Intelligent Access Control Solutions:
Security, Safety and Efficiency on Utility-Scale Solar Projects
Utility-scale solar projects are booming, with expansive sites covering thousands of acres and hosting high-value, high-energy infrastructure. Securing these vast areas with multiple access points is challenging and costly with traditional methods. McCarthy Building Companies, a leader in renewable energy construction, chose BoxLock’s Intelligent Access Control Platform to solve these challenges efficiently. This whitepaper explores how BoxLock provides a scalable, secure, and cost-effective solution that meets the specific demands of large-scale solar projects.
Industry Challenges for Utility Grade Solar Sites
Utility-grade solar installations present unique security and operational challenges:
Vast Perimeter Security Needs: Solar farms are often located in remote areas with multiple access points, making traditional gate guards or manual key systems costly and difficult to manage.
High Energy Density and Worker Turnover: With frequent contractor access for maintenance, inspections, and installations, controlling site access while maintaining security and safety standards is essential.
Compliance with Safety Regulations in High-Energy Environments: Electrocution is the third leading cause of job site fatalities, concerning in energized environments like solar farms, where compliance with safety protocols is crucial.
Perimeter Access Control
With the average acreage for a utility-grade solar project in the U.S. being on average between 5 and 10 acres per megawatt of installed capacity, small projects are around 250 - 500 acres and larger projects span thousands of acres. This poses challenges for anyone trying to meet the requirements of securing such a vaster perimeter that’s often atypically shaped and may not be contiguous.
Perimeter security is crucial due to the high density of materials that can be resold and the high energy density.
Historically, gate guards are used to manage access to solar sites and each worker is checked in manually at each gate. In the past, these lists had been managed with a clipboard. More recently this is done using one of the various digital form based tools allowing the worker to submit on their mobile phone or on the mobile phone of their colleague.
The number of gates per project can vary, though planners need to take into account:
Access for Emergency Services
Maintenance and Operations
Security Measures
Local Regulations
Projects can have anywhere from 15 gates to 40 plus gates, with an average manned gate guard cost exceeding $37k per year, the annual cost for gate guards on a 20 gate single shift project can run close to $1 MM per year with overtime.
BoxLock solution eliminates the need for the manned gate guard by providing full audit logging of who’s entered the perimeter, can turn off access dynamically by worker or during off hours using their existing worker badges. BoxLock’s Alarm Mode can notify site security in the event a gate has been tampered with, allowing them to dispatch security.
The result is a 30-40x ROI over a red rope policy with manned gate guards.
| Project Name | Location | Acreage | Power Outage |
|---|---|---|---|
| Topaz Solar Farm | California | 4,700 | 550 MW |
| Mesquite Solar Farm | Arizona | 4,000 | 400 MW |
| Desert Sunlight Solar Farm | California | 3,800 | 550 MW |
| Invanpah Solar Electrical Generating System |
California | 3,500 | 392 MW |
| Solar Star | California | 3,200 | 579 MW |
| Top 5 Solar Projects in the U.S. | |||
Lockout Tagout Procedures
Enhancing Safety on Combiner Boxes, Photovoltaic Systems, Substations, and Battery Energy Storage Systems (BESS)
Lockout Tagout (LOTO) is a critical safety procedure designed to protect workers by isolating hazardous energy during maintenance or servicing tasks. Utility-scale solar projects, with their vast array of high-energy infrastructure, present unique challenges that require innovative LOTO solutions to maintain compliance and worker safety while enhancing operational efficiency.
Challenges in Solar LOTO Implementation
Complex Energy Isolation Needs: Combiner boxes, PV systems, substations, and BESS contain diverse and high-voltage components that require precise energy isolation protocols to prevent accidents.
Distributed Assets Across Expansive Sites: The decentralized nature of solar farms increases the logistical complexity of managing LOTO processes efficiently.
OSHA Compliance: Solar sites must adhere to stringent OSHA regulations for LOTO, which necessitate rigorous documentation and regular auditing.
Key Applications Requiring Lockout Tagout
Photovoltaic (PV) Systems
High-voltage combiner boxes concentrate energy from PV strings, making them hazardous during servicing.
Combiner Boxes
PV systems remain energized even when disconnected from the grid, posing a constant threat to maintenance crews.
Substations
Substations handle the transition of high-voltage energy, where improper LOTO can lead to electrocutions or equipment damage.
Battery Energy Storage Systems
BESS units store massive amounts of energy and can discharge rapidly, creating risks during repairs or inspections.
BoxLock’s LOTO solutions empower solar project operators to safeguard their workforce and infrastructure while meeting compliance standards and streamlining operational workflows. By integrating advanced technology with proven safety protocols, BoxLock supports the seamless execution of LOTO across critical components like combiner boxes, PV systems, substations, and BESS. This approach not only mitigates risks but also drives operational efficiency in the demanding environment of utility-scale solar farms.
Intelligent Access Control for Solar Projects
BoxLock’s Intelligent Access Control Platform is incredibly effective for managing high-density, high-energy sites like solar farms. Trusted by five of the top seven utility-grade solar contractors, BoxLock combines durable, connected padlocks with a centralized software platform, meeting the security, safety, and compliance needs of modern solar projects.
1
Cost-Effective
Perimeter Security
Challenge
Utility-grade solar projects span vast, remote areas, requiring extensive perimeter security. Traditional gate guards are expensive and impractical on high-density sites with numerous access points.
BoxLock Solution:
BoxLock’s connected padlocks provide secure perimeter control at a fraction of the cost of gate guards, which can cost up to 40 times more per access point. By replacing physical guards with BoxLock devices, contractors can secure each gate affordably, reducing security costs while maintaining robust access control across expansive sites.
2
Controlled Access
to Energized Areas
Challenge
Solar installations with high-voltage equipment pose significant safety risks. Ensuring that only authorized personnel can access energized zones is essential to prevent accidents and protect workers.
BoxLock Solution:
BoxLock’s platform provides site managers with remote access control, enabling them to restrict entry to sensitive, energized areas. With temporary digital keys and automated logging, BoxLock ensures only authorized individuals enter high-risk zones, supporting safety protocols and reducing unauthorized access risks.
3
Streamlined Lockout
Tagout Compliance
Challenge
Solar sites require rigorous LOTO procedures to safely manage energy isolation during maintenance and repairs. Traditional LOTO methods can be time-consuming and error-prone, risking compliance violations.
BoxLock Solution:
BoxLock’s digital LOTO system automates lockout procedures, allowing safety managers to secure de-energized equipment remotely and ensure LOTO compliance. Each activity is logged in real time, providing a reliable audit trail that meets OSHA standards and supports safety documentation, helping reduce human error and improve compliance.
4
Real-Time Alerts
for Safety Compliance
Challenge
Unauthorized access, LOTO non-compliance, and security incidents are ongoing challenges for utility-scale solar sites, particularly when managing numerous remote access points.
BoxLock Solution
BoxLock’s alarm mode and real-time notifications alert site managers to unauthorized access attempts or changes in LOTO status. These proactive alerts allow immediate response to potential security breaches or safety risks, ensuring safe and compliant operations without the need for constant on-site supervision.