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GlobalSolarReport:2025EditionTheStateof
PVPerformance©
2025RaptorMaps
.Allrights
reserved
.1IntroductionExecutiveSummaryChapter
1:ScalingPower,SharpeningPerformanceChapter2:Anatomy
of
Power
LossChapter3:Benchmarking
DC
HealthConclusionAboutRaptor
MapsContents©
2025RaptorMaps
.Allrights
reserved
.2RaptorMapsstudies
theperformanceandriskprofilesofsolarassets
around
the
world
in
order
to
distill
industry
trends
and
to
highlight
opportunities
for
the
rapidly
growing
solar
industry.ThisreportisasummaryofRaptorMaps’research.The2025Global
Solar
Report
draws
upon
193GWdc
of
utility-scaleandcommercialandindustrial(C&I)solarPVanalysis,with
67GWdc
of
analysis
in2024alone.Inthisreport,youwillfind:·
Assetperformancemetricsover
thelast5yearsandfindings
onmacro-trendsdrivingunderperformance·Commonproblemsfoundandtheirimpactonpower
production·Trendsinsiteworkautomationandresourcedeployment
·
Awiderangeofperformancebenchmarksby:
Typeofpaneltechnologyutilized
Capacityofinstallation
U.S.electricpowermarketsandU.S.statesNoteonUnderperformanceData:Weassignunderperformance(power
loss)by
each
granular
issueobservedtocalculate
power
loss.
This
reportcorrectsfor
sitesinspected
multipletimesinasingle
calendar
year
(an
increasing
trend)
and
significant
outliers.Introduction3ExecutiveSummaryIn2024,thesolarindustrydemonstratedremarkablegrowthandresilience,surpassing2terawatts(TW)in
global
capacity
just
two
years
after
broaching
1terawatt
[1].Thephotovoltaic(PV)markethascementeditspositionasarobustandcompetitivealternativetotraditionalenergygeneration,withtheInternationalEnergyAgency(IEA)projectingsolartoaccountfor80%ofrenewablesgrowthby2030withstronginstallationfromsomeoftheworld’slargesteconomies:[2][3]·Chinaisexpectedtoaccountfor60%ofglobalcapacityexpansion.·TheEuropeanUnionisforecastedto2xtheirinstalledcapacityby2030.·Indiaisexpectedtoemergeasthefourth-largestmarket,growing3.5xincapacity.·TheUnitedStatesinstalled40.5GWin2024,bringingthetotalto219GW.Thesectorhassolidifieditsroleasaneconomicdriver,with$60billioninprivateinvestmentand280,000
jobsnationwide.However,expansivegrowthinthesolarindustryisnotwithoutitschallenges,especiallyasamaturingfleetrevealsnewandat
timesunexpectedriskcategories:·Equipment-drivenunderperformancehastripledoverthelast5years,highlightingacontinuedneedforefficientlydeployingresourcesforreportingissuesandcorrectivemaintenance.·Increasingriskprofiles,emphasizedbysolar’sexposuretoclimatechange-drivenrisks,suchasstorms,floodsandfires.Industrymodelscontinue
tounderestimate
theeffectsofweather-relatedeventsby300+%[4].Assetownershaveturnedtocreativemethods
tomanagerisk,suchaspreventativeinvestmentindesignandmaintenancetoreducecosts.·Ongoinglaborconstraints,especiallyasoperatorscontendwithbothincreasingfleetsizesandaverageinstalledcapacity.In
theU.S.specifically,“nearly70%of
the
truecostofsolarO&Mcomesfromlabor-basedinflationarycosts”[5].[1][2]“Solar
PV
power
capacity
in
the
Net
Zero
Scenario,2015-2030.”IEA,www.iea.org/data-and-statistics/charts/solar-pv-power-capacity-in-the-net-zero-scenario-2015-2030.[3]“Solar
Market
Insight
Report
Q42024.”SEIA/Wood
Mackenzie,10Jan.2025,seia.org/research-resources/solar-market-insight-report-q4-2024.[4]“SolarRiskAssessment.”kwHAnalytics,2024,/solar-risk-assessment.i[5n
i“Tghhtes
Cost
of
Solar
O&M
Is
Increasing.”
Origis
/
Wood
Mackenzie,
2022.
/insights/the-true-cost-of-solar-om-is-increasing-
Raptor
Maps
Global
Solar
Report
:
2025
Edition/TruePoliticalheadwinds,suchasPresidentTrump’stariffsandtheU.S.leavingtheParisClimateAccords,couldimpactthegrowthofU.S.solarasinfrastructureinvestorsmight
gravitate
towardslenientpoliciesfordomesticnaturalgas.ThemomentumofsolargrowthremainsuncertainintheU.S.,evenasDecemberprojectionsstillshowed43GWdc
addedannuallyoverthenextfiveyears[6].Thesethreeindustry-widetrends-rapidgrowth,changingenergypolicylandscape,andincreasingfinancialpressure-underscorethe
importanceofensuringthatalreadyinstalledassetsperformasmodeledtocontinuedeliveringreliable,low-costcleanenergy.Tothatend,RaptorMapshasuncovered4maintrendsinthisyear’sReport:·Whilethegrowthinaverageunderperformanceyear-over-yearhassloweddown,there
isstillsignificantopportunityforownerstoclosethegapbetweenmodeledandactualperformance.In2024,theaveragesolarfarminourdatasetlostupto$5,720/MWdcperyearfromunresolvedequipmentissues.Extrapolatedtothewhole
industry,thatindicatesanannualizedpotentialrevenuelossof$10.0billion[7]from
solarunderperformance.·Ownersandoperatorsareboth
increasinglyadoptingAIandautomationtoreduce
truckrolls,deployingrobotics(suchasremotelyoperateddrones)toinvestigatespecializedusecases.Amongtheseinspections,erosionandcrackinginspections
havebecomemostpopular,comprising23%and18%ofnon-aerialthermography
inspections,respectively.·Highpriorityissuesaccountedfor42%oftotalidentifiedissues,butwereresponsiblefor90%of
observed
revenue
loss.·Over
thepast5years,underperformancehasincreasedacrosssitesofallsizes,butin
2024,weobservedthewidestrangeinperformanceacrossC&Iassets.[6]
“Solar
Market
Insight
Report
Q42024.”SEIA/Wood
Mackenzie,10Jan.2025,
seia.org/research-resources/solar-market-insight-report-q4-2024.[7]Excludesresidentialcapacityandusesglobal
totalaccording
toIEA.Raptor
Maps
Global
Solar
Report
:
2025
Edition
5Aboutthe
dataTheRaptorMapsplatformidentifiesandcategorizesissuesonsolarassets
thatcancausesafety,compliance,orperformanceissues.Ournormalizedandaggregateddatasetof193GWcontainsdataonissuesrangingfromdamagederosionBMPstomodulecracking
to
thermographicanomalies
thatindicatepowerloss.Thisallowsus
to
analyze
theperformanceandconditionsacrosssolarassetsandidentifyindustry-wide
trends.MostofthisreportwillfocusonDChealth,modulecracking,andequipment-driven
underperformance–apotential$10Bproblemfortheglobalsolarindustry.In2024alone,theRaptorMapsplatformanalyzeddatafrom67GWofPVsystems,ofwhich52GWwereforDChealthanalysis.Notably,lostcapacityfromequipmentanomalieshastripled(3.1x)overthelastfiveyears,underscoringthegrowingchallenge
forsolarownersandoperators.ThefollowingsectionhighlightskeytrendsinDChealth
performance,usingdata
tovalidatepatterns
thatmanyin
theindustryhavealreadysensed.Powerlossiscalculatedbyapplyingalossfactor
toeachimpactedmodulebasedon
the
severityof
thedetectedissue.Thisyear’sreportappliesarefinedmethodology
toaccountforassetswithmultipleinspectionswithin
thesameyear,whichisarising
trend
thatRaptorMapshasobserved.200.0150.0100.050.00.021
.3GW
-Non-AerialThermographyDataset172
.0GW
-AerialThermographyDataset2019
20202021
202220232024Raptor
Maps
Global
Solar
Report
:
2025
Edition
6RaptorMaps
DatasetCumulativeGW
over
timeChapter
1SCALINGCAPACITY,SHARPENING
PERFORMANCEIn2024,
theaveragesolarassetexperiencedapotential
revenue
loss
of
$5,720per
MWdc,
peryearfromequipment-drivenunderperformance.Thatrepresentsincreasesof15%from2023and
214%over
the
past5years.7$6000$5000$4000$3000$2000$1000$0AverageSystem
Revenue
Loss
Potential,Annualized$
per
MWdc$5
,720$9772020
2021
2022
2023
2024In2024,powerlossfromDChealthandotherequipmentissues(“powerloss”)continuedits
steadyclimb,withsolarsitesexperiencing5.77%underperformance,upfrom5.00%in2023
[1].Theconsistentincreaseinpowerlossisexpectedasownersandoperatorsnavigatethe
complexitiesofmanagingincreasinglylargerutility-scalesolarsitesandportfolios.[
1
]PowerlosscalculationsassumeDCpowercapacityforannualfigures
.Withtheindustryadjustingtorisingdemand,itiscriticalforownerstotakeproactivestepsin
recoveringlostrevenue—theaverageassetexperiencedannual
izedlossesof$5,720/MWdcin
2024,upfrom$4,617MWdcin2023.Forcontext,a100MWsiteexperiencing5.77%underperformancefromyeartwoofoperationsuntildecommissioningwouldseeitsproject
IRRdropby249basispoints(Modelsource:
NREL,RaptorMapsanalysis)AverageSystem
Power
Loss%ofTotalCapacity5
.77%UnderperformanceContinuestoRise6.00%5.00%4
.00%3
.00%2
.00%1.00%0.00%Raptor
Maps
Global
Solar
Report
:
2025
Edition
82020
2021
2022202320241
.84%Industry
TrendsUnderpinning
RisingUnderperformanceRaptorMaps’datasetprovidesanindicatorintotheoverallDChealthofalreadyinstalled
solarcapacity,providingfurthercontextintothefollowingtrendsinlaborandmanufacturing.First,intheUnitedStates,thegrowthofoperationallaborisfailingtokeeppacewith
therapidexpansionofsolarcapacity.AccordingtotheUSIRECJobsCensusandSEIA/WoodMackenzie,solarcapacityhasgrownby182%over
thepastfiveyears(2019-2023),whileoperationallaborhasincreasedbyonly91%duringthesameperiod
[1][2].With
27%of
operations&maintenance
hiring
due
to
churn,the
costs
of
hiring,
onboarding,andretentionexertadditionalpressuresonbudgetsandtime[3].Second,majorstridesinmanufacturinghavebeenmadeoverthepastdecade,astrackedbythePVELScorecard[4].Infact,morethan20newmanufacturerswererated
TopPerformerswithinthescorecard.However,PVELhasa
lsoobservedacontinuedrise
in
BOM-level
failures
with41%of
BOMs
experiencing
at
least
one
failure
-
up
from32%in2023.Asthesolarindustrycontinuestomatureandscale,efficientlymonitoring
andmanagingpotentialequipmentfailureswillbecritical.Finally,both
themagnitudeandfrequencyofnaturalcatastropheeventscontinue
togrow.In
the2010s,there
were
13.1NOAA
billion-dollar
weather
events
per
year.Theannual
count
more
than
doubled
in2024with27billion-dollar
weather
events
[5].
Fromhailstorms
thatcausecracking
tolightningstorms
thatcanstrikeequipment,owners
andoperatorscontinuetoprioritizetimelyextremeweatherresponse,increasinglyrelyingontechnologyandinnovativeoperatingprocedurestomitigaterisk.[1][3]“NationalSolarJobsCensus”IREC,2024,/census-solar-job-trends/.[2]“SolarMarketInsightReportQ42024.”SEIA/WoodMackenzie,10Jan.2025,/research-resources/solar-market-
insight-report-q4-2024.[4]“The2024PVModuleReliabilityScorecard”KiwaPVEL2024,/.[5]“U.S.Billion-DollarWeatherandClimateDisasters”NOAANationalCentersforEnvironmental
Information(NCEI),2025.
/access/billions/.252015105,,,,,U
.S
.Employment
inSolar
Operations
&
Maintenance
,allfunctions(source
:
IREC)0000000000000000Raptor
Maps
Global
Solar
Report
:
2025
Edition
9CumulativeU
.S
.Installed
SolarCapacity
,GWdc200150100500201920182018202120202023202220212019202020222023+182%+91%3002502001501005,,,,,,0000000000000000000Operations&
MaintenanceAll
OthersWholesaleTrade
&
DistributionManufacturingInstallation
&ProjectDevelopment2019
20202021
2022
2023Spotlight:
OnlyaFractionofSolarJobsforMaintenance6%12%8%29%20%Othercategories:
Management/Professional(29%) Administrative(20%) Sales(12%) Production
and
Manufacturing(8%) All
Other(6%)In2023
,26%ofOperations&
Maintenance
jobs
wereinthe“Installation&Repair
”category27%ofNew
Hires
inOperations
&MaintenancewerebackfillsduetoChurnRaptor
Maps
Global
Solar
Report
:
2025
Edition
10Othercategories:
ExistingEmployee
AddsSolar
Responsibilities(43%) New
Positions(29%)U
.S
.SolarJobs
by
Sector[1
]“National
Solar
Jobs
Census
”IREC
,
2024
,/census-solar-job-trends/
.27%29%26%43%In2024
,PerformanceIntelligenceIs
BridgingPower
Loss
GapsLastyear,RaptorMapsidentifiedmorethan10.8millionDChealthissuesacross44
uniquegigawattsofsolarassetsanalyzed,or249issuesperMWdc.Asmoresolaris
installedandasubstantialportionofinstalledassetsage,assetmanagersandO&M
teamscontinue
toface
thedifficultactofbalancingbetweencorrectiveandpreventativemaintenanceofDChealthissuesandbeyond.AccordingtoRaptorMaps,
dataset,32%of
identified
issues
were
categorized
as“High
Priority”,
accounting
for
90%oftheobservedpowerloss.56%and12%ofidentifiedissueswere“LowPriority”
and“MediumPriority”,respectively.Aerialinspectionsallowforrapiddiagnosingand
geolocatingof
those“HighPriority”issues,especially
thosecausingSCADAalerts,providing
thenecessaryintelligenceforeffectiveandefficientremediation.Thedataemphasizes
thecritical
ityofmaintainingdetailedrecordsofsolarassetperformanceandsiteinfrastructureconditions.Whileaddressingimmediaterepairsnaturallydemandsattentionwhenresourcesarelimited,
theanalysisreveals
thatnearly
70%ofidentifiedissuesfallintomediumorlowprioritycategories,making
itverydifficulttotrack,muchlessremediate,non-highpriorityissuesthatareatriskofescalating
tolargerproblems-andwhichissuesarenot.Thisrealityhasledmanyorganizationstoinvestincentralizedsystemsofrecordandmoreadvancedmethods
ofcapturingdatatomaintaincleardocumentationofthesedevelopingissues,including
morefrequentand
targetedinspections.100%80%60%40%20%0%Raptor
Maps
Global
Solar
Report
:
2025
Edition
11Prioritizing
DC
HealthIssues
:
Frequencyvs
.
Power
Loss
ImpactPriority
Low
Medium
HighIssueFrequency
Power
LossAShift
Towards
Targeted,
RepeatedInspectionsThekey
toemployingperformanceintelligenceisprioritizing
thehighest-impactissues
andleveragingdata
tomakemoreinformedresourcingdecisions.Inlarge-scalesitesbetween50-200MW,low-prioritydefectscontribute
just0.2kWofpowerlossperdefect,
whereashigh-prioritydefectscause6-8kWofpowerlossperdefect.However,itisimportant
tonoteforC&Iandsmallerutility-scalefarms,module-leveldefaultscancause
15-20%ofpowerlossandarenotinsignificantwhenaddressingsiteperformance.Given
currentlaborconstraintsandtighterO&Mbudgets,fixingeverydefectisneitherpractical
norcost-effective.Savvyoperations
teamshavebegun
toshift
towardsdata-informed,
targetedinterventionstorecoverpowerfasterwhileminimizingwindshieldtime.Furthermore,industrydatareflectsashiftawayfrom
treatingaerialinspectionsasisolated
assessmentsandratherasascalableapproach
towardspreventativemonitoring.Notably,
someownersandoperatorshaveinternalized
this
trend,inspecting
thesamesites70%morein2024thanin2023.Withagrowingvolumeofdefectstoremediateormonitor—estimatedatnearly249defectsperMWperyearin2024—operationsteamsarefacinganoverwhelmingbacklog
ofissues
tomanage,andincreasinginspectionfrequencyisnotviable.These
trendshighlighttheurgentneedfortechnologysolutionstoefficientlyidentify,prioritize,andmonitorissuesonsolarfarmswithoutmobilizingpersonnel.Asaresult,manyoperators
areturningtonewtoolstosupportbalancingbetweenmonitoring,preventative,andcorrectivemaintenance,ensuring
themostcriticalissuesareaddressedat
theright
time.
Software-enabledsensorsandon-siteroboticsprovidefrequent,autonomous,andgranulardiagnosesintositehealth.Thisallows
teams
tobedeployedefficiently,inatimelymanner,andonlywhenhumaninterventionisneeded—reducingunnecessarytruck
rolls,automatingreports,andensuring
techniciansarrivepreparedwithclearguidanceand
necessaryequipment,ensuring
techniciansafetyandreducing
timespenton-siteper
task.<5MW5-10
MW10-20
MW
20-50
MW
50-100
MW 100-200
MW 200+
MW
Dataset
total0%
20%
40%
60%
80%
100%Legend
Low
Medium
High<5MW5-10
MW
10-20
MW
20-50
MW
50-100
MW 100-200
MW 200+
MW
Dataset
total0%
20%
40%
60%
80%
100%Raptor
Maps
Global
Solar
Report
:
2025
Edition
12IssueFrequency
,bySeverity
,bySiteSizePowerLoss
,bySeverity
,
bySite
SizeDifferent
Needs
forDifferent
FleetsElevatedpowerlossfromequipmentissuescreatesdifferentchallengesandopportunities
foreachsolarindustrysegment.Forexample,commercialandindustrial(C&I)sitesless
than5MWdcexperiencedanaverageof264identifiedDChealthissuesperMWdc,which
presentssignificantlostrevenueriskwhenaggregatedatthefleet-level.WithC&Iandcommunitysolarfleets
typicallyspreadacrossmanydifferentlocations,balancingpreventativeandcorrectiveeffortscanbecomedifficult,butwithoutthoseefforts,sites
riskhighermagnitudeeventssuchasfiresoroutages.Inresponse,someassetownersandoperatorshaveunlockedeconomiesofscopebyexpanding
thecapabilitiesof
their
teams.Forexample,severalofRaptorMaps’customers
have
trained
technicians
toflydronesandself-performaerialdatacollection,enablinghigh
frequencyperformanceinsightson
theirassetsand
thereallocationof
technician
timepreviouslyspentonmanualinspections
tomoreimpactfulactivities.Assitesgetlarger,
thevolumeofdataandconditions
thatassetmanagersandO&Mteamsmustcareaboutincreasesexponentially,withmanyrequiringsomeformofmanual
intervention.However,increasingportfolios,sitesizes,anddistancesfrompopulationcentershavemadeitdifficulttoconductalltheactivitiesundercontract.Asaresult,RaptorMapshasobservedariseinautomationofmanyvisualinspectionactivitieswithremotelyoperatedrobotics.Forexample,RaptorMapscustomersleverageremotelyoperateddronesinstalledon-sitetoconductinvestigationsofalertsfromSCADAsystems,
whichallowfortechnicianstobedeployedforremediationwiththerighttools,supplies,anddata.Furthermore,usingremotelyoperatedroboticsasafirstmethodofresponsereduces
technicianexposure
topotentiallyhazardousorhigh-voltagesituations,drastically
increasingsafetyandsupportingworkforceretentionefforts.<5MW5-10
MW10-20
MW20-50
MW50-100
MW100-200
MW200+
MWDatasetavgRaptor
Maps
Global
Solar
Report
:
2025
Edition
13IssueFrequency
perMWdc2024
AveragebySiteSize0
100
200300
400
500AutomatingGroundInspections&SiteWalksRemoteoperationsarenottheonlysolutiontopreservingtechniciantime--customers
arealsowidelydeployingaerialinspectionsfornon-DChealthusecases.In2024,civil
worksinspectionswerethemostpopulartypeofnon-DChealthinspectionanalyzedin
theRaptorMapsplatform.Erosion/SWPPPandPerimeterInspections
make
up
more
thanathirdofallnon-DChealthorders.Inaddition,SpecialtyCrackingInspections(e.g.
for
thedetectionofhairlinecracking)havealsogrownpopularasaway
tomitigate
the
riskoffireandgroundfaultsonutility-scalesites,makingup18%ofnon-aerialthermographyinspections.Typicalgroundinspectionsarebeingreplacedacross
theentireO&Mecosystemand
steadilyincreasingincadenceaswell.Ownersandoperatorshavebeenincreasing
the
rateofaerialinspectionsontheirassetsovertime,withinspectionspersiterising70%
from2023to2024.ThisincludesalltypesofinspectiontypesintheRaptorMapsdataset.Historically,from2019to2023,ownersandoperatorstypicallyconductedan
annualaerialinspectionwithanoccasionalmid-yearcheck-inafterabigstormorperformanceissues.Morerecently,theevolvingneedsoftheassetownerhavedriveninspectioncadences
updrastically.Technologyhasenabledtheon-demandcollectionandanalysisofdata
at-scale,allowingformoreproactivemanagementofriskwhilereducingwhentruckrolls
areneeded.Ownerscannowuseaerialinspectionsasapreventativemeasure,ratherthandeployingreactionaryinspections-especiallyonutility-scalesiteswheresiterisks
canexacerbateandbecomeverycostly.P
.O
.I
.*12%Cracking18%Perimeter15%Wiring5%Substation9%Vegetation
1%Erosion/SWPPP23%Breakdownof2024Non-AerialThermographyInspections
,bytype70%
Increase
inConstruction*P.O
.I
.-PointofInterconnection/yr
Inspections
per
Site17%14Raptor
Maps
Global
Solar
Report
:
2025
Edition
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