Module 10:

Maintain
The Toolbox on Solar Powered Irrigation Systems is made possible through the global initiative
Powering Agriculture: An Energy Grand Challenge for Development (PAEGC). In 2012, the
United States Agency for International Development (USAID), the Swedish International
Development Cooperation Agency (Sida), the German Federal Ministry for Economic
Cooperation and Development (BMZ), Duke Energy, and the Overseas Private Investment
Cooperation (OPIC) combined resources to create the PAEGC initiative. The objective of
PAEGC is to support new and sustainable approaches to accelerate the development and
deployment of clean energy solutions for increasing agriculture productivity and/or value for
farmers and agribusinesses in developing countries and emerging regions that lack access to
reliable, affordable clean energy.

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Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH on behalf of BMZ as
a funding partner of the global initiative Powering Agriculture: An Energy Grand Challenge for
Development (PAEGC) and
The Food and Agriculture Organization of the United Nations (FAO)

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GIZ Project Sustainable Energy for Food – Powering Agriculture

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1.0 (March 2018)

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ABREVIATIONS

Ah Ampere hour
CWR Crop Water Requirement
DC/AC Direct Current / Alternating Current
ET Evapotranspiration
FAO Food and Agriculture Organization of the United Nations
Gd Daily Global Irradiation
GIZ Gesellschaft für Internationale Zusammenarbeit
GIWR Gross Irrigation Water Requirement
GPFI Global Partnership for Financial Inclusion
HERA GIZ Program Poverty-oriented Basic Energy Services
HT Total Head
IEC International Electrotechnical Commission
IFC International Finance Corporation
IRR Internal Rate of Return
IWR Irrigation Water Requirement
MPPT Maximum Power Point Tracking
NGO Non-Governmental Organization
NIWR Net Irrigation Water Requirement
NPV Net Present Value
m2 square meter
PV photovoltaic
PVP Photovoltaic Pump
SAT Side Acceptance Test
SPIS Solar Powered Irrigation System
STC Standard Test Conditions
TC Temperature Coefficient
UV Ultraviolet
Vd Daily crop water requirement
W Watt
Wp Watt peak
 MAINTAIN

1. Establish and refine maintenance plan

2. Select suitable service provider

3. Implement maintenance routines

4. Documentation and monitoring

4
MODULE AIM & ORIENTATION

Maintaining an SPIS does not require

advanced technical skills. The overall
effort is relatively low when compared to
most other technologies. However, it does
require good and systematic monitoring to
anticipate problems and react timely to
service needs. Given the relatively high
initial investment in SPIS, it is important to
properly maintain each component. In
addition, it is important to monitor changes
in other factors that affect the performance
of the system, such as water availability,
soil health, etc.

PROCESS STEPS

The maintenance routines will influence

the efficiency of operation as well as the
lifetime of the SPIS. The plan can be
formulated by the producer with the help of Concrete irrigation canal
a professional service provider. This
module provides examples of (Source: Lennart Woltering)
maintenance checklists. It is important that
the maintenance activities are
documented and monitored precisely.

1
 1. ESTABLISH AND REFINE MAINTENANCE PLAN

After installation of the system an be considered include the ambient

operations manual should be handed over temperature, the heat dissipation
to the producer (see SET UP Module) by capability (ventilation) and the
the technology supplier, or service relative humidity. For service and
provider. The operations manual includes maintenance purposes, the
instructions for operation, maintenance controller should be easily
and troubleshooting, along with the accessible. Furthermore, there has
contact details of the service provider. to be a circuit breaker between the
Based on this, the service provider and PV generator and the controller.
producer should develop a maintenance Insects and small animals, such as
plan. The producer and the agricultural lizards, like to build their nests in
advisor should revise the maintenance junction boxes and may destroy
plan regularly. electronic components (e.g. by
formic acid). Proper sealing of all
Checklists are helpful tools to ensure that
openings (e.g. with cable glands) is
maintenance is done regularly and
essential
properly. For this SPIS toolbox have been
developed with checklists on the proper  Irrigation System: If drip irrigation
maintenance of the PV generator and the is applied, the water must be
irrigation system. The following aspects filtered because the drip emitters
are important for each of the main can clog easily. Depending on the
components of an SPIS: sediment load of the water, the
filters must be cleaned regularly –
 Water source and pump: Solar this can be up to several times a
pumps generally do not need a lot day. This requires a certain level of
of maintenance if used in clean technical knowledge and skills. In
water, free of sand, sediments or addition, the drip lines must be
aquatic plant growth. The water flushed regularly and the drip
source therefore needs to be kept elements must be examined for
clean. Under these conditions blockages and replaced if
pumps can last up to 10 years. necessary. The SPIS tool
 Solar panels and mounting MAINTAIN – Water Application
structure: Solar panels and their Uniformity Guide is applied to
mounting structure generally check the uniformity of water
require very little maintenance distribution in a drip irrigation
since there are no moving parts. system. The test is part of the
Panels need to be kept clean and system acceptance (see module
free of shade however, while the SET UP) but is also part of a
mounting structures should be routine check. It should also be
stable. The PV array should be considered that for hard water
protected from animals and falling (irrigation water with high dissolved
objects. Well cared for solar panels lime concentrations), scaling up
and mounting structures last up to and clogging of pipes will occur if
20 years. pipes are exposed to heat (direct
 Electronics and controls: As sunshine).
controllers/inverters are sensitive
to overheating, they have to be On the next page an overview of common
installed in a place where faultless failures from the field and the associated
operation is guaranteed. Factors to fixes are given.

2
EXAMPLES OF COMMON INSTALLATION MISTAKES

Example of a dangerous cable

connection
Although the installer already used rubber
tape to insulate the wires, the cable
connection is exposed on the ground.
Electrical safety is questionable,
particularly during irrigation or strong rains.
Galvanic corrosion of a manual
tracking system
Over time, metal objects are subject to
rust and corrosion. Corrosion is normally
associated with non-precious metals such
as steel, zinc and aluminum. In the
presence of air, water or salt, these metals
will corrode rapidly and need to be
covered with a protective sealant.
Limited heat dissipation capability of
corroded controller housing
The metal housing of the pump controller
is extensively corroded. Furthermore, the
housing has no natural ventilation and
after closing its front door, overheating of
the controller may happen.

EXAMPLES OF INADEQUATE
MAINTENANCE

Accumulated grime at the lower end of

a PV panel
Even though only a small part of the panel
is covered in grime it has a big negative
impact on the efficiency of the panel. It can
be easily removed through scrubbing with
a cloth covered sponge or soft brush with
clean water.
Example of shadowing by not
maintained ground vegetation
Solar panels produce less power when
they are shaded and should be placed
where there is no risk of shadows on Example of a dangerous cable connection; Galvanic
corrosion of a manual tracking system; Limited heat
them. A shadow falling on a small part of a
dissipation capability of corroded controller housing;
panel can have a surprisingly large effect Examples of inadequate maintenance Accumulated
on output because the cells within a panel grime at the lower end of a PV panel; Example of PV
are normally all wired in series, the shaded shadowing by not maintained ground vegetation-
cells will affect the current flow of the (Source: Andreas Hahn, 2015)
entire panel!

3
OUTCOME / PRODUCT  agricultural advisors;
 technology and service providers
 Maintenance plan; (electricians, companies providing
 MAINTAIN – Maintenance PV systems).
Checklist;
IMPORTANT ISSUES
 MAINTAIN – Water Application
Uniformity Guide.  Regular maintenance is
indispensable for efficient and long
DATA REQUIREMENTS term operation of any pumping and
irrigation system.
 Instructions on proper maintenance
of each component of the SPIS;  An SPIS is reliable and
maintenance costs are low if
 checklist on water analysis. maintained adequately.
PEOPLE / STAKEHOLDER  Maintenance plans should be
reviewed regularly together with
 Producers / producer groups; the technology/service provider
and the agricultural advisor.
Photo: Lennart
Woltering

Cleaning of solar panels in Ghana as a routine maintenance activity

(Source: Lennart Woltering)

4
 2. SELECT SUITABLE SERVICE PROVIDER

Since the SPIS contains multiple  discuss proposals with technical

components that might not be installed by providers to understand the details;
one provider, it is very likely that several  decide and contract the service
stakeholders are involved in the provider before the system starts
maintenance of the SPIS. operating.
The following maintenance services are
relevant: OUTCOME / PRODUCT

 training/introduction on operations  Service contract.

and use of maintenance tools;
 regular inspection and DATA REQUIREMENTS
maintenance visits (especially in
first months of operation);  Quotations from service providers;
 provision of an operation manual  contract details.
and maintenance tools
(hardcopies); PEOPLE / STAKEHOLDER
 warranty on components;
 Producers / producer groups;
 troubleshooting service (online,
telephone).  agricultural advisors;
 technology and service providers
Ideally the contract with the technical
(electricians, companies providing
provider and / or company responsible for
solar-powered systems).
installation should include maintenance
services. IMPORTANT ISSUES
In case of system failure, do not forget to
check if there is warranty on the  Ideally, the contract with technical
components and service. However, do not provider and / or the company
try to repair the defective component on responsible for installation should
your own. There is a risk of losing include maintenance services.
warranty!  Technology and service providers
In case of the solar panels, warranty can provide valuable assistance /
means performance guarantee, which training, ask for it!
usually decreases with the years (e.g.
90% performance after 10 years, 80%
performance after 20 years).
It is recommended to select an installer
who can also provide maintenance
services. If this is not possible, two or
three quotations of different service
providers should be obtained and
compared:
 determine if prices are quoted for
same range/ type of service;
 discuss proposals with other
technical experts (agricultural
advisors, research institutes, etc.);

5
 3. IMPLEMENT MAINTENANCE ROUTINES

Once the maintenance plan is in place and e) blockage of drip emitters;

the responsible persons identified, the f) condition of water storage facility
maintenance should become a routine. and pipes (leaks, water level);
Critical regular maintenance activities are: g) condition of solar panels and their
mounting system (stability,
1. Check daily if the system is working. cleanness).
If the pump is not working:
a) check the water source and pipes 3. Clean solar panels every two to four
(any dirt, blockage, enough water?); weeks:
b) check the electronics (any burned a) clean water and a little scrubbing
parts, loose wires, emergency with a cloth covered sponge or soft
lights?). brush should remove the most
persistent grime;
2. Inspect the system once a week with b) clean in the early morning or late
respect to: evening, when panels are cool;
a) energy generated by PV system; c) do not step or walk on the panels as
b) pump performance (pumping rate); they could be damaged.
c) condition of water source (purity of
water);
Note: Hot panels should not be sprayed
d) condition of controller and
with cold water – they might crack!
electronics (visible signs of
malfunctioning);

Visual check of the solar panels

(Source: Lennart Woltering)

6
4. Throughout the year (every two to IMPORTANT ISSUES & DECISIONS
three months) the PV system should
be checked thoroughly so that:  Maintaining an SPIS does not
a) no plants grow close to the panel, require advanced technical skills
the mounting structure, water and the overall effort is relatively
source, controller, junction box, etc.; low, when compared to other
b) there is no shade on the panels technologies.
(plants, poles, fences etc.), so as to  It is important to establish
permit maximum radiation; inspection and maintenance
c) the fencing of the solar array is not routines and to schedule them as
damaged; part of the work plan of the farm.
d) the mounting structures are stable.

In addition, the reservoir should be

cleaned and the irrigation system should
be flushed regularly.
Note: Inspect your system always after
strong winds, hail storms, lightening or
earth quakes have occurred in your
region.
After the first experience with a particular
maintenance plan, the timing and
frequency of maintenance can be adapted
to suit the local conditions and capacities
of the producer.
Note: Call your technology provider
(panels, pumping, and controller) or
electrician (electronics) who installed the
system for help – this should be part of the
service contract.

OUTCOME / PRODUCT

 Maintenance plan;
 maintenance sheets;
 checklist for visits to farm;
 weekly inspection sheet;
 bi-monthly inspection sheet;
 MAINTAIN – Maintenance
Checklist.

PEOPLE / STAKEHOLDERS

 Producers /producer groups;

 agricultural advisors;
 technology and service providers
(electricians, companies providing
solar powered systems).

7
 4. DOCUMENTATION AND MONITORING

The monitoring system of a SPIS contains

water meters, pressure meters and other DATA REQUIREMENTS
gauges. The measurement of water flow,
water levels and system pressures are  Costs incurred for replacements
critical for the operation of a SPIS. In and services (bills, dates, brief
addition, the monitoring system is used to: description of cause);
 findings during maintenance visits
 provide system data for the
by agricultural advisors and/or
acceptance test after installation;
technology/service providers
 observe the system’s operation (maintenance check list);
and performance at any time;
 system failures (date, description).
 control water provision and
consumption; PEOPLE / STAKEHOLDERS
 prevent ground water depletion and
connected environmental risks.  Producers /producer groups;
 agricultural advisors;
Even a simple monitoring system with just
 technology and service providers
a water flow meter and a water level
(electricians, companies providing
gauge will be useful for improved decision
solar powered system).
making on SPIS operation.
During daily operation and regular IMPORTANT ISSUES
inspections of the SPIS, the producer
should collect and register systematically  Collecting data should be linked to
data about the system and its the maintenance plan;
performance. This data is fundamental for  data should be compiled regularly;
the producer and service providers, to do  producer might need assistance
regular analysis of the system or/and training initially to enable
performance. Observations, results of correct data registration and
performance checks and repairs should be analysis;
documented systematically. The
establishment of a “log book” is strongly  maintenance efforts can be
recommended obsolete when groundwater in the
region is not managed adequately.
OUTCOME / PRODUCT Groundwater levels should
therefore also be monitored.
 Monitoring data booklet.

8
FURTHER READING, LINKS AND TOOLS

Links
NETAFIM: Drip Irrigation Maintenance. Retrieved from http://www.netafim.com/

SPIS tools
MAINTAIN – Maintenance Checklist
MAINTAIN – Water Application Uniformity Guide

The following tools that are assigned to other Modules are also relevant:
DESIGN – Site Data Collection Tool: on the human resources available on the farm for
operation and maintenance

9
TECHNICAL GLOSSARY

Aquifer Underground geological formation(s), containing usable

amounts of groundwater that can supply wells or springs for
domestic, industrial, and irrigation uses.
Chemigation The process of applying chemicals (fertilizers, insecticides,
herbicides, etc...) to crops or soil through an irrigation system
with the water.
Conveyance loss Loss of water from a channel or pipe during transport, including
losses due to seepage, leakage, evaporation, and other losses.
Crop coefficient Ratio of the actual crop evapotranspiration to its potential (or
reference) evapotranspiration. It is different for each crop and
changes over time with the crop's growth stage.
Crop Water Requirement The amount of water needed by a plant. It depends on the
(CWR) climate, the crop as well as management and environmental
conditions. It is the same as crop evapotranspiration.
Current (I) Current is the electrical flow when voltage is present across a
conductor, or the rate at which charge is flowing, expressed in
amperes [A].
Deep percolation Movement of water downward through the soil profile below the
root zone. This water is lost to the plants and eventually ends up
in the groundwater. [mm]
Drawdown Lowering of level of water in a well due to pumping.
Drip irrigation Water is applied to the soil surface at very low flow rates (drops
or small streams) through emitters. Also known as trickle or
micro-irrigation.
Emitter Small micro-irrigation dispensing device designed to dissipate
pressure and discharge a small uniform flow or trickle of water
at a constant discharge which does not vary significantly
because of minor differences in pressure head. Also called a
"dripper" or "trickler".
Evaporation Loss of water as vapor from the surface of the soil or wet
leaves. [mm]
Evapotranspiration (ET) Combined water lost from evaporation and transpiration. The
crop ET (ETc) can be estimated by calculating the reference ET
for a particular reference crop (ETo for clipped grass) from
weather data and multiplying this by a crop coefficient. The ETc,
or water lost, equals the CWR, or water needed by plant. [mm]
GIWR The Gross Irrigation Water Requirement (GIWR) is used to
express the quantity of water that is required in the irrigation
system. [mm]
Fertigation Application of fertilizers through the irrigation system. A form of
chemigation.

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Financial viability The ability to generate sufficient income to meet operating
expenditure, financing needs and, ideally, to allow profit
generation. It is usually assessed using the Net Present Value
(NPV) and Internal Rate of Return (IRR) approaches together
with estimating the sensitivity of the cost and revenue elements
(See Module INVEST).
Friction loss The loss of pressure due to flow of water in pipe. It depends on
the pipe size (inside diameter), flow rate, and length of pipe. It is
determined by consulting a friction loss chart available in an
engineering reference book or from a pipe supplier. [m]
Global solar radiation (G) The energy carried by radiation on a surface over a certain
period of time. The global solar radiation is locations specific as
it is influenced by clouds, air humidity, climate, elevation and
latitude, etc. The global solar radiation on a horizontal surface is
measured by a network of meteorological stations all over the
world and is expressed in kilowatt hours per square meter
[kWh/m²].
Gravity flow The use of gravity to produce pressure and water flow, for
example when a storage tank is elevated above the point of
use, so that water will flow with no further pumping required.
Head Value of atmospheric pressure at a specific location and
condition. [m]:
Head, total (dynamic) Sum of static, pressure, friction and
velocity head that a pump works against while pumping at a
specific flow rate. [m];
Head loss Energy loss in fluid flow. [m]
Infiltration The act of water entering the soil profile.
Insolation The rate at which solar energy reaches a unit area at the earth
measures in Watts per square meter [W/m2]. Also called solar
irradiance.
Irradiation The integration or summation of insolation (equals solar
irradiance) over a time period expressed in Joules per square
meter (J/m2) or watt-hours per square meter [Wh/m2].
Irrigation Irrigation is the controlled application of water to respond to crop
needs.
Irrigation efficiency Proportion of the irrigation water that is beneficially used to the
irrigation water that is applied. [%]
Irrigation head Control unit to regulate water quantity, quality and pressure in
an irrigation system using different types of valves, pressure
regulators, filters and possibly a chemigation system.
Lateral Pipe(s) that go from the control valves to the sprinklers or drip
emitter tubes.
Latitude Latitude specifies the north–south position of a point on the
Earth's surface. It is an angle which ranges from 0° at the
Equator to 90° (North or South) at the poles. Lines of constant
latitude, or parallels, run east–west as circles parallel to the

11
 equator. Latitude is used together with longitude to specify the
precise location of features on the surface of the Earth.
Leaching Moving soluble materials down through the soil profile with the
water.
Maximum Power Point An important feature in many control boxes to draw the right
Tracking (MPPT) amount of current in order to maintain a high voltage and
achieve maximum system efficiency.
Net Irrigation Water The sum of the individual crop water requirements (CWR) for
Requirements (NIWR) each plant for a given period of time. The NIWR determines how
much water should reach the crop to satisfy its demand for
water in the soil. [mm]
Power (P) Power is the rate at which energy is transferred by an electrical
circuit expressed in watts. Power depends on the amount of
current and voltage in the system. Power equals current
multiplied by voltage (P=I x V). [W]
Photosynthesis Photosynthesis is a process used by plants and other
organisms to convert light energy into chemical energy that can
later be released to fuel the organisms' activities (energy
transformation).
Pressure The measurement of force within a system. This is the force that
moves water through pipes, sprinklers and emitters. Static
pressure is measured when no water is flowing and dynamic
pressure is measured when water is flowing. Pressure and flow
are affected by each other. [bars, psi, kPa]
Priming The process of hand-filling the suction pipe and intake of a
surface pump. Priming is generally necessary when a pump
must be located above the water source.
Pump Converts mechanical energy into hydraulic energy (pressure
and/or flow).
Submersible pump: a motor/pump combination designed to be
placed entirely below the water surface.
Surface pump: pump that is not submersible and placed not
higher than about 7 meters above the surface of the water.
Root Zone The depth or volume of soil from which plants effectively extract
water from. [m]
Salinity (Saline) Salinity refers to the amount of salts dissolved in soil water.
Solar panel efficiency Solar panel efficiency is the ratio of light shining on the panel,
versus the amount of electricity produced. It is expressed as a
percentage. Most systems are around 16% efficient, meaning
16% of the light energy is converted into electricity.
Suction lift Vertical distance from the surface of the water to the pump. This
distance is limited by physics to around 7 meters and should be
minimized for best results. This applies only to surface pumps.

12
Surface irrigation Irrigation method where the soil surface is used to transport the
water via gravity flow from the source to the plants. Common
surface irrigation methods are:
Furrow irrigation – water is applied to row crops in small ditches
or channels between the rows made by tillage implements;
Basin irrigation – water is applied to a completely level area
surrounded by dikes, and
Flood irrigation – water is applied to the soil surface without flow
controls, such as furrows or borders.
Transpiration Water taken up by the plant's roots and transpired out of the
leaves. [mm]
Voltage (U or V) Voltage is the electric potential between two points, or the
difference in charge between two points, expressed in Volts [V].

13