Detailed Project Report on solar dc cable

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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:

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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Detailed Project Report (DPR) includes Present Market Position and Expected Future Demand, Technology, Manufacturing Process, Investment Opportunity, Plant Economics and Project Financials. comprehensive analysis from industry covering detailed reporting and evaluates the position of the industry by providing insights to the SWOT analysis of the industry.

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