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From Guestimation to Optimisation Redefining Utility-Scale PV Design Workflows

18th June 2025

     

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The global energy landscape is undergoing a monumental shift, with solar energy emerging as a dominant force in the transition to clean energy. As the International Energy Agency (IEA) forecasts over 5,500 GW of renewable energy to be added globally by 2030, with new solar capacity accounting for 80% of this growth, the imperative for efficient and precise utility-scale solar design has never been greater. 

“The traditional approach to designing utility-scale solar farms is often met with inefficiencies, leading to project delays and missed opportunities for optimisation,” says Paul Nel, Chief  Executive Officer at 7SecondSolar, who has developed breakthrough software - AUTOPV used to automate the design of large, complex photovoltaic installations. “With the trajectory of the solar sector, energy engineers should be adding design automation to their toolbox so that value engineering can be the focus from the outset.” 

Designing utility-scale solar farms has historically been a protracted process, often taking months to complete, due to the complexity and manual nature of traditional design methods. Following the traditional design approach, engineers are often forced to work with a single design iteration, often without the opportunity to fully explore alternatives. This isn't just inefficient; it's a significant impediment to maximising the potential of solar energy.

Each megawatt of solar is typically designed only once, leaving little to no room for crucial optimisation or value engineering. “This is a staggering reality given that an estimated $27 billion will be spent on designing utility-scale solar projects over the next five years, translating to roughly 100,000 work years - requiring 20,000 engineers to keep pace. Despite this immense investment of time and resources, the industry largely foregoes the benefits of iterative design,” says Nel.

AUTOPV™ fundamentally transforms this paradigm and enables engineers to produce multiple construction-ready designs in a matter of minutes or hours, rather than months. This rapid iteration capability allows for comprehensive comparisons of various site layouts and equipment configurations. The software goes beyond basic feasibility, delivering detailed design iterations that optimise the revenue of PV plants over their entire lifecycle.

“The benefits of AUTOPV™ extend to the core pain points of energy engineers. The software automates every step from stringing logic to cable routes, eliminating the need for manual redrawing with every design change. This liberates engineers from tedious, repetitive tasks, allowing them to dedicate their expertise to strategic optimisation. We understand the frustration of spending weeks in CAD and spreadsheets, constantly battling design changes. Our aim is to provide a tool that moves as fast as an engineer's thinking, enabling them to unlock the best version of their PV site quickly and accurately."

As the world is rapidly moving towards a future powered by clean energy, the demand for utility-scale solar will only intensify. Solutions like AUTOPV™ are not merely incremental improvements; they represent a fundamental shift in how large-scale solar projects are conceptualised, designed, and optimsed. By embracing computational design and iterative exploration, the industry can confidently scale solar to its maximum potential, ensuring a greener, more prosperous future.

Edited by Creamer Media Reporter

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