Digital Technology for Efficient Partial Revamping and Module Warranty Claim Management
RES has partnered with Above for a cost-effective and digitalised solution for module warranty claim management and revamping of modules.
INTRODUCTION
As PV modules age, degradation, corrosion, delamination and many other module defects all have an impact on the yield of the solar assets. It is an increasingly important task to replace these defective modules to maximise the yield of ageing solar assets.
As O&M contractor for a solar site in Cornwall, RES were aware that the 10-year PV module product warranty was due to expire. To ensure that the performance of the site was maximised, defective modules had to be identified and replaced whilst under warranty. However, given the vast number of panels on the site, this was no easy task.
Traditional methods such as utilising excel and manual recording of serial numbers are labour-intensive and not cost-effective. Also, the site’s module inspection and replacement records were incomplete as there were a variety of O&M providers overseeing it over the years.
SOLUTION
RES were already in possession of a “defective list” of serial numbers as well as original “As-Built” drawings showing where the different batches of modules were supposed to be. They used Above’s software to confirm the location of the “defective list” as well as the impact that these modules were having on plant performance.
With Above’s EyeSite mobile app, all the serial numbers of the site were to be scanned and recorded into a digital plant record. RES’ in-house scanning methodology and Above’s software allowed this to be done at record speed, ensuring the serial numbers were scanned with 100% accuracy and mapped to the exact module within the digital plant record.
Immediately, it became clear that the batches of serial numbers were not located as per the original drawings. Without this information the revamping activities would have become almost unmanageable. However, with this knowledge, RES was able to organise the revamping activities smoothly and efficiently.
Additionally, RES carried out a series of IV curve tests at a string and module level to confirm the performance impact of the defective modules and uploaded these into Above’s platform.
RESULTS
The approach taken ensured records were accurate and enabled RES to identify over 2,000 panels under warranty needing replacement. Due to many of these panels being obsolete, the module manufacturer issued newer, more powerful and larger in size modules. RES’ in-house Engineering Team was able to carry out a feasibility study for electrical and mechanical compatibility of the new modules.
RES used the digital record of the site in Above’s software, which shows both a geospatial and electrical layout of the site, to easily identify the areas with high/low concentration of defective modules. With this information, decision on how to best repower the site with the new modules was easy to take. It allowed RES to plan the repowering of entire areas of the site, whilst maintaining the electrical integrity of the array and the site’s Total Installed Capacity (TIC). Based on the digitally stored data, RES compiled a plan of action employing Above’s Task list, a software functionality that allows one to attribute and track tasks on site. They efficiently replaced all defective modules and scanned all the new serial numbers into the SolarGain digital plant record.
Finally, RES created a new
“As-Built” drawing with which Above updated the digital record of the site ensuring a correct digital plant record of the site for future activities.
FINAL OUTPUT
In summary there were four main outcomes of this project:
Firstly, the revamping activities were performed at a significantly reduced cost and much better ROI than with a traditional pen and paper approach. This approach has now been adopted widely within RES.
Secondly, the solar plant yield and performance increased significantly.
Thirdly, the warranty claim with the OEM was smoothly and professionally managed due to all the data being available in Above’s digital plant record instead of various unconnected excel files.
“We are delighted to have this partnership with Above where we can offer the full package of defective modules warranty claim management and revamping from the beginning till the end with our in-house team. This process has been a cost-effective solution for our client which has provided already a significant gain in yield in their asset. Also, a digitalised record has helped to show the Asset Owners, Managers and O&M provider the real health of the asset”
Naseer Mirza, RES O&M Project Manager
Lastly, the asset owner now has a complete and accurate digital plant record of the site which is beneficial for the management of future O&M activities, H&S and module warranty claims. It is now possible to integrate all test and inspection results taken from site against each module within SolarGain. In the future, this will help to identify quickly which modules are failing and to organize any further warranty claim or revamping activities efficiently.