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Article history:
Received 18 May 2014
Received in revised form
27 March 2015
Accepted 2 May 2015
Available online 31 May 2015
Failure mode and effect analysis (FMEA) is an inductive and conservative system reliability analysis
approach, here applied to photovoltaic system. A system is a complex combination of components and
sub-components, where technical and disciplinary interfaces apply in their mutual interactions. FMEA
processes the individual analysis of each system's sub-component with the task to identify the various
failure modes affecting each part, along with causes and consequences for the part itself and the entire
system. In the proposed analysis the system's component and sub-components have been identied
from the design of the Northeast Solar Energy Research Center (NSERC) photovoltaic research array
located at Brookhaven National Laboratory's (BNL). The complete FMEA analysis is presented, along with
the applied ranking scales and nal results. The approach is discussed in its benets and limitations, the
latter mainly identied in the limited amount of open source information concerning failure probabilities for the photovoltaic system parts.
& 2015 Elsevier Ltd. All rights reserved.
Keywords:
FMEA
Photovoltaic systems
Reliability
Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . .
2. The FMEA process . . . . . . . . . . . . . . . . . . . .
3. The system model and its components . . .
4. The available data and the scoring system.
5. The FMEA table . . . . . . . . . . . . . . . . . . . . . .
6. Conclusions . . . . . . . . . . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1. Introduction
Electric utilities and grid operators face major challenges from
an accelerated evolution towards an extensive integration of
variable renewable energy sources into the electric power grid,
such as solar photovoltaic (PV). The integration of such a variable
energy source into the existing, sometimes weak or overloaded,
electric grid requires an adequate risk-informed decision making
approach. The ideal grid integration design for PV systems should
optimize the mutual benets between the grid and the PV system
itself; this has to take into consideration the PV source variability,
availability, reliability, as well as the stability of the electric grid.
The aim is to reduce or promptly intervene with outages and
http://dx.doi.org/10.1016/j.rser.2015.05.056
1364-0321/& 2015 Elsevier Ltd. All rights reserved.
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804
805
805
806
807
807
809
805
Fig. 1. Block diagram representing the FMEA process followed along this study.
806
Fig. 2. The simplied PV system diagram showing the components and sub-components considered in the analysis.
Table 1
Component and sub-components of the PV system.
Component
PV module
Sub-component
Module
Junction box/bypass diode
Connectors
Encapsulantion
Rack
Rack structure
Grounding/lightning
protection system
Cable
Aerial cables
Underground cables
String
Fuse
combiner
Disconnect
Power
Reverse polarity diode
conditioning Fuse
Breaker
Inverter
Disconnect
Transformer
Protective relays
a
b
807
Table 2
Severity ranking criteria.
Rank
Description
1
2
3
4
Table 3
Occurrence ranking criteria.
Rank
Description
1
2
3
4
5
Table 4
Detection ranking criteria.
Rank
Description
1
2
3
4
5
[9], the numerical scale has been set 1 to 5 instead of 1 to 10; this
because the additional sensitivity given by a range of scoring values
for a selected single criterion has not been considered necessary in
this work, given the limitations already expressed on the quantitative
data available. Consequently, the RPN values are ranked on a scale
between 1 and 125; also in this case, the smaller the RPN the better,
the larger the worse.
FMEA work has been done in collaboration with George Washington University [16]. The work points at the use of a surprise index
(SI). The surprise index is based on the information score of the
failure mode probability. By weighting the risk priority by the
failure mode's information score, we are increasing the inuence
of extremely unlikely, yet extremely catastrophic, events in risk
management decision contexts. This also decreases the amount of
prominence placed on relatively likely events in the decision
context. Thus, if an increasing RPN indicates a higher priority for
redundancy investments, the SI should be used to prioritize the
development of contingency plans [16].
6. Conclusions
The application of the FMEA approach has been discussed and
demonstrated for PV systems. The methodology proved the inverter
and the ground system of the PV eld to show the highest values of
the RPN, calculated according to Eq. (1). This is in line with what
reported in existing literature [15] and with the experience personally discussed with some PV plant operators. However, the FMEA
shows also the importance of maintenance activities for the early
detection of some hidden failure modes that could not affect
immediately the plant, but could degenerate into a system problem
if not promptly handled.
Despite the use of FMEA and risk analysis techniques in the PV
industry [17], the lack of publically available FMEA analysis for PV
systems makes it difcult to validate the results. Interactions with
industry, working groups and researchers in the PV eld have been
used to support the development and understand the proper level
of details to be considered for a meaningful evaluation in respect
to the available numerical information. Future analyses along with
808
Table 5
FMEA table.
Potential failure
mode
Potential causes
Rack structure
Loss of
conguration
Potential effects
Severity
rating
Occurrence
rating
Detection
rating
Risk
priority
number
30
32
No energy output
No energy output, safety, thermal
damages, re
Reduced energy output, no energy output,
thermal damage
Reduced energy output, loss of module
power, overcurrent
5
5
1
1
3
2
15
10
16
16
15
15
No energy output
10
20
20
20
12
18
48
20
20
24
10
10
12
16
16
10
No energy output
16
No energy output
Activation with different variable range
5
3
1
1
1
5
5
15
Bad lamination, high voltage stress, hot spots, high cell/ Humidity/water/contaminant entrance,
increased degradation, reduced energy
module temperature, corrosive effects in the module
structure, aging, damage from frame distortion, cleaning output, no energy output
actions, extreme wind, snow load, vandalism, animals,
lightning, earthquake, accidental impacts
809
Table 5 (continued )
Potential failure
mode
Open without
stimuli
Does not open
Inverter
Fails to transfer
Degraded output
Open
Potential causes
Potential effects
Severity
rating
Occurrence
rating
Detection
rating
16
No energy output
20
48
12
the access to system information and data for a statistically relevant time span for the system operation could provide the validation of the results. This is a rst attempt to provide a complete
FMEA analysis for PV systems and it required a substantial work in
collecting information. However, despite the limitations given by
the lack of validation of the results with published work, the work
has highlighted a large set of failure modes along with causes and
effects that will feed a probabilistic risk analysis for safety-related
and production-related issues.
The application of traditional reliability, hazard analysis and
risk analysis techniques into new environments, such as PV, are
possible [18] and desirable for reliability improvements and riskinformed decision making.
References
[1] Review of Failures of Photovoltaic Modules, IEA-PVPS T13 report; 2014, http://
www.isfh.de/institut_solarforschung/les/iea_t13_review_of_failures_of_pv_
modules_nal.pdf.
[2] Flicker, J., Kaplar, R., Marinella, M., Granata, J., PV inverter performance and
reliability: what is the role of the bus capacitor? In: Proceedings of the IEEE
38th photovoltaic specialists conference (PVSC), volume 2, 2012.
[3] Colli, A., An FMEA analysis for photovoltaic systems: assessing different
system congurations to support reliability studies introduction to PRA
analysis for PV systems. In: Proceedings of society for risk analysis annual
meeting. San Francisco, CA; 2012.
[4] Colli, A., Extending performance and evaluating risks of PV systems failure
using a fault tree and event tree approach: analysis of the possible application.
In: Proceedings of the 38th IEEE photovoltaic specialist conference. Austin TX;
2012.
[5] Su C-T, Lin H-C, Teng P-W, Yang T. Improving the reliability of electronic paper
display using FMEA and Taguchi methods: a case study. Microelectron Reliab
2014;54:136977.
Risk
priority
number