Latest Briefings

Health and Safety on Solar PV Projects

By Kevin Kerin, Managing Director
Posted on:

With the rapid growth of large-scale solar energy/photovoltaic (PV) field installations within the UK, this design of renewable energy generation is becoming a major contributor to the UK as well as global energy supply. While these utility-scale solar farms provide clean and sustainable power, they also present unique safety challenges. From electrical hazards to environmental risks, ensuring a safe installation and maintenance process is crucial for both workers and long-term system reliability.

Due to the size and design of solar PV projects, these projects differ majorly, in the way we have traditionally developed, implemented and maintained Health and Safety Management systems for construction projects.

This blog explores key Health and Safety risks as well as opportunities for best practices for solar PV field installations.

Often located away from largely populated areas, with immediate access to emergency service support, as well as (due to the size of current projects) project personnel workers located in the extremities of the project area, the planning for project support, welfare and emergency response must be carefully planned and executed.

Worker Safety Concerns to consider;

  • Exposure to extreme weather conditions (hot and cold) temperatures in open fields can lead to worker health issues.
  • Remote working areas.
  • Slips, trips, and falls due to uneven terrain and cable placement.
  • Electrical injuries being sustained from underground/overground electrical infrastructures.
  • Manual handling – Heavy lifting and equipment handling injuries.
  • Interface management between personnel and moving plant and machinery.
  • Access to welfare facilities and first aid support. 

Pre-Construction Development

As with all successful and safely managed construction projects, the development, design risk management and planning with safety in mind is essential for solar PV projects.   As detailed in the ‘short’ list above of considerations, the physical and geographical positioning of the projects themselves as well as the working activities within an expanded project space must all be carefully designed and assessed. 

1. Main hazards and risks associated with Solar PV installations:

Electrical Hazards

  • High voltage risks: Large-scale solar farms operate at high voltage levels, increasing the risk of electric shock and arc flashes.
  • Faulty connections and cable joints: Poorly installed or damaged wiring can lead to short circuits, power loss, and fire hazards.
  • Electromagnetic interference (EMI): Large PV systems can generate EMI, potentially affecting communication and control systems.

Undisclosed underground services crossing sites as well as overhead electrical cables may also pose significant risks in relation to access to the site as well as key activities such as crane operation on the site close to or under power cables .

Fire and Thermal Hazards

  • Overheating of inverters, transformers, and electrical connections can lead to fires and thermal run away within the Battery storage unit infrastructures installed.
  • Accumulation of dry vegetation around solar arrays increases the risk of fire spread.

Structural and Environmental Risks

  • Unstable ground conditions can lead to shifting panels and structural failures from electrical infrastructures to piles and even whole table rows.
  • Extreme weather events such as strong winds, hail, or lightning can damage PV modules and electrical infrastructure – correct and sufficient earthing is essential.
  • Wildlife interference, such as rodents damaging wiring, can impact system performance and hinder construction phases, ecology inspections can help mitigate against this.

2. Best Practices for Safe Solar PV Field Installations

A. Pre-Installation Safety Measures

Site Assessment and Planning

  • Conduct a thorough geotechnical survey to ensure the ground can support mounting structures.
  • Assess environmental risks, including flood zones, wind exposure, and fire hazards.
  • Develop a detailed site layout to optimize panel placement and reduce cable clutter.

System Design and Compliance

  • Follow local and international electrical safety standards.
  • Choose high-quality PV modules, inverters, and mounting structures tested for durability. • Design an efficient grounding and lightning protection system.

Fire Prevention Strategies

  • Clearing of vegetation and maintaining a firebreak around solar arrays where possible during summer months or periods of hot weather.
  • Use fire-resistant cable coatings and enclosures for electrical components.
  • Install temperature sensors and fire suppression systems in critical areas (BESS, Transformers, combiner boxes etc).

Detailed emergency response and communications strategies, remembering the need for planning procedures for serious and imminent danger, ensuring (where safe to do so) in fighting fire or moreover the safe evacuation and accounting for project personnel in the event of emergencies including fire.

B. Safety During Installation

Worker Safety and Personal Protective Equipment (PPE)

  • Use insulated gloves, protective clothing, and arc-flash-rated gear.
  • Provide sun protection (hats, sunscreen, hydration stations, and shade) to prevent heat-related illnesses.
  • Use harnesses and fall protection when working on elevated structures.
  • High quality PPE for inclement weather and to see and be seen!

Electrical Safety Measures

  • Effective Permit to Work and isolation LOTO systems, supported by training, signage and emergency procedures.
  • De-energize circuits before handling electrical components and ensure to test dead.
  • Label all electrical panels, disconnect switches, and live areas.
  • Conduct insulation resistance tests and verify proper grounding before system activation as per UK electrical safety standards.

Safe Equipment Handling

  • Planned and controlled use of cranes, forklifts, and lifting tools for heavy PV panel packs and mounting structures where possible.
  • Train workers on the correct lifting techniques to prevent musculoskeletal injuries.
  • Store and transport solar modules and cabling carefully to avoid damage and electrical faults.
  • Dedicated logistics areas with loading and stacking limitations as well as controls on ‘split-packs’ where risks of falling materials exists.

Weather and Environmental Safety

  • Medium- short range monitor of weather conditions and halting work during high winds, lightning storms, or extreme heat and cold to prevent injuries.
  • Implement dust control measures in dry environments to prevent respiratory hazards.
  • Secure all loose materials to prevent windborne debris (PV panel instillation tasks).

C. Post-Installation Safety Measures

System Testing and Inspection

  • Perform voltage and continuity tests before system activation.
  • Check for loose connections, overheating components, and adequate grounding.
  • Ensure all warning labels and emergency shutdown procedures are clearly visible and rehearsed before energising.

Security and Access Control

  • Install perimeter fencing to prevent unauthorized access and vandalism.
  • Use surveillance cameras and security patrols to monitor the site.
  • Restrict access to electrical control rooms and substations (Introduce a PTW – permit to work system).

Vegetation Management

  • Schedule regular mowing or grazing to prevent plant overgrowth around solar panels and electrical infrastructures.
  • Use non-invasive ground cover to reduce erosion and dust accumulation.

Ongoing Maintenance and Monitoring

  • Conduct infrared (thermal) inspections to detect overheating components.
  • Monitor system performance using SCADA (Supervisory Control and Data Acquisition) systems.
  • Perform routine inspections for signs of wear, corrosion, or rodent damage to wiring.

3. Emergency Preparedness for Solar PV Fields

Develop a Robust and Practiced Emergency Response Plan

  • Train workers on emergency shutdown and evacuation procedures.
  • Establish clear communication protocols for reporting hazards.
  • Conduct fire and electrical hazard drills regularly.
  • Ensuring effective communications with emergency services is key.  Remembering that emergencies may not be at the front of the site or within the compound, meaning emergency services may need to gain access to emergency areas at points well within the project space.

First Aid and Medical Readiness

  • Provide first aid stations equipped with adequate supplies determined from the hazards associated with the site/works.  Remembering that access must be at the ‘point of need’, meaning that additional and strategically-place first aid and medical response will be needed across the project space. 
  • Ensure there are appointed first aiders throughout the shifts, these must be adequately trained.

Lightning and Storm Preparedness

  • Shut down systems to be developed and in place before severe storms hit.
  • Ensure grounding and surge protection devices are functioning.
  • Ensure fence breaks are designed into the fencing in case of overhead line drops occur due to lightning strikes.
  • Provide designated safe areas for workers during extreme weather events.

Conclusion

The surge toward sustainable energy, especially in the realm of solar PV represents an exciting but demanding challenge in the realm of Health and Safety.  The careful planning and implementation of project safety processes and procedures, together with robust management of workable health and safety solutions is fundamental to execution of a successful and safe project. 

The development of core health and safety requirements within an expanded and mostly remotely place project space, requires careful consideration and planning.

Safety in solar PV field installations is not just a regulatory requirement, it is essential for protecting workers, ensuring system longevity, and preventing costly failures. By implementing a good level of safety procedures, cultural development through active involvement of project personnel, as well as the development of robust emergency preparedness measures, solar PV projects can be constructed and operate efficiently while minimizing risks to project personnel and other key stakeholders such as emergency services.

How can USP help:

USP support a number of Solar clients across the UK, providing the fundamental support and processes to ensure a safe and successful project.

If you want to speak with one of our consultants, please email us at info@universal-safety.co.uk or call us on 01903 942996.