Solar carports may look deceptively familiar to a variation of a rooftop or ground mount project: steel, modules, inverters, conduits. But not so fast! Treating carports that way is one of the most direct paths to rework, delays, and uncomfortable...

Owners & developers want long-term performance. EPCs want to get steel in the ground and pass inspections.Between those two priorities lies the real challenge: how much of your project should be standardized, and when does customization pay off?

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The 2026 edition of the National Electrical Code (NEC) introduces a wide range of updates that affect how solar PV systems are designed, installed, and inspected. While many revisions are editorial or structural, several changes have real...

Driven by grid stability & reliability needs and by the integration of renewables, Standalone BESS (battery energy storage systems) are moving from pilot to mainstream. But anyone who has tried to develop or engineer one, especially in dense, highly...

Interconnection queues are more congested than ever, and the path to approval is increasingly opaque. Developers are spending serious money on land control, studies, and legal work, only to hit delays when grid studies surface surprises late in the...

In the public eye, there is hardly a conversation about utility-scale solar without addressing the fear of losing valuable farmland. Debates with community involvement tend to be polarized. Developers see open fields as ideal for solar, while...

U.S. distributed energy resources (DER) capacity is expected to increase by 217 GW by 2028, according to a Wood Mackenzie Report. A staggering number, even to the seasoned solar industry professional. One of the challenges is connecting the massive...

Messenger wire systems have become the preferred choice for wire management in large-scale ground-mount solar projects. They provide the advantages of lower installation costs, easier maintenance access, and less trenching compared to traditional...

Disconnect switches are often overlooked in the planning and installation of commercial PV systems—until they result in cost overruns, code compliance issues, or safety hazards. During a recent roundtable of Pure Power's senior project managers with...

Distributed solar generation continues to accelerate. According to SEIA, the US added 50 gigawatts of new solar in 2024, with commercial solar growing 8% yearly. However, the path to electrification is increasingly shaped by two critical hurdles:...

Well-executed utility-scale solar projects follow a specific pattern, allowing for completion on time and without additional cost. Arguably one of the most critical factors in the development is managing the intersection of electrical, civil, and...

In the complex world of solar interconnections, cable limiters have long been a point of confusion, debate, and evolving regulation. They are key in ensuring safe and compliant system design and operation. This brief update allows developers, EPCs,...

Energy Storage Systems (ESS) have become a critical component of modern energy supply for Commercial, Industrial and DG users. Building-connected Energy Storage Systems (ESS), in particular, offer a range of benefits, from load shifting and demand...

Delays are just about the worst problem for a developer or EPC working on a commercial solar project. Slowdowns cause project costs to quickly accumulate and potentially spiral out of control which can have ripple effects, leading to even further...

Solar developers continue to search for ways to reduce system installation costs while maintaining a safe and reliable asset. They have begun to look to UL 3741 PV Hazard Control as a means of meeting the National Electrical Code (NEC) rapid...

If you are looking to invest in Commercial & Industrial (C&I) solar + storage projects, you may have heard of the term Owner’s Engineering. It’s an essential function that can save time and money on large solar deployments. Planning errors and...

Through our work as an Owner’s Engineer, Pure Power has extensive experience evaluating, inspecting, and commissioning PV power systems. While I-V curve tracing is an essential tool in these efforts, it is not necessarily the best tool for every...

Drone surveys are powerful tools that help maximize the return on investment (ROI) in Distributed Generation PV systems. They offer unmatched precision in the design process, which can significantly increase a solar + storage project’s system...

In the first part of this two-part article, I covered the roof membranes and roofing systems commonly used in commercial and industrial (C&I) buildings. Roof identification is important because this information drives other design and engineering...

Commercial and industrial (C&I) roof-mounted solar photovoltaic (PV) systems present a unique set of engineering challenges and technical risks. Some commercial roof considerations—such as the structural analysis and roof loading plan—apply...

The U.S. energy storage capacity is expected to nearly double by the end of 2024! This significant growth is driven by the expansion of large-scale battery storage systems, which enhance the integration of renewable energy sources and improve grid...

Mother Nature provides an unlimited source of clean energy from the sun. However, she also has a dark side that can wreak havoc on your array. As your Owners Engineer, Pure Power ensures the assets you build and acquire are designed for all the...

When designing utility-scale solar energy projects, optimizing central inverters is a crucial aspect that project developers, EPCs, and stakeholders often overlook. The strategic placement and design of central inverters plays a significant role in...

Pure Power has provided clients with professional services for more than a decade, including electrical, structural, and mechanical engineering, energy modeling, project development support, and PV plant performance analysis and reporting. The...

Companies continually seek ways to maximize efficiency, reduce costs, and streamline their operations in the increasingly competitive solar industry. A common strategy many firms adopt involves outsourcing engineering services despite the presence...

In the competitive world of solar engineering, the allure of saving money on upfront costs might seem like a wise choice for many EPCs. However, deciding to opt for a lower-cost overseas firm often comes with hidden costs and risks that can...

RE+ 2023 brought together leaders, innovators, and stakeholders from the renewable energy industry to discuss the latest developments, challenges, and opportunities in the field. Amidst the numerous booths, presentations, and discussions, several...

Structural Engineering is a small but critical part of the engineering for a rooftop solar project.  It can make or break the feasibility of the project or have significant effects on the system size and cost of racking. 

This is a follow up to the article Design Recommendations for 1500V String inverters, where we only briefly mentioned "Free Voltage Drop" and wanted to dive in a little deeper here.

When we value engineer a large solar project, we can take advantage...

At Pure Power Engineering, our engineers work closely with project originators, developers and EPC firms to reduce the upfront capital costs of construction without sacrificing long-term operating costs. Given the dynamic nature of solar...

Carports and canopies are the most expensive type of racking or PV module support structure. Therefore, its critical to optimize equipment selection and value engineer these projects.

Carports and canopies are the most expensive type of racking or PV module support structure. Therefore, its critical to optimize equipment selection and value engineer these projects.

Protective Relays are an advanced area of electrical engineering and contracting that can be intimidating, but they don’t have to be! This series of 3 articles will introduce basic relaying to the non-engineers in the solar and energy storage...

Protective Relays are an advanced area of electrical engineering and contracting that can be intimidating, but they don’t have to be! This series of 3 articles will introduce basic relaying to the non-engineers in the solar and energy storage...

Protective Relays are an advanced area of electrical engineering and contracting that can be intimidating, but they don’t have to be! This series of 3 articles will introduce basic relaying to the non-engineers in the solar and energy storage...

PV connector mismatch is one of the most common solar project deficiencies. In our work as an Owner’s Engineer, Pure Power identifies mismatch connectors on roughly 25% of our clients’ projects. While PV connector mismatch is a persistent and...

Long before a system completes construction and starts its 25+ year generation life, it all starts with the design.  The design is a multiplying force where a small mistake can cause big problems and introduce risk throughout the life of the system.

Nowadays, it’s not uncommon to find solar panels installed by a solar independent engineer on the roof of both residential and commercial buildings. These solar panels comprise small cells referred to as photovoltaic cells. These cells are the...

As the installed capacity of solar PV systems in the US continues to scale and more geographic regions of the country achieve high penetration rates of renewables, grid congestion is becoming a high priority consideration for many large-scale...

To fund solar and energy storage projects, developers must first clear a lender’s bankability hurdle. In this context, bankability is directly related to investor confidence and the perceived risk associated with project returns. Due diligence...

Workmanship and equipment warranties are the only thing that survive the passing of guardianship as a solar asset is developed, constructed and operated. Throughout a project’s lifecycle, different stakeholders pass the hot potato of responsibility...

For IPPs that acquire solar assets after projects are developed and designed—rather than during development or design stages—there are relatively fewer opportunities to fix design problems or engage in value engineering. Nevertheless, it remains...

Independent power producers (IPPs) have different business models for solar asset acquisition. Some IPPs actively engage in development activities, such as site selection and preliminary design studies. Other IPPs look to acquire PV power systems...

When companies do not have in-house engineering—or when an independent third-party perspective is required—outsourcing is common practice. This typically involves engaging an independent engineer (IE) or an owner’s engineer (OE) for professional...

Technical due diligence is essential to solar project success in commercial, industrial and utility applications. Large PV power systems are capital-intensive expenditures with a service life of 30 years or more. If these assets do not operate...

As an Owner’s Engineer, Pure Power often supports clients by making strategic decisions about how best to repair, re-power, or optimize the performance of operational solar assets. In this role, our team of experts and engineers often relies on...

The strategic and efficient use of resources for PV system commissioning and operations and maintenance (O&M) are critical to optimizing solar PV power system revenue and profitability. Through our work as an Owner’s Engineer, Pure Power has...

At Pure Power, our project managers and engineers use photovoltaic simulation software developed by PVsyst, Folsom Labs, and the National Renewable Energy Laboratory (NREL). By having access to and experience with multiple complementary tools, we...

Technical Debtis the cost to the system owner as a result of prior decisions made to save time or money during the engineering, procurement, or installation of a solar project.

Pure Power has been helping our client’s de-risk in their assets with our Independent Engineering (IE) & Owner’s Agent services. We cover the complex technical aspects of due diligence, while you focus on the financial and management side of the...

There is a well-known business adage called the “Cost of Quality”. This is a sliding scale that says, the closer to completion a project gets, the more expensive it is to fix quality issues.

Modules can underperform for a variety of environmental and non-environmental factors. With good design and operation practices we can mitigate non-environmental factors. However, we cannot control the environment. We can only predict its behavior,...

Modules can underperform for a variety of environmental and non-environmental factors. With good design and operation practices we can mitigate non-environmental factors. However, we cannot control the environment. We can only predict its behavior,...

Torque is a commonly used term in Solar PV system inspection, which refers to the act of tightening a mechanical fastener. The fastener can cover a wide array of details, not limited to attaching structural members, electrical connection and weather...

Conducting technicaldue diligencebefore a purchase/acquisition is essential for reducing risk and operating expense.

Pure Power has been helping buyers de-risk in their asset acquisition with ourOwner’s representativeandIndependent Engineeringservices. We specialize in the technical due diligence and operation, allowing you to focus on the financial and...

Spring cleaning also applies to solar! After harsh exposure to winter’s snow, ice, and rain, systems benefit from routine inspection and maintenance. This ensures performance will be optimal as the season progresses.

A Photovoltaic (PV) System may change hands multiple times over its 20+ year operational lifespan. The buyer and seller in each transaction may view the same project or portfolio from very different perspectives. Simply put, the seller will...

Unlike conventional PV modules that convert only front-side irradiance into electrical power, bifacial modules convert both front- and back-side irradiance into electricity. While the additional rear-side irradiance improves plant performance in...

The basic goal of ASTM E2848, “Standard Test Method for Reporting Photovoltaic Non-Concentrator System Performance,” is to compare the ratio of a PV power plant’s actual in-field performance to its expected performance based on a system model. The...

In recent years, an increasing number of clients have come to Pure Power Engineering for assistance repowering legacy solar PV and energy storage systems. A fundamental goal of repowering is to replace underperforming or obsolete equipment while...

Roughly 80% of Pure Power’s customers have some level of internal engineering capabilities. Judging a book by its cover, this vast majority may seem counterintuitive. After all, why would engineering, procurement and construction (EPC) contractors...

Bifacial PV modules convert both front- and back-side irradiance into electricity. This bifacial boost improves solar project performance both in terms of yield and the levelized cost of energy (LCOE). Due to these benefits, bifacial PV modules are...

What is a "Neutral" conductor?

To an Engineer: A "neutral" is a current-carrying conductor that carries the unbalanced current in 3 phase systems, and is intentionally connected to the ground. In North America, the neutral is color-coded white or...

A principle goal of value engineering is to deliver long-term performance and reliability at the lowest cost practicable. One effective way to reduce the levelized cost of energy (LCOE) in large-scale or commercial and industrial (C&I) solar...

As interest in stationary energy storage grows, it is tempting to assume that energy storage systems (ESS) in general—and battery energy storage systems (BESS) in particular—will follow a similar growth curve as solar photovoltaics (PV). In this...

Power engineering is a broad electrical engineering field that covers all aspects of the bulk electric power system, including power generation as well as transmission and distribution. As a full-service engineering firm specializing in photovoltaic...

Effective grounding in photovoltaic (PV) systems is the creation of a low-impedance reference to ground at the AC side of the inverter—or group of inverters—that is designed to be compatible with the distribution network’s requirements and existing...

Pure Power performs many types of power system studies, and the Arc Flash Study may be the most important because it is all about worker safety. However, since it’s not always a code requirement and doesn’t have a direct impact on generation, it is...

Pure Power performs many types of power system studies, and the Arc Flash Study may be the most important because it is all about worker safety. However, since it’s not always a code requirement and doesn’t have a direct impact on generation, it is...

EV chargers currently come in three different models: Level 1, Level 2, and Level 3. Level 3 is also commonly known as Direct Current Fast Charging (DCFC). In Level 1 & 2. the EV is connected to AC power, 120V or 240V, and a battery charger in the...

How does Pure Power keep its stellar reputation year after year?  Simple… our team stays together and gains more experience every year.

NEC 2017 brings with it some advantages and disadvantages. The new rapid shutdown rules that require MLPE are the biggest change (that is an advantage for safety, but disadvantage for project costs).

Pure Power is looking to add more A-Players to our team. However, they are few and far between, so we need your help! If you refer us to a candidate and we hire them, we will send you a $1,000 Amazon gift card!

Developers of solar projects are facing the question…what are you doing to prevent the issues Walmart encountered?

There are many things about EVs that are similar to an internal combustion engine (ICE) powered vehicle, but there are also some important differences and some less understood equivalencies. In this article, I will discuss some of these comparisons...

The ac collection system in commercial roof-mounted PV systems generally extends from the inverter ac output terminals to the low-voltage point of interconnection (POI). The exception is when the system interconnects at medium-voltage levels, in...

We often see the 3 mistakes below being made on many solar projects. These mistakes have an effect on the long term operation, quality, and safety of the system. Perhaps since they don’t have an immediate effect on project closeout, it's not on the...

With 21 engineers between our NJ, CO, and CA offices, we have unmatched bandwidth to design your solar & energy storage projects fast. What does that mean for your project? Quick turnaround time from quality engineers means you can complete your...

This is a simplified version of my previous article on the new Rapid Shutdown codes taking effect on January 1, 2019. For those interested in the technical details of the code, refer to 2017 NEC 690.12 Rapid Shutdown – Important Changes.

The 2017 National Electric Code (NEC) dramatically changes the requirements for "Rapid Shutdown of PV Systems on Buildings." Half of the states already adopted NEC 2017 and several more will in the next few months (such as NJ and CT), so you can’t...

Its common knowledge that Aluminum (Al) conductors cost less than Copper (Cu). But how big is the difference in price? The answer may shock you.

Our first article 2014 NEC 690.12 Rapid Shutdown for String Inverters on Flat Roofs we explained the basics of implementing a rapid shutdown system using string inverters on a roof.  In that article, we gave a simple example of a single array.

The 2014 National Electric Code added a new section of code 690.12 requiring "Rapid Shutdown of PV Systems on Buildings".  Below is the first of 1 of 2 articles we put together to help you understand this code (here is the other: 2014 Rapid Shutdown...

In a previous article “The 120% Rule Explained – 2011 NEC 705.12(D)(2)” we clarified the philosophy of the 120% rule for load (supply) side interconnections of solar PV systems. The 2011 code was clean, understandable, and easy to safely apply.

480 to 208 Transformers are commonly needed to step down 480V inverters for 208V services. Unfortunately electrical rooms are often crowded with existing equipment. Sometimes there isn’t room for a transformer, so we are often forced to locate the...

Here is something that’s crazy, and yet we completely understand why they did it. Some evil genius put duct tape around the vents of a NEMA 3R transformer. If this transformer is heavily loaded it runs the risk of overheating, but at least snow cant...

Everyone knows about the 120% rule, but not everyone understands the situation it is trying to protect against. This article will explain Pure Power’s philosophy on the 120% rule.

Pure Power engineered a rooftop solar PV system with an innovative new method for mounting string inverters. The inverters are mounted on strut stands directly over cable tray, and the AC and DC wiring is all neatly and compactly run in the cable...

Im not sure which of these photos is the scariest...

Thermal (IR) cameras are a great tool for preventative maintenance and inspection of your PV system. With a little thermography “know-how” and some image focusing, problems can be discovered quickly before they create a fault or safety hazard in the...

On this system, the installer stacked ballast so high that it shades the modules at noon of each day. Why would anyone use a hollow block for ballast?

This photo is an excellent example of an inverter installation on the roof. Keeping the inverters next to the array allows the unfused string wires to be kept at a minimum length, increasing safety. Notice how the inverters are tilted to the north...

We were called out to investigate a performance issue at a site, and were shocked to see this wire management. We suspect the AHJ made this contractor install physical protection after the strings were installed, which is why the contractor cut the...

Just when I thought I have seen it all... Notice the mid-clamp that was never attached because the module was raised off the rail. Scary!

I appreciate Shoal's new arc fault technology as shown in this advertisement, however I was shocked to see the photo of a man standing on PV modules.

When you select the wrong transformer enclosure rating, moisture will get into the transformer enclosure and cause faults. NEMA 3R transformers are effective at keeping out rain, but sometimes no snow drifts.

While conducting O&M on a Satcon 250kW central inverter, we noticed this fan with an object lodged between the blades.

In a recent project we were able to value engineer a DC combiner feeder by running an overhead line rather than trenching an underground duct bank. The feeder would have been a 175 feet underground duct bank routed across a high traffic driveway...

In this installation, an AC panel board was located at ground level which combined the AC circuits from string inverters on the roof. We wanted to avoid entering the top of the enclosure with conduits, so a trough was used so that the feeders could...

During O&M we often find combiner boxes and disconnect switches with water inside them, despite the box being NEMA 4 and fully gasketed, no top or side penetrations, and weather tight connectors properly installed.

Ground Mounted Solar Projects

Municipal Zoning/Planning Approval (566 Municipalities in NJ) All land development activities in the State of New Jersey require some level of Municipal approval. Typically, solar farms require site plan approval from...

At this site, the intermodule wiring is zip-tied to the rails but the string homeruns are laying loose on the roof, which is poor workmanship. Over time the rough shingles will wear away on the insulation compromising its integrity and putting the...

Many roofs are designed to support thousands of pounds of HVAC units and large air handlers, so the additional weight of an inverter is feasible in many cases.

A roof drain clogged causing the water to rise in the surrounding area. This installation has poor wire management, as shown by a connector sitting loose on a ballast block. Once the water rose and got in the connector, it began to short out (burn...

Be careful with Aluminum Conductors

The cost savings of Aluminum conductors is too good to ignore. Both the engineer and the electrician must respect the differences between copper and the less forgiving aluminum. However, if designed and installed...

When deciding what size and quantity of combiner boxes to use, always remember to use the full capacity of what you are buying.

On our first operation and maintenance trip to this site, we discovered an old broken module stashed under a HVAC unit. This module was not secured, and would surely have become airborne during a hurricane or tropical storm. This module could have...

Value Engineering Combiner Boxes

You can save up to 25% on combiner boxes and DC disconnects switches if they are properly designed. It is well known that you size equipment for 1.56x of the short circuit current. However, with certain solar...

Over the years, we have seen just about every combination of equations and numbers used to calculate the NEC required values on a DC disconnect switch. NEC requires these values to be calculated and shown on the DC disconnect switch, but it doesn't...

Two things went wrong here. First, the vegetation was not maintained, allowing it to grow tall enough to shade the modules and cover the modules in lots of pollen. The second mistake is improper seeding. If the site has proper low-growing ground...

This installer gets full points for creativity, but fails miserably for inappropriate construction means and methods. These cables are not protected from physical damage, and they are not outdoor rated so the UV rays will deteriorate the cables...

NEMA 3R and 4 inverters and outdoor cabinets may be rated for outdoor use, but any scratches in the paint will expose the metal to rusting. Once the rust gets a foothold, it will quickly spread. In this case, the corrosion should be sanded, primed,...

PVC conduits are acceptable when used properly (lots of expansion joints). Metallic conduits (EMC, IMC, RGS) are more expensive, but should be in areas subject to physical contact with other items (such as riser up walls, in electrical rooms, etc)....