The Importance of Considering O&M in Solar PV System Design

By Johan van der Watt, Owner and Operator of Solar Clean Cape

When designing a solar photovoltaic (PV) system, the focus is often on maximizing energy output and minimizing upfront costs. However, one critical aspect that is sometimes overlooked is the operation and maintenance (O&M) requirements of the system. As the owner and operator of Solar Clean Cape, I’ve seen firsthand how thoughtful design choices can significantly impact the long-term performance, safety, and cost-effectiveness of a solar PV installation. Failing to account for O&M during the design phase can lead to increased costs, inefficiencies, and even situations where maintenance becomes impossible. Here’s why O&M considerations—such as layout, walkways, safety provisions, water points, and vehicle access—should be at the forefront of every solar PV system design.

The Cost of Short-Term Savings

It’s tempting to cut corners during the design and installation phase to save on initial costs. However, these short-term savings can lead to significant long-term expenses. For example, a poorly designed layout may make it difficult or impossible to access panels for inspection, cleaning, or repairs. Without proper access, issues like dirt accumulation, shading, or electrical faults may go unnoticed, reducing the system’s efficiency and lifespan. In extreme cases, a lack of maintenance access can render parts of the system effectively unmaintainable, leading to premature degradation and costly replacements.

Key O&M Considerations in Solar PV Design

To ensure a solar PV system remains efficient and cost-effective over its 20–30-year lifespan, the following design elements must be prioritized:

Layout and Walkways

The arrangement of solar panels plays a critical role in accessibility. Large, uninterrupted blocks of panels may maximize space usage, but they can make inspection and maintenance a logistical nightmare. Without designated walkways, technicians cannot easily access panels in the middle of an array to check for issues like loose connections, cracked glass, or debris buildup. For instance, while robotic cleaning systems may handle surface dirt, they cannot inspect the underside of panels for corrosion or wiring issues. Incorporating walkways into the design ensures safe and efficient access to every panel, enabling thorough inspections and timely maintenance.

Safety and Fall Arrest Provisions

Safety is non-negotiable when it comes to O&M. For rooftop installations, fall arrest systems, guardrails, and anchor points are essential to protect maintenance personnel working at heights. Ground-mounted systems also require safe access routes and stable surfaces for technicians to navigate. Neglecting these provisions not only puts workers at risk but can also lead to delays or increased costs due to the need for specialized equipment or additional safety measures during maintenance.

Water Points for Cleaning

Dust, bird droppings, and other debris can significantly reduce a solar panel’s efficiency. Regular cleaning is essential, especially in dusty or coastal environments like those in the Cape. Designing a system with accessible water points simplifies the cleaning process, reducing labor costs and downtime. Without nearby water sources, cleaning becomes more time-consuming and expensive, as teams must transport water to the site or rely on less effective dry-cleaning methods.

Vehicle Access for Ground-Mounted Systems

For large-scale ground-mounted solar installations, vehicle access is a critical but often overlooked factor. Maintenance teams need to transport equipment, such as cleaning tools or replacement parts, to the site. If the system is designed without clear access roads or pathways, vehicles may struggle to reach the panels, leading to delays and increased costs. Proper access also ensures that heavy equipment, like cranes or cherry pickers, can be deployed when necessary for repairs or replacements.

The Long-Term Impact of O&M Design

By prioritizing O&M during the design phase, system owners can avoid a host of issues down the line. A well-designed system with accessible layouts, safe working conditions, and provisions for cleaning and repairs will:

Extend System Lifespan: Regular maintenance prevents small issues from escalating into major problems, ensuring the system operates at peak performance for decades.

Reduce Costs: Easy access and proper infrastructure lower the time and labor required for maintenance tasks, saving money in the long run.

Maximize Energy Output: Clean, well-maintained panels produce more electricity, improving the system’s return on investment.

Ensure Safety: Proper safety provisions protect maintenance teams, reducing the risk of accidents and associated liabilities.

A Call to Action for Smarter Design

As the solar industry continues to grow, it’s crucial for designers, installers, and system owners to think beyond the initial installation. At Solar Clean Cape, we’ve seen how small design oversights can lead to significant challenges during maintenance. By incorporating O&M considerations—such as thoughtful panel layouts, walkways, safety systems, water points, and vehicle access—into the design process, you can ensure your solar PV system remains efficient, safe, and cost-effective for its entire lifespan.

Investing in O&M-friendly design may require a slightly higher upfront cost, but the long-term savings and performance benefits far outweigh the initial expense. Let’s build solar systems that not only generate clean energy but also stand the test of time through smart, maintainable design.

Johan van der Watt is the owner and operator of Solar Clean Cape, a leading provider of solar PV cleaning and maintenance services in the Western Cape.