Category: Blog

Is the U.S. Ready for 100% Renewable Energy?

Posted on by Mike Zimm

Renewable energy has grown by leaps and bounds in recent years. But is the U.S. fully prepared to move forward with a 100% clean energy program? 

In 2021, renewable energy produced about 20% of all utility-scale electricity in the U.S., but only about 2.8% (115B kWh) was supplied by utility-scale solar energy operations, not including the additional 49B kWh generated by smaller-scale solar operations. The number may seem small, but it’s been growing annually and gives people hope that a fully green grid may be possible. 

Two things are clear if you’ve followed the news over the past several years. Fossil fuels won’t be the answer forever, and renewables still have a couple hurdles to jump to pick up the slack. 

The U.S. has some pretty ambitious energy goals, and the Biden administration has hinted that it would like to take steps to move away from traditional fossil fuels. This includes an ambitious proposed plan to reach 100% clean electricity by 2035. 

Though some experts believe it’s possible to hit the goal in short order, more than 60% of our energy is dependent on fossil fuels. It will take more effort, investment, and support to achieve. 

Is the U.S. Ready to Take the Next Step? 

At first glance, it might sound like a loaded question – but the answer may be yes. 

Several high-level studies, including one by Stanford in 2015, believe the United States can ultimately run on renewable energy… just not by 2035. They peg the year at a more realistic and gradual 2050. Though the study has been questioned, inspiration can be taken from it and its methodology. 

This isn’t to say progress isn’t being made in certain states and regions toward a fully renewable future. Rhode Island recently signed legislation into law committing to 100% renewable energy by 2033. The move puts the tiny state at the forefront of the renewable revolution, and it could be the first in the nation to go fully renewable. 

Earlier this year, California also made headlines when the state was powered only by renewable energy. The conditions were perfect, allowing California to produce more energy than it needed using only renewable power. 

The Golden State has proven that renewable, carbon-free, and sustainable energy sources can replace traditional power generation methods like coal and natural gas. In 2019, about two-thirds of the state’s power came from renewable energy systems like wind, solar, hydro, and nuclear. According to one energy manager with the Union of Concerned Scientists (UCS), investing heavily in solar and wind technologies will get us the bulk of the way, up to 90 percent, toward our clean energy goals. 

Why It’s So Hard to Quit Fossil Fuels 

If renewables are the future and everyone is scrambling to become the first to be rid of fossil fuels, how come we can’t seem to make it happen more quickly? 

The problem is that despite all of the pollution and the trouble we go through to use fossil fuels, they’re energy-dense and efficient forms of energy production. This means they produce energy at a higher rate than other forms of energy, including wood and biomass. 

Although oil isn’t typically used for electricity production, natural gas and coal are high-energy generators. They can pick up the slack on days the wind doesn’t blow and clouds block the sun’s rays from hitting solar panels. 

Even on that record-breaking day when California produced all of its electrical needs using renewable energy, fossil fuels were working behind the scenes. Fossil fuel power plants take hours to come online, so it’s easier to keep them running than risk not having enough power during peak use hours. 

How Do We Make the Move to 100% Renewable Energy? 

The easiest way to increase the adoption of renewable energy is to continue investing in it. 

This means investing in more green technology, including increasingly efficient solar panels, better wind turbines, and innovative batteries that can store generated electricity for longer. Part of the equation to reach a fully renewable future involves “overbuilding” the electrical grid, meaning we build enough infrastructure to supply more energy than we need. 

Some projections spot the number at about 2.5 times the total energy demand to ensure we cover all the bases. That growth means utilities and companies must invest in solar and wind energy, requiring more workers, materials, and space to build. 

Another issue we’ll have to tackle soon is energy storage. Wind and solar are variable energy producers, meaning the amount of electricity they produce relies on several factors. On perfect days, harnessing all the excess energy produced and effectively storing it can go a long way toward a clean energy grid. 

Recently, researchers in Finland have created a device that allows low-grade sand to store heat energy for months. The heat energy is used to warm homes and even a local swimming pool. The storage system isn’t as efficient when turning heat into electricity, but could potentially be improved to meet rising energy demand with low-cost solutions. 

Ensuring Workforce is Ready 

Amid a labor shortage, companies across many industries find it tough to attract enough workers to keep operations running smoothly. Electricians, in particular, are in high demand, making it even tougher to attract and retain talent. 

Sun-Pull Wire is one of many companies on the edge of innovation, developing products like bundled wire systems that can be installed quickly and save up to 80% of the installation time of string PV, helping with labor shortages and enabling DC installers to take on more projects. 

The Government Needs to Step Up 

If the U.S. wants to rely on renewable energy sources to power the country, support has to come from the top. 

The Biden administration took a big step forward by suspending solar tariffs for two years against four Asian countries, including Cambodia, Thailand, Vietnam, and Malaysia. In another encouraging step, the government recently lifted solar tariffs on goods coming in from Canada, a move made in 2018. 

Without the tariffs, utilities can import solar panels and other components at a lower price and reduce the number of delays and cancellations. Fewer tariffs also allow the installed solar capacity to continue growing at a healthier rate. 

Unfortunately, tariff concerns did have an impact on the market. The Solar Energy Industries Association (SEIA) reported in its Q2 2022 insights that about 18 GWdc worth of projects were put on hold for at least a year. Another 450 MW was outright canceled. 

Reduced tariffs aren’t all rainbows and butterflies, though. U.S. solar manufacturers may find it harder to compete against low-cost imports, claiming it as a disadvantage. On the other hand, utilities and other companies gain access to affordable panels, spurring the country toward its renewable energy goals. 

Ready to Learn More About Solar?  

Sun-Pull is ready to support a cleaner, renewable future with simple-to-use PV wire solutions. 

Our knowledgeable team of solar experts is ready to answer your questions and get the right products into your hand as fast as possible with the shortest lead times in the industry. The Sun-Pull team is ready to support you from start to finish, including blueprint analysis, product help, and decades of solar experience. 

Contact us today to see how we can get your utility-scale solar project off the ground quickly and cost-effectively.

Rhode Island Sets Stage for 100% Renewable Energy

Posted on by Mike Zimm

Rhode Island may be the smallest state in the nation, but it is making a big splash regarding the future of green energy in the United States. 

On June 29, 2022, Governor Dan McKee signed legislation that puts the Ocean State on pace to be the first in the U.S. to reach 100% renewable energy. The law requires that by 2033, 100% of the state’s electricity be offset by renewable energy. Although the law doesn’t prevent using fossil fuels for energy production or use, they will be offset by clean energy sources like wind, solar, and geothermal. 

According to Gov. McKee’s office, the new law is expected to create thousands of new jobs while cutting the cost of renewable energy across the state. 

“We’ve seen a 74% increase in green jobs since 2014, and that trend is going to continue as we deepen our commitment to renewables,” State Rep. Deborah Ruggiero said in a statement. Ruggiero anticipates thousands of new jobs to come online to support renewable energy sources that will come online over the next several years. 

Blueprint for Success: Incremental Increases to Reach Renewable Goals  

If Rhode Island wants to be the first to reach 100% renewable energy, it needs to invest in emerging forms of electricity production. This will likely mean leaning more into geothermal energy, wind energy, and developing solar energy systems that take efficiency to another level. 

One way to encourage more renewable energy is by turbocharging green initiatives. Under previous state laws on the books, the state was annually increasing the percentage of renewable energy generated by 1.5 percentage points. Under the newly signed law, the number picks up speed each year until reaching a 100% Renewable Energy Standard in 2033. 

 According to the law, the Renewable Energy Standard percentage will increase by 4% in 2023, jumping by one percent annually through 2026. The increases then become smaller, staying flat in 2027 and then rising by a half percent each year through 2032. 

So, how does the new law work? Each year, utilities must buy renewable energy certificates for a certain percentage of power sold annually. These certificates help offset the amount of energy produced and sold by traditional fossil fuels in the state. Besides the certificates, the law also leans on renewable energy producers to up their production using everything from solar energy technologies and offshore wind to hydroelectric facilities and other sources. 

What Does Energy Look Like in Rhode Island Today?  

It might seem like a lofty goal for any state, but Rhode Island has an opportunity to make some waves. 

U.S. Energy Information Administration (EIA) data suggests Rhode Island uses the least energy per capita in the U.S. The state also produces about 90% of its current electric supply using natural gas, the highest percentage in the nation. Only about 12% of the state’s energy came from renewables, with half coming from solar panels. 

While it’s encouraging to see such an aggressive clean energy law on the books, there is certainly work to be done. In March 2022, for example, Rhode Island’s renewable energy production reached about 79k MWh, a far cry from the 478k MWh produced by its natural gas-fired plants. 

The data paints a picture of a state in transition. Renewables aren’t a major energy producer in the state yet, but current production is still four times more than it was in 2018. Rhode Island is also an environmentally conscious state, pumping out the second-lowest CO2 emissions in the nation, only behind Vermont.  

Solar Goals in the U.S.  

Rhode Island is not the first state to push for a 100% renewable future. California was among the first to lean into clean energy, but states on both coasts are now getting involved using the blueprints laid out by early adopters. 

It will take years to wean ourselves from fossil fuels – it also won’t be likely to turn our backs on such efficient forms of energy. Thankfully, renewables are rising in popularity, and their efficiency is expected to increase as innovations are achieved. 

The improvement isn’t hard to see, either. In 2021, renewable energy sources totaled about 20% of U.S. electricity; it could increase due to recent tariff exemptions enacted by the Biden administration. The two-year exemption is expected to keep several upcoming solar projects on track while reducing the number of delays and cancelations over the next 18-24 months. 

Companies like Sun-Pull Wire are also ready to do their part to ensure the solar industry grows as quickly as possible. This means producing solar photovoltaic (PV) bundled wire systems that are easy to install, simple to use, and can be done using fewer workers to address labor shortages or take on even more projects. 

Ultimately, the goal is to make widespread utility-scale solar arrays a possible and affordable option throughout the United States.  

Rhode Island’s Investment in Renewables is Important  

Yes, Rhode Island is a small state, but being successful could prove that fully renewable energy is no longer a pipedream. It’s a tangible goal that can be reached with radical transformation and aggressive building toward the finish line. 

The law is aggressive but also puts Rhode Island on the cutting edge of the renewables curve. Their commitment to green energy is launching it ahead of other states like California, New York, and North Carolina. 

It should come without saying that the solar industry is excited to see what a renewable future looks like. We’re ready for whatever might come next and excited to help serve everyone’s solar needs today, tomorrow, and for years to come!

What Do Tariff Suspensions Mean for U.S. Solar Energy?

Posted on by Mike Zimm

Business is looking a little sunnier for U.S. companies, thanks to several encouraging announcements from the White House. 

In June, President Joe Biden announced a 2-year exemption for solar imports, lifting restrictions on solar products coming in from four Asian countries; Cambodia, Malaysia, Thailand, and Vietnam. The announcement follows in the footsteps of an investigation launched in March regarding anti-dumping regulations imposed by the U.S. on China several years ago. Although the tariff exemption is big news, it does not apply to China or Taiwan, which both still have their tariffs in place. 

Asia is a massive player in the solar panel industry. In fact, upward of 80% of the solar panel imports come from Asia, meaning that America’s solar goals are somewhat contingent on having a relationship with our overseas trading partners. Pausing tariffs on incoming solar panels helps utilities and other companies that had paused their plans to restart the process. 

Besides the exemptions, the Biden administration also invoked the Defense Production Act (DPA). This opens the door for additional government investment in clean energy projects, including solar. According to the Department of Energy (DoE), this money is for companies to expand clean energy manufacturing, build new facilities, and help consumers access greener products. 

The hope is that with more investments, U.S.-based companies can boost domestic solar panel production so the country can rely less on imports. As the DPA effort ramps up, the 2-year tariff will serve as a temporary solution to give domestic manufacturers a chance to make enough supplies to catch up to what is imported. 

Who Stands to Win with Tariff Exemptions?  

As with any governmental announcement, there will be winners and losers. In this case, several clear winners emerge in the near- and long-term.  

Domestic Companies with Solar Projects  

Tariffs have a contentious and complicated history in the United States, often acting as a defensive mechanism used by countries to protect domestic manufacturing. Unfortunately, what typically happens is that consumers get saddled with higher prices associated with the tariffs, and production doesn’t always keep up. 

With solar tariffs in place, products like solar panels become more expensive, making it harder for companies to fund previously planned projects. As a result, some planned projects were either delayed or outright canceled.  

According to the Solar Energy Industries Association (SEIA), the organization cut its solar installation forecast by half in 2022, mainly due to supply chain issues and uncertainty related to the government’s investigation into possible Chinese anti-dumping tactics.  

By cutting at least a little of the bureaucratic red tape, the U.S. is giving domestic companies a chance to complete their solar projects with fewer costs and more certainty. Although the eased restrictions aren’t going to bring back previously canceled projects, there is a chance that delayed projects could get back on track.  

The move can’t come soon enough, either. SEIA recently reported about half of all energy added to the grid in the first quarter of 2022 was solar, so there is an appetite for renewable technology. 

Domestic Solar Manufacturers  

Although the tariff exemptions are meant to ease import costs for solar panels, the activation of the DPA is designed to spur solar manufacturing stateside. 

The White House announced in June with additional government support, domestic solar manufacturing was on pace to triple in 2024, going from a current manufacturing capacity of 7.5 gigawatts to 22.5 gigawatts by the end of 2024. This would be enough production capacity to help more than 3 million homes convert to solar energy production annually. 

June’s DPA announcement bolsters the production of several solar components, including photovoltaic (PV) modules. The resulting products will give companies domestic options that don’t need to be imported or subject to tariffs. The announcement and expected production increase is also fantastic news for companies that produce other solar components used in solar arrays, including Sun-Pull. Our wire is used to string solar panels together, letting generated electricity flow back to the combiner box. 

Perhaps the best part of the tariff exemptions and DPA announcement is that thousands of jobs associated with the solar industry won’t be eliminated. There’s even optimism that solar jobs will increase due to more projects. 

Although this is fantastic news for stateside manufacturers, there’s some reason for concern. It’s worth knowing that earlier tariffs imposed to bolster domestic manufacturing have not always resulted in increased production. 

The Environment  

It’s no secret the United States has climate goals it wants to reach in the coming years, including a series of renewable energy benchmarks in 2035. 

The first quarter of 2022 was not particularly great for utility solar energy as only 2.2 GWdc was installed. According to SEIA, it was the weakest quarter of growth in two years and was a far cry from what was considered a strong finish during the final quarter of 2021. 

Adding to the problem is the March investigation into China possibly skirting anti-dumping regulations by sending materials to other Asian countries. A month before, Auxin Solar, a small manufacturer, asked the government to investigate the situation, leading to even more uncertainty. The political climate made moving forward with some projects risky, leading to 17.6 GWdc worth of solar projects becoming delayed by a year and another 450MW canceled. 

Fewer tariffs, on the other hand, mean domestic companies can once again import low-cost solar panels to complete their projects. It also means current projects can proceed as scheduled with fewer delays, and new projects can get off the ground to bring more solar energy online. 

More solar energy is great news for the environment because it lessens our dependency on fossil fuels and other carbon dioxide-emitting power sources. Of course, ramping up the solar industry isn’t like turning on a faucet. It will take months, if not years, to get back up to speed. However, the tariff exemption may go a long way toward getting us started until domestic manufacturers can catch up and bring their own products to market. 

What Do We Expect?  

It’s tough to look at the tea leaves and find a definitive answer to what we think might happen. Still, the tariff exemptions are a good sign for Sun-Pull and the entire solar industry. 

Removing tariffs for a few countries doesn’t fix all the issues we’re currently facing. It won’t be easy for domestic manufacturers to compete with low-cost imported options overseas, but it can be done. The announcements do give manufacturers a much-needed fighting chance, allowing them to meet increased solar needs from a growing number of Americans. 

Companies like Sun-Pull Wire are poised to make the most of solar’s growth, with bundled wire systems that will carry the future of energy to millions of Americans across the country. We’re looking forward to seeing brighter, cleaner, and more sustainable energy take the next step.

How Solar BOS Costs Impact Utility-Scale Solar Construction Projects

Posted on by Mike Zimm

Renewal energy production is booming. The International Energy Agency (IEA) reports that annual renewable capacity additions increased 45 percent in 2020 to almost 280 GW – the highest year-on-year growth since 1999.

For solar producers, however, there may be a few bumps in the road ahead. According to Reuters, global supply chain issues and a surge in costs for components, labor, and freight threaten to slow the solar energy boom.

In this environment, cost containment is critical for solar producers and EPCs building out utility solar construction projects (defined as 5 megawatts or higher by the National Renewable Energy Laboratory). While photovoltaic (PV) panels are the single largest budget line item for most solar projects, real (and often overlooked) savings can be achieved by optimizing solar Balance of System (BOS) costs.

Are Cable Installation Labor Costs Sabotaging Your Solar BOS Budget?

Solar balance of systems includes all photovoltaic system components except for PV panels — solar inverters, battery banks, chargers, mountings, switching, and wiring. As well as hardware, BOS also includes labor, permitting, and inspection fees.

Of all BOS elements, the labor cost of installing PV wire can create the most significant financial exposure for project owners and EPCs. There are several contributing factors:

  • Installing PV cable is time-consuming and labor-intensive, and traditional installation methods make it difficult to forecast labor costs and completion times accurately. Delays and labor-cost overruns are common.
  • Project developers face supply chain challenges and inconsistent wire quality. Product quality issues can create the need for ‘rework,’ impacting labor costs, deadlines, and margins.
  • EPCs are under significant pressure to complete solar projects on time and budget. Delays due to completing cable work are a major cause of liquid damages for EPCs.

While PV wire installation has traditionally created headaches for solar developers, recent innovations in bundled cable design and installation best practices can help slash labor costs, reduce rollout times, and improve project and financial forecasting.

Custom Bundled Cables — A New Approach to Installing PV Wire

Sun-Pull Wire and Cable takes a three-phased approach to optimize cable installation across the solar project lifecycle. The results are compelling — using Sun-Pull’s solar PV bundled wire system, a four-person crew can pull one megawatt of PV string wire per day and reduce installation time by up to 80%.

The three components of Sun-Pull’s solar bundled cable solution are:

Planning. Pre-construction planning and design can minimize product order discrepancies, improve project forecasting, and help reduce labor costs. Planning components are:

  • Construction blueprint analysis
  • Pre-construction reviews and site surveys
  • Project planning
  • String wiring analysis and layout

Product. Sun-Pull’s custom cut and printed bundle cables can help slash installation times and eliminate project rework. Sun-Pull’s bundled PV solutions include:

  • Pre-cut, pre-printed wire bundles, ‘Made in America’ with strict quality control
  • Up to 30,000 feet of bundled wire on a single reel
  • Every Sun-Pull solar PV wire bundle is configured to customer-required lengths and specific breakouts
  • Each PV wire bundle also includes custom printing every 6″ for string number, combiner box, or inverter identification
  • Pull-heads are located on the inside or outside of each bundle according to installation requirements

Installation Support Sun-Pull takes a hands-on approach throughout project implementation and offers several services to help optimize each rollout. These include:

  • Phased product deliveries
  • Spool and pallet removal to save disposal costs
  • Installation training and ‘boots on the ground’ troubleshooting

The Benefits of Lower BOS Costs

Lower cable labor costs and shorter project timelines are positive outcomes for solar providers facing thin margins and aggressive construction schedules. For EPCs, faster project turnaround times can minimize liquid damages due to project delays.

While most people think of PV panels when they see large commercial solar farms, it’s often the ‘hidden’ BOS costs that determine the profitability of these projects. Deploying bundled PV cable solutions can help many solar producers and EPCs meet their project schedules and financial targets.

Contact us today to learn more about Sun-Pull’s solar bundled wire system.

Projected Renewable Energy Growth by 2030

Posted on by Mike Zimm

Is It Possible For New York and Other U.S. States to Reach 70% Renewable Energy By 2030? Yes! But only if they use the One-Pull bundled wire system!

The solar industry has experienced major growth in the last decade at around an average growth rate of 42% per year. However, is it growing fast enough to support the renewable energy goals of the next decade? The United States hopes to have at least 70% of energy consumption coming from renewable energy by 2030. To achieve a grid powered mostly by renewable energy, it will require the U.S to increase its carbon-free capacity by at least 150%. These goals are possible, however, to be able to reach the intended capacity by 2030, the U.S. will need to save time and money.

To examine what it will take to achieve a 70% renewable energy grid, we will examine statistics from the state of New York. New York is one of the top 10 states whose homes are powered by photovoltaic (PV) solar energy with an average of 170 homes powered per Megawatt(MW) of PV. New York is also one of the leading states in adopting the “70 by 30” goal.

New York’s Renewable Energy Plan

The Governor of New York, Cuomo, released a Green New Deal goal to obtain 70% of New York’s electricity from renewable sources by 2030; in addition to a state mandate for a 100% emissions-free electricity grid by 2040. Several new wind and solar projects are already underway, which are expected to generate over 2.5 million megawatt-hours of renewable energy annually. Additionally, the Green New Deal set specific Megawatt goals such as adding 3,000 MW of storage and adding 6,000 MW of distributed solar all by 2030.  

The Department of Public Service along with the New York Energy Research and Development Authority (NYSERDA), issued a whitepaper dictating a plan for New York to follow to help achieve the full 70%. The whitepaper sets out a schedule with a target of 4,500-gigawatt-hours annually, around a 33% increase in where the target is now. Staying within the time constraints on this plan is crucial. As New York is one of the first states to adopt the goal of a majority renewable energy grid, it is setting an example for other U.S. states who are striving toward an emission-free energy sector.

How Can One-Pull Help Reduce Time?

With only 10 years to meet its goals, and with lag times between completion and operation of installations, time is important. One-pull products, specifically the pre-bundled solar wire harness, are designed to cut project time. Traditional setup for PV wire installations involves a great amount of labor, setup, and labeling. Installing solar PV wire to power a 1-megawatt (MW) solar project typically takes a team of 3-5 electrical professionals one to two weeks to pull wire the traditional way. In comparison, it only takes one day when installing a pre-cut, pre-labeled, and pre-bundled wire system.

One-Pull’s pre-planned, pre-cut, pre-labeled bundled cable solutions can save electrical contractors up to 80% of the time it takes to pull PV wire.

The images below show a before and after image of the usage of regular pulled wire compared to the one-pull bundle wire.

i) Traditional Wire Pull

non-bundled-wire

ii) Bundled Wire Pull

Reducing time on one project can also free up labor to work on other projects, thereby speeding up the installation process for many projects.

Despite the growth in the renewable energy sector, to reach their 70% target growth in the next 10 years, hundreds of gigawatts of solar energy need to be installed as much as five times faster than it is currently. Projects would require extreme measures to stay on the required time schedule, unless they utilized products like one-pull’s pre-cut and pre-labeled bundles, which would cut their project time by up to 80%.

Learn more about how bundled cable helps electrical contractors boost margins

4 Benefits of Utility-Scale Solar

Posted on by Mike Zimm

Utility-scale solar has experienced immense growth over the past decade, hitting 50 gigawatts today, up from 1 gigawatt in 2011. It is predicted to be on track to continue driving the growth of the solar industry. While there are several challenges that come with the installation of utility-scale projects as detailed in this article, there are a slew of benefits.

The following are the benefits of utility-scale solar projects:

 

1. Cost Effective

The cost of solar energy has decreased consistently over the past decade. Utility-scale solar helps to save money over time by stabilizing electric prices. Solar power is more predictable than other energy sources like fossil fuels, where prices are constantly inflating. Predictability allows for the industry to be more reliable over time.

Utility-scale solar projects produce energy on-site. Due to their low environmental impact, they can be built closer to communities. Both factors eliminate the costs for transmission equipment. Additionally, utility-scale photovoltaic (PV) systems provide a great amount of output, while being less expensive than other solar installations. Utility scale PV solar installations are half the cost per Megawatt (million watts) generated compared to rooftop solar installations. Since utility scale solar has optimal output, there is more energy generated for a lower price.

 

2. Storage for Later Use

Utility-scale solar systems require a balance of system (BOS) which is the equipment and services beyond the PV modules that are needed to ensure the safety and functionality of a project. One of the components of a balance of system is battery storage that optimizes solar energy output.  An energy source that can provide power at times of great demand is known as “dispatchable generation,”. This includes traditional power sources such as coal or natural gas. Solar power is not dispatchable because it is only available during hours of sunlight. Therefore, batteries are used to store energy and distribute it at times of need, like at night. Battery storage increases the flexibility of the grid and allows for the energy to be distributed to the grid at times when demand is high. This increases the reliability of utility-scale systems.

 

3. Environmental Impact

Utility-scale solar systems are better for the environment than traditional energy sources, like fossil fuels. The burning of fossil fuels emanates harmful carbon emissions into the atmosphere contributing to climate change. Nitrogen emissions from such fuels could also cause health problems. Communities with a limited access to power sources could harness solar energy, keeping the grid clean and producing zero carbon emissions.

 

4. Community

Solar installations can improve the economic activity of a local community. Because the size of the project mandates a variety of service providers, utility-scale solar projects can create local construction jobs, and send business toward providers in operations and maintenance. Solar projects also provide communities with higher tax revenue. Because of the longevity of utility-scale solar this could result in substantial additional tax revenue.

Solar projects could also be beneficial to the overall quality of life of the community. In the case of farmland, replacing land with these solar projects eliminates the use of fertilizers and chemicals improving the water supply and decreasing soil runoff. Projects are also required to implement storm management plans, to ensure that projects do not contribute to flooding or erosion. When a utility-scale solar project is no longer efficient and the equipment is removed, the land returns to its original condition prior to the installation, and there is no lasting negative effect of the project.

Utility-scale solar installations, compared to residential and commercial solar projects, continue to take up a larger share of solar installations in the U.S. This, coupled with the projected growth of the solar energy market, only gives more reasons to invest in utility-scale solar.

 

Learn more about what a utility-scale solar installation is and its distinguishing features from other solar projects.

 

 

Challenges of Utility-Scale Solar Projects

Posted on by Mike Zimm

Utility-scale solar installations are never easy to manage. They have numerous phases from financing to the ongoing operation and maintenance of the system, which are complex and intricate. Knowing the right steps to take to deal with the challenges in every step of the process and manage the risks associated with the installation, could be the differentiating factor to ensure a profitable project.  

The following are challenges associated with utility-scale solar projects: 

 

1. Varying site requirements. 

All utility-scale projects differ. This is because requirements vary from project to project. Requirements vary by transmission region, state, and utility. Therefore, it is important to plan effectively and understand all the requirements of the installation site. Some states like Texas require frequency and voltage droop, voltage control, and active power curtailment.  For utilities, some have requirements such as field witness test while others do not. Being aware of these requirements and having a good understanding of them will reduce the potential consequences resulting from a compliance failure. 

 

2. Insufficient risk management.

This results from poor planning at the beginning of the project. Upfront planning helps in the identification of potential risks associated with the installation. Some of the risks include accessibility of the site, material supply, vegetation control, and design of the installation. Failure to identify some of these risks could not only delay the project but also result in losses affecting the overall profit margin.  

 

3. Too many equipment vendors.

Utility-scale solar projects require several components commonly known as balance of system. These are often purchased from  multiple vendors. Many purchasing decisions are based on pricing with little regard to interoperability of the components. While purchasing from one vendor ensures an integration between the components, purchasing from different vendors could cause interoperability issues with the balance of system. Other issues such as supporting contracts, training, and replacing parts could also come up down the line, potentially driving up the overall expenses of the project. Consequently, seemingly saving on pricing at the beginning of the project by utilizing multiple vendors could potentially entail increased costs in maintenance and part replacements later on. 

 

4. Reluctance to change.

Beside BOS improvements, there have been other solar power technology advancements in recent years. Through research and development, there have emerged tracking technologies, more efficient solar panels, and technologies that optimize solar and energy storage. Reluctance to switch to modern technologies could mean inefficiencies that result in loss of productivity.  

 

5. Lack of labor and expertise.

Finding experienced personnel for utility-scale solar installations can be quite challenging. Labor varies in different regions since different solar projects have different requirements in different regions. In a mature solar market for example, utility-scale installation expertise is easily accessible. This is not the case in regions that do not invest in the solar market. For such regions, projects could be costly because of the high labor costs resulting from training. These are not one-time costs either since constant training is required to bring the labor up to speed with more efficient processes.  

 

While this article highlights some of the challenges with utility-scale solar installations, there are many other challenges that arise with the growth of the solar industry. What’s certain though is that careful planning and coordination between the various vendors, the EPC, electrical contractors, and subcontractors are critical.  

 

Learn more about how ECs are winning more solar projects with bundled cable. 

 

What Is a Utility Scale Solar Installation?

Posted on by Mike Zimm

When talking about solar projects, “residential” and “commercial” are typically the ones heard of. However, these are not the only types of PV installations. Utility-scale solar is another type of solar project that is a major source of solar energy.
Utility-scale installations keep taking up the larger share of installations- accounting for 57% of installed capacity in Q1 2018. With this tremendous growth of utility PV installations and growth in the industry driven by utility-scale projects, it’s surprising that there is no commonly accepted definition as to what project size constitutes utility-scale.

What then is a utility-scale solar installation?

A utility-scale solar facility is one which generates solar power and feeds it into the grid, supplying a utility with energy.
Utility-scale solar projects can be massive spanning multiple acres of land. Different entities claim different minimum size thresholds for these projects. They can range anywhere from 25 kilowatts to 50 megawatts. Size, however, is a major distinguishing factor of utility-scale solar installations from other solar projects.

The other distinguishing features of utility-scale solar projects include:

 

1. They are sold to wholesale utility buyers

This is the primary differentiating factor of utility-scale solar from other solar projects. The electricity produced is not directly used at the host site. It is sold to wholesale utility buyers and not end-use consumers. Every utility-scale solar facility has a Power Purchase Agreement (PPA) with a utility, guaranteeing a market for its energy for a fixed term of time (usually 10 to 25 years).

Some of the utility-scale solar project participants include:

  • Wholesale utility companies that purchase the generated power
  • Project developers and EPCs (engineering, procurement, construction)
  • Project financiers
  • Contractors and installers
  • Local government agencies
  • Solar and energy storage equipment manufacturers
  • Solar project owners

 

2. They are usually ground-mounted arrays

Because of the massive size of utility-scale solar plants, the installations are usually ground-mounted arrays. These arrays can be set at the perfect angle on the power plant to maximize sun exposure hence optimizing energy production.

Sometimes the ground-mounted arrays include the use of solar trackers to maximize energy production.

 

3. They utilize several solar technologies

A utility-scale solar power plant can utilize several solar technologies – primary photovoltaics (PV), concentrating photovoltaics (CPV), or concentrated solar power (CSP).

While often confused, CPV and CSP technologies are intrinsically different. CPV technologies use the photovoltaic effect to directly generate electricity from sunlight while CSP uses heat from the sun’s radiation to make steam to drive a turbine which produces electricity using a generator. The concentrated thermal energy from CSP can be stored and used to produced electricity as needed regardless of the time of day.

 

4. They are highly reliable as a source of energy

Utility-scale solar projects can guarantee energy production since most of the installation designs can include energy storage capacity that provides power when the sun is not shining and increases grid reliability and resiliency.
In addition to this, utility solar plants are popular with utility companies since they provide the benefit of fixed-price electricity during peak demand periods when electricity from fossil fuels is expensive.

The solar market is growing rapidly in the US with utility-scale solar driving most of that growth. It’s therefore essential to understand what exactly these installations entail including the components necessary to create an operational utility-scale solar project.

 

To learn more about utility-scale solar and its components, check out our recent article on balance of system for utility-scale solar.

 

 

How ECs Are Winning More Solar Projects With Bundled Cable

Posted on by Mike Zimm

For electrical contractors (ECs), bidding and delivering the wiring component of a commercial solar farm project can be a complex, high-risk undertaking. Variables like material requirements, labor costs, and completion times can negatively impact an EC’s profitability and create unwanted financial exposure.

A common challenge for contractors is not having a detailed project plan or complete information in hand during the bidding process. This ‘partial picture’ can result in inaccurate assumptions in the planning phase, leading to unexpected costs and delays as the project unfolds.

At Sun-Pull, we take a unique approach to bundled cable quoting and project delivery that helps eliminate those uncertainties. By partnering with ECs to develop, validate, and execute a detailed wiring plan, Sun-Pull helps fine-tune and optimize material and labor requirements. Together with our printed, customized PV cable bundles, this approach enables ECs to win more solar farm business and deliver projects faster with greater profitability.

The Devil (and the Margin) Is in the Details

Even modest solar farm projects can range from 5-25 megawatts and require 50-500 solar PV cable bundles. Often ECs receive only partial blueprints in the bidding process, and many don’t have the time or the in-house expertise to build out detailed wiring plans with the limited information available. As a result, ECs may order more PV wire than they need or end up taking a ‘brute force’ approach by pulling individual wires in the field as the job progresses. These scenarios can inflate material and labor costs while taking a big bite out of margins.

Completing The Picture — A Detailed Plan

For the Sun-Pull team, blueprints are just the starting point. We use a comprehensive pre-construction checklist to help ECs capture key project details, resolve any outstanding questions, and confirm a range of project parameters. This data allows the Sun-Pull team to create a high-level wiring plan that provides ECs with a more accurate projection of the material and labor needed to execute the project.

‘Measure Twice, Cut Once’ — The Site Inspection

No two solar farm projects are the same, and even the most detailed project layouts often change during implementation. For example, rocks or other obstacles on the job site may require crews to relocate trench locations, significantly altering PV cabling requirements.

That’s why Sun-Pull conducts a site survey after construction begins to confirm that the wiring plan aligns with the actual job site. It’s an important step that must take place before starting the production of the cable bundles. Once wire cutting and printing begins, those ‘sunk costs’ can’t be reclaimed.

We also visit the site during the pilot installation of the first row to ensure everything goes smoothly. If there is an issue, our team can see it first-hand and work with the EC to resolve it quickly.

Reducing Labor Costs: Printing Versus Labeling

Many ECs install solar cable the traditional way, which involves labeling the ends of every PV wire before pulling it. The wire is then ‘roughed in’ by estimating the pulls over acres and acres of the job site. These estimates are rarely precise to the foot, so many wires have to be cut and re-labeled before they’re terminated to the solar module at one end and the inverter at the other. This re-labeling process is time-consuming and labor-intensive.

Instead of labeling, Sun-Pull custom prints inverter and string numbers every 12 inches along the entire length of the conductor. That way, there’s no need to re-label the wire if it needs to be cut or re-terminated. Our PV wire printing can save ECs substantial labor costs and countless hours that otherwise might be lost to re-labeling.

It Takes a Team

Sun-Pull takes a team approach to quoting and delivering wire solutions for solar farm projects. Our designers, engineers, and project managers all play a part in providing the most competitive and cost-effective solutions to our EC customers.

This approach extends to our back-office and production teams as well. Our supply chain is among the best in the industry. We create our printed, custom PV wire bundles in a dedicated facility using the most efficient, high-quality manufacturing processes. Post-delivery, Sun-Pull provides end-to-end support to our EC customers through the successful completion of every solar farm project.

Cutting Project Times Boosts Revenue

For ECs, speed is key to increasing revenue. Reducing the time it takes to complete a solar farm project frees up resources to take on other jobs.

Sun-Pull’s pre-planned, pre-cut, pre-labeled bundled cable solutions can save ECs up to 80% of the time it takes to pull PV wire. With Sun Pull’s bundled wire system, your 3-4 person team can pull 1 MW of PV string wire per day and reduce your installation time by up to 80%.

A Competitive Edge For Electrical Contractors

Sun-Pull’s comprehensive approach to quoting and delivering bundled cable solar farm solutions helps ECs reduce their risk by optimizing material and labor costs throughout each project. By partnering with Sun-Pull, ECs can compete more effectively, improve margins, and increase revenue by completing projects faster.