The rapid expansion of solar power capacity in China is increasing the need for reliable inspection and maintenance systems at large photovoltaic (PV) installations. A major integrated renewable energy base in southwest China is using the FLIR T540 thermal imaging camera to identify equipment faults, improve inspection efficiency and support preventive maintenance.
China accounts for more than 40% of global photovoltaic capacity, making the country a key market for solar power development. However, large PV installations face challenges such as fluctuating power output, equipment failures, operational risks and the high cost of conventional inspection and maintenance.
At an 80 GW integrated hydro, wind and solar power base in southwest China, the FLIR T540, equipped with a FlexView dual field-of-view lens, is being used across a range of inspection activities. The system allows operators to switch between a 24-degree standard field of view and a 14-degree telephoto view without changing lenses. This helps maintenance teams inspect equipment efficiently and locate faults more accurately.
For solar module inspections, thermal imaging helps identify hot spots caused by shading, physical damage and diode failures. Temperature differences of more than 5°C can indicate potential problem areas, allowing maintenance teams to take corrective action and reduce the risk of power losses.
The camera can also help identify micro-cracks and poor solder connections that may appear as low-temperature linear or mesh patterns. Early identification of these issues can help operators schedule repairs and extend module service life.
Thermal imaging is also used to identify potential PID-related degradation, which can appear as high-temperature patterns along the edges of PV modules. Early detection allows maintenance teams to address affected modules before the problem becomes more serious.
Beyond PV modules, the FLIR T540 is being used to inspect key electrical equipment, including inverters, transformer boxes, battery banks, insulated busbars, SVG systems and incoming cables. Thermal inspection can identify overheating at inverter heat sinks and electrical terminals, helping operators address problems before equipment failure. Battery inspections can reveal abnormal temperature increases and localised hot spots that may affect battery performance and safety.
The system can also detect poor electrical contact and insulation deterioration in busbars, as well as abnormal temperatures in SVG power modules, reactors and cable connections. The dual field-of-view capability allows operators to inspect equipment from a safer distance while maintaining detailed thermal visibility. This is particularly useful when inspecting high-voltage equipment and areas where direct access presents safety risks.
The deployment demonstrates how thermal imaging can support a preventive maintenance approach at large renewable energy facilities. By identifying faults at an early stage, operators can reduce unplanned downtime, improve equipment reliability and manage maintenance resources more effectively as solar power capacity continues to expand.
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