HelioTholta has released ‘PV -Connectors: The status of the field“A new report that emphasizes the persistent risks of cheap PV system components, in particular connectors, for solar investments. The white paper details observations of more than 5 GW of independent field inspections carried out by HelioVolta in hundreds of utilities and commercial solar projects in the United States.
For years, industry professionals know that the connectors have made it incorrect that connectors introduce significant safety risks for PV systems. Since 2008, successive revisions from the National Electrical Code have aimed at reducing connector-related malfunctions with new installation requirements. Almost 20 years later little has changed: connector errors remain one of the most common threats for the safety and reliability of the PV system.
“It is absurd that one of the cheapest components in a PV system is responsible for the most notorious industry failures,” said David Penalva, CEO of HelioVolta. “We are talking about a dollar of plastic and metal that endangers assets of millions of dollars and people in danger. It is unacceptable.”
The Connector Report analyzes field data, presents connector failure and remediation case studies and shares connector Risk -mitigati tactics for power owners, O&M providers and EPC teams.
The most important findings from the field inspections of HeliOolta are:
- 83% of the projects inspected suffered from at least one connector-related issue.
- 45% of the sites had important connector problems that require urgent maintenance.
- 4.3% of the projects were confronted with critical connector defenses that require partial or total system development.
- Most problems stem from preventing causes such as incorrect installation.
These figures signal the growing urgency for assets owners and managers, who undergo increased downtime, significant maintenance costs and exposure to liability when connector problems are not solved. The costs of connector failure and remediation were, for example, equal to 58% of the annual income of a commercial solar port feuille and 19% for the power plant.
The report also presents a clear path ahead. HeliOolta outlines risk reduction strategies, such as quantifying the connector -based risk for various system configurations, connector types and installation methods during the design phase. Implementing purchasing specifications to ensure cross-brand compatibility of connectors made in the factory further reduces the risk. HelioTolta acknowledges that the availability of product is often limited, outlines improved quality control and R&M procedures for projects with system configurations with a higher risk.
The HelioTolta report notes that the prevention of connector error also requires supporting EPC and O&M field teams with better tools, training and documentation methods. Training must treat the correct installation techniques, measure thermal abnormalities (“hot connectors”) and visual inspection guidelines. Finally, performing third-party inspections of connectors during construction and during the entire project lifecycle assets owners helps the safety of their fleet over time.
“The right connector installation is clearly important, but assessing these components for each preventive maintenance visit is just as essential,” says Jesse Waters, CEO of Servist Energy, an O&M provider. “Because connector problems become riskier as systems work, finding and solving problems is the best way to prevent disaster strikes to prevent campaigns with high costs.”
The report is concluded by emphasizing innovations in the connector space, including the rise of crimpless connectors, efforts to standardize connector terminology under the leadership of Sandia National Laboratories and an initiative to develop a universal connector standard of National Renewable Energy Laboratory (NREL).
News item from HeliOolta
