First-time acceptance of a solar plant, often referred to as commissioning or taking over, involves transitioning from construction to operation, which introduces several safety and operational hazards., the key hazards are:
1. Electrical Hazards (High Risk)
Electrocution/Shock: Solar panels generate electricity whenever light hits them, meaning circuits are energized even if not fully connected. Live DC circuits can pose fatal risks, especially during testing of arrays and cabling.
Arc-Flash/Arc Faults: High voltage DC or AC systems (up to 1,500V) can create arc faults that cause fires or explosive arcs of up to 35,000°F (19,500°C). This is common in energized combiner boxes.
Short Circuits: Caused by damaged, loose, or improperly grounded cables and components.
Step Potential: The risk of electric shock from ground voltage differences during a fault, which can occur across the entire site.
2. Operational & Physical Hazards
Slips, Trips, and Falls: Uneven terrain, loose cables, and mounting structures create tripping hazards, while working at heights (roof-top or carport) poses serious fall risks.
Mechanical Hazards: Moving parts in trackers, power tools, and closing mechanisms, such as cabinet doors, can cause injuries.
Collisions: Vehicle and machinery movement across large, often quiet, sites.
3. Environmental and Structural Hazards
Fire: Risk of fire from electrical failure (arcing) or external sources.
Lightning Strikes: Metal structures attract lightning, posing a high risk during electrical storms.
Weather-Related Injuries: Heatstroke, sunstroke, dehydration (from working in, direct sun) or cold/rain-related illnesses.
Site Hazards: Mud, standing water, and difficult terrain affecting safe movement.
4. Technical and Commissioning Hazards
Inverter Malfunctions: Sudden failures due to manufacturing defects or improper design.
Improper Grounding: Failure to properly bond metallic components can lead to energized structures.
Hidden Damage: Structural damage or wiring faults that were not identified during construction.
5. Other
Hazardous Materials: Handling components that may contain cadmium telluride or other toxic substances.
Animal/Insect Hazards: Wildlife or insects (e.g., snakes, spiders) in remote or rural locations.
Key Mitigation Measures:
Lockout/Tagout (LOTO): Ensuring circuits are not energized during testing.
Personal Protective Equipment (PPE): Using arc-rated clothing, insulating gloves, and harnesses.
Rapid Shutdown Procedures: Testing that PV modules reduce voltage within required timeframes (e.g., <80V within 30 seconds).
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