If your solar plant is old and the power generation is not like before, you’re not alone. Many solar plants start producing less electricity after a few years because parts get weak, dust problems increase, wiring becomes loose, or inverters start giving faults.
Repowering is the solution when normal maintenance is not enough.
This blog explains repowering in simple words, so anyone can understand.
What Does “Repowering” Mean?
Repowering means upgrading an old solar plant to improve electricity production and reduce breakdowns.
It’s like this:
- If your bike is not running well, sometimes you service it.
- But if the engine, tyres, and parts are old, you replace important parts to make it run like new.
Same way, when a solar plant becomes old, repowering means:
replacing or upgrading important parts so the plant works better for many more years.
Repowering vs Normal Repair (What’s the Difference?)
Normal Repair / Maintenance
This includes:
- cleaning panels
- tightening loose connections
- fixing small faults
- replacing small damaged parts
This helps, but only up to a limit.
Repowering
Repowering is bigger than normal repair. It may include:
- replacing old panels with better panels
- changing old inverters
- upgrading DC/AC wiring and protection boxes
- improving monitoring system
Repowering is done when the plant needs a “major upgrade”.
When Do You Need Repowering?
You may need repowering if you notice these common problems:
1) Your plant generation is reducing every year
Even after cleaning, output stays low.
2) Inverter problems are happening often
- inverter trips
- frequent shutdowns
- error alarms
- long downtime
3) Panels are damaged or weak
- hotspots (heating in one part of panel)
- cracks
- yellowing
- water inside panel junction box
4) Wiring and connectors are aging
- loose joints
- burnt connectors
- damaged cables due to sunlight or rats
5) Structure has rust or loosening
- bolts are loose
- structure rusting
- alignment not proper
If these problems repeat again and again, then repowering becomes a smart decision.
What Parts Can Be Upgraded in Repowering?
Here are the most common upgrades in an old solar plant:
1) Solar Panel Upgrade
Old panels may be low wattage (example: 250W/300W). New panels produce more power in the same area.
Panel replacement is done when:
- too many panels are weak or damaged
- output is low even after cleaning and checks
2) Inverter Replacement
Inverters are like the “brain” of the solar plant. When they get old, breakdowns increase.
Inverter replacement helps when:
- frequent faults happen
- spare parts are not available
- efficiency is low
3) DC Side Improvements (Wiring, Strings, Connectors)
Many plants lose power due to:
- loose joints
- damaged DC cables
- mismatch in strings
- old connectors
Fixing these improves output and reduces heat losses.
4) Combiner Boxes & Safety Protection
Old combiner boxes or protection devices can cause failures.
Upgrades may include:
- better SPDs (surge protection)
- improved fuses and terminals
- better sealing against rain/water
5) Monitoring System Upgrade
In many older plants, monitoring is weak. You don’t know which string or inverter is causing loss.
Upgraded monitoring helps:
- find faults quickly
- reduce downtime
- maintain better performance
6) Structure Strengthening / Alignment
Even if panels and inverters are good, poor structure alignment can damage modules and reduce output.
Structure work may include:
- rust correction
- bolt replacement
- rail leveling
- row alignment
What Should You Do Before Repowering?
Before deciding repowering, check:
- Compare current generation with earlier years
- Check inverter fault history
- Inspect panels for hotspots/cracks
- Check DC wiring and connectors
- Check structure rust and loosenings
- Confirm if downtime is too high
A plant inspection helps decide whether you need:
- small repairs only
or - full repowering plan
FAQs
1) Is repowering only panel replacement?
No. Repowering can include inverter upgrade, wiring improvements, monitoring upgrade, and BOS improvements too.
2) Can repowering be done in stages?
Yes. Many plants do it step-by-step to reduce shutdown time.
3) Do I need approvals for repowering?
It depends. If the plant capacity or connection changes, approvals may be required. For normal replacements in the same setup, it may be simpler.
4) How do I know if my plant needs revamping or repowering?
If issues are small and fixable, revamping is enough. If problems repeat and output is continuously low, repowering is a better option.