Technoeconomic Analysis of Robust PV Module Designs to Mitigate Glass Failure

Glass breakage has become a major reliability issue in utility-scale photovoltaic power plants over the last ~5 years, as module sizes have trended larger and glass thickness has decreased to decrease module cost per watt. Module failures have been reported as both ‘spontaneous’ and resulting from extreme weather such as hail and high windspeeds. Here we explore the costs associated with more robust module types, including smaller form factors and thicker glass and frames. We consider not only module costs but also system level effects for components, shipping, and installation. Our analysis shows that ‘hail-resistant’ thicker glass and thicker frames are cost-viable strategies for improving glass reliability. Reverting to smaller modules, however, prohibitively increases system-level costs.