Every renewable energy asset owner knows that performance losses are an eventuality, given that these types of assets are operational for decades.
They also know that, if not managed correctly, a routine issue could turn into a complex technical challenge, one that could shut down a significant portion of a site for months, if not more.
This is where proactive and strategic asset management proves its value.
Fixing things can be complex, but the real challenge is in anticipating potential problems and protecting performance before problems turn into losses. An experienced asset manager will plan effective preventative maintenance schedules and accurately assess any performance discrepancies.
How big of an impact can a proactive and experienced operations and maintenance team make? Read on to find out.
Solar repowering: A case study
In early 2024, during a regular inspection of one of our clients’ solar sites, our engineers noticed early-stage signs of internal instability in a transformer. A series of oil sample tests revealed irregularities, prompting our O&M team to set up exclusion zones around the affected areas and prepare a safe intervention plan while further diagnostics were carried out.
A series of in-depth tests failed to shed any light on the irregularities, and no evidence of a major issue was found. The only way to get to the bottom of oil sample irregularities would be to de-tank the large, hermetically sealed transformer, a highly time-consuming operation which would ultimately cost more than a new transformer would. After exhausting all other options, the transformer was returned to service after an oil replacement, and a sharp eye was kept on the situation.
For a while, things returned to normal. The transformer operated without issue for a couple of months, during which time we carried out further testing, but nothing else came up. Eventually, the transformer suffered an unavoidable and catastrophic failure, with no hope of repair.
Reacting quickly to protect performance
A transformer failure can mean significant downtime, revenue loss, and in worst cases, grid connectivity complications impacting the entire site. Our priority was clear: keep the asset generating power.
Time is money, and our client needed the site back at full capacity fast. A new transformer was needed, but procurement times are measured in months, not days. Working quickly, we installed a backup option – an old transformer that the client had in storage – so the site could continue operating with minimal disruption while a new transformer was procured. From logistics planning to grid safety coordination, between our in-house engineers and specialist subcontractors, every step was tightly managed to protect capacity and safeguard revenue.
To complete the transformer swap successfully, we brought in expert partners to build a temporary access road so heavy lifting equipment could safely crane the new unit into place. Yet another example of how asset management isn’t just technical, it’s strategic.
Recapturing ROI for solar assets
Just when we thought the worst was behind us, the temporarily refurbished transformer began failing, too. While the client’s decision to use a matching transformer that they already owned made immediate financial sense, it was ultimately only delaying the inevitable.
Instead of reacting with short-term fixes, the team took a smart, long-term approach. After completing an evaluation of the long-term health of the site, we concluded that the best path forward was to upgrade the transformer setup and pivot from a Type 1 enclosed housing to a Type 2 standalone setup, which would be more resilient and better suited for long-term serviceability and monitoring.
The client was now faced with a choice: go for the easy choice, or the right choice. Installing a Type 2 transformer, traditionally much larger than what was already in place, would require considerable work to be done to facilitate.
Fortunately, the client understood the total ROI of this solution and went for the upgrade. We were able to undertake the enabling works that went with it, before the temporary replacement had been FAT tested, enabling a frictionless transition from temporary replacement to long-term solution.
Mindful of the need to maintain availability, we completed the repowering with just one-third of the site experiencing partial performance loss during the works, an exceptionally low impact for this type of overhaul.
Maintenance is only part of the solution
What keeps renewable assets performing isn’t just the ability to repair what goes wrong; it’s the ability to plan and prevent disruption in the first place.
From transformer failure to housing redesign, the project highlighted three key truths about effective renewable asset management:
- Performance protection begins before breakdowns. Routine sampling and predictive diagnostics make all the difference.
- Flexible problem-solving is essential. Sometimes, solving the problem means reshaping the site and the strategy.
- The real measure of success is performance loss avoided. Keeping production impacts to a minimum is the number one goal.
Asset Management is risk management
This site is just 10 years old, well within its expected lifecycle, yet it faced a critical failure that could have sidelined production for months. Instead, through early detection, strategic planning, and agile re-engineering, the site kept generating value, with minimal disruption.
This is what Ethical Power’s O&M is built for. We don’t just maintain your assets, we protect their performance and extend their lifetime.
If you need help maximising the financial and engineering performance of your renewable energy site, get in touch today.