Preventing Costly Delays: Early QA Uncovered Hidden Design Risks in a PV Tracker + Cleaning Robot System
When a KSA-based solar developer ordered a cleaning-robot-integrated PV tracker system, their technical team needed confidence that the equipment matched the design, calculations, and contractual requirements. Trackers are structural systems: when drawings, materials, or calculations don’t align, even small inconsistencies can escalate into performance loss, premature wear, or mechanical failure.
Intertek CEA was brought in to help the client understand what was really being assembled in the factory, and whether it met the expectations set in the contract.
What We Found: A Disconnect Between Documents and Delivered Equipment
During on-site QA inspections, our engineers noticed details that didn’t fully match the project documentation, prompting a deeper technical review.
We uncovered:
Inconsistencies between the design documentation and the engineering assumptions behind it
Differences between the assembled components and what was contractually required
This type of misalignment is common when design, documentation, and manufacturing are carried out by different teams - but without early detection, it can affect how the system performs over its lifetime.
Why It Mattered: Protecting System Reliability and Installation Efficiency
Without early intervention, the inconsistencies could have led to:
Installation delays, as crews reconcile documentation with components delivered on site
Additional labour and rework costs due to incorrect information
Reduced long-term reliability, including mechanical or operational issues stemming from misaligned design assumptions
How We Helped: Going Beyond a Standard QA Inspection
Although verifying the engineering basis behind the documentation was not included in our original scope, our inspectors expanded the review to protect the client’s long-term interests.
We:
Compared documentation sets to identify the source of inconsistencies
Clarified gaps that could lead to mismatches between expected and delivered equipment
Advised the supplier to update documentation and align the delivered components with contractual expectations
Provided the client with a clear view across design, manufacturing, and installation workflows, helping them avoid future disputes
Most auditors simply “inspect to the drawing” – verifying that the factory assembly matches the drawings. In this case, doing so would have overlooked the deeper issue: a mismatch between the design documents and the as-built equipment.
By applying a broader engineering lens, we helped the client understand not only what was being assembled at the factory, but whether that work aligned with the original design intent.
The Outcome: Confidence Restored and Future Risk Reduced
Following our review, the supplier updated their documentation and took corrective steps to align with the contractual agreement.
The client gained:
A system that aligned with the intended design and project requirements
Fewer installation uncertainties, reducing avoidable delays
Clear assurance that the delivered equipment supported long-term performance
Independent validation of the supplier’s corrective actions
The client expressed strong satisfaction with the depth of insight and the proactive approach of our team.
Our Value
This project highlights how early QA, combined with engineering insight, helps clients identify issues that standard inspections often miss. At Intertek CEA, we don’t simply inspect the equipment to be delivered against drawings; we help ensure that documentation, design intent, and installed components are aligned across the full workflow.
For developers or EPCs procuring customized trackers and robotic cleaning systems, Intertek CEA can significantly reduce project risks and support long-term asset health.
