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Repowering Legacy PV and ESS Systems
In recent years, more and more clients have turned to Pure Power Engineering for help in repowering old solar PV and energy storage systems. The main goal of repowering is to replace outdated or underperforming equipment while keeping the rest of the system in good working order. This process requires a blend of technical knowledge, experience, and creative thinking—making it as much an art as a science.
Most of the systems being repowered today are 10 to 12 years old. Over that time, many equipment manufacturers have disappeared, and industry standards have evolved significantly. Electrical codes, safety regulations, and system design practices have changed, especially regarding voltage levels, grounding, arc-fault detection, rapid shutdown, and wiring conventions. These changes make repowering more complex than building from scratch—it’s both an engineering challenge and a project owner’s concern.
We’ll explore some of the key reasons behind repowering and offer practical tips to help stakeholders overcome common obstacles during the process.
*Courtesy: Sun & Wind Energy (via BayWa r.e.)*
**Who Is Repowering Systems and Why?**
Pure Power Engineering works with various stakeholders on repowering projects. While there are many financial reasons to repower, we’ll focus on two real-world scenarios. One is when long-term owners want to boost returns. Another is when developers or EPCs see an opportunity to turn existing clients into repeat customers.
**Repowering to Improve Returns**
Although PV modules can last decades, power-conditioning equipment usually has a 10-year warranty. After that, maintenance becomes costly, especially if parts are no longer available. In such cases, repowering can increase energy output and reduce operational costs. Modern string inverters are more efficient, often reaching 96%–99% efficiency compared to older models at 90%–95%. They also lower performance risks and repair costs.
**Repowering for Repeat Business**
Changes in incentive programs can also make repowering attractive. For example, New Jersey’s expired SREC program led to new initiatives like TREC and SuSI. Developers use these opportunities to show clients how repowering can generate more revenue by combining legacy and new incentives.
**Pro Tips for Overcoming Repowering Challenges**
Repowering is more complex than installing a new system. Sometimes, you need to redesign circuits or modify structures. But with the right team, every challenge is manageable. Here are some expert tips:
**Never Trust the As-Builts; Verify the Conditions**
As-built drawings from older systems may not match current conditions. Many were created without accurate records, and repairs over the years might not be documented. A thorough site survey is essential before starting any work.
**Coordinate with the AHJ and Pull Permits**
Repowering often requires approval from the Authority Having Jurisdiction (AHJ). Codes have changed, so older systems may not meet current standards. Early communication with AHJs helps avoid delays and ensures compliance.
**Structural Modifications Require Engineering Oversight**
Upgrading modules or inverters may require structural changes. Engineers must review any modifications to ensure they’re safe and compliant. Manufacturers may also need to approve certain changes.
**Listed Equipment Modifications Need Certification**
Modifications to listed equipment, like inverters or mounting systems, may require field evaluation and certification. Always consult with vendors early to ensure compatibility and safety.
**Engineering Expertise Reduces Risk**
Legacy systems vary widely, and a one-size-fits-all approach won’t work. Choosing a qualified engineering partner ensures that your project is designed and executed correctly.
Looking for more insights on C&I solar and ESS projects? Contact Pure Power Engineering to learn about our value-engineered design and construction services. With over a decade of experience and a team with nearly 400 years of combined expertise, we’ve seen it all—and we’re ready to help your project succeed.