Solution : Access Platforms
Location : Remote Solar Farm, Exterior
Overview
Provide safe access to existing high voltage inverters, replace ladder work, minimize production downtime
Solar farms have a limited window of operation as they do not produce energy when there is no sun, so every minute the sun is shining is precious time and it can’t be rescheduled. Welding near cable trays and operating inverters was not practical. Typical post construction was impossible due to the cable tray congestion beneath the inverter. Workers were using ladders to access the inverters which was not safe, fast or efficient.
Mechano Max designed a solution that minimized posts and clamped to the existing inverter frame. This provides safe, efficient access to the inverter; was quick to install with no Hot Work required. Our solution minimized downtime during assembly and maximized solar generation time.
Benefits
Safety
Fast Setup
No Welding
Exact Fit
See the video walkthrough of this project.
The Solution To Unsafe Access
The solar farms operations personnel were using ladders to access the inverter equipment. The ladders were placed on a sloped gravel surface making this an urgent safety concern.
Climbing up and down, repositioning the ladder or trying to carry tools and equipment was unsafe and time consuming. Year round access in rain, mud and snow only magnified the problems. Working with other people at the same time with the need for multiple ladders would amplify the problem.
Traditional solutions involve welded platforms which add costs and delays while the platform is engineered, fabricated and inspected. Conventional post construction was impossible due to the cable tray congestion beneath the inverter.
A weld-in-place solution requires extended downtime when the inverter would be de-energized and not producing electricity. Welding also presents risks to safety of people and equipment. Inverter cable trays require protection from heat and mechanical damage from welding and grinding. Welding also means Hot Work permits, inspection and delays and then more delays as the metal is painted to stop rust.
The use of motorized lifts was also not an option due to steep gravel slope, mud, snow and congested site conditions.
With all the costs, delays, risks and complexity, plus all the production downtime, traditional methods were not acceptable.
Key Points
Ladders
- Ladders are a leading causes of workplace injury
- Difficult to carry tools and equipment
- Slow and inefficient to relocate
- One person at a time
Welding
- Long operational shutdowns
- Long delays
- Loss of revenue
- Permits and inspection
- Extra engineering costs and delays
Application factors
- Proximity to high voltage cables
- Uneven terrain
- Gravel surfaces
Mechano Max Modular Platform Solution
Exact Fit to Existing Equipment
The solar inverter was on its own frame which required a custom fit access platform. This made off the shelf or welded solutions impossible. Mechano Max’s fully custom designs provide an exact fit to the inverter’s existing frame.
Safety Gates are provided in high visibility colours and automatic closure to improve safety in all locations and conditions.
Adjustable Safety Railings
Full-height hand rails can be combined with mid-height railings to provide complete safety even when carrying tools and equipment. Mid-height rails prevent larger items from falling off and causing damage or needed to be retrieved.
Anti slip fiberglass grating provides solid and wear resistant surface that safe year round in any weather conditions including rain or snow. The design provides traction even with muddy boots.
Fiberglass grating will never rust and can easily be cut to any configuration. It is lighter then welded steel grating and is easily removed to improve access for maintenance or repair.
Custom stairs specially designed for gravel to make it safe and easy to access and remain stable under repeated use and heavy foot traffic.
Solid footings for any surface including compacted gravel. Can be designed for use with or without footings or concrete pads.
Custom platform design reduces the need for additional footings or ground contacts. This make assembly times much shorter. No concrete had to be poured for this work platform installation.
Custom designed mounting system using specialized clamping connections gives this solution a safe and secure way to integrate without welding, drilling or modifying the existing steel structure. This means less downtime for specialized contractors, no Hot Work permits or inspection and less time de-energized and more time producing electricity.
Removable railings, kick plate and gratings simplify access to equipment for maintenance and repair.
Mechano Max - Engineered by Experts Assembled by Anyone
A different approach was called for. One that does not require welding, waiting, or costly rentals. A solution that safe, simple and efficient.
Mechano Max designed a custom work platform that did not require any welding or additional concrete work and would integrate to the existing solar inverter skid without drilling into or welding to it.
This was done with an innovative connector system that, like everything Mechano Max designs, uses pre-engineered modular steel components that quickly and easily bolt together.
The solution includes stairs to replace ladders, and an anti-slip platform where multiple people can be working on the inverters easily and safely. It includes plenty of room for tools and equipment and still be safe to move about in any weather, all conditions, and year round.
Because downtime means less profit, the solution was designed to be assembled around the existing inverter unit with minimal de-energized time. This could be done because all the pre-engineered components can be put in place by the installers by hand and without heavy lift equipment. The platform and stair assembly was bolted together piece by piece on site.
3 hours downtime instead of days
This revolutionary approach meant that the inverter would only have to be de-energized for 3 hours. Welding often costs days of downtime. When it comes to speed and simplicity of installation there is no comparison with Mechano Max winning every time.
Meeting safety and functionality requirements and bringing timelines forward, That is the Mechano Max way.
Additional Benefits
The solution for the inverter platform also has removable railings and gratings. In the event of major repair or replacement, the pre-engineered modular component can be just as easily unbolted to give extraordinary access to the inverter equipment.
The solution also includes a walkover for the cable trays running into the inverter. This means that the equipment can be accessed from any location without safety concerns or damage risks to the tray or the high voltage cables running into the inverter.
Solving problems for today with flexibility for tomorrow through expertise and innovation.