Cables for Wind Turbines–Tackling Extreme Challenges

Wind turbines present extreme conditions for their electrical cabling. The cables and wires used must be able to withstand multiple electrical and mechanical challenges. The nacelle is constantly turning in the wind, subjected the cables in the cable loop to intense bending and torsion forces and extreme climatic conditions. Furthermore, the cables must be able to endure moisture, salt, and changes in temperature. These extraordinary loads call for the use of insulation materials of the highest quality, chosen specifically for the application. As a systems supplier, HELUKABEL develops custom wind turbine cables for every part of the system—from the tip of the hub to the medium-voltage transformer station at the foot of the tower.

• Maximum torsion resistance: specially developed cable construction withstands far more cycles than required of WEA manufacturers.
• Extreme durability: more than 20 years of reliable operation subjected to the harshest conditions.
• One-stop shop for complete solutions: data, control, & power cables, medium-voltage and network connections, compression grips, compression joints, and appropriate tools.
• Immediate availability: many standard and specialty products are available ex stock.
• Solutions for nearly all customer requirements: halogen-free designs or special, global approvals are standard in our warehouse.
• Expert support: technical advice—from planning to installation—from our experienced wind-power specialists.

Wind turbine cables must withstand extraordinary loads: constant torsion due to wind direction tracking, mechanical vibration stress, UV radiation, temperature fluctuations from -40°C to +90°C, as well as chemical influences from oils.

Our wind power cables are suited for use in onshore applications as well as for the demanding internal cabling of offshore systems. Typically, offshore systems are encapsulated, protecting them from salty sea water, however HELUKABEL cables are resistant to salt spray and are therefore designed for long service lives.

Standardisation and quality: testing wind turbine cables

All HELUKABEL wind power cables comply with international standards as well as specific wind turbine standards. Comprehensive tests guarantee long-term reliability under extreme conditions.

In wind turbines, different cable types are used: low-voltage cables in the nacelle and in the base of the tower subjected to very different temperature ranges. Middle-voltage cables conduct electricity to the grid feed. Torsion cables make tracking the direction of the wind in the loop between the tower and the nacelle possible. Data cables transmit control and monitoring signals between the nacelle and the base of the tower. Our complete range includes solutions for all of these. Additionally, we offer pre-assembled fibre-optic cables and accessories for complete solutions. For us, top-quality service from project support specialists both in the office and the field is standard.

The HELUWIND WK POWERLINE ALU power cable for energy transmission combines extreme flexibility with reduced weight. The low-weight aluminium conductor is exceptionally easy to handle, is robust in continuous use, and more affordable than comparable copper cables. This cable is available for immediate delivery in our Online Shop.