Case Study: Ensuring Solar Module Lifecycle Quality
Overview
We recently spoke with Natalie Campbell, Asset Manager for a large-scale solar power plant in the UK, about her experience using Above’s “Module Condition Monitoring” factory to field quality assurance solution in partnership with Kiwa PI Berlin and 2DegreesKelvin. Faced with the challenge of ensuring long-term reliability and performance for her solar assets, Natalie chose this end-to end solution to mitigate risks, reduce costs, and maximise her plant’s operational lifespan.
THE CHALLENGE: ENSURING QUALITY AND RELIABILITY IN A RAPIDLY EXPANDING MARKET
Reflecting on the state of the UK solar market, Natalie noted, “Between 2014 and 2016, many solar assets were procured without independent quality checks. Back then, we all relied on the warranties and assurances provided by module manufacturers and EPC contracts. We thought the warranties would protect us, but that’s not always the case.”
As many early solar assets reached the end of their warranty periods, systemic issues began to arise—backsheet failures, junction box defects, and accelerated cell degradation. Determined to avoid these same problems with her new plant, Natalie sought a solution that would monitor quality and performance from the outset.
THE SOLUTION: MODULE CONDITION MONITORING FACTORY TO FIELD QUALITY ASSURANCE
To tackle these challenges, Natalie enlisted Above, Kiwa PI Berlin, and 2DegreesKelvin for a rigorous, step-by-step quality assurance approach that spanned the entire lifecycle of her modules:
Quality Control at the Manufacturing Stage: Kiwa PI Berlin began their work with Natalie’s modules by performing initial checks directly at the manufacturing facility. “The factory testing was essential,” Natalie shared. “This step verified that our modules met all specifications and quality standards before they left the factory, which will help us avoid problems down the line.”
In addition to upfront testing, Natalie valued the impact Kiwa’s oversight had on the manufacturer’s accountability. “Having a third party like Kiwa overseeing production meant the manufacturer knew someone was watching,” he said. “It encouraged them to meet their own quality standards rather than cutting corners.”
Pre-Shipment and Post-Arrival Inspections: Quality checks didn’t stop at the factory. To ensure the modules were delivered in the same high-quality condition, additional inspections were conducted before shipping and upon arrival in the UK. “This extra layer of checks was invaluable,” Natalie explained. “It reassured us that the modules were in top condition and ready to be installed, minimising risks from any transport damage.”
Drone-Based Thermography: After installation, drone-based thermography was conducted to detect potential performance issues. “Thermography is a game-changer,” Natalie said. “The images give us a fast and detailed view of module performance across the entire site, pinpointing anomalies like hotspots or damaged cells that could lead to power loss if left unaddressed.”
Lifecycle Tracking through Digital Twin Technology: One of the most significant aspects of the solution was integrating data from each quality checkpoint into Above’s SolarGain digital twin. “SolarGain gives us a complete historical record of each module,” Natalie said. “By storing and tracking all relevant data in one place, we can easily monitor the health of each module over time and quickly identify any issues.”
SolarGain provides Natalie with a diagnostic tool that allows her to compare module data from multiple points in its lifecycle, from factory test results to pre-shipment checks, thermography and years of operational testing. “Having that level of insight is incredibly powerful,” he noted. “We will see how each module performs over time and catch issues before they impact power generation. We can also look for anomaly trends with the batches of modules provided
THE RESULTS: ENHANCED QUALITY, REDUCED COSTS, AND STRONGER WARRANTY SUPPORT
Boosted Manufacturer Accountability With Kiwa PI Berlin overseeing production, Natalie was able to see the test results of batches of modules before they even left the factory. “Kiwa PI Berlin has released testing data from 2023 that shows only 10% of module batches tested were found to be defect-free at the manufacturing stage. Kiwa tested our modules at the manufacturing stage and made sure that they were of high quality. ”
Improved Warranty Claim Success Another significant benefit has been the ability to support warranty claims more effectively. “With this thorough documentation, we have all the evidence we need to back up our claims,” Natalie said. “If a defect arises, we can pinpoint where it occurred— whether in the factory, during transport, or on-site. This minimises the back-and-forth with manufacturers and strengthens our case.”
Early Detection of Manufacturing Issues Natalie highlighted the advantage of catching minor inconsistencies during upfront inspections. “These checks picked up small issues before they could escalate,” he explained. “Addressing these early saves a lot of trouble and ensures that the modules installed on-site are the best possible quality.”
CONCLUSION
Reflecting on the project, Natalie emphasised the value of the partnership with Above, Kiwa PI Berlin, and 2DegreesKelvin. “By investing in quality checks at each stage —from factory production to installation and operation— we’ve reduced the risks associated with module defects, improved warranty support, and enhanced our plant’s longterm performance,” he said. “This proactive approach to quality assurance safeguards our investment and ensures our solar assets perform reliably for years to come.”
Service Highlight: Module Condition Monitoring
This collaborative service provides UK solar asset managers with:
Comprehensive factory-to-field quality assurance.
Drone-based thermography for precise performance insights.
Digital twin technology for long-term condition tracking and diagnostics.
By combining technical expertise and innovative tools, this solution ensures the longevity and reliability of solar assets.