SOLAR DC CABLE
[CODE NO.3949]
A solar cable is the interconnection cable used in photovoltaic power generation. Solar cables interconnect solar panels and other electrical components of a photovoltaic system. Solar cables are designed to be UV resistant and weather resistant. They can be used within a large temperature range.
DC cables are lifelines of the Solar Power Plant and interconnect modules to combiner boxes to inverters. These cables constitute only around 1-2% of total solar project cost but have a significant role and impact on the power output with poor design and/ or cable selection leading to material safety and performance issues.
DC cables are certainly different than the AC cables in construction and perform power evacuation with certain differences in their operation. Though significantly cheaper, Normal AC cables must not be used for DC PV power evacuation. Copper is the ideal material for string DC cables due to the metal’s high flexibility, superior current carrying capacity and better thermal performance. The DC cables should be made of flexible copper conductors. DC power does not demonstrate the skin effect like AC power and therefore any small change in the copper per unit length of the conductor leads to significant impact on the power evacuation capability of the cable.
COST ESTIMATION
Plant Capacity 1.6 MT/Day
Land & Building (4000 sq.mt.) Rs. 4.48 Cr
Plant & Machinery Rs. 2.55 Cr
Working Capital for 2 Months Rs. 5.04 Cr
Total Capital Investment Rs. 14.42 Cr
Rate of Return 20%
Break Even Point 64%
INTRODUCTION
DUTY PARAMETERS FOR SOLAR DC CABLES:-
1. HIGH TEMPERATURE
2. UV RADIATION
3. FIRE
4. OZONE
5. WATER
6. SHOCK RELATED HAZARD IN DC CABLE
ELECTRICAL CHARACTERISTICS
THERMAL CHARACTERISTICS
MECHANICAL CHARACTERISTICS
EU DIRECTIVES
CHEMICAL CHARACTERISTICS
FIRE PERFORMANCE
FAILURES IN DC CABLES
CASE OF BURNT CABLE
A) PV MODULE TO PV MODULE & PV MODULES TO ARRAY JUNCTION BOX
TYPE 1
TYPE 2
TYPE 3
B) ARRAY JUNCTION BOX TO MAIN JUNCTION BOX AND MAIN
C) INVERTER TO TRANSFORMER PRIMARY
D) TRANSFORMER SECONDARY TO RMU/SWITCHYARD
E) RMU TO SWITCHYARD
SIZES OF DC CABLE
TYPE 1- DIMENSIONS
SOLAR DC CABLES FROM PV MODULE TO ARRAY JUNCTION BOX
TYPE 2 – DIMENSIONS
TYPE 3 – DIMENSIONS
TYPE 1– CURRENT CARRYING CAPACITY
USES AND APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURING PROCESS
(1) DRAWING
(2) ANNEALING
(3) STRANDING
(4) INSULATION
(5) QUALITY CONTROL
CABLES ARE MANUFACTURED AND UNDERGO THE FOLLOWING TESTS:
(A) TYPE TEST:-
THE FOLLOWING TESTS ARE TYPE TEST OF ELECTRICAL POWER CABLE.
PHYSICAL TESTS FOR INSULATION AND SHEATH
(B) ACCEPTANCE TEST:-
THE FOLLOWING SHALL CONSTITUTE ACCEPTANCE TEST:
(C) ROUTINE TEST:-
THE FOLLOWING SHALL CONSTITUTE THE ROUTINE TEST.
CONDUCTOR RESISTANCE TEST OF ELECTRICAL POWER CABLES
TEST FOR THICKNESS OF INSULATION OF POWER CABLE
APPARATUS REQUIRED TESTING FOR THICKNESS OF INSULATION
OF POWER CABLE
PROCEDURE FOR TESTING OF THICKNESS OF INSULATION
OF POWER CABLE
ANNEALING TEST FOR WIRES AND CONDUCTORS
PROCESS OF ANNEALING TEST FOR WIRES AND CONDUCTORS
TENSILE TEST OF CONDUCTORS
APPARATUS REQUIRED FOR TENSILE TEST
METHOD OF TENSILE TEST OF CONDUCTORS
PROCEDURE
PERSULPHATE TEST OF CONDUCTOR
WHY COPPER WIRES ARE TINNED?
METHODS
METHOD A:
METHOD B:
TEST SPECIMEN FOR TINNING TEST (FOR~METHOD B)
WRAPPING TEST FOR CONDUCTORS
(6) COILING AND PACKING
MARKET POSITION
SOLAR CABLE MARKET GROWTH
SOLAR CABLE MARKET DYNAMICS
GLOBAL SOLAR CABLE MARKET GEOGRAPHICAL SHARE
PLANT LAYOUT
SUPPLIERS OF SOLAR DC CABLE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF COPPER WIRE ROD
SUPPLIERS OF PVC COMPOUND CABLE GRADE
SUPPLIERS OF PACKING MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF WIRE DRAWING MACHINES
SUPPLIERS OF PVC EXTRUSION PLANT
SUPPLIERS OF ANNEALING FURNACE
SUPPLIERS OF WIRE STRANDING MACHINE
SUPPLIERS OF WIRE STRATNING MACHINE
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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