Ensuring Project Success: The Role of Comprehensive Inspection Services in Large-Scale Renewable Energy Projects

As the global renewable energy industry accelerates project timelines are tightening and technology complexity is increasing. In this environment, comprehensive inspection services are no longer optional – they are a strategic imperative for ensuring quality, minimizing risk, and meeting ambitious climate targets.

The Complexity of Large-Scale Renewable Energy Projects

As renewable energy projects grow in scale and complexity, they present unique challenges. Large projects often involve multiple stakeholders, tight schedules, and the integration of new technologies. In these environments, ensuring the quality and performance of every component—from production to transportation to installation – is vital. However, the speed at which these projects need to progress often leaves little room for error. This is where comprehensive inspection services play a crucial role.

SCOPE

• In-Process Inspection
• Pre-Dispatch Inspection (PSI)
• Container Loading Inspection (CLI)
• Laboratory Testing Witness

CHALLENGES

1. Schedule Conflict & High Volume Production: Coordinating inspection and reporting under the fast-tracked time scale of manufacturing 450MW within 6 months (approx. 1.5MW/day).
2. Stakeholder Communication Gaps: Ensuring seamless coordination among production teams and technical requirements on inspection procedures due to varied opinions and procedures.
3. Daily Reporting Discipline: Aligning report schedules, walkthroughs, and validations to enable project monitoring and decision-making.
4. Quality Oversight for New Technologies: Qualifying regular quality of new G12 TOPCon modules that have yet to be extensively installed.
5. Deviation in Internal Process Tests: Chances of bypassing or inadequately conducting critical tests such as Hi-pot, EL, or lamination Gel content etc. because of pressure from production.
6. Production and Rejection Data Tracking: Inability to trace line-wise and batch-wise rejection data for early diagnosis and corrective measures in process.
7. Critical PSI Deviations: Non-adherence in critical PSI activities, particularly in IV measurement consistency and sampling discipline.
8. Shop floor Environment Noncompliance: Factors like inadequate lighting, excessive dust, or unsuitable handling procedures impacting module integrity.
9. Untrained Operators: Lack of training for important processes like stringing, lamination, or inspection, resulting in defective modules being cleared undetected.
10. Inadequate Time Allotment for Key Processes: Curing and buffer time between lamination, framing, and packaging not adhered to, compromising product stability.
11. Preventive Maintenance Verification: Infrequent preventive maintenance on stringers, laminators, and simulators, resulting in equipment-based quality problems.

SOLUTION

1. On-Ground Inspection Teams: Utilization of 4 dedicated full-time SgurrEnergy inspectors working across shifts for continuous Inspection services during production.
2. Clear Scope Establishment: Alignment of scope with written inspection flow, PSI lot sizes of 10MWp, well-defined roles, and expectations communicated with client
3. Structured Reporting Mechanism: Standardized daily reporting in the form of PDF-based highlights (Hi-pot, EL, IV) and Excel checklists for in-process checkpoints, with reports within 24 hours.
4. Stakeholder Alignment: Arranged introductions between SgurrEnergy inspectors and client’s production management before team deployment to allow seamless execution from Day 1.
5. Benchmark Compliance Monitoring: Monitoring tolerance levels during reflash (within 1%, +ve only), test integrity, and sharing visual records of inspections in real-time.
6. Proactive Process Corrections: Process inspectors with authority to intervene at process deviations, halting and correcting procedures in real time.
7. Daily Monitoring of Internal Testing: Ongoing verification of EL, IV, Hi-pot, and curing station performance by checking against checklist standards and operator feedback.
8. Rejection Data Monitoring: Gathering and comparing rejection trends daily to suggest real-time improvements and material or machine adjustments.
9. Rapid Operator Training: Impromptu training of line staff at locations where recurrent problems occur, enhancing primary-level quality control.
10. Line Control Parameter Monitoring: Regular monitoring and adjustment of process machine parameters (i.e., stringer solder temp, laminator pressure/vacuum) for process stability.
11. Preventive Maintenance Recording: Periodic check of maintenance records and equipment status to avert equipment-rejection causes and provide process integrity.

IMPACT

1. Proactive Quality Assurance: Timely intervention and constant coverage minimizes rework, defect rates and improves quality.
2. Documentation Standardization: Documents as per the requirement, making it traceable and real-time project decisions.
3. Production Schedule Synchronization: Inspection coordinated with the manufacturing plan allows uninterrupted monitoring and escalation.
4. Transparency Across Stakeholders: Clear update and daily reports along with snapshots and highlights giving full visibility to client.
5. Enhanced A-Grade Yield: Greater percentage of error-free modules through defect checking, prompt correction, better SOP following and training.
6. Process Optimization & Industry Compliance: In-line process audits and PM checks bring production in line with best practices, reducing long-term risk and delays.

At a Glance:

• 450 MW modules inspected over 6 months
• 4 full-time inspectors deployed across shifts
• 100% daily reporting compliance
• >95% A-Grade yield achieved
• >25 SOP deviations resolved in real time

Optimizing Long-Term Success

Inspection services are not just about addressing immediate concerns – they are about creating long-term value. By continuously monitoring key metrics, providing real-time updates, and aligning stakeholders’ goals, inspection services help streamline processes and ensure project stability. Furthermore, regular audits and preventive maintenance checks help identify potential future risks, allowing teams to take corrective action before issues escalate.

The result? A more reliable, cost-effective, and compliant renewable energy project that can stand the test of time.

Read more: SgurrEnergy

At SgurrEnergy, we understand the complexities of large-scale renewable energy projects and the critical role inspections play in ensuring their success.

Discover how our tailored inspection services can streamline your project’s execution, minimize risks, and maximize performance.

Author: Shravan Shanbhog, Senior Engineer – Inspection Service (PV modules)