Wind Cable Guide
Table of contents:
Chapter 1: What is Wind cable?
How wind generates?
It’s when a difference occurs between temperature and pressure. This difference cause air to move, which produces wind.
What is wind power?
The wind is moving, which means it is the form of kinetic energy. We convert this kinetic energy into electrical energy. So we call this energy, wind power.
What is the need for wind cable?
The wind is a form of renewable energy. Soon all the fossil fuel reservoirs are going to run out. Then we will be only left with renewable energy sources. So it’s market demand is increasing day by day.
Wind cable is specific for wind power plants and transmission of wind power
The wind cables we are making are a big help to users. They struggle with renewable power energy generation. Our wind cable 100% meets the standards. It has all the features that are the need for a Wind cable.
It is our responsibility to make environment-friendly materials.
Chapter 2: What is the construction of the Wind Cable?
Typical construction of a Wind cable is as follows:
| Conductor: The bare copper conductor is present in a wind cable |
| Insulation: A wind cable has insulation of any of the following PVC, Polyester elastomer, Nylon. |
| Jacket: Black C&M Duralon with separator tape |
| Shield: Tinned Copper Braid Shield |
| Fillers: Fibrillated Polypropylene Fillers, solid Polyvinyl chloride (PVC), |
| are found in a wind cable. |
| Wrap: Aluminum (Out)/Polyester Tape, |
| Expanded Polytetrafluoroethylene (PTFE) Tape, Nylon Spun Tape. |
Chapter 3: What are the types of Wind Cable?
| Standard Flex Wind Power Cable (WTTC Rated) |
| Premium Flex Wind Power Cable (WTTC Rated) |
| Megaflex Wind Turbine Energy Cables (WTTC Rated) |
| Servo Cable (WTTC Rated) |
| VFD Cable (WTTC Rated) |
Chapter 4: What are the model specifications of the types of Wind cable?
Standard Flex Wind Power Cable
Standard Flex Wind Power Cable (WTTC Cable) Standards:
UL Dual Listed:
WTTC Cable and TC-ER
c(UL) CIC
DRY FT4
Test: WTTC cable undergoes testing of 1 million cycles
Standard Flex Wind Power Cable (WTTC Cable) Ratings:
Voltage:
WTTC can bear 1000 Volts
TC-ER 600 Volts
Temperature:
Maximum temperature WTTC can carry 90°C.
Standard Flex Wind Power Cable (WTTC Cable) Applications:
Wind Power Cable has applications in wind turbines.
Standard Flex Wind Power Cable (WTTC Cable) Construction:
| Conductor: 4 Bare Copper Conductors are present in conductors |
| Insulation (Inner): WTTC has PVC insulation |
| Insulation (Outer): WTTC has Nylon insulation |
| Color Code: Black with White Numbers and a Green/Yellow Ground are present in WTTC |
| Fillers: Solid PVC Filler is present in WTTC |
| Wrap: WTTC has Nylon Spun Tape, 25% overlap |
| Shield: Tinned Copper Braid, 85% Coverage |
| Jacket: PVC with Separator Tape |
| Jacket Color: Black is the color of the jacket in WTTC. |
Standard Flex Wind Power Cable (WTTC Cable) Features:
It is recyclable
Standard flex wind power cable resists oils, solvents, chemicals, and fuels
Standard flex wind power cable is abrasion-resistant
It is flexible and easy to install
It is suitable for tight spaces
Its design is for light to moderate flexing applications
Premium Flex Wind Turbine Cable (WTTC Cable):
Standards:
UL Dual Listed:
The standards of the cable are following
WTTC Cable Premium Flex can bear a voltage of 1000 Volts
TC-ER 600 Volts
c(UL) CIC
DRY FT4
WTTC Cable Premium Flex can take a temperature of 90°C
Tests: WTTC cable undergoes testing of 20 mullion cycles
Premium Flex Wind Turbine Cable (WTTC Cable) Applications:
Wind turbine cable has applications in renewable energy power transmission
Premium Flex Wind Turbine Cable (WTTC Cable) Construction:
Conductor: The cable has 4 Bare Copper Conductors
Insulation (Inner): WTTC has a Polyester Elastomer insulation
Color Code: WTTC color code is Black with white numbers, Green/Yellow Ground
Fillers: Fibrillated Polypropylene Fillers are present in WTTC cable
Wrap: Expanded PTFE Tape wraps the cable. It overlaps 50%.
Jacket: Black C&M Duralon with a separator tape
It is a Thermoplastic Rubber Blend. The durability of the material is 15 years. It is resistant to chemicals and abrasions. It is also resistant to continuous flexion.
Premium Flex Wind Turbine Cable (WTTC Cable) Features:
WTTC Cable has recyclable features
WTTC cable resists oils, solvents, chemicals, and fuels
WTTC cable is abrasion-resistant
WTTC cable is flexible and easy to install
WTTC cable is suitable for tight spaces
WTTC cable design is for light to moderate flexing applications
WTTC VFD Cable:
WTTC VFD Cable, Wind Turbine Cable Standards:
UL Dual Listed:
WTTC VFD Cable can bear a 1000 Volts
TC-ER 600 Volts
c(UL) CIC
DRY FT4.
Tests: WTTC VFD Cable undergoes testing to 20 million cycles.
WTTC VFD Cable can bear a temperature of 90°C
WTTC VFD Cable Applications:
WTTC VFD Cable has applications in wind turbines.
WTTC VFD Cable Construction:
Conductor: It has 4 Bare Copper Conductors.
Insulation (Inner): WTTC VFD had Polyester Elastomer insulation
Color Code: It has a color code of Black with white printed numbers, Green/Yellow Ground
Fillers: Fibrillated Polypropylene Fillers are present in WTTC VFD Cable
Wrap: Aluminum (Out)/Polyester Tape wraps WTTC VFD Cable. It has a 25% overlap.
Shield: Tinned Copper Braid Shield is presenting WTTC VFD Cable. It has 85% Coverage on the cable.
Jacket: Black C&M Duralon with separator tape
Material is 15 years durable. It is a thermoplastic rubber blend. Jacket us resistant to chemicals, abrasions, continuous flexion.
WTTC VFD Cable Features:
| WTTC VFD Cable is recyclable |
| WTTC VFD Cable resists oils, solvents, chemicals, and fuels |
| WTTC VFD Cable is abrasion-resistant |
| WTTC VFD Cable is flexible and easy to install |
| WTTC VFD Cable is suitable for tight spaces |
| WTTC VFD Cable has a design for light to moderate flexing applications |
Megaflex Wind Turbine Energy Cables
Industry Standards for Wind Power Cable:
UL Dual Listed:
WTTC can deal with 1000 Volts
TC-ER 600 Volts
c(UL) CIC
DRY FT4
It can bear a temperature of 90°C
Test: The cable undergoes testing to 10 million cycles
Megaflex Wind Turbine Energy Cables (WTTC Rated) Construction:
Conductor: Bare Copper is the conductor
Insulation (Inner): Polyvinylchloride (PVC) is the inner insulating material
Insulation (Outer): Nylon is the outer insulating material
Color Code: Color code of WTTC Cable in Black, Brown, Blue, Green/Yellow Ground
Number of Conductors: 4 bare copper conductors are present in WTTC Cable
Fillers: Solid Polyvinylchloride (PVC) Fillers are present in WTTC Cable
Wrap: Expanded Polytetrafluoroethylene (PTFE) tape wraps the cable. It overlaps the cable up to 50%
Jacket: C&M Duralon with separator tape
Jacket material has the durability of 15 years. The thermoplastic rubber blend is the material of the coat. It shows resistance to chemicals, abrasions, and flexion.
Jacket Color: Black is the color of the jacket
Megaflex Wind Turbine Energy Cables (WTTC Rated) Features:
WTTC Cable is recyclable
WTTC Cable resists oils, solvents, chemicals, and fuels
WTTC Cable is abrasion-resistant
WTTC Cable is flexible. It is easy to install
WTTC Cable is suitable for tight spaces
WTTC Cable has a design for light to moderate flexing applications
Chapter 5: What are the features of Wind Cable?
Design of a Wind Cable:
A wind cable should have rubber insulation, proper sheathing, and thermosetting.
The temperature range of a Wind cable should be -40°C to 90°C.W
Also, such cables must be available that can bear temperatures of +120°C.
Torsion Capability:
A wind cable has torsion capability. It should have a small bending radius. The wind cables need bending, so it should have high flexibility
Resistance: the wind cable is resistant to oils, chemicals, abrasions, fuels, and saltwater.
Saltwater resistant: When the wires are present onshore wind power plants, they are salt water-resistant. This property is fundamental in wind cables. The wind cable has to carry power to overseas supply plants. They have to go through the water in the seas.
Low-smoke, zero-halogen: The wind cable doesn’t produce smoke. The wind cable may burn but doesn’t provide a large amount of smoke.
Halogens are highly reactive gases. Halogens are fluorine, chlorine, bromine, iodine, etc. These gases produce free radicals. The free radicals are harmful to the environment.
The Wind cable does not have halogen in its structure. In this way, the wind cable is environment-friendly.
Flexibility:
The conductor that we use in the Wind cable is copper. It is a highly flexible, annealed soft copper. The copper conductor has strandings. Strandings in a conductor make it flexible. The Wind cable is flexible, which makes it installation easier.
Copper and aluminum cables:
Aluminum is also present as a conductor. It is favorable in ways because it is light in weight. Aluminum is 50% light in weight. Copper is an excellent conductor. The conduction capacity of copper is more than aluminum. Aluminum is cheaper than copper. Though copper has high flexibility, aluminum also meets its needs.
Flame retardant: The wind cable has gone through flame tests. Where we expose the wind cable to a flame, the cable extinguishes the leftover of the fire.
Withstand rigors:
The wind cable is environment-friendly, but it also has to bear the extremes of mother nature. The wind cable has to withstand the pressure of winds. The areas where the wind cable exists have high exposure to winds. The vast regions with thunderstorms and winds need sturdy and durable wire. The wind cable is capable of facing it all.
Electromagnetic interference: The wind cable is resistant to electromagnetic interference. EMI is a phenomenon where interference of magnetic fields. Every wire, cable, and machinery produces a magnetic field. Magnetic fields then interfere with each other and affect the performance.
Ozone resistance: The wind cable has a characteristic feature of UV light resistance.
Environment-friendly: The wind cable is need of the hour. We have to face the challenges of global warming. We have to develop natural sources of power generation. The builders have to make such things that can save the environment. Wind power is a renewable energy source. We are providing wind cables that can be of help in the wind power generation. The wind cable is halogen-free. It has a feature of low smoke.
Chapter 6: What are the applications of Wind Cable?
The demand for renewable energy is increasing. With the problems of global warming we are facing, it is a crucial requirement to chose natural sources. The energy that we generate through natural sources has the least adverse effects on the environmental. Of all the naturals energy sources, wind power is safest.
A wind cable can withstand 15,000 rotations. Wind cable is specific for installation in wind power plants.
Wind power plants are present in areas with winds. The location of Windpower plants includes coastlines, offshore areas, hills, and islands. It is more beneficial to plant on drylands with shores nearby. Its area is less efficient to plant in waters. A wind plant consists of a cable network. There is a network of cables that connect the turbines. Then it transfers that energy to another distribution network.
A high voltage conducting cables are present that connect the wind power plant to the national grid
In wind power plants: Wind cables have applications in wind power plants. There are wind turbines. Wind turbine applications are as follows actuators, automation networks, control circuits,
sensors, pitch controls, and power supply circuits.
In the nacelle:
The wires inside a nacelle connect sensors to control and power devices. The cables that we place in the nacelle should be flexible. Flexible cables can deal with the vibrations of rotation because rotating machinery is present in the nacelle.
Inside a nacelle are present pumps, fans, pitch systems, drives, and fans.
Gearboxes can leak oil and destroy the cable. But the wind cable remains safe as it is oil resistant. We use wind cable in the nacelle because of this property.
In the tower: Inside a tower, wind cables are present. We select wind cables for their unique properties. Every property is serving a purpose. We need a cable that is resistant to oils. Gearboxes often leak and damage the cable. Using an oil-resistant cable can prevent this hazard.
All the cables that we are using in a tower must be flame resistant. The wind cable has a label of FT4. They all go through a flame test.
We use the wind cable in a tower because it can carry a voltage up to 1000V.
Inside a tower, we need cables with higher flexibility. The wind cable meets our needs. It shows flexibility, even in cold temperatures. The wind cable can also work at -40°C temperature. It can withstand vibration at extreme temperatures
Use of High voltage wind cable:
To connect the generator with a power conversion panel, we use high voltage cables. A generator produces a voltage of about 800V. To carry this enormous voltage, we connect several wires in parallel to each other. This combination can carry currents as high as 2400A per phase. A high voltage cable has applications here. The wind cable which can take high voltage is flexible, temperature resistant and with a broad cross-section
Use of underground cable for wind power transmission:
Underground cables to transmit wind power have to face some extremes. It has a bear with the environmental conditions of the soil. Soil could be moist, dry, and can have chemicals. When the cable lays in the ground for a long time, it undergoes deterioration. The wind cable is resistant to chemicals and moisture.
Chapter 7: Where do we use Wind Cable in the wind energy power plant?
Parts of Wind Energy Power plant:
Nacelle
Tower
Collecting system
Substation and transmission
Grounding and SCADA system
Wind cables in the Wind Energy Power plant:
Nacelle Cables: We call Wind cables, Nacelle cables. Nacelle cables are the following: W
Fiber optic, signal cable, control cable, low voltage power cable, medium voltage power cable, grounding wires, cable assemblies. These cables can withstand torsion and vibrations. The cables are easy to install.
Tower Cables: We call the wind cables in the tower, Tower cables. It has the following:
Fiber optic, signal cable, control cable, low voltage power cable, medium voltage power cable, grounding wires, cable assemblies. In a tower, the cable placing is vertical. Copper and aluminum conductors are flexible and easy to install. The cable will remain static and flexible.
Collecting system Cables:
When we use wind cable in the collecting system, we call them collecting cables. The following are collecting cables:
Fiber optic, low voltage power cable, medium voltage power cable, grounding wires, submarine power cables.
The properties of the cable are high dielectric strength and low dielectric loss. Underground cables transmit power to the substation for distribution.
Substation and transmission Cables:
The wind cables that we use in substation and transmission are
Fiber optic, control cable, low voltage power cable, medium voltage power cable, bare overhead conductors, underground transmission cables, submarine power cables.
To transmit power from the substation to the power grid, we use underground and overhead conductors.
Grounding and SCADA system cable:
The wind cables that we employ in the grounding and SCADA system are
Fiber optic cable and grounding wire.
Fiber optics are present for monitoring and operation for wind power plants.
Chapter 8: What are the precautions of the installation of the Wind Cable?
Please carefully observe the given instructions and the special instructions that are present with the equipment you are using.
IMPORTANT:
First of all, observe the site before starting the installation. Think of all the possible hazards.
IT IS LETHAL CONTACTING POWER LINES:
Make sure there are no power lines in the surrounding. Masts antennas, any wire or cables can fall or come in contact.
If a person comes in contact with any of the cable, he might be dead. The wires may fall on people leading to severe injuries or death.
Kindly keep in mind that there should be zero contact possibility between a person and equipment.
During working, you will always see overhead lines. You must keep in mind that they are power lines.
There is a distance between tower, mast, or antenna to the nearest power line. This distance is horizontal. The horizontal distance should be double that of the total length of mast or antenna.
This horizontal distance will not allow the tower to come in contact with power.
Precautions for working at a height: Select a location where you can install your system with ease. Use simple equipment.
Never try installation alone. Always do the work with a friend or labor that has a command over the use of Ladders should always be non-conducting. A big mistake that is done us using a material that is conducting. Horrible hazards can occur because of it. Your shoes should have a sole. Use rubber gloves during working.
Never try to catch a falling tower. Allow it to fall. In your attempt to capturing, you can get hurt.
Never touch a wire during a hazardous situation. The tower can sometimes come in contact with a power line. Call emergency services instead.
Most of the time, on windy days, there are problems in antennas. Never try to fix your antennas or towers on windy days.
Grounding: Grounding is necessary. Never underestimate it. Grounding of all towers and masts is a safety requirement.
Also, see if the electrical cables are in contact with antennas.
INSTALL LIGHTNING ARRESTORS:
The wind power plants are present in vast areas. These areas have frequent thunderstorms and lightning. Having lightning arrestors can prevent such hazards. These arrestors can also prevent short circuit incidents.
Use corrosion-resistant connectors.
What to do when a person comes in contact with a wire?
Do not touch a person who has come in contact with electrical power. People reach to help that person because he can not move. Use nonconducting stuff like a board, wooden stick to push that person away.
Call an emergency service
After the person is forced away from the power line, perform CPR.
