Photovoltaic Training Course - Module 4.1 - Importance of maintenance

1. Photovoltaic Systems Training
Plant Maintenance
4.1 IMPORTANCE OF MAINTENANCE
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2. Operations & Maintenance
Types of maintenance
Predictive:
Maintenance based on plant performance predictions, to prevent unwanted outcomes.
Only used in plants with suntracking systems
Eg, Replacing elements a year before the end of their predicted life times.
Preventive:
Periodical maintenance intended to guarantee efficient performance during a component’s life time.
Eg,: Periodical lubrication of suntrackers, retightening fixings, etc.
Corrective:
Repair of parts that are broken or under-performing.
Eg, Replacement of broken elements, recalibration etc, following storm damage.
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3. Compliance with legislation
Where there is national legislation requiring maintenance or control tasks, those duties must be integrated in the solar plant’s
maintenance program.
Where national legislative requirements are inadequate to meet high quality standards, the company should, itself, draw up a
maintenance program that will ensure high quality.
Operations & Maintenance Options
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4. Operations & Maintenance Options
Establishing Maintenance Priorities
Maintenance priorities can be set in many different ways. The size of the plant will be a major deciding factor.
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Issue Options
Responsible for
maintenance
 The plant developer or installer
 A specialized maintenance company
Plant staff
 Continuous presence
 Intermittent presence
 Presence only if an incidence happens
Control &
Supervision
System
 Advanced monitoring system
 Simple monitoring system
 Only inverter monitoring system
Surveillance
System
 Personal
 Remote Surveillance System
 Combination

5. Operations & Maintenance Options
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POWER MW WITH SUNTRACKER WITHOUT SUNTRACKER
0,1-0,5 MW 1 PERSON INTERMITTENT INFORMATION FROM THE INVERTERS
0,5-1 MW 1 PERSON HALF-TIME INFORMATION FROM THE INVERTERS
1-2 MW
1 PERSON FULL TIME
WITH MONITORING SYSTEM
1 PERSON. HALF-TIME
2-5 MW
2 PEOPLE FULL TIME
WITH MONITORING SYSTEM
1 PERSON. FULL TIME
WITH MONITORING SYSTEM
FOR EACH 5 MW ADDED .+ 2 PEOPLE FULL TIME .+ 1 PERSON. FULL TIME
Consider the resource needed to carry out the maintenance requirements:
Maintenance Requirements

6. NOTE:
Correct management
of spare parts and
consumables is
essential if staff are to
operate efficiently.
Operations & Maintenance Cost Control
Maintenance staff capabilities
Maintenance supervisor training is essential. He or she must be capable of:
• Efficient repair when breakdowns occur.
• Carrying out Functions independently
• Creating records and management documents independently.
Spare Parts stock management
Inefficient stock management of spare parts can stop plant energy production for days.
It is essential to have an updated list of all spare parts in the plant, ensuring they are
available quickly when needed
Consumables stock management
While consumables are rarely as business-critical as spare part, poor stock management
can lead to losses.

7. Operations & Maintenance Cost Control
Surveillance
The cost of repairs and replacement due to thefts can be very high.
Theft also leads to lost power production and increased labor costs
The solutions are either vigilant staff or remote surveillance.
Monitoring
Well implemented plant supervision can avoid major expenditure on
corrective maintenance. Where breakdowns do occur, early detection is vital
to limit or prevent consequent losses
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8. Insurance
Insurance must cover all meteorological risks, risks of theft or vandalism. Some
insurance policies will cover for production losses/
Land rental
It must clearly specify: site dimensions, terms & conditions and costs, including
how rents will be reviewed.
Taxes
The costs of taxes must not be forgotten from estimates.
Supplies: Water, light, internet…
Any regular service charges must be included in operational costs.
Operations & Maintenance Cost Control
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9. Operations & Maintenance Cost Control
Conclusion
A broad estimate of annual operations and maintenance costs as a percentage of total revenues would be:
Solar plant without suntracker: 1 %
Solar plant with suntracker 1.3 %
Solar rooftop installation 0.7 %
Note:
This does not include the cost per hour of physical surveillance, which can be substantial.
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