More than 22% of the Cowboy State’s power comes from renewables now. 

West Virginia and Kentucky have been slower, however. Less than 1% of Kentucky’s energy comes from renewables, while West Virginia fares slightly better at 4%. 

Though the numbers don’t seem encouraging, there’s room for improvement. What we’re seeing across all three states are concerted efforts to improve energy diversity and promote new industries and jobs in economically depressed areas. 

Why Renewables? Why Now? 

It’s hard to break generational ties sometimes, but leaving coal in the dust could benefit everyone.  

Renewables like solar and wind are on the upswing as technology improves. And for the people of coal country, adjusting to a solar-powered future could create more opportunities. 

Pro-Environment Movement 

One of the main drivers of renewable energy, including solar, is its ability to generate clean power. 

Burning coal for energy creates several problems for the environment. First, it pumps greenhouse gases into the atmosphere at rates higher than other fuel sources. 

Mining companies also commonly use surface mines to find and extract coal from the Earth. This process can cause coal dust to enter the air and water, impacting health.  

Secondly, coal mining massively changes local landscapes. To reach underground seams, companies cut off mountain tops. The result is a litany of environmental concerns, ranging from human health issues to river damage, habitat destruction, and air pollution. 

Emerging Job Markets 

The U.S. Bureau of Labor Statistics (BLS) reports that coal mining jobs have dropped over 50% since January 2012. 

Coal’s decline coincides with the recent rise in renewable energy jobs across the United States. According to E2, a nonpartisan group, nearly 560,000 Americans work in renewable energy generation, up 14% since 2020. 

Job growth should remain strong throughout the rest of the decade as the U.S. invests in solar, wind, and other renewables. 

Economic Factors 

Not long ago, coal was one of the most cost-effective energy generation methods. 

However, the rise of low-cost natural gas, rapidly decreasing solar costs, and battery storage solutions have impacted coal. Divesting from coal becomes easier once the numerous tax credits and government programs driving renewable adoption get involved. 

The Government is Involved 

Thanks to government support, there is no shortage of programs to make renewable energy attractive. 

While the country moves closer to its net-zero carbon emissions goal, renewables will benefit from massive government investments. 

The Inflation Reduction Act introduced and extended several programs and incentives, including ITCs and PTCs. Solar installers can also access DSIRE to find state and utility incentives. 

Public Perception is Changing 

Although coal still has a role in America’s energy portfolio, many people, organizations, and government officials want cleaner energy. 

The reality is that coal jobs will likely continue dwindling. At the same time, new high-paying skilled jobs in solar and wind are coming in. For former coal towns, people can seamlessly move into a new, growing industry with a strong future. 

Three States, Three Stories 

Luckily, utility-scale solar isn’t strictly for sun-soaked states like California and Texas. 

For states like Wyoming, West Virginia, and Kentucky, the race is on to pivot from coal to solar and wind. Coal is a hallmark of their economies, but money, people, and technology are helping them push toward solar. 

Wyoming 

The leading coal-producing state has started building one of the nation’s largest solar farms. 

Wyoming is heavily involved in wind power, but solar is picking up steam. Currently, Wyoming ranks 46th in the nation for solar generation, per the SEIA, but recent developments will help the state evolve into a renewable energy powerhouse. 

Totaling 771 MW, Cowboy Solar I and II will feature 400 and 371 MW utility-scale solar farms, respectively. The sites will also include battery storage systems of 136 and 133 MW. 

Though the project is in its early stages, completing it would give Wyoming a massive shot of solar energy. 

Kentucky 

Kentucky ranks 43rd in the nation for solar generation but is a top-five coal producer.  

Recent projects could add more than 950 MW of solar to the state’s portfolio. Developers recently broke ground on a 160 MW solar project in western Kentucky that could power up to 120,000 homes. Called Unbridled, the project will be the state’s largest solar installation once it goes live. 

Another planned project on the eastern side of the Bluegrass State will soon be its largest by far. The 800 MW solar farm will begin construction in 2026 and could introduce hundreds of solar jobs to the region. 

The prospective site sits on the former Starfire Mine, and its flat terrain is perfect for solar panels. It also has most of the infrastructure for connecting to the larger grid and moving materials and people. 

West Virginia 

West Virginia has made several moves to add more solar energy by giving new life to former mines. 

A 250 MW solar farm located at an old mine began construction in 2022 and should be operational by the end of this year. Over the next five years, developers will start work on another 150 MW site with plans to complete it over the next decade. 

The excitement for solar in West Virginia has seeped into the private sector, too. Titanium Metals Corporation, an aerospace manufacturer, could eventually run on only solar power. Plans to build the 106 MW solar farm with a 50 MW battery system should kick off in 2025. 

The state is also home to groups like the Appalachian Climate Technology (ACT Now) Coalition, which represents 21 counties in West Virginia. Its mission is to introduce and promote clean energy jobs and projects where coal was once a major driver. Ultimately, the goal is to create new high-paying jobs in emerging industries. 

What Have We Learned? 

Developing a new industry where one didn’t exist is difficult but not impossible. 

Thanks to mining, coal states like Wyoming, West Virginia, and Kentucky have the tools needed to support solar energy. Their infrastructure is largely in place, the landscape easily supports solar, and many workers are available. And, once again, the states aren’t abandoning coal – they’re simply diversifying energy sources. 

The government also hasn’t lost sight of its own renewable energy goals. Federal and state governments have invested heavily in new technology by funding as many projects as possible. This support is critical for states as they switch from fossil fuels to clean energy generation. 

We can’t expect change to occur overnight, especially with an industry as ingrained in our culture as coal. But with investment, time, and continued effort, it’s possible to chart a new path forward.

Has the Solar Industry Improved Under Inflation Reduction Act?

Posted on by bop-admin

When President Biden signed the Inflation Reduction Act (IRA) into law on August 16, 2022, it opened the door for a clean energy renaissance. 

Since then, a flurry of activity has occurred, especially in the burgeoning solar industry. Many new manufacturers and solar installations are cropping up across the country, but has the IRA had the intended effect we thought it would? 

What Did the Inflation Reduction Act Do? 

From the get-go, the Inflation Reduction Act laid out several ambitious goals. 

  • Make solar adoption more affordable 
  • Increase domestic manufacturing 
  • Create solar jobs 

In theory, the IRA would deliver the best of both worlds. The IRA instituted billions of dollars in programs, tax incentives, and development projects to bolster renewable energy production. Manufacturers also lined up, investing billions of their own dollars, with government support, to reshore solar development and production. 

But beyond the basics, the IRA has given the industry and government several things to cheer about. 

Solar Costs Drop 

When the IRA took effect, the inflation rate was over 8%, making it harder for businesses to fund projects. Despite the high cost of borrowing, the Inflation Reduction Act enhanced and extended programs to make solar more affordable. 

Among them were a series of tax credits, including Investment Tax Credits (ITCs) and Production Tax Credits (PTCs). Solar EPCs can claim ITCs upfront based on system costs. PTCs, meanwhile, are based on the amount of electricity produced over the project’s first 10 years. 

Every project is different, but deciding which credit makes more sense depends on project size, power output, and eligibility. 

Other credits encourage investments in low-income areas, rural communities, and abandoned sites like brownfields. These projects create jobs in underserved communities, add formerly abandoned sites to the tax rolls, and improve access to low-cost electricity. 

At the same time, utility-scale solar costs have leveled out in recent years, according to the National Renewable Energy Laboratory. Other costs, including labor and permitting, have also been resilient.  

Meanwhile, several tax credits tied to prevailing wages and brownfield development have helped lower costs. 

Domestic Manufacturing Blossoms 

As part of the IRA, the Biden administration pushed for more domestic solar manufacturing. So far, the Inflation Reduction Act has done what it intended to do. 

The IRA introduced Advanced Manufacturing Production Tax Credits for solar energy, which ties incentives to producing renewable components. Also known as 45X MPTC, manufacturers receive the credit per unit produced and sold. Eligible products include solar photovoltaic (PV) modules, inverters, batteries, trackers, and critical minerals. 

Another tax credit helping manufacturers is the Advanced Energy Project Credit (48C ITC). Like the previously mentioned credit, this applies to manufacturers building or upgrading facilities. However, it incentivizes companies to outfit their buildings or facilities with greener installations. These installations must reduce greenhouse gas emissions by 20% through low- or zero-carbon heat systems. 

Although the two credits cover different aspects of solar energy, companies cannot take both. 

Spurring Investment 

Beyond tax credits, the IRA allows more public/private investments to produce renewables. 

According to the White House, companies have announced about $265 billion in clean energy projects since August 2022. Many of those projects are in areas living below the median household average, bringing high-paying jobs and low-cost energy to underserved communities. 

Other information from the Clean Investment Monitor tells a similar story. In the first half of 2024, companies invested $147B into clean energy manufacturing and deployment. The amount has increased dramatically each year since 2022 as companies find ways to incorporate renewables into manufacturing, energy production, and operations. 

From opening new manufacturing facilities to upgrading critical infrastructure, solar and other renewables are thriving under the IRA. 

Bringing Back Jobs 

One of the most attractive features of the IRA was its ability to create manufacturing and skilled labor jobs. 

Since August 2022, the IRA has helped launch 330,000 new clean energy jobs. Manufacturing jobs are also coming home as the U.S. attempts to wean itself from overseas solar panels from Asia. 

Facts and Figures: Assessing the IRA’s Impact 

One way to analyze how well the Inflation Reduction Act has performed so far is to look at the metrics. 

What have we seen over the past 24 months, and is it enough to call the law successful? 

Clean energy investments are taking off. Source: Clean Investment Monitor (Tallying the Two-Year Impact of the IRA (cleaninvestmentmonitor.org))

Renewable Investments are Way Up 

Clean energy investments totaled about $147 billion through June 2024. 

Though the number is impressive, it’s more exciting when compared to investment figures before the IRA. In 2021, clean energy only garnered about $141 billion for the entire year. Seeing the number eclipsed in half the time is wildly impressive. 

All told, clean energy projects have pulled nearly $500 billion in investments. Some of the most welcome growth came from the manufacturing and transportation technology industries, with $89 billion invested. The total was more than four times the amount in the two years leading up to the IRA. 

More Projects Coming Online 

Officials have announced hundreds of projects across at least 40 states, with many tied to solar, wind, electric vehicles (EVs), and battery storage. 

According to RMI Analysis, the government has only disbursed about $66 billion in funds through the first half of 2024. More projects will come online in the next few years, including an estimated 320 GW of clean energy projects. 

More importantly, as new manufacturers and clean energy projects launch, added jobs will become available. RMI expects the solar industry alone will need 500,000 workers by 2033, doubling the number of jobs available today. As a result, we need more educational and certification programs today to develop tomorrow’s workers. 

Better Grid Resilience 

What good is generating a ton of renewable energy if the current electrical grid can’t support it? 

The IRA has provided a lifeline for grid operators to improve the grid. As more green energy comes online, including wind farms and utility-scale solar power, the grid must support it. That means investing in efficient power plants and transmission and distribution lines to move electricity effectively. 

Grid resilience could take several forms. One choice is to add to the grid to help it accommodate more electricity. Expanding the grid is not popular, as substations and massive transmission lines cause problems for communities. 

Another possibility is to improve transmission lines with new conductors. Most conductors crisscrossing the United States are aluminum wrapped around a steel core. The conductor design is over a century old (the patent is from 1908), so minor improvements could go a long way. 

A third option is to add more microgrids. Microgrids are small community grids that can run independently. If a storm takes down the larger grid, a microgrid can disconnect to still provide power to homes and businesses. 

The goal is to equip rural communities with microgrids powered by renewables and energy storage. Residents get reliable, low-cost energy produced close to home, and utilities can use microgrids to quickly pinpoint and correct problems during an emergency. 

Because the grid is such a critical piece of infrastructure, the government is stepping up to help. Luckily, the IRA and Bipartisan Infrastructure Law combine to create the largest investment in the power grid’s history. The laws will upgrade and rebuild infrastructure to accommodate new technology, expand service, and increase resiliency. 

Not All Sunshine 

No legislation is perfect, and the Inflation Reduction Act has shortcomings. 

Though the law does a lot for the green energy community, there are several holes, including some outside its control. 

The Rules Can Be Murky 

No government initiative would be complete without endless confusing and difficult rules. 

Between understanding how to qualify for the ITC and PTCs, navigating community, county, state, and federal regulations, and chasing down funding, getting projects off the ground is slow. Worse yet, the ITC and PTC dollars are sometimes not easy to qualify for and will only get harder to reach in later years. 

Despite the occasional trouble, companies have invested billions of dollars into developing a vibrant solar energy industry. 

Interest Rates Are Still High 

The long-term solar industry is growing by leaps and bounds, but high interest rates temper some investments. 

High interest rates make projects, facilities, and infrastructure upgrades more expensive. Everything comes with an extra added cost, potentially leading to delays or cancellations for builds. 

High interest rates have also resulted in a sharper increase in solar LCOE compared to fossil fuels. Though solar is experiencing an uptick in cost, fossil fuels still have a higher LCOE, making solar and other renewables more cost-efficient over the long run. 

Additionally, anticipated rate cuts in the coming months may kickstart investments in other projects, keeping the good times rolling. Investments are booming dramatically under the IRA despite currently high interest rates. 

We Still Rely on Others for Panels 

In June 2022, the Biden administration issued a two-year moratorium on solar panels from four Asian countries to keep projects going while domestic manufacturers caught up. 

The temporary pause is over, and new tariffs have been added to overseas solar products.  

Why? To protect a bevy of new manufacturers in the U.S. Without tariffs, cheap solar panels could flood the U.S. market, driving domestic manufacturers out of business. 

While solar manufacturing is making headway in the U.S., the industry cannot compete with low-cost panels. Tariffs keep the playing field even until U.S. manufacturers can sufficiently meet demand. 

Despite the tariffs and occasionally frosty relationship with China, the United States relies on many solar products. China controls roughly 80% of the global solar supply, from raw material sourcing to finished goods. 

Prices could skyrocket if solar EPCs and other installers lose access to overseas solar panels. American-made products are high quality but come at a high cost – sometimes too high for a budget to absorb. 

Spiking prices could cripple U.S. solar expansion until the domestic manufacturing supply chain catches up. 

Looking to the Future 

All things considered, renewable energy is moving in the right direction. 

Domestic manufacturing is increasing, and public/private investments are pouring in. Under the IRA and other initiatives, the industry should reliably expand over the next decade. Costs are stable, the government has incentivized expansion and development, and consumers are saving money in the long run. 

Though the long-term prospects look good, the upcoming 2024 election could affect the future of renewables. Depending on who assumes office and what agendas are announced, portions of the IRA could be rolled back or scrapped entirely. 

Overall, the IRA has done its job. Solar and renewable investments are exploding, the industry is vibrant, and there is real hope for a carbon-neutral future.

Will High Interest Rates Stifle Solar EPC Development?

Posted on by bop-admin

Solar development is thriving across the United States, but why? 

While we can suggest growth is directly tied to climate change goals, nuance is missing. Climate change drives solar adoption, but maturing technology and lower costs influence it, too. 

Lower Costs, More Adoption 

New technology is always expensive when it first hits the market.  

Like electric vehicles, computers, and MP3 players, solar panels cost less than what they did when they were first sold. According to the National Renewable Energy Laboratory (NREL), the cost of residential, rooftop commercial, and utility-scale solar fell 64%, 69%, and 82%, respectively, from 2010 to 2020. 

In 2022, a tariff moratorium benefited the solar industry by allowing companies to import low-cost solar panels from Asia. Though the tariff is ending, it has given domestic manufacturers time to increase production. Domestic panels may be more expensive but cost less to ship and have a shorter supply chain. 

Soft costs are also improving, though more slowly than hard costs. Unfortunately, there isn’t one universal policy, leaving communities and states to create rules. This results in processes that slow down solar projects and potentially increase costs. 

Despite political and technical hiccups, solar installations are up. Solar Energy Industries Association (SEIA) data suggests solar accounted for 75% of new electricity capacity added in Q1 2024. The organization also mentioned utility solar projects were doing well, setting quarterly records in Q1 2024. 

But amongst all the excitement, a storm cloud could derail momentum. 

Tackling Climate Change with Solar 

Generating electricity isn’t always clean or cost-effective, but it’s part of our daily lives. 

Unlike fossil fuels, solar energy and other renewables are cheaper, cleaner, and infinitely available. As a result, solar farms are playing a critical role in upgrading our clean energy portfolio. 

According to the U.S. Energy Information Administration (EIA), the country added 15.8 GW of solar power from January to September 2023 – up 30% year-over-year. While it’s great news for the industry, the country, and the environment, the solar boom is facing headwinds. 

Wood Mackenzie, a data and analytics company, believes inflation could temper solar energy’s sunny outlook. When inflation rises beyond the normal range, it sends ripples throughout the economy. With inflation spiking in recent years, Wood Mackenzie fears the renewable market could be impacted more than other industries. 

The group says photovoltaic (PV) installations are expensive to establish, resulting in high investments and low returns. However, solar has long been an attractive choice because of its levelized cost of electricity (LCOE), a metric comparing different types of energy to one another. 

Solar has a much lower LCOE than fossil fuels like natural gas, but its advantage shrinks as inflation rises. 

Inflation Looms Large 

Inflation-wise, life was pretty good for many industries emerging from the Great Recession. 

Rates were low and steady, allowing businesses and the economy to flourish. But after more than a decade of stability, COVID-19 ruined the party. 

As the world reopened and life returned to normal, inflation boomed. By the middle of 2021, the 12-month inflation rate had risen to more than 5%. A year later, we saw inflation rates around 9%. The rate has cooled but still sits far above where it was only a few short years ago. 

Some inflation is good because it encourages businesses to invest, but excessive inflation does the opposite. Over time, higher inflation means less profit. High inflation makes operating costlier, ultimately hurting industry growth, especially in emerging markets. It also makes it harder to plan for future projects because money is “more expensive.” 

How Higher Inflation Affects Solar EPCs 

The simple response to the impact of inflation on the industry is to say, “Everything is more expensive.”  

However, several areas of solar development may feel the brunt more than others. 

Projects Are More Expensive 

When interest rates increase, so do financing costs. 

In straightforward terms, financing costs are tied to borrowing money for funding projects. These costs include loans, interest, and other fees. As these costs increase, it’s harder to afford more or larger projects. 

For solar sites, upfront costs make up the majority of expenses. Engineering, Procurement, and Construction (EPC) companies must purchase racking, solar panels, wiring, and connectors while juggling permits, taxes, and land costs. Once the project is complete, costs fall dramatically as maintenance and operation costs are much lower. 

Of course, the upfront costs bring new solar projects online. When rates are high, companies are less willing to jump into new projects. Over time, the number of delays increases alongside cancellations. 

A Ripple Effect 

Delayed or canceled projects have impacts far beyond one job. 

Higher interest rates may cause delays and cancellations, potentially impacting solar development in certain areas. With fewer projects, there aren’t as many jobs for installers, electricians, and other professionals. 

On the other hand, solar is still a growing industry with a shortage of qualified professionals. More delays may lead to fewer opportunities in the short term and more trouble finding labor if demand picks up. 

Additionally, as we saw during COVID-19, supply and demand metrics can throw the entire supply chain off. When interest rates are high and projects slow down, companies are less likely to hang onto inventory because it’s more expensive. When materials sit on shelves, it creates sunk costs because inventory isn’t moving. 

Supply chains could suffer, especially when the solar panel moratorium ends. For two years, solar installers have had access to low-cost panels from overseas, specifically East Asia. The moratorium was supposed to help increase domestic manufacturing, but the domestic supply still poses concerns.  

In this case, companies may have to pay more for materials while dealing with supply chain hiccups. 

Beating Back Inflation 

Inflation may be high, but there’s hope for companies, installers, and the industry. 

The Federal Reserve will likely reduce interest rates this year, but it’s not guaranteed. With that said, solar installers have options to reduce costs and keep projects moving. 

Take Advantage of the Inflation Reduction Act (IRA) 

The IRA has plenty of initiatives and incentives to encourage solar development. 

Some of the most common are ITC and PTC credits that kick in upfront or over time. For example, an ITC credit does not change based on variables, but a PTC credit could change based on project costs, other available credits, and even the environment the array is in. 

Expanding on the IRA’s benefits, the law also includes other incentives and programs for underserved regions. Their goal is to encourage the development of low-cost, reliable energy projects in rural, low-income, and tribal areas. 

Simplify Permitting 

One problem associated with solar development is navigating a maze of permitting red tape. 

Though the process has improved, states and communities may have vastly different procedures. Solar EPCs should look for communities, regions, and states welcoming solar. These areas are more likely to have simpler permitting processes, which can get projects off the ground faster. 

Several organizations and agencies have information available to streamline the permitting process, including: 

Improve Productivity 

Besides materials, labor is a massive cost center – especially on larger projects. 

Keeping projects on track often means using parts that reduce in-field work as much as possible. Pre-made components limit mistakes in the field because all parts have been tested before leaving the factory. They also allow crews to get on and off the site faster, letting them move on to the next project. 

For example, bundled wire and pre-made PV connectors cost slightly more than single reels and field-made connectors. The higher cost is more than returned in savings, as workers can install PV wire up to 80% faster. Over several projects, the labor and time savings more than cover the extra cost with fewer workers on site. 

Light at the End of the Tunnel 

Inflation remains high but is slowly falling. 

As with anything in life, what goes up must come down. Construction input prices have slipped recently, leading some experts to take it as a sign of easing inflation. The hope is with softening prices, the Federal Reserve may cut interest rates in the coming months. 

Though construction is tangent to solar farm installation, it offers the economy hope. Solar EPCs are in a unique situation right now. Although costs are increasing in the short term, so is the demand for renewable energy. 

We thought the market might slow down, but it has stayed strong. This has encouraged installers and manufacturers to continue pushing for long-term projects and development. Meanwhile, the industry is navigating a labor shortage, opening the door for people to access high-paying solar jobs. 

The industry is stronger than ever, prompting companies, utilities, and communities to invest in solar. These installations provide clean power to the electrical grid and help reduce greenhouse gas emissions caused by fossil fuels. 

EPCs still have options to save money despite the economic environment. It only requires forward-thinking site placement, permitting strategies, material sourcing, and labor decisions.

Bright Idea: Converting Brownfields into Solar Farms

Posted on by bop-admin

Go for a drive anywhere in the United States, and you probably won’t be far from a current or former brownfield site. 

According to the Environmental Protection Agency (EPA), more than 450,000 brownfields litter the U.S. But what is a brownfield, and why are governmental, public, and private organizations so interested in them? 

As it turns out, brownfields may play a vital role in our ongoing solar energy development. The EPA defines a brownfield site as “a property where expansion, redevelopment or reuse may be complicated by the presence or potential presence of a hazardous substance, pollutant or contaminant.” 

Typically, brownfields are former locations used for industrial or commercial activities, including manufacturing, storage, or processing. Using this explanation, examples include factories, gas stations, railyards, and landfills. 

Unfortunately, their ties to chemicals, heavy metals, and other potential pollutants make them unattractive development sites. Unlike greenfield locations, which are undeveloped pieces of land ripe for expansion, brownfields require rehabilitation before use. 

Not Every Brownfield is the Same 

Although every brownfield requires cleanup before reuse, some need more than others. 

Depending on the location and surrounding area, rehabilitation could be worthwhile. Some sites have found new lives as golf courses, offices, shopping areas, mixed-use spaces, and even solar farms. 

But none of this happens without investment, and even then, it could be years before a site is ready for development. However, with enough time, money, and work, formerly forgotten properties can find new life and return to the tax rolls. 

From Brown to Bright 

One type of brownfield receiving a lot of interest from the solar community these days is landfills. 

Landfills are disposal sites for municipal solid waste (MSW), construction and demolition debris (D&C), and hazardous waste. There are two types of facilities: Subtitle D programs, which include non-hazardous municipal and industrial solid waste, and Subtitle C programs, which accept hazardous waste. 

Depending on the location, your local dump can operate for decades, collecting and compacting community garbage. But, like everything else in life, the good times have to end eventually, setting the stage for decommissioning. 

Once the landfill reaches capacity, workers pack it down, install mitigation systems for gas and water to escape, cap it with soil and plants to prevent contamination, and closely monitor it for 30 years.  

While this might seem like the end of the story, solar energy is breathing new life into former dumps. 

Making Something Out of Nothing 

According to a 2021 RMI report, the U.S. has over 10,000 closed or inactive landfill sites. 

Seeing an opportunity, the EPA launched the RE-Powering America’s Land Initiative. The program promotes renewable energy projects on former industrial sites like landfills, mines, and other forgotten places. 

So far, the RE-Powering program has completed 530 projects and installed 2,580 MW of power, including 93% from solar and 5% wind. Even more importantly, the program has completed brownfield redevelopment projects in nearly every U.S. state. 

Every state is different, but some offer financial incentives or streamlined permitting processes to rehabilitate brownfields. Certain states, like New Jersey, New York, and Massachusetts, offer both! 

But what has the program done for former dumping grounds? 

Small Projects, Massive Impact 

Of the 530 projects touted by the RE-Powering program, 60% (318) sit on top of landfills or landfill buffers. Though most of the solar projects generate less than 5MW of power, 16 produce more than 20MW of electricity. 

The EPA’s RE-Powering program is only one of many federal, state, and local projects promoting brownfield redevelopment. For example, Governmental agencies like the Departments of Energy and Transportation tackle national initiatives, while others, like the Appalachian Regional Commission, focus on specific areas. 

According to the EPA, its programs and grants, including the Brownfields Revitalization Act, are making a difference. Through 2023, grant recipients leveraged about $20 per EPA brownfield grant dollar received. But grant money is often only one part of the brownfield puzzle. The agency highlights strong partnerships between local governments, organizations, and public/private groups to find more money. 

Despite the financial costs, federal, state, and local initiatives are addressing several long-term issues at the same time. They are finding new and creative ways to reuse brownfields and meet increasing electricity demand. 

Why Landfills Make Great Solar Sites 

Let’s be real: landfills are often not great spots to put a community park. However, they’re excellent places to set up a solar site. 

But what makes a landfill conversion so alluring for solar development? Turns out former dumping grounds are a popular choice for several reasons. 

  • Landfills are not prime real estate development targets. They require money, time, and labor to rehabilitate and carry the stigma of former pollution. 
  • Dumps tend to be in areas near roads and electrical transmission lines. Their placement makes it easier for solar energy producers to move power from the site to the electrical grid. 
  • Landfill sites may already be zoned for renewable energy development, streamlining the planning and permitting process. 
  • Solar sites near populated areas like towns may have access to guaranteed power buyers, especially in high-demand regions. 
  • Landfills have a welcoming landscape for solar energy, with little shade, unobstructed views, and even hilltop access in some instances. 
  • The land is typically cheap, making it attractive for some buyers willing to pay for rehabilitation. 
  • Depending on their size, dumps can accommodate community- or even utility-scale projects. 

Combine this with the growing number of local and state incentives available, and it makes sense why landfills have become part of the clean energy game plan. 

Potential Concerns 

Like any other prospective site, former landfills come with considerations affecting the project. 

Brownfields require special attention because of former pollution, hazardous waste, or other environmental concerns. Bulldozing everything in sight creates more problems than solutions, and developers must show restraint. 

Solar developers need to be careful around the cap.  

Grading the land is one of the first things developers do when they install a solar array. Unfortunately, grating and excavating to level land for the solar racking can damage the cap. If equipment damages the cap, contaminants and gas could escape into the air and water. 

To prevent unnecessary damage, stage heavy equipment away from the cap. If crews need to grade or excavate the area, do it carefully. And ALWAYS follow state and federal rules to avoid dangerous situations. 

Don’t penetrate the cap or damage the landfill’s mitigation system. 

The cap prevents methane and other gases from escaping outside specially controlled areas. Damage to the system could result in dangerous leaks that put the entire operation at risk. 

If an employee damages the mitigation, monitoring, piping, or other systems, it could result in dangerous gases escaping. The gas could then ignite if it encounters an accidental spark or arc. 

Dust poses a risk to workers and the community. 

Dust is simply part of the job during every solar installation but takes on a different tone at a landfill site. 

During grading and installation for a standard solar project, most crews use water trucks to moisten dirt and keep dust from flying around. The problem is that water trucks are heavy. 

Heavy water trucks and other equipment can damage underground gas and drainage systems. They should not drive on the cap if they don’t need to and be careful when required to be near fragile systems.  

Erosion and stormwater runoff are always a threat. 

Landfills have systems in place to remove water from a capped site. When rain or other liquid enters the landfill, these systems quickly flush it out to prevent damage. 

When crews grade and excavate sites, it opens the door for moisture to enter the system. Grading removes vegetation and dirt from the top of the cap, allowing water to penetrate. When that happens, it can flood landfill gas piping, preventing gas extraction. 

Hard rain can cause more cap erosion and slope instability, reducing the cap’s effectiveness. 

New Life for Old Sites 

Thanks to their location and design, landfills have become an attractive choice for solar companies. 

Beyond generating low-cost electricity on redeveloped land, landfill solar farms create a host of other benefits, including: 

  • High-paying jobs in a rapidly expanding solar industry 
  • Increase tax revenue for communities where solar farms live. Solar companies reintroduce vacant or abandoned properties to the tax roll. 
  • Fewer brownfields. When companies clean up and redevelop sites, they remove many (but not all) contaminants from the location. 

As solar energy expands across the U.S., more landfills will inevitably become solar sites. For solar EPCs, utilities, and innovative companies, there are plenty of opportunities to take advantage of ongoing development programs.  

These programs streamline the solar process, especially in states embracing renewable energy across the Northeast and mid-Atlantic. Other programs may be available on a state-by-state basis but could require more research. 

Are you interested in brownfield redevelopment? Programs like the RE-Powering America’s Land Initiative are changing the landscape, but it’s a long-term effort requiring time, money, and work. 

Talk with your state’s environmental representatives or contact your regional EPA office to learn more.

Making the Case for Prefabricated Solar PV Wire Solutions

Posted on by bop-admin

Driving past a solar installation sometimes feels daunting. Arrays can have dozens of rows of panels, stretching on for what feels like miles. 

Not only are some solar energy projects massive, but they’re also complex. Companies have hundreds of variables to consider, and the process takes years from initial planning to completion. They also cost millions of dollars between installing solar panels, securing permits, doing tests, and paying employees. 

Solar EPCs always try to manage costs, reduce installation times, and produce better results. While hard costs like solar panels and PV wire have fallen over the years, soft costs like permitting, taxes, and labor haven’t shown the same decline. 

How can companies save money on soft costs? The answer may be found in the wire holding everything together. 

Small Cost, Massive Impact 

When we look at the total cost of a utility-scale solar energy system, PV wire is low on the list. 

However, choosing the right solar wire can save time and money on your solar project installation. For example, prefabricated wires have a higher upfront cost but slash installation times. 

So, how do bundled, prefabricated solutions make the most of their engineering to save time and money? It all comes down to ease of use, consistency, and automation. 

When combined, teams can shave hours and dollars off their projects without additional effort. 

Why Do Installers Choose Pre-Fab Solutions? 

Despite all the planning and effort, sometimes you get what you pay for. 

Using single PV cables for a rooftop solar system is fine, but they can slow a utility-scale project to a crawl. Bundled pre-fab cables remove constant trips up and down each row, replacing them with one pass. 

For the average project, not making multiple trips shaves hours off each row and days off a project. But beyond faster installations, why are solar companies choosing pre-fab wire products? 

Wires are Pre-Cut and Factory Assembled 

What is the difference between a pair of jeans purchased off the rack and a custom-tailored pair? 

Jeans from the store come in many sizes, but they only offer a general fit. Meanwhile, custom-tailored jeans are specifically manufactured to fit you and only you. The same concept applies to buying single wire reels versus pre-fab bundled wire. 

Manufacturers cut pre-fab bundled cable to specific lengths matching the project’s layout, preventing wasted wire. The manufacturer also properly installs connectors, performs quality control testing, adds labels, and mounts the cable to reels. 

Not only are the manufactured cables ready to install as soon as they reach the job site, but workers don’t have to cut, crimp, or install connectors themselves. 

Less Room for Mistakes 

Employees on the job site often have varying skill levels and experience. 

Small mistakes, like a loose connection, can have dangerous implications. Fires, arcs, and shorts may cause severe damage and cost hundreds of thousands of dollars to repair or replace. 

Factory testing eliminates many issues before installation occurs. The manufacturer is also much more consistent than multiple workers on the job site. 

The other thing installers like about pre-fab wire solutions is the exact measurements used to cut each wire to length. Single wire reels often create waste during installation. Despite the higher cost, pre-fab solutions limit scrap and speed up installs because workers can immediately use them. 

Building on Labor Savings 

Pre-fab solar power cables help workers make fewer mistakes, but do they make installers faster?  
 
Instead of walking cables one at a time down the row to each solar panel, installers make one trip with all the cables. Once they reach the end of the row, they walk back down and connect each wire in the bundle to its corresponding panel. Customers can have cables marked as well, further reducing accidents and miscommunication. 

Pre-fab solutions, including bundled wire, limit opportunities for mistakes. The faster speeds also reduce labor costs dramatically, sometimes by as much as 80%.

Besides allowing works to move more swiftly on the worksite, pre-fab solutions also make solar installation teams more efficient. In many states, including those across the Northeast, solar projects ramp up in the spring and slow down toward the end of fall for the winter season. The ebb and flow of project seasonality, which is a challenge for many solar companies. 
 
When teams are using pre-fab bundled wire, projects are completed more quickly with fewer people. In turn, crews can work on more jobs during the busy season, and companies benefit from better labor allocation and shorter ramp-up and ramp-down times. 

Safer Installs 

Prefabricated PV wires are easier to work with, simplifying the job. 

Think about field-made connectors for a second. Depending on the workers’ experience, they could make mistakes as they strip, crimp, and attach connectors to the wires. While issues may not appear immediately, they could develop over the long term, limiting power generation. 

Bundled solutions remove the guesswork from the installation process. Workers only attach the connectors to the panels and the combiner box to power the system. 

Beyond being easy to use, prefabricated bundled wire is also cleaner, as there’s only one bundle of wires to worry about. The result is an organized installation with fewer mix-ups and nicer-looking outcomes free of tangled wire. 

Short- and Long-Term Savings 

Pre-fab wire solutions like bundled cable cost more than single cable options but save time and money on labor. 

Single wire reels work for small residential solar panel systems but bog down larger projects, like utility and community solar. Running single-wire reels is inefficient, more error-prone, and opens the door for waste. 

Combining the wires for a row together shortens installation times and gets workers on and off the site faster. Best yet, potential savings increase as the projects get bigger. 

Bundled Wire Leads to Better Installs 

The United States relies on clean energy more than ever, so investing in solar improvements is critical. 

Solar array technology has improved dramatically, from bifacial panels and tracking systems to more effective connectors and accessories. The same can be said for PV wire, too. 

Bundled PV wire solutions allow employees to do better work faster. Solar installations can then produce energy sooner, leading to lower electric bills for communities and businesses. 

That’s good news for everyone.