Torque is a frequently encountered term in solar photovoltaic (PV) system inspections, referring to the process of tightening a mechanical fastener. These fasteners serve various purposes, such as securing structural components, establishing electrical connections, and ensuring weatherproof seals on conduits and enclosures.
Why is this important for owners and financiers?
Loosely torqued fasteners are a common underlying cause of catastrophic electrical and mechanical failures, yet they are among the simplest issues to prevent. By exercising diligence during both construction and operations & maintenance (O&M) activities, these problems can be completely eliminated.
[Image 1: Mechanical Lug]
[Image 2: Compression Lug]
[Image 3: Structural Bolt]
[Image 4: Failed Torque Demonstration (hot spot due to poor torque)]
Hardware can fail in several ways due to improper torque application:
**Over Torque:** When the tightening exceeds the specified limit, it can result in:
- Galled hardware, where the bolt and nut fuse together, necessitating breaking the bolt to separate them.
- Stressed hardware, where the material approaches its limits, leading to early failure.
- Deformation, where the bolted connection becomes crushed and damaged.
**Under Torque:** When the tightening falls below the specified limit, it may cause:
- Components to disassemble under environmental stressors like wind or snow.
- Electrical connections to heat up, potentially causing arcing or fires.
To set up for success:
**Step 1 – Documentation and Planning for Construction**
Start with thorough documentation and appropriate tools during construction. Look for:
- All torque values clearly indicated in relevant drawings or installation manuals for each task and fastener type.
- Tools used must match and be calibrated to the specific task.
- Avoid battery-powered tools unless they include an under-torque lockout feature to prevent under-torque due to low battery voltage.
**Step 2 – Maintaining Diligence During Construction QC Inspections**
Effective quality control methods are crucial during construction:
- Mark all inspected connections to minimize the gap between inspection and work completion.
- Use UV-rated paint markers for mechanical connections to ensure visibility for years.
- Apply QC gel to electrical connections to detect any tampering visually, prompting reapplication if necessary.
- Keep detailed test records, including target limits, pass/fail notes, and photos of failures.
**Step 3 – Long-Term Inspection and Maintenance**
The final step involves verifying the system’s long-term health:
- Utilize infrared (IR) thermal scans to detect hotspots over time.
- Conduct visual inspections for wear, tear, or corrosion on mechanical fasteners.
What are the most significant quality pitfalls related to torque?
Avoid retorquing electrical connections in maintenance routines. Torquing should be treated as a one-time event. Instead, rely on IR scans to identify under-torqued hardware requiring adjustment.
**Who Ensures Proper Torquing Practices?**
Pure Power employs field engineers specializing in quality control inspections, commissioning, and construction monitoring. We ensure your installer follows correct torquing practices.
As systems age, maintaining accurate torque levels remains essential. Even slight deviations can lead to costly repairs or safety hazards. By adhering to these guidelines, owners and financiers can significantly reduce risks associated with improperly torqued connections.
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