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In recent years, more and more clients have turned to Pure Power Engineering for help in repowering older solar PV and energy storage systems. The goal of repowering is not just to replace outdated or underperforming components, but also to maintain or upgrade the parts that are still functioning well. This process blends technical precision with creative problem-solving, requiring a deep understanding of both past and present technologies.
Most systems being repowered today are around 10 to 12 years old. Over this time, many equipment manufacturers have come and gone, and industry standards have evolved significantly. Voltage levels, grounding requirements, DC arc-fault detection, rapid shutdown protocols, and wiring conventions have all changed, making it essential to align legacy systems with current codes and best practices.
Repowering isn’t as straightforward as installing new systems from scratch. It involves complex design challenges and requires coordination between engineers, owners, and installers. In this article, we’ll explore some of the key drivers behind repowering and share practical tips to help stakeholders navigate the process successfully.
At Pure Power Engineering, we work with a range of stakeholders on repowering projects. Two common motivations stand out: improving financial returns and creating repeat business opportunities. For long-term owners, repowering can be a smart move to boost energy output and cut maintenance costs. Modern inverters, for example, are far more efficient than older models, offering better performance and reliability.
For developers and EPCs, repowering opens the door to converting existing customers into loyal clients. Changes in incentive programs—like the shift from SRECs to TREC or SuSI in New Jersey—can make repowering financially attractive. By connecting new capacity under updated programs while retaining legacy incentives, developers can maximize revenue streams.
Repowering is not without its challenges. Here are some key tips to keep in mind:
**Always verify the existing conditions.** Don’t rely solely on old as-built drawings. Many legacy systems lack accurate documentation, so a thorough site survey is essential. Document everything—from conductor types to conduit sizes—to avoid surprises later.
**Work closely with the AHJ.** Repowering often requires approval from local authorities. Codes and standards change over time, and what was acceptable in the past may no longer be compliant. Early communication with the AHJ can prevent costly delays and rework.
**Get engineering supervision for structural changes.** If you're upgrading modules or changing mounting structures, professional oversight is crucial. Structural modifications can affect load distribution, shading, and system performance, so ensure they’re done correctly.
**Check for certification needs.** Some equipment modifications require field evaluations and certifications. Always consult with vendors and engineers to ensure compatibility and compliance with safety standards.
Finally, experience matters. Repowering is a nuanced process, and not all solutions work across different system configurations. Choosing a trusted engineering partner like Pure Power Engineering ensures that your project is handled with expertise and care.
With over a decade of experience and a team with nearly 400 years of combined knowledge, we’ve seen it all—from small commercial systems to large utility-scale projects. Whether you're looking to revitalize an aging system or expand your solar footprint, we're here to help you achieve your goals.
Looking for expert guidance on your next C&I solar or ESS project? Contact Pure Power Engineering today to learn how our value-engineered design services can support your success.