Solar PV Systems: Design, Maintenance and Risk Management

Solar photovoltaic (PV) systems are becoming a key part of the energy strategy for many businesses. By reducing electricity bills and enhancing sustainability, these systems offer significant benefits. However, to fully realise these benefits and ensure long-term reliability, proper design, installation, and ongoing maintenance are essential.

This guide explains the key parts of solar PV systems. It covers risk management, testing, and the need for good insurance. For those looking for further technical detail, make sure to take a look at the link provided at the end of this guide.

Introduction to Solar Photovoltaic (PV) Systems

PV systems convert sunlight to generate electricity, providing a clean, renewable energy source. Adoption is growing across all industries, ranging from manufacturing to real estate. These systems offer an effective way to reduce costs while meeting sustainability goals. However, successful implementation requires attention to design, installation, and maintenance to avoid costly disruptions and ensure optimal performance.

Lessons from a Solar Panel Fire: The Importance of Electrical Safety

While solar PV systems are generally safe, improper installation or component failure can lead to serious incidents, including fires. One notable example is the fire that broke out at Lidl’s distribution centre in Peterborough in February 2024.

According to Cambridge Fire & Rescue Service, an electrical fault in the solar pv panel system caused the fire. This system had 21 rooftop solar arrays. More than 50 firefighters worked to bring the fire under control.

Fortunately, no one was injured, and the 45,000m² building was saved, but significant damage occurred to the roof. Investigations showed that a problem in the electrical system caused the solar panels to catch fire. This highlights the need for proper tests and inspections of solar PV systems.

2 Key Takeaways:

• Electrical Faults: Electrical faults in cabling or inverters/micro-inverters can develop even in new installations, posing a serious fire risk. Regular inspections of solar PV system cabling and other components are vital to prevent such incidents.

• Fire Risk Management: This case shows the importance of regular maintenance and inspections. These steps help find problems before they get worse. Without these measures, minor issues can result in major fires.

This case study, reported by Roofing Today, is an appropriate reminder that even well-designed and modern solar PV systems can carry risks if not properly maintained​.

PV System Design

Designing the system is the critical first step in preventing issues like those seen in the case study above. A thorough site assessment, which considers factors such as roof orientation, shading, and available space, is the first step.

A good system layout is important. This includes the arrangement of panels, inverters, and energy storage. A proper layout helps maximise efficiency and reduce risk.

Accurate energy yield projections are essential to predict the system’s output and determine a return on investment. Well-designed systems improve energy performance and lower the risk of equipment failures. This can save money in the long run. Compliance with industry standards, such as the IET Code of Practice and MIS3002, ensures the design meets regulatory requirements and supports long-term reliability.

Solar PV System Installation Process and Safety

The installation phase is where theoretical designs come to life, and it’s also where potential risks can arise if not managed carefully. To ensure a safe and efficient installation, the following steps and standards should be followed:

• Load-Bearing Capacity: Ensure the roof can handle the additional load of the PV system. If there’s any doubt about the roof’s strength, a structural engineer should be consulted to confirm it can support the installation.

• Mounting Panels: Solar panels must be securely mounted to withstand environmental pressures like wind and rain. Proper anchoring is essential to ensure the system’s longevity and performance.

• Cabling and Inverter Installation: Installing solar panel cabling correctly is crucial to prevent electrical faults. Inverters need enough ventilation to prevent overheating. Overheating can cause system failure or even start a fire.

• Compliance with Standards:

  • Make sure the system follows BS EN IEC 62109 for inverter safety. This standard covers the rules for power converters in PV systems.

  • Follow the IET Code of Practice for Grid-Connected Solar PV Systems to meet electrical safety and performance regulatory requirements.

  • Adhere to MIS3002, the standard that covers installation practices to ensure all system components are safe, reliable, and in line with current UK regulations.

• Ventilation and Heat Management: Inverters generate significant heat, so proper ventilation is critical. Install them in well-ventilated areas away from excessive heat sources to prevent overheating.

Following these steps lowers the risk of equipment failure. It also helps the system meet regulatory standards. This is important for getting the right insurance coverage.

Comprehensive PV System Maintenance

Regular maintenance is important to keep your PV system running well. This helps it provide reliable energy for a long time. No law specifies how often this should occur. However, experts usually recommend doing these checks at least once a year.

A structured PV system maintenance checklist is a helpful tool. It helps you keep track of important tasks. These tasks can prevent system failures and expensive repairs.

Key tasks in a maintenance checklist should include:

• Visual Inspections: Conduct a visual check of the panels, cabling, and mounting systems. Look for any visible damage, build-up of debris, or signs of wear, especially after adverse weather conditions.

• Cleaning Solar Panels: Dust, dirt, and debris can drastically reduce the efficiency of solar panel systems. Regular cleaning—done by trained personnel—is essential to maintain high energy output. The frequency of cleaning should be determined based on environmental factors and the results of performance monitoring.

• Electrical Component Checks: Inspect the inverters and wiring for signs of degradation or faults. Pay particular attention to DC isolators, which are critical for ensuring electrical safety. Thermographic imaging can help identify hot spots in panels and other components, allowing for early detection of potential issues.

• Performance Monitoring: Use the system’s energy monitoring tools to track energy output. Regularly compare current performance to baseline projections. This helps identify any drops in efficiency. Such drops may signal a need for further inspection or repairs.

• Preventative Maintenance: Schedule yearly visits from certified contractors. During these visits, they can perform detailed inspections and tests. This includes testing electrical components, verifying inverter performance, and checking mounting systems for stability.

Following this PV system maintenance checklist not only ensures that your system continues to operate efficiently but also minimises the risk of major faults or system downtime. Regular maintenance helps a PV system last longer. It also lowers the chances of costly repairs or insurance claims later.

Testing and Inspections

Solar photovoltaic (PV) system test and inspections are crucial for confirming that the system is performing as expected. Performance tests should verify that the energy output matches projections and that all components are functioning correctly.

• Solar Energy Performance Testing: This process checks whether the system’s energy production aligns with initial expectations. Significant deviations could indicate faults that need addressing.

• Electrical Inspections: Regular electrical inspections ensure the wiring, inverters, and connectors are in good condition. These checks are vital for preventing electrical faults that could lead to fires.

Consistent testing helps identify potential issues early, reducing the risk of system failure or operational disruptions.

Energy Monitoring Systems and Performance Optimisation

Energy monitoring systems play an important role in tracking the performance of PV systems. These systems provide real-time data on energy output and help identify any underperforming components. Advanced monitoring solutions can also detect issues early, enabling swift intervention and preventing prolonged downtime.

Monitoring systems not only help optimise energy performance but also support warranty claims by providing documented evidence of system performance. By keeping the system running efficiently, businesses can ensure maximum return on their investment.

Risk Management and Insurance for PV Systems

There are inherent risks to any PV installation. Operational risks such as fires, electrical faults, and system degradation must be carefully managed. Environmental risks, including weather-related damage from storms or extreme heat, can also impact system performance.

Mitigating these risks requires comprehensive insurance coverage. Policies should cover a range of risks, including property damage, equipment failure, and business interruption. Adequate coverage ensures that if something goes wrong, your investment is protected, and business continuity is maintained.

Insurance solutions designed for the specific risks of solar PV systems are important. They help ensure the long-term safety of these installations. Regular system maintenance, testing, and inspections can also help to lower insurance premiums by reducing the risk of claims.

Ensuring Long-Term Success with Solar PV Systems

A well-designed, properly installed, and diligently maintained solar PV system can offer long-term energy savings and operational resilience. A comprehensive approach is required to address the risks involved, from installation faults to environmental damage. This includes routine maintenance, regular inspections, and proper insurance coverage.

Our range of risk services includes data-driven reports and expert-led site surveys. We offer digital, hybrid, and in-person options. This makes Exposure-Appropriate Risk Management easy for everyone to access.

We ensure that your clients remain safe and secure. Find out more about our latest desktop Risk Management solution for PV systems - Rapid Risk Management.

For more in-depth technical details, explore our Technical Bulletin on Solar Photovoltaic Systems.