Tag: utility-scale solar

How Does Humidity Impact Solar Projects?

Posted on by Gino Geruntino

Summer is here, and that means three things: barbeques, beach vacations, and seemingly constant humidity. 

Humidity is everywhere, but location and environment play a role. For example, relative humidity in Florida, Texas, and Mississippi is higher than in Arizona, New Mexico, and Nevada. This is because the former states are located near large bodies of water, as opposed to arid deserts. 

Unfortunately, humidity is becoming a problem in the United States. According to a 2025 scientific study, humid heat waves have become stronger. As temperatures rise across the board, they lead to more water evaporation. As water evaporates, it increases humidity, which is bad for people, animals, and solar panels alike. 

Luckily, solar developers have several tools to prevent humidity and moisture from damaging their installations. Knowing how humidity works is the first step toward protecting sites from damage and lost output. 

What is Humidity? 

Humidity is an environmental condition measured by the amount of water vapor in the air at any given time. This moisture typically comes from water evaporating from bodies of water, but can also come from plants, soil, and rain. 

There are two types of humidity (absolute and relative), but relative is the one most people are familiar with. Relative humidity determines the percentage of water vapor in the air compared to its potential maximum. As temperatures rise, relative humidity decreases. As temperatures fall, the air holds less water vapor, creating dew and fog. 

Easy access to water sources results in higher humidity levels for those living in those regions. This is why Florida and Louisiana have higher levels than drier states like Arizona and New Mexico. High heat keeps relative humidity low since the air can hold more water vapor. 

Though humidity is a constant presence, it becomes more of a threat during the summer when temperatures rise. Hot air holds more moisture than cold air, which is why you don’t hear about humidity during the winter – the air is drier. 

How Does Humidity Impact Solar Sites? 

It might not sound like it, but as the air outside gets moister, the resulting humidity can slowly cripple a solar farm. 

And like many weather-based issues, it impacts every component from the ground up. 

Solar Panels 

When humidity is a concern, so is condensation. As temperatures retreat from their daytime highs, water vapor in the air forms droplets. Those droplets fall onto solar panels, mixing with dust and other gunk already there. 

As the water evaporates again, the dust left behind sticks to the panels and becomes hard to remove. If enough dust becomes stuck, panels may struggle to collect sunlight, reducing performance. The attached dust is also dried on, meaning crews must do more intense cleaning. 

Beyond simply making panels dirty, moisture can also become trapped inside panels. If that happens, water can create a film that could increase panel operating temperatures and hurt power generation. 

Reduced Performance 

Reduced performance comes in many forms, including Potential-Induced Degradation (PID). 

PID occurs when there’s a combination of hot temperatures and high humidity. When long strings of panels are tied together, those on the ends of the row carry the largest electrical pressure difference. These voltage differences between the solar cells and their frames may create small leakage currents. 

So, how exactly does humidity impact performance? When small leaks occur, rain and humidity increase system conductivity, leading to greater losses. It can also add stress to panels, as humidity fluctuations can leave water droplets on the panels’ faces. 

But sometimes performance issues stem from something simpler. Excess moisture can cause a wide range of problems when it gets inside a panel. For example, errant water can cause delamination inside the panel, along with mold growth in or on its face. In both cases, the panel can’t efficiently collect sunlight, limiting output. 

Wire and Connectors 

If moisture gets into a faulty, damaged, or improperly installed connector, it can immediately affect the system. 

Wet connectors are a breeding ground for short circuits and faults, which can drastically reduce output. However, water can also enter through cracks in damaged wire insulation. 

When moisture penetrates a PV wire’s insulation, it can damage the wiring. If installation or maintenance crews don’t spot the damage, it could lead to arcs, shorts, and faults. Worse yet, it could spark a fire, damaging nearby panels and racking. 

Racking 

Racking may not be exciting, but it’s critical to a solar project’s overall power generation. 

High humidity introduces moisture to the equation, which can ravage unprotected metal racking systems. Solar developers should either invest in corrosion-resistant materials or use coatings to make the racks resistant to corrosion. 

Without proper protection, the systems are more likely to rust and show wear while leaving the door open for mold growth. If mold or rust forms around tracking system components, it could prevent panels from moving with the sun. 

Preventing Damage from Humidity 

While it’s impossible to stop humidity from occurring, it’s possible to protect solar sites from damage. All it takes is a little preparation and patience. 

  • Invest in hydrophobic coatings. These specialized coatings repel water, preventing it from accumulating or entering sensitive areas.  
  • Keep up with cleaning. Regular maintenance cleaning removes dried bits of dust and other crud from solar panels. It also gives moisture fewer opportunities to create mud on the panels, reducing performance. 
  • Don’t skimp on seals. Seals prevent outside debris and moisture from entering solar panels and causing damage to sensitive components. 
  • Invest in high-quality PV wire products. Work closely with manufacturers that install connectors in-house and perform quality control testing. Unlike field-made connectors, which could be mistake-prone, employees test every connector to ensure a tight seal. This prevents moisture from entering through openings and shorting wires. 
  • Use the right wire for the job. Utility-scale solar projects are massive endeavors and long-term installations, so buy high-quality wire when possible. Invest in UL 4703-certified PV wire, as other types may offer less protection. PV wire can withstand harsh outdoor environments and is moisture, weather, abrasion, and UV resistant. 
  • Explore your conductor options. Copper is the most common PV wire conductor, offering good conductivity across many applications. Aluminum is lighter than copper and more affordable but needs larger gauges to match copper’s conductivity and may oxidize over time. Tinned copper offers better corrosion protection than copper alone, but developers will pay extra for additional peace of mind. 

Risk, Rewards, and Resilience 

Humidity is a necessary and important component of our natural environment. However, solar technology is rapidly improving to make solar projects more resilient against its effects. 

As products and methods improve, solar sites enjoy increased clean energy production, higher levels of safety, and longer project lifespans. Meanwhile, consumers benefit from low-cost renewable energy, utilities and operators produce more power, and sites generate higher ROIs. 

Solar sites require an incredible amount of planning, and no one knows everything. When questions pop up, know who to reach out to for advice and guidance. Oftentimes, this means reaching out to a trusted manufacturer or distribution partner. Their insight can simplify the installation process and make it easier to maintain products over their usable lifespan. 

This ultimately leads to better, more efficient projects that benefit everyone.

Going Domestic: Why Builders Want American-Made PV Wire

Posted on by bop-admin

If you’ve been paying attention, you’ve likely seen one news story after another hyping up the U.S. solar industry. 

We’ve seen years of growth as clean energies like wind and solar take over new generating capacity. In 2024, for example, solar comprised two-thirds (66%) of U.S. electricity-generating capacity additions. Overall, the solar industry installed about 50 GWdc of capacity last year, hitting a new one-year record. 

Tailwinds and Headaches 

So, what’s driving companies, utilities, and communities to dive into solar energy? As it turns out, several factors combined to get us here. 

The Inflation Reduction Act (IRA) has had a couple of years to come into form. Incentives made through the program extended and broadened solar tax credits, making large-scale solar projects a better investment. 

The IRA also created measures to develop sustainable domestic supply chains for solar panels, racking, and wire. Previously, solar companies imported foreign solar components, dealing with everything from long delays to questionable quality. The costs were lower, but the industry struggled. 

Today, domestic manufacturing is taking a monumental step forward. Recently, the SEIA announced the U.S. had reached a critical manufacturing milestone. Domestic solar module production capacity hit 50 GW, large enough to meet current U.S. demand. Backed by Section 45X and Section 48C tax credits, incentives bolster an already booming industry. 

Despite some potential governmental headwinds, industry experts are bullish on solar energy’s future. 

Does Buying Domestic Matter? 

The U.S. is encouraging developers to use American-made goods, including PV wire. But does domestically produced wire warrant the higher cost? 

In many cases, the short answer to that question is yes. Although all PV wires may look similar, subtle details impact quality, lifespan, and performance. We must also consider project scopes, including timelines, budgets, locations, and job requirements. 

Depending on the situation, American-made PV wire could be a cost-saver. 

Quality and Build 

Solar wire made in the United States meets or exceeds Underwriter Laboratories, National Electrical Code (NEC), and ASTM standards, including: 

UL 4703 – This UL standard is specific to PV wire. UL 4703 tests a wire’s ability to handle sunlight exposure, high temperatures, weather, and other threats. 

UL 1581 – Also known as the VW-1 test, UL 1581 is a vertical flammability test. Essentially, UL 1581 determines how much a flame propagates (spreads) along a wire section. 

ASTM B-1, B-3, B-8, and B-33 – These wire configuration standards correspond to specific wire types. In order, they are hard-drawn copper (B-1), soft-drawn copper (B-3), concentric lay twisted strands (B-8), and tinned copper (B-33). 

American-made PV wire undergoes heavy scrutiny, resulting in high transparency. Additionally, strict standards add a layer of safety to every product, ensuring the wire does what it should. This may not be the case with products shipped from overseas, as other countries’ standards may be less stringent. 

NEC Section 691 – This portion of the NEC corresponds to several aspects of utility-scale solar sites with generating capacity over 5 MW. It covers factors like operating voltages, disconnects, fire mitigation, engineering, and other critical safety measures. 

Supply Chains and Lead Times 

Timelines matter – whether it’s a utility-scale solar array or a small community solar project. 

One massive advantage American-made products have is their shorter supply chains. Because the manufacturing and shipping are both within the U.S., production lead times tend to be much shorter. Shipping times are also shorter because products don’t have to travel by boat to the United States. 

On top of the shorter shipping and lead times, buying from domestic manufacturers helps developers avoid tariffs and duties. Importers often pay tariffs on materials from other countries, adding costs to the products they buy. Duties, on the other hand, are taxes paid on imported goods. 

Domestic production is also handy if problems arise. When customers find defects in their solar wire, they can return it to the manufacturer easily. Because the route is much shorter, the amount of time it takes to switch the wire is faster. Cutting a weeks-long wait down to only a few days is crucial when developers are racing to meet looming deadlines. 

Weighing Costs with Lead Times 

If deadlines aren’t an issue and the company has time to wait, sometimes shipping products from overseas could be an option. 

Buyers take on risks with the purchase, including the threat of geopolitical issues coming into play and tariffs. However, despite longer customer lead times and riskier supply chains, developers could save money on large-scale projects by using imported wire. 

Budgetary Constraints 

Developers endlessly search for ways to deliver the best results with the most savings possible. 

To that end, U.S. materials offer solid production, quality, and price. American-made materials follow a strict production process to ensure higher durability, longer lifespans, and better manufacturing traceability. The result is a product that often lives up to the price point. 

But every dollar counts, especially when you’re dealing with solar systems with hundreds of aisles of panels. Wire is a pretty small piece of the overall budgetary pie, but as projects grow larger, so does the cost of wire. 

Project Requirements 

Sometimes, it isn’t about price, performance, or any other factor – the project just requires domestic PV wire. 

Over the years, solar projects have become more specific, especially as the federal government attempts to bolster domestic manufacturing. As a result, more solar projects are pushing to meet domestic content requirements like BABA. The products called for are then “spec’d in,” requiring developers to source those materials for the project. 

BABA, or the “Build America, Buy America” program, ties funding and tax credits to solar projects. For example, ITCs and PTCs contain language about using American-made materials in the site’s development. We wrote a blog about these rules, which you can find here. 

State and local domestic product incentives could also be in play, depending on the project’s location. 

The Case for Imported Wire 

So, with so much focus on domestic production, is there a place for imported PV wire? 

Imported wire can do the job, but it’s important to ALWAYS work with a trusted, vetted international partner. Different countries have different standards, so it’s on the developer to verify who they buy from is reputable. 

Price – Larger projects call for more wire – often to the tune of hundreds of thousands of feet. Imported wire is generally more cost-effective, reducing overall project costs. 

Access to In-Stock or Unique Products – On occasion, solar projects may call for uncommon wire, which could lead to longer lead times. Overseas vendors may have specialized products in stock, keeping projects moving on time. 

Once again, DO YOUR RESEARCH before purchasing thousands of feet of wire from an international vendor. A trusted partner can meet safety standards and be transparent about their processes, ensuring high quality. 

Small Line Item, Huge Impact 

Wire is a crucial component of any utility- or community-scale solar installation. Without it, electricity doesn’t move from the panels to the electrical grid. 

Buying American isn’t solely about supporting the Red, White, and Blue. Builders get faster shipping, fewer added shipping costs, top-quality products, and peace of mind. 

Some overseas products may have similar quality, but EPCs must do their due diligence. This means building trust and verifying those manufacturers produce high-quality products. 

At the end of the day, not all wire is the same. No matter where the wire comes from, only work with trustworthy manufacturers that meet the highest standards. The result will be better installations, safer projects, and long-lasting performance for decades. 

What is a Virtual Power Plant?

Posted on by bop-admin

One of the worst feelings is the dread one feels when the power goes out. 

Homes and businesses typically rely on electricity from local power generation plants. For the most part, consumers can reliably power our daily routines and keep life moving smoothly. But it also comes with a massive disadvantage. 

When the power goes out, electricity doesn’t go to end users, leaving them in the dark. While crews work feverishly to restore power, home and business owners worry about spoiled food, lost revenue, and boredom. 

However, emerging technology supported by electrification is changing how power disruptions impact our lives. These virtual power plants (VPPs) can keep the lights on using power created by our neighbors. 

Though they sound complicated, VPPs are the next step toward developing a more dynamic electrical grid. 

What is a VPP? 

By definition, a virtual power plant is a network of decentralized production and storage units combining to send power to the grid. 

But what does that mean in human terms? 

“Decentralized production and storage units” are basically all the pieces making up the VPP. These distributed energy sources (DERs) include everything from solar panels and batteries to electric vehicles (EVs) and smart products. If it can create, store, or control electricity, it can be part of a VPP. They also don’t need to originate from a singular location – VPPs can cover small or large areas. 

The best part is anyone can join a virtual power plant. Potential VPPs can include residential, commercial, industrial, or community-scale systems, though rooftop solar is the most common DER. 

VPP technology has existed for several decades but has taken off dramatically in the last ten years. The Department of Energy estimates that 30-60 GW of VPP grid capacity exists today. 

How Does a VPP Work? 

Let’s pretend a neighborhood has several rooftop solar systems, EVs, and smart homes. If these systems are part of a virtual power plant, utilities can draw from them during an emergency to power other homes and businesses. 

And just like that, a storm rolls through, knocking out a critical power line supplying electricity to several neighborhoods. When power outages or peak demand occurs, the utility activates the VPP. The utility can then remotely “talk” to connected DERs to turn thermostats down, reduce electricity use, and discharge EVs. 

Power flows from connected devices to the grid, sending electricity to other impacted neighborhoods. At the same time, energy loads drop, ensuring enough power is available. 

NOTE: This ONLY happens if the customer has opted in – VPPs require remote control from outside operators, like utilities. 

It might not seem like much, but localizing the grid to specific areas makes it more stable. Utilities can worry less about burning more fuel to send electricity across transmission and distribution lines and focus more on repairs. For end users, VPPs keep the lights on during peak times and emergencies using power supplied by others. 

VPPs Are NOT Smart Grids 

If you know the phrase, “A square is a rectangle, but a rectangle is not a square,” the VPP/smart grid relationship makes sense. 

Think of it like individual states in the nation. For example, Vermont is only one part of the larger United States. 

A VPP is a type of smart grid, but it’s only one piece of the larger smart grid infrastructure. Unlike a virtual power plant, smart grids cover the entire electrical grid, utilizing new technology to improve reliability and resiliency. 

Smart grids create large-scale two-way networks between operators or utilities and end users. Utilities can optimize electricity output and flow through the network, better incorporate renewable energy, and perform real-time monitoring. 

The result is a more dynamic electrical grid that reduces power loss, improves reliability, and saves money. 

Why They’re Gaining Steam 

Storms are getting worse, making power outages more severe. 

In 2023 alone, the U.S. experienced 28 “Billion Dollar” weather events, totaling an eye-popping $95 billion in damages. Weather is also the cause of more than 75% of power outages in the U.S., making it the grid’s number one threat. 

At the same time, the push for groundbreaking technology has never been stronger. More things rely on electricity than ever, requiring vast amounts of electricity. But with smarter electronics and power generation systems, we also have more opportunities to share power. 

Reducing Risk, One Neighborhood at a Time 

Our nation’s electrical grid is showing its age, as many pieces of infrastructure are well over 25 years old. 

Because of its age, the grid is more susceptible to damage caused by storms, physical threats, and cyberattacks. Unfortunately, when systems go down, people and communities are at risk. 

Communities once relied on central power plants to deliver electricity to neighborhoods, businesses, and other locations. But during outages, those people sat in the dark until power was restored. 

Under a VPP, during an outage or demand spike, the utility can remotely call on DERs to discharge power to the grid. Those opting into the program become power plants, drawing on stored energy to electrify those around them. 

Long-Term Savings 

Beyond grid security, VPPs reduce the number and size of electrical transmission and distribution peaks. 

What does that mean for the average person? When peaks occur, it stresses the grid since it has to support more electricity. The strain could lead to problems ranging from blown transformers and substation faults to overheated wires. Fewer peaks mean less threat of overloading the system. 

Peaks occur when there’s more demand than usual. To support the higher demand, peaking power plants generate electricity to meet the need. The problem is these power plants are expensive to run. Someone has to pay those costs, and it’s most likely the end user. 

VPPs take the pressure off power plants to meet peak demand by discharging electricity from DERs. As a result, the utility spends less money on fuel sources and limits energy loss along power lines. Meanwhile, customers receive steady power while VPP participants earn cash or credits for their electricity. 

Best yet, expanding VPP services goes beyond short-term savings. According to the Department of Energy, if the U.S. deploys 80-160 GW of VPPs by 2030, it could save $10 billion in grid costs. 

Taking Advantage of Incentives 

Like other renewable energy initiatives, there are programs and incentives available for VPPs. 

Depending on location, rebates and programs make commercial, industrial, and community-scale solar possible. For example, Maryland’s Distributed Renewable Integration and Vehicle Electrification (DRIVE) Act requires investor-owned utilities to develop programs rewarding DERs and establish incentives.  

Utilities and community solar energy operators also have programs to finance and promote VPPs. The Department of Energy has funded various clean energy installations through Title 17, which provides loans for innovative projects. 

In other cases, state and local incentives for solar and other renewable projects could be available. And don’t forget to research what incentives stack, as organizations and programs cover different initiatives. 

VPPs for Consumers 

Consumers participating in virtual power plants and installing DERs add clean energy to the grid. As more clean energy systems come online, we rely less on large-scale power plants and fossil fuels. Over time, this may reduce electricity costs. 

Additionally, VPPs ensure homes and businesses have power during an outage, reducing other losses. From allowing small businesses to stay open to preventing food spoilage, small power providers keep everything running smoothly. 

As for the bottom line, consumers sending power to the larger grid earn money or credits on their energy bills. Those credits can offset upfront costs related to installing a solar system or battery or buying an EV. 

Downsides and Cautions 

For everything virtual power plants do well, there are some drawbacks to how the system operates. 

Despite owning the power they produce, consumers don’t always have control. When signing up for a VPP, consumers give operators the right to draw energy from DERs when necessary. If that happens, EVs, batteries, solar panels, and smart products connected to the network begin discharging and conserving power. 

Operators have also launched programs to pre-enroll consumers, though they can opt out later. Though it’s easy for utilities to enlist homes, businesses, and others into the program, consumers should be well informed. Participants must understand the program’s details, what to expect, and how utilities will compensate them. 

Not Enough Participants 

Experts believe virtual power plants could help address future energy demands, especially as older plants retire. 

Coal use has declined for years, with 4 GW of coal-fire capacity retiring in 2024. Before last year, retirements averaged about 9.8 GW each year for the previous decade. Worse yet, as retirement and deployment schedules fluctuate, we’re looking at a 200 GW gap in peak demand needs. 

VPPs could fill the potential gap, but the country must act fast. We need about 80-160 GW of capacity by 2030 to meet rising U.S. demand. The current total is only about 30 GW, far from the low-end goal. 

Not a Replacement for Grid Upgrades 

Electricity demand is rising rapidly, thanks to more electronics, a growing number of data centers, and a manufacturing renaissance. 

The result is a fevered effort to find new ways to generate power for the grid. Unfortunately, the current grid isn’t entirely ready for a wave of innovation. Instead, the design supports older power production methods powered by fossil fuels. 

The grid currently can’t reach its full potential because it desperately needs upgrades. Solar projects across the U.S. face massive delays because of red tape and interconnection problems. Other infrastructure has reached its usable lifespan, so we should replace and upgrade it. 

Everyone Plays a Part in Clean Energy 

Utilities, solar companies, businesses, government, and consumers all stand to benefit from VPPs. 

With planning and strong execution, we can cut costs throughout the supply chain. On top of the financial costs, VPPs help improve grid resiliency, leading to fewer power outages. Adding diverse electricity options also gives utilities more access to clean energy, reducing reliance on fossil fuels. 

The future is leaning toward cleaner power, but we still have lots to do. It means finding answers for rising demand, aging infrastructure, interconnections, and industry support. But as we check each box, powering our future becomes more possible.

Solar Project Anatomy: Exploring Remote Monitoring Systems 

Posted on by bop-admin

When you ask the average person about solar, their answer generally extends to what they see – endless rows of solar panels, racking systems, and thick bunches of PV wire.  

But beyond the main parts and pieces, vital accessory systems keep utility-scale solar operations running smoothly. From tracking weather and fighting fires to system monitoring and electrical grounding, these systems are the eyes and ears of every site.  

Though every solar project is unique, most large-scale sites share several monitoring systems. When they combine, the data they collect gives operators unparalleled insights into every aspect of their site.  

Remote Monitoring Systems  

Like the home security system protecting your house, cloud-based remote monitoring systems (RMSs) protect solar sites from potential damage.  

These systems monitor performance metrics and track voltage, output, and system status. Sensors collect data in real time and then send it via an internet connection to the cloud. Operators can access the data anytime to get vital information, see status changes, and make system changes remotely.  

Remote monitoring systems make operators more proactive, keeping power flowing with less boots-on-the-ground troubleshooting.  

Eyes in the Sky  

When used correctly, RMS identifies system failures before they cause damage or lost production.  

Sensors collect data 24/7, using the information to create baselines and trends. If something occurs at the solar site – for example, damaged panels or inverters, the system pings the operator. From there, the utility or owner can take action.  

But not every issue is a full-blown disaster. Remote monitoring’s ability to spot trends makes it easier to find improvement opportunities. If performance drops at certain times, for example, operators can send a crew out to look for shaded panels. A consistent performance decrease over time could signal soiled panels, meaning a cleaning might be due.  

Having access to detailed reports is a game-changer for operators. Remote monitoring works alongside other systems, including weather stations, to produce comprehensive reports using historical data. With it, operators can constantly make tweaks to improve performance. 

Remote Monitoring Limitations  

Unfortunately, remote monitoring systems aren’t perfect.  

Rural solar installations may not have reliable internet access, making it harder to send data to the cloud. With that said, operators have several options, including 4G/5G wireless connections, satellite internet, or point-to-point wireless networks.  

Additionally, like any internet-connected device, there’s always the risk of a cyberattack. If that happens, bad actors could access sensitive data and systems. For operators, cyberattacks may result in power disruptions and shutdowns or data loss and theft.  

Finally, monitoring systems can be expensive. Operators may need outside experts to set the system up correctly and ensure it’s collecting accurate data. With that said, hiring the right team is critical to getting everything you need out of the RMS.  

Solar Weather Monitor - Sun-Pull Wire

Weather (Meteorological) Stations  

Like remote monitoring systems, weather stations collect vast amounts of data. The difference is that the data they collect is environmental, not performance.  

Weather monitoring stations collect everything from solar radiation and temperature measurements to rain and snowfall totals, wind speed, and humidity data. Once combined, the data paints a picture of the overall conditions to help operators understand performance data.  

Together, RMS and weather data can answer questions tied to overall performance. For example, the two systems can explain what happens during weather events, giving operators the tools to develop maintenance, cleaning, or repair plans.  

Neither Snow, Nor Rain, Nor Heat…  

Although weather is unpredictable, it can be used to spot seasonal trends over time. 

As the WMS collects data, operators see more clearly what to expect during different parts of the year. It might not seem like much, but in areas with four distinct seasons, weather trend data is invaluable. With it, crews can plan for cleanings, maintenance, and other work when openings allow. 

For the average operator, accurate data does more than make scheduling easier. Over time, forecasting accuracy increases, backed by years of tracking data. Based on expected weather trends, operators can change panels’ tilt and facing to meet conditions and increase production.   

Trend data also helps operators determine the amount of risk weather events may cause to the system. Historical data can determine what past events did to the system, giving workers valuable clues about what to expect. 

More information leads to better risk management and fewer setbacks. 

Weather Monitoring Limitations  

Although WMS data is comprehensive, it’s also highly technical.  

Operators need specialists to set up and calibrate each monitoring station. Unfortunately, large solar farms can cover many acres, and conditions change from one spot to another. Depending on the size of the site, operators could need multiple stations to get full coverage and accurate data.   

Despite the cost, meteorological stations drastically improve the quality and quantity of data collected, especially when combined with remote monitoring systems.  

Fire Suppression Systems  

A fire is one of the worst things that can occur at a solar site.  

PV systems produce a lot of electricity, and fires can start if there is an arc, fault, or wire damage. Unfortunately, many utility-scale systems sit in remote areas, making it hard for crews and firefighters to respond quickly.  

When fires occur, expensive repairs are needed, potentially costing millions of dollars to get back up and running. 

Solar Farm Fire Risk Factors  

You’d be surprised how little it takes for a fire to erupt at a solar power site.  

Common causes include:  

Electrical issues: Small nicks in the wiring can create arcs and faults, leading to fires. Other components also pose fire threats, including overheating panels, inverter issues, and even short-circuiting battery storage.  

Lightning: Solar sites occupy a lot of land, making them targets for lightning strikes. When lightning hits the installation directly, it can damage panels, wiring, inverters, and other components. Indirect strikes are just as bad, leading to power surges and ground currents that could increase fire risk.  

Objects and plants: This is a two-fold problem. Plants and objects touching panels or electrical components risk getting shocked, electrocuted, or starting a fire.  

Meanwhile, plants or trees that cover parts of the solar panel with shade create hot spots. Over time, hot spots can lead to overheating and reduced power generation.  

Accidental damage: We all make mistakes, but sometimes mistakes lead to massive problems down the line. Nicks in the PV wire, damage to the panels, or even a faulty connector can start a fire.  

Fighting Fires from Afar  

Site operators have several options for remote fire suppression, ranging from water and misting to foams and carbon dioxide.  

Fire suppression systems monitor the site for issues and act to extinguish fires before they can spread. If a fire breaks out, these systems are the first line of defense, protecting valuable components until responders arrive.  

Of course, as good as a fire suppression system is, it doesn’t replace vigilance and planning. Operators need a fire prevention and protection plan to keep crews, local responders, utilities, and others informed.  

Grounding Systems  

When power surges or faults occur at a solar site, they threaten the entire system.  

Utilities rely on grounding systems to create a low-impendence route for electricity and prevent temporary overvoltage (TOV). When TOVs happen, the voltage rises above its usual levels for a sustained period. Unlike lightning strikes, which may spike voltages for a short time, TOVs could highlight fault conditions or other problems.  

Grounding systems are critical to any solar installation. Without them, solar sites could see component failures, fires, and total system failures. Grounding reduces the potential difference between the earth and energized surfaces is almost zero. 

Keeping Up with Codes  

From a safety standpoint, installing a grounding system makes sense. But if that isn’t enough evidence, effective grounding is required by many code departments.  

For prospective solar operators, that means working closely with local code departments to follow NEC standards. They might seem like additional hoops to jump through, but they ensure every project is as safe as possible.  

In other cases, many insurers require proper grounding for all systems before issuing an insurance policy.  

Systems for a Better Solar Energy Industry  

Solar sites across the United States rely on an intricate web of monitors to protect and optimize their sites.  

Let’s face it – clean energy projects are huge investments. If there’s a way for operators to protect them with cost-effective solutions, they will.   

Combining performance data, weather information and trends, and fire detection monitoring helps operators maximize their investments. As more features tie into the ever-growing Internet of Things (IoT), operators will continue making better decisions faster. Additionally, their teams are more effective because they aren’t relying on hunches and incomplete data. 

Solar energy is taking off in the United States – it’s only fair to assume site technology will grow alongside it. Most importantly, better technology leads to improved power output, more reliable systems, and happier end users.

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.

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.

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.