Bui Solar Farm Extension Ghana – 10MW Renewable Energy PV Project

In early 2024, we received a comprehensive cable procurement inquiry from Bui Power Authority (BPA), Ghana's leading renewable energy developer. The request centered on the Bui Solar Farm Extension – 10MW Renewable Energy PV Project, a strategic expansion located within the Bui Power Enclave in Ghana's Bono Region. Spanning approximately 297 hectares adjacent to the existing Bui hydroelectric facility, this project represents a critical milestone in Ghana's commitment to the United Nations Framework Convention on Climate Change and the nation's renewable energy roadmap.
The client's challenges were multifaceted and urgent. Situated in a tropical savanna climate zone, the project site experiences extreme environmental stressors: intense year-round ultraviolet radiation, ambient temperatures regularly exceeding 40°C, and prolonged monsoon seasons with humidity levels above 85%. Previous cable installations from other suppliers had demonstrated premature aging within 18-24 months—insulation cracking, conductor oxidation, and connector failures that compromised both energy yield and operational safety.
BPA's technical specifications were non-negotiable: full compliance with IEC 62930 and EN 50618 standards was mandatory for grid interconnection approval. Additionally, the project timeline was aggressive. Any delivery delays would result in daily opportunity costs exceeding $50,000 in lost generation revenue. The client needed a partner capable of delivering certified quality, technical precision, and logistical agility at scale.
Technical Solution Design: Precision Engineering for Three-Tier Architecture
Through three rounds of technical workshops, we developed a comprehensive cable architecture matching the project's electrical topology. The Bui Solar Farm employs a centralized inverter configuration, requiring distinct cable solutions for DC collection, AC transmission, and internal distribution networks.
Tier 1: DC Collection – The Critical Link Between Array and Inverter
Primary Product: H1Z2Z2-K Photovoltaic DC Cable
• Specification: 2×10 mm² solar cable (twin-core construction, 10mm² per conductor)
• Quantity Supplied: 285,000 meters
• Technical Attributes: Tinned copper conductors (IEC 60228 Class 5), cross-linked halogen-free dual-layer insulation, 1500V DC rating, operational temperature range -40°C to +90°C, TÜV-certified with AD8 water resistance rating
The selection of 2×10 mm² solar cable in twin-core configuration was strategically optimized. This design reduces field joint quantities by approximately 50% compared to single-core alternatives, minimizing contact resistance points and potential failure modes. The 10mm² cross-sectional area was calculated precisely for 1500V system architecture: voltage drop remains below 1.5% across typical string lengths, maximizing energy harvest efficiency.
Manufactured through electron-beam cross-linking technology, the H1Z2Z2-K insulation demonstrates exceptional resistance to UV radiation, ozone exposure, and chemical degradation. Accelerated aging tests project a 25-year service life, aligning with photovoltaic module warranty periods. The tinned copper conductors prevent galvanic corrosion in high-humidity environments—a critical consideration for coastal and tropical installations.

Tier 2: AC Transmission – Inverter Output to Grid Interface
Primary Product: H07V-K AC Distribution Cable
• Specification: 1×35 mm² (single-core, 35 square millimeters)
• Quantity Supplied: 42,000 meters
• Application: Inverter AC output to step-up transformer low-voltage side
The 35mm² conductor size was determined through comprehensive load flow analysis, accounting for inverter rated output current and 50-meter transmission distances. This specification ensures conductor temperature rise remains below 60K at full load operation, preserving insulation integrity over decades of service. The H07V-K series utilizes high-grade PVC compound, offering superior flexibility and oil resistance for outdoor tray installations.
Tier 3: Internal Distribution – Building Services and Auxiliary Systems
Primary Product: H07V-U Internal Wiring Cable
• Specifications & Quantities:
◦ 1×2.5 mm²: 18,000 meters (lighting and control circuits)
◦ 1×4 mm²: 12,000 meters (small power distribution)
◦ 1×6 mm²: 8,000 meters (medium loads)
◦ 1×10 mm²: 6,000 meters (power equipment)
◦ 1×16 mm²: 4,000 meters (heavy-duty connections)
This multi-size configuration enables optimized circuit design across control rooms, switchgear facilities, and building services. The single-core solid conductor construction (Type U) is ideal for conduit installation, providing high mechanical strength and cost efficiency for fixed wiring applications.
Total Project Volume: 375,000 meters of cable, occupying three 40-foot high-cube containers, with a project value exceeding $1.2 million USD.
Safety Assurance: Certification Framework and Quality Architecture
The client's selection decision was fundamentally influenced by our comprehensive international certification portfolio. In photovoltaic applications, certifications represent more than compliance documentation—they constitute technical assurance of long-term reliability.
Dual IEC and EN Certification Standards
Our H1Z2Z2-K cable range maintains concurrent certification to IEC 62930 (Photovoltaic Systems Cable Standard) and EN 50618 (European Photovoltaic Cable Standard). These standards establish rigorous benchmarks across mechanical, electrical, and environmental performance domains:
• Insulation Resistance: Minimum 1000 MΩ·km at 20°C, ensuring zero leakage current in saturated humidity conditions
• Dielectric Strength: Withstands 6500V AC for 5 minutes without breakdown—more than 4× system rated voltage
• Thermal Aging: 20,000-hour accelerated aging at 135°C, projecting 25-year operational lifespan
• Fire Safety: Compliant with IEC 60332-1-2 single vertical flame test; low-smoke zero-halogen (LSZH) properties ensure life safety during fire events
TÜV Rheinland Certification: The Gold Standard
TÜV certification represents the photovoltaic industry's most respected third-party validation. Our manufacturing facility undergoes annual TÜV Rheinland surveillance audits, covering raw material verification (tinned copper rod purity ≥99.95%) through finished goods testing (100% high-voltage production testing). This distinguishes our offering from competitors relying solely on type testing—every meter of cable carries certification pedigree.
Differentiated Value Propositions: Beyond Certification
Beyond our certification advantages, two critical capabilities differentiated our proposal:
1. EPC-Grade Project Experience
We operate not as commodity traders but as cable system integrators with direct experience in 50MW+ photovoltaic installations. For the Bui project, we delivered cable sizing calculations, voltage drop verification reports, and installation methodology recommendations—value-added engineering that optimized client tray utilization by 12%. Our anticipatory approach identified installation efficiencies: recommending twin-core 2×10 mm² solar cable reduced MC4 connector requirements by 50%, directly lowering both failure probability and labor hours.
2. Agile Supply Chain Architecture
West African logistics present documented complexities: extended ocean freight durations, customs clearance variability, and inland distribution challenges. We maintain bonded warehousing at Tema Port, Ghana, with strategic pre-positioning of 2×10 mm² solar cable inventory (80,000 meters safety stock for this project). When design modifications required urgent supply of 15,000 meters H07V-K 1×50mm² cable, we executed warehouse withdrawal to site delivery within 72 hours—preventing construction standstill. This regionalized supply chain infrastructure represents a structural advantage unavailable from traditional manufacturers.
Execution Excellence: From Dongguan Manufacturing to Ghanaian Installation
Project execution commenced March 2024, employing a phased rolling delivery strategy synchronized with construction milestones:
Phase 1 (Shipped March 15): 2×10 mm² solar cable 150,000 meters + H07V-K 1×35mm² 25,000 meters. Priority allocation to array field construction, ensuring outdoor installation completion before monsoon season onset.
Phase 2 (Shipped April 20): Remaining 2×10 mm² solar cable 135,000 meters and complete H07V-U range. Coordinated with inverter commissioning schedule for precise indoor electrical construction alignment.
Phase 3 (Shipped May 10): Supplementary and contingency cables, including client-requested H07RN-F 1×25mm² flexible cable (3,000 meters) for mobile equipment applications.
All shipments utilized wooden drum packaging + moisture-barrier film + steel banding to withstand ocean freight stresses. Each drum featured meter-marking inkjet coding and QR-code certification tags, enabling instant digital access to production batch data, inspection reports, and certificate documentation—streamlining client receiving inspection and lifecycle asset management.

Project Outcomes and Operational Validation
Grid synchronization was achieved June 2024. Through Q1 2025, the cable system has maintained zero-fault operation, with actual generation exceeding design projections by 3.2%. This performance premium derives substantially from the low-resistance characteristics of 2×10 mm² solar cable, minimizing resistive losses across the DC collection network.
BPA technical staff reported 20% faster installation progress than scheduled, attributing efficiency gains to reduced jointing requirements from twin-core cable architecture. Recent annual inspection data confirm all cable insulation resistance values remain above 95% of initial measurements, with zero observable aging degradation.
This successful delivery has reinforced our market position in West African renewable energy infrastructure. BPA's subsequent 50MW floating solar initiative has initiated preliminary technical discussions, with cable specification optimization leveraging operational data from the Bui installation.
Partnership Value: Why Engineering-Driven Suppliers Matter
The Bui Solar Farm project systematically addressed three client pain points: quality uncertainty, delivery risk, and technical integration complexity.
• Certification as Trust: IEC + TÜV dual certification eliminated technical risk, with 25-year life projections matching module warranty terms
• Engineering Partnership: From sizing calculations to installation guidance, we deliver system solutions rather than commodity products
• Supply Chain Agility: Regional inventory positioning and phased logistics transform long-lead materials into manageable flow assets
For EPC contractors, developers, and engineering firms planning photovoltaic installations, cable selection represents a foundational decision with 25-year consequences. The quality of 2×10 mm² solar cable and associated infrastructure directly determines operational expenditure and energy yield realization.
Connect With Our Technical Team
Whether developing utility-scale ground mounts, commercial rooftop systems, or off-grid storage solutions, we provide IEC 62930, EN 50618, and TÜV-certified cable systems engineered for your specific application requirements.
Dongguan GERITEL Electrical Co., Ltd.
• Tel/WhatsApp/WeChat: +86 135 1078 4550 / +86 136 6257 9592
• Email: manager01@greaterwire.com
• Website: www.greaterwire.com