PV Commissioning Tips and Best Practices: Page 2 of 5

Analyze hazards. Like any other employer, commissioning service providers need to systematically assess and address job hazards and develop clearly defined and documented safety procedures. Commissioning technicians face many of the same job hazards as installers, and some commissioning activities may even carry a greater degree of risk. To perform operational tests, for example, technicians must have the PV system up and running, which exposes them to lethal shock and arc-flash hazards. Commissioning tests intentionally simulate all possible operating conditions. To test safety devices, technicians must even simulate faults and failure modes that could result in unintended consequences or equipment damage.

To comply with OSHA requirements, companies need to not only document safe working practices, but also train and supervise workers to ensure that they follow these practices. When developing a safety plan, consider every testing procedure with an eye toward unwanted results. By considering these hazards in advance, you can ensure that workers in the field have access to the appropriate personal protective equipment (PPE) and training.

While a comprehensive discussion of safe work practices is beyond the scope of this article, commissioning personnel need to keep a few safety issues at the forefront of their minds:

  • Identify all sources of power before opening any panel or enclosure.
  • Always utilize lockout and tagout procedures to prevent others from accidentally energizing components that you are testing.
  • Never assume that no voltage or current is present in a conductor unless you test it yourself, even if you just opened a disconnect.

To work safely, every commissioning technician needs at a minimum to have a digital multimeter with an amp clamp that can read both ac and dc current, electrically insulated screwdrivers and gloves, and safety glasses or a face shield. These PPE requirements get more stringent as operating voltages and arc-flash hazards increase.

Develop a test plan. Visual inspections as well as performance and operational tests are an important part of the commissioning process. The extent of these tests will depend on the size and scope of the project. As project scale increases, it becomes impractical to visually inspect or physically test every system subcomponent. So what and how many components will you inspect or test?

When developing a functional test plan, you need to balance testing costs against the potential financial benefits associated with avoided problems. Many installers understand this balance intuitively. On the one hand, it is a function of risk and probability: What are the worst-case consequences of a component failure and how common is that failure? On the other, it is a function of expedience: How easily or quickly can you run the test?

A good commissioning test plan produces maximum effect with minimum effort. Large systems often necessitate sampling, in which agents test a representative set of units (source circuits, combiner boxes, fuses, disconnects and so forth) rather than all units. If multiple units within a randomly selected sample fail in the same way, you may have identified a recurring problem. In this case, you should expand the sample size. When examining these additional units, it is not necessary to run the whole battery of tests—just check for signs of a systemic issue.

By the time the project is ready for testing, you should have confirmed the commissioning test deliverables, completed installation checklists and prepared the test plan. Except in cases of recommissioning or retro commissioning, most PV system commissioning activities take place after installation is complete but prior to project closeout. In this scenario, the commissioning team is responsible for ensuring that the fielded project meets the owner’s requirements before the owner takes control.

In an earlier SolarPro article (see “Commissioning like a Pro” for more details), Blake Gleason describes the basic elements of a PV system commissioning as follows:

  • Verify that the installation is complete.
  • Verify that the installation is safe.
  • Verify that the installation is aesthetically acceptable.
  • Verify that the installation is robust and permanent.
  • Document as-built conditions.
  • Verify system performance and proper operation.
  • Complete required acceptance documentation.

Since Gleason elaborates on these steps, we will not specifically consider each task here. Instead, we will share some tips for successful commissioning, recommend how and when to perform critical tests, and discuss some specialized tools that commissioning agents use. Larger commercial and industrial-size systems, for example, require additional assurance beyond using checklists and testing voltage and current, which is where you will need more-advanced tools such as infrared (IR) cameras and I-V curve tracers.

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