Challenges Faced by the Power Sector and How Cable Quality Helps

1. Integrating Renewable Energy

Renewable generation is not constant. A solar plant, for instance, produces differently in the morning, afternoon and evening. Cloud cover can affect output, while wind generation changes with weather conditions.

As more renewable capacity is connected to the grid, the supporting electrical infrastructure needs to handle these variations without compromising performance.

Cables used in these installations have their own requirements. Renewable energy cables in photovoltaic systems may remain outdoors for years, exposed to sunlight, moisture and changing temperatures. They also need to handle the electrical conditions of the system.

IEC 62930 specifies requirements for single-core cross-linked insulated power cables with cross-linked sheaths for photovoltaic systems, covering DC applications up to 1.5 kV. It also specifies a normal continuous maximum conductor temperature of 90°C.

So, cable selection for a renewable project cannot stop at the question of how much current a cable can carry. Where it will operate matters just as much.

2. Dealing With Harsh Installation Conditions

A power cable can spend decades in an environment that is far from ideal.

In an industrial facility, it may be exposed to heat, chemicals, vibration or mechanical stress. An outdoor installation brings UV exposure, rain and temperature fluctuations. Underground cables have different concerns around installation, access and maintenance.

If the cable materials and construction are not suited to these conditions, performance can deteriorate over time.

This is why cable selection needs to consider the actual site. Temperature, moisture, chemicals, mechanical protection and installation method all have a bearing on the cable that should be specified.

For renewable projects, Renewable energy cables need the same level of attention. A cable may perform well electrically on day one, but long-term exposure to the installation environment is a different test altogether.

3. Handling Higher Power Loads

Growing electricity consumption puts more pressure on generation, transmission and distribution infrastructure. Cables, in turn, need to carry the required load while maintaining their electrical and thermal performance.

The materials used in cable construction make a difference here. XLPE insulation, for example, has higher thermal capability than conventional thermoplastic PVC insulation in applications where its specifications are suitable.

Suyog Electricals manufactures XLPE power and control cables for applications involving higher power, overload and short-circuit requirements, with an operating temperature of up to 90°C.

The same thinking applies to renewable installations. Renewable energy cables should be selected according to the system voltage, expected load and operating environment rather than simply by product category.

There is also the question of cost. A cheaper cable may reduce the initial purchase price, but premature replacement can introduce labour, shutdown and maintenance costs later.

4. Maintaining Safety and Compliance

Electrical systems are not forgiving when unsuitable components are used.

Cable insulation, conductor construction and overall design all contribute to safe operation. Standards and testing therefore have an important role in cable selection.

The relevant standard varies with the cable and its application. IEC 60502-2, for example, covers extruded-insulation power cables for rated voltages from 6 kV to 30 kV and includes requirements for construction and testing.

Meeting a standard does not, by itself, make a cable suitable for every project. The product still has to match the voltage, load, environment and installation conditions. But recognised standards and testing give project teams a basis for evaluating cable performance.

Reliability Over the Service Life

Cable failure can be disruptive, particularly when the cable is part of a large power or renewable installation.

Replacement may require shutting down equipment, arranging specialised labour or accessing difficult sections of the installation. The cost is not limited to the cable itself.

A cable designed for its intended conditions, with appropriate insulation, sheathing and construction, is better placed to maintain its performance over its service life.

Protection From the Environment

The environment around a cable matters just as much as the electrical system it connects.

Heat, moisture, chemicals, UV radiation and mechanical stress can all affect cable performance. The right construction provides protection against the conditions the cable is expected to face.

This is particularly relevant for Renewable energy cables, many of which are installed outdoors. Their insulation and sheathing need to be selected with long-term environmental exposure in mind.

For higher-voltage systems, IEC 60840 covers power cables and accessories for systems above 30 kV up to 150 kV and includes requirements and tests relating to areas such as water penetration and fire performance.

Making Safety Part of the Selection Process

Cable quality starts with choosing a product that actually fits the application.

Voltage rating, conductor size, insulation, environmental resistance, mechanical protection and applicable standards all need to be considered before installation. Testing then provides a way to check whether the cable meets the required specifications.

It is a fairly straightforward approach, but an important one: specify correctly first, then verify performance.

There is no single cable that suits every power project. The choice depends on the application and the conditions at the installation site.

Some important considerations are:

• Operating voltage and current

• Expected load and temperature

• Installation method

• Indoor or outdoor exposure

• UV, moisture and chemical exposure

• Mechanical protection

• Fire performance

• Applicable standards

• Expected service and maintenance conditions

For renewable installations, the electrical system and the environment need to be considered together. Renewable energy cables used in solar applications, for example, need to be appropriate for the DC side of the photovoltaic system as well as the conditions in which they will remain installed.

The challenges facing the power sector cannot be solved by cables alone. Grid expansion, energy storage, transmission planning and better management of renewable generation all have a role to play.

But every large power system is built from individual components. Their performance adds up.

Suyog Electricals has more than four decades of experience in manufacturing customised cable solutions for demanding applications. Its portfolio includes XLPE and PVC power and control cables, as well as specialised cables for instrumentation, thermocouples, fire survival, KYNAR/PVDF and EPR applications. The company is ISO 9001:2015 certified and lists approvals and endorsements from organisations including CPRI, ERDA, PGCIL, NTPC, BHEL and RDSO.

As renewable generation expands, the focus will remain on producing and moving electricity reliably. That puts greater importance on every part of the infrastructure supporting it, including the cables connecting generation systems to the wider network.

For a power project, cable quality is therefore not simply a product specification. It is part of the infrastructure’s long-term reliability.