The changing solar landscape

he solar market in the US has been continually ramping up over the last handful of years. According to the latest update from the Solar Energy Industries Association, at the end of 1Q22, the US had installed enough solar photovoltaic (PV) capacity to power 22 million American homes.1 Additionally, of all the new electricity-generating capacity added in the first quarter, solar accounted for 50%.

Despite the impressive numbers, the solar market was not able to reach its full potential in 1Q22 due to an unexpected tariff investigation on the import of solar cells and modules originating from Cambodia, Malaysia, Thailand, and Vietnam. This uncertainty – along with increasing costs for materials, labour, and transportation – increased the overall capital cost of new solar installations.

In June 2022, however, solar companies welcomed the federal government’s announcement of emergency measures to increase critical supplies to US solar manufacturers, declaring a two-year tariff exemption on solar panels from Southeast Asia.

The changing s Adam Bernadi, Burns & McDonnell, USA, outlines the ways in which the solar industry is booming in

With this change, new solar projects can achieve the full-speed-ahead rate that the industry had previously been operating under in the last few years, and can continue supporting the increased decarbonisation goals that are ramping up all over the country.

Widening the door for solar

Companies and investors are becoming more driven to support businesses that prioritise environmental, social, and governance (ESG) opportunities. This new development is changing the way some companies with larger carbon footprints, such as oil and gas companies, operate, and is expanding what they spend their time and energy on, such as renewable generation.

From cost savings and competitive options, to investment tax credits and attraction of investors, companies from all industries are looking to expand their typical operations to include the integration of renewable generation assets. These renewable projects can also offer carbon tax reductions that can help offset some emissions from the oil and gas facilities.

solar landscape in the current climate, and discusses how integrating energy storage systems will hel p the sector grow fu rth er .

Although the benefits that can be gained from implementing renewable sources such as solar are clear, making the transition can be a little more complex than it may seem. For example, heavy industrial and manufacturing companies cannot rely on solar 24/7 because the sun is not always shining. This means these companies would likely need to include dispatchable sources to bridge those gaps when solar cannot be utilised.

Creating solar project efficiencies

With the vast increase in interest surrounding new solar projects, it is crucial that efficiencies are created that can support fast and seamless implementation. With some solar projects covering hundreds and sometimes thousands of acres, efficiency is key.

There are many moving parts and pieces involved in completing a successful solar project. For example, a standard solar project can include site selection, geotechnical investigation, pile design, pile installation, pile corrosion design, underground cable sizing, equipment selection, module installation, wire management, construction, SCADA requirements, and more.

As more solar projects are completed, tailored applications and proficiencies can be used for the repetitive actions involved in installing hundreds of PV panels. Oftentimes, an engineering-led EPC team can help utility owners navigate the challenges and difficult-to-meet schedules involved in these projects.

Incorporating EPC and technology

Integrated EPC has a demonstrated track record for improved safety, quality, cost control, and schedule certainty. As of late, it is also evolving to drive innovations in digital technology applications applied to work on solar project sites. The engineering team often will begin with a geospatial survey of the topography, which is then loaded into AutoCAD to build a comprehensive layout with detailed locations of each pile. From there, the team can utilise digital instructions to set the bracket heights for the piles, eliminating the need for the typical lasers and string line processes. Using integrated EPC and updated digital technology applications can help Figure 1. Construction of Vistra’s 65 MWdc Brightside solar facility. Burns & McDonnell served improve pile installation for solar projects as the integrated EPC contractor for this project, which helped alleviate supply chain and by reducing the amount of rework logistics challenges. needed, shaving time from the schedule and reducing costs because fewer workers are needed on site. Additionally, one of the greatest benefits of EPC combined with innovative technology applications is the improved communication throughout the project. With the flexibility of EPC contracting and the data at hand, the construction and engineering teams are enabled to collaborate and develop solutions that are continually improving project deliverables. Figure 2. Solar projects are not just being constructed in warmer environments. Burns & McDonnell is currently the EPC contractor for Wisconsin Power & Light’s solar programme as they look to construct approximately 1100 MW/dc of solar in Wisconsin as part of the company’s larger Clean Energy Blueprint.

Keeping storage in mind

As both need and demand for solar continue to increase, energy storage systems are being installed to meet electrical grid challenges that come with an increase in renewable sources.

Solar and storage together are a very powerful combination. This is in part because storage can be used to better

allow solar to contribute to the power supply even when the sun is not shining. Storage is also important in helping to fill in the gaps as more baseload units start to retire.

There are many types of energy storage options attracting attention in today’s market, including lithium-ion batteries, redox flow batteries, hydrogen, thermal, and LNG. The electric vehicle market continues to be the driving force for lithium-ion technology advances and market pricing. As the power industry evolves and works toward meeting decarbonisation goals, storage technologies – and solar – have enormous opportunities for growth and utilisation on the horizon.

Putting solar panels into play

Alliant Energy, a public utility that provides power to businesses and residents in Iowa and Wisconsin, the US, hired Burns & McDonnell to provide EPC services for its solar programme in Wisconsin. Alliant Energy’s Clean Energy Blueprint programme was developed to help accelerate the transition to renewable energy in Wisconsin. In total, the programme involves 12 projects, with nine of the 12 projects being executed by Burns & McDonnell. The solar development programme is estimated to create thousands of new construction jobs in the area, while providing reliable energy for years to come.

For one of those projects – a 1200 acre, 150 MW solar project in Wood County, Wisconsin – Burns & McDonnell developed electrical designs and environmental studies for permitting needs. Additionally, the firm created structural and civil designs for transmission and distribution power lines, PV modules, and substations. The PV modules in the solar panels are made up of silicon semi-conductors that absorb sunlight and produce electric current.

As part of the project, AZCO, a Burns & McDonnell subsidiary, is providing pile driving, equipment and electrical installation, and steel fabrication services.

With the rareness of one firm providing the full spectrum of services from start to finish, Burns & McDonnell was able to keep this and other projects within the programme on schedule despite challenges involving the COVID-19 pandemic, market volatility, and supply chain issues. The EPC approach allowed the firm to utilise internal procurement, installation, and commissioning experience and insights in order to maintain and streamline processes.

Beyond the typical project responsibilities, such as maintaining the timeline and staying on budget, the firm was dedicated to building positive relationships with members of the Wood County community. This includes educational opportunities and tours for those who want to learn more about the project and the overall programme.

Upon completion, the 12 Alliant Energy solar projects will span nine Wisconsin counties and be able to generate approximately 1100 MW of power, enough to serve nearly 300 000 homes.

References

1. ‘U.S. Solar Market Insight’, Solar Energy Industries Association, (June 2022).

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