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Torque is a frequently mentioned term in solar photovoltaic (PV) system inspections, referring to the process of tightening mechanical fasteners. These fasteners play a crucial role in securing various components, including structural elements, electrical connections, and weatherproof seals on conduits and enclosures. However, improper torque application can lead to serious consequences.
This concept holds significant importance for both owners and financiers. Under-tightened or over-tightened fasteners often serve as a primary cause of catastrophic electrical and mechanical failures. Fortunately, these issues are relatively easy to prevent through meticulous attention during construction and operations & maintenance (O&M) activities. Ensuring diligent execution can completely eliminate such problems.
Below are some visual examples to illustrate different types of fasteners:
**Image 1: Mechanical Lug**
[An image of a mechanical lug]
**Image 2: Compression Lug**
[An image of a compression lug]
**Image 3: Structural Bolt**
[An image of a structural bolt]
**Image 4: Failed Torque Demonstration (Hot Spot Due to Poor Torque)**
[An image showing a failed torque demonstration]
Hardware can fail in two main ways due to incorrect torque application:
### Over-Torque:
When the applied torque exceeds the specified limit, it can result in:
- **Galled Hardware**: The bolt or nut fuses together, requiring the bolt to be broken to separate them.
- **Stressed Hardware**: Material limits are pushed beyond their capacity, leading to premature failure.
- **Deformation**: The bolted connection becomes crushed and damaged.
### Under-Torque:
When the applied torque falls below the required specification, it may lead to:
- **Loose Connections**: Fasteners may come apart under environmental stresses like wind or snow.
- **Electrical Hazards**: Electrical connections can heat up, causing arcing or even fires.
To set yourself up for success, consider the following key points:
### Step 1: Documentation and Planning for Construction
Successful installations begin with thorough documentation and the right tools. Ensure:
- All torque values are clearly outlined in relevant drawings or manuals for each task and fastener type.
- Tools are appropriately matched and calibrated to the specific requirements of the task.
- Avoid using battery-powered tools unless they include an under-torque lockout feature to prevent under-torque caused by low battery voltage.
### Step 2: Maintain Diligence During Construction QC Inspections
Quality control is essential throughout construction. Follow these practices:
- Clearly mark tested connections to minimize gaps between inspections and actual work.
- Use UV-rated paint markers for mechanical connections to ensure visibility for years.
- Apply QC gel to electrical connections to detect tampering and prompt reapplication if needed.
- Keep detailed test records, including target limits, pass/fail notes, and photos of failures.
### Step 3: Long-Term Inspection and Maintenance
Regular checks help maintain the system’s long-term health. Focus on:
- Using infrared (IR) thermal scans to detect potential hotspots over time.
- Conducting visual inspections for signs of wear, tear, or corrosion on mechanical fasteners.
One major pitfall to avoid is frequent re-torquing of electrical connections. Instead, treat torquing as a one-time event. Use IR scans to identify under-torqued hardware that might require re-torquing.
Finally, ensuring torque is applied correctly requires specialized expertise. At Pure Power, our field engineers specialize in quality control inspections, commissioning, and construction monitoring. We’ll make sure your installers adhere to proper torque practices, safeguarding your investment.
In conclusion, torque management is a fundamental aspect of solar PV systems that demands careful attention at every stage—from initial installation to ongoing maintenance. By following these guidelines, you can significantly reduce risks and maximize the lifespan of your system.