Customer Challenge - Custom Test Lead Cable Sets for Wind Turbine Testing

Wind Turbine LPS Testing - Test Leads

Customer Challenge

A customer presented us with a challenge to provide a solution that would enable them to conduct LPS testing of wind turbines.

The LPS testing of wind turbines becomes a challenge when you consider that the LPS ground station Micro-Ohmeter needs to be at ground level, a ground needs to be connected to the blade band and the LPS probe tips need to be at the blades of the turbine.

This requires test leads that are long enough to extend out across the length of the nacelle and then down to the ground.  

This was the challenge that we were presented with by a customer.

Requirements and constraints

The following requirements and constrainsts were established:

• The solution had to be functional using the Valiro AG VG-BAT-150 Micro-Ohmmeter Wind Turbine LPS Tester;
• Must be able to conduct 4-wire measurement;
• Must be cable of reaching a height of 280m by the use of a 200m cable and extensions;
• Cables must be mounted on reels, but not fixed to the reel to they can be unwound completly from the reel.
• The cable needs to be robust and be able to withstand light abrasion against turbine furniture and the ground surface;
• As light as possible;

Our Solution

To address this challenge we decided to choose a solution that uses the following:

Hand reels. In two sizes.  One for 200m lengths and one for lengths less than 100m. 

The reels are made from Impact Copolymer Polypropylene with ABS centres and very light weight (large reel - 785gms, small reel - 375gms).

A 0.75mm² twinflex cable with the following features:

Twisted pair for noise reduction

Non-magnetic conductor construction

High tensile strength / abrasion resistance

Flexible in cold and hot conditions

Meets DEF 61-12 PT 17

Voltage rating: 300/500V

Insulation:  PVC

Kelvin Crocodile clips rated at 25A with a jaw opening of 51mm to enable easy clamping on to turbine blade bands and grounds.

 4mm Banana Plugs and Sockets.  Enabling easy and reliable connection to the micro Ohmmeter and to join different lengths of cable together.

Complete solution

Turbine Kelvin Cable Set, consisting of:

200m 0.75mm2 Twinflex Cable on Cord Wheel, HD Kelvin Crocodile Clip to 4mm Straight Banana Plugs.

50m 0.75mm2 Twinflex Cable Extension on Packreel, 4mm Staright Banana Plugs to 4mm Straight Banana Sockets.

30m 0.75mm2 Twinflex Cable Extension on Packreel, 4mm Staright Banana Plugs to 4mm Straight Banana Sockets.

2x 10m 0.75mm2 Twinflex Cable on Packreel, HD Kelvin Crocodile Clip to 4mm Straight Banana Plugs.