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In recent years, an increasing number of clients have turned to Pure Power Engineering for help in upgrading older solar PV and energy storage systems. The main goal of repowering is to replace outdated or underperforming equipment while preserving or modernizing the components that are still functioning well. Making these decisions requires both technical knowledge and creative thinking, blending detailed analysis with industry experience.
Most of the systems being repowered today are 10 to 12 years old. Over that time, many manufacturers have disappeared, system designs have evolved, and safety standards have changed significantly. Voltage levels, grounding requirements, dc arc-fault detection, rapid shutdown rules, and wiring practices have all seen major updates. This makes repowering more complex than starting from scratch—it’s a challenge that involves both engineering design and operational considerations.
At Pure Power Engineering, we work with various stakeholders on repowering projects. While there are many financial benefits to consider, two common scenarios stand out. One is when long-term owners want to boost returns by improving efficiency and cutting maintenance costs. Another is when developers or EPCs look to convert existing clients into repeat customers through strategic upgrades.
Repowering can significantly improve system performance. For instance, older transformer-based inverters typically operate at 90%–95% efficiency, while modern string inverters can reach 96%–99%. This not only increases energy output but also reduces repair and replacement costs over time. Additionally, repowering allows for the integration of newer, more efficient modules, which can lead to higher overall system capacity.
In some regions, changes in renewable energy incentives have made repowering even more attractive. For example, in New Jersey, the SREC program has expired, but new programs like TREC and SuSI now offer opportunities for increased revenue. By repowering, project owners can take advantage of both legacy and new incentive structures, maximizing their financial returns.
Repowering isn’t without its challenges. It often requires careful planning, coordination with local authorities, and thorough site assessments. As-built drawings may not reflect current conditions, so it's crucial to verify everything on-site. Electrical codes have evolved, and some older systems may need adjustments to meet current standards.
Structural modifications, such as replacing modules or adjusting mounting systems, should always be supervised by a qualified engineer. Similarly, any changes to listed equipment must go through field evaluation and certification to ensure compliance with safety standards.
Ultimately, the key to successful repowering lies in having the right engineering partner. At Pure Power Engineering, we bring over a decade of experience and nearly 400 years of combined expertise in C&I and utility-scale solar and storage projects. We understand the complexities of repowering and are committed to delivering solutions that align with each project’s unique goals.
If you're looking to upgrade your solar or energy storage system, contact us to learn how we can help you maximize performance and return on investment.