The Engineering Gap Costing Solar Companies A Fortune #356

A single design error on a commercial solar project can cost $60,000 to $70,000 to fix. Scott Wyssling and Catherine Kelso of Wyssling Consulting explain what quality design actually looks like, why AI cannot replace a licensed engineer reviewing plans, and how battery integration really fits into commercial solar today.In this episode, Tim Montague sits down with Scott Wyssling, founder and principal at Wyssling Consulting, and Catherine Kelso, Director of Commercial Design and electrical engineer at the firm. Wyssling provides structural and electrical engineering and design for residential and commercial solar and storage projects across the United States. With 75 employees and an engineer-owned, engineer-led structure, the firm has built its reputation on quality control, fast turnaround, and a refusal to treat the PE seal as a formality.With the ITC safe harbor deadline pushing a construction boom through 2027, the pressure to move fast is real. Scott's point is direct: speed without engineering integrity creates liability that lands on the EPC and installer, not just the firm that signed the plans.What you'll learn in this conversation:Why a single design error on a commercial project can cost $60,000 to $70,000 to fix, and how $3,000 to $4,000 in better upfront engineering eliminates that risk entirely.How Wyssling's QAQC process actually works, including internal peer reviews and a 20% audit of already-delivered projects, and why that sets a different standard than automated or outsourced design.Why Catherine Kelso says battery integration is simpler than most EPCs expect, whether you're retrofitting storage onto an existing system or designing it in from day one, and what to watch for when choosing a manufacturer.Scott Wyssling's direct case against letting AI replace hands-on engineering review, and why a licensed PE needs eyes on the actual roof, the actual photos, and the actual electrical equipment.How 15 to 20 year old solar farms are creating a new engineering challenge as 600-volt inverters age out in a market now built around 1,000 and 1,500-volt equipment, and why this only grows from here.Quality control gets treated as optional right up until a six-figure correction lands on your desk. This episode gives you concrete criteria for telling a serious engineering partner from a shortcut operation before you sign anything.Connect with Guests Website: https://www.wysslingconsulting.com/Scott LinkedIn: https://www.linkedin.com/in/scott-wyssling-5b2aa77/Catherine LinkedIn: https://www.linkedin.com/in/catherine-kelso-pe-997b014a/ Support the showConnect with Tim  Clean Power Hour  Clean Power Hour on YouTubeTim on TwitterTim on LinkedIn Email [email protected] Review Clean Power Hour on Apple PodcastsThe Clean Power Hour is produced by the Clean Power Consulting Group and created by Tim Montague. Contact us by email:  [email protected] sponsors who share our mission to speed the energy transition are invited to check out https://www.cleanpowerhour.com/support/The Clean Power Hour is brought to you by CPS America, maker of North America’s number one 3-phase string inverter, with over 6GW shipped in the US. With a focus on commercial and utility-scale solar and energy storage, the company partners with customers to provide unparalleled performance and service. The CPS America product lineup includes 3-phase string inverters from 25kW to 275kW, exceptional data communication and controls, and energy storage solutions designed for seamless integration with CPS America systems.  Learn more at www.chintpowersystems.com