Noor IV Solar PV Plant (Ouarzazate, Morocco)

The Noor Ouarzazate Solar Complex stands as one of the world's most renowned renewable energy facilities, with a total installed capacity exceeding 580MW. This hybrid complex combines photovoltaic and concentrated solar power technologies, with Noor IV serving as the sole photovoltaic unit featuring approximately 70-72MW capacity, commissioned in 2018.
Situated on the edge of the Moroccan Sahara Desert, the project spans 130-230 hectares and receives exceptional solar irradiance of 2,635 kWh/m² annually. However, this extreme environment presents severe challenges for cable systems: temperature swings exceeding 20°C daily, intense UV radiation, abrasive sand and wind, and scorching dry heat reaching 40-50°C in summer—all accelerating cable degradation and increasing O&M costs.
As the EPC contractor, the client faced multiple pressures: stringent equipment certification requirements from multilateral financiers including the World Bank and African Development Bank; extreme sensitivity to LCOE (Levelized Cost of Energy) from investors; and harsh desert construction conditions with tight schedules. They needed more than cables—they required a comprehensive power transmission solution ensuring stable generation across 25 years of operation.
Problem Diagnosis: Six Critical Pain Points in Desert PV Cable Systems
Through in-depth discussions with the project team, we identified six key challenges:
Uncertainty of Cable Lifespan Under Extreme Climate—Concerns about rapid outer sheath aging, cracking, and chalking under intense UV exposure, potentially causing maintenance costs to surge within 5-10 years.
Mechanical Damage Risk from Sand and Dust—Continuous abrasion from sand particles on cable sheaths, with ground cabling and tray installations particularly vulnerable to wind-blown sand, creating DC short-circuit risks if outer layers breach, compounded by extremely high fault location costs in desert terrain.
Voltage Drop Issues from Long-Distance Collection—Large ground-mounted plants spanning tens of megawatts face significant distances from module areas to inverters and step-up stations, where excessive voltage drop directly impacts generation efficiency and IRR.
Balancing Cost and Quality Pressures—Strictly compressed EPC budgets drive aluminum replacing copper as the mainstream trend, yet clients constantly worry about the trade-off between cost reduction and quality assurance.
Certification and Delivery Risks—Multilateral financing demands strict TÜV/IEC compliance, with clients fearing rejected certifications causing customs clearance or acceptance delays.
Construction Efficiency Requirements—Poor desert working conditions and high labor costs mean poor cable flexibility increases joint quantities and failure risks, impacting project schedules.
Solution Design: Three-Layer Cable System Covering Full Chain Requirements
Based on these pain points, we customized a three-layer cable solution for Noor IV covering the entire chain from DC string side to medium-voltage collection.
Layer One: DC Side Photovoltaic Cables (PV String Cabling)
Selected Products: PV1-F / H1Z2Z2-K Solar Cables
Specifications:
• Inter-module jumpers: 4mm² (mainstream)
• Long strings/high-current branches: 6mm²
Product Characteristics:
Specifically designed for PV system DC sides with 1.5kV DC rated voltage, featuring XLPO (cross-linked polyolefin) insulation and UV-resistant black sheathing. Certified by TÜV (Certificate No. B 126326 0001 Rev.00) and UL 4703 (UL File No. E552397). Operating temperature range of -40°C to +120°C fully accommodates Morocco's desert temperature extremes.
Why This Solution Over Standard Cables: Conventional PVC cables show sheath chalking within 2-3 years under intense UV, while XLPO with carbon black sheathing extends UV resistance beyond 25 years. The 4mm² specification balances cost with current carrying capacity for mainstream modules, while 6mm² serves long-string designs with lower line losses.
Layer Two: AC Low-Voltage Side Cables (Inverter Output)
Selected Products: XLPE 0.6/1kV Power Cables
Specifications:
• Inverter to step-up transformer: 3×70mm², 3×95mm², 3×120mm²
Product Characteristics:
Cross-linked polyethylene insulated power cables offer excellent thermal and electrical properties, with 90°C rated operating temperature and 250°C short-circuit tolerance. Copper conductors ensure low resistivity, minimizing power losses at inverter output.
Layer Three: Medium-Voltage Collection System (MV Collection Network)
Selected Products: 15kV/20kV/33kV XLPE Medium-Voltage Cables
Specifications:
• Box transformer to collection lines to step-up station: 1×240mm² Al, 1×300mm² Al (aluminum core)
Product Characteristics:
This represents the project's key profit segment and cost control core. Aluminum alloy conductors replace copper, reducing material costs approximately 40% while maintaining current capacity. UL 1072 medium-voltage certified, compliant with IEC 60502-2, suitable for 33kV and below. XLPE insulation with MDPE or HDPE sheathing provides superior abrasion and chemical corrosion resistance.
Why Aluminum Core Solution: In desert long-distance collection scenarios, aluminum cables' lightweight characteristics reduce transportation and installation difficulty, while conductivity fully meets large-scale PV plant collection needs. The 33kV voltage level is becoming mainstream for Moroccan solar projects, effectively reducing line losses and improving overall IRR.

International Certification System Eliminating Compliance Risks
For Noor IV-type projects involving multilateral financing, certification compliance is a prerequisite for supply. Our cable products hold these core certifications:
• TÜV Certification: Certificate No. B 126326 0001 Rev.00 (photovoltaic cables)
• UL 4703 Certification: UL File No. E552397 (photovoltaic cables)
• UL 1072 Certification: Medium-voltage power cables
These certifications ensure IEC standard compliance and Moroccan grid connection requirements, eliminating client concerns during customs clearance and acceptance.
Additionally, our production follows ISO 9001 quality management systems. Every cable batch undergoes 100% electrical performance testing and visual inspection, with complete Factory Acceptance Test Reports provided to satisfy project financier documentation audits.
Logistics and Construction Coordination in Desert Environments
Noor IV delivery faced unique logistics challenges: equipment needed transport from our Dongguan factory to Morocco's Ouarzazate desert interior, involving ocean freight, customs clearance, and inland transportation. We developed phased delivery plans:
Phase One: DC photovoltaic and low-voltage cables delivered first to meet on-site module installation and inverter commissioning needs.
Phase Two: Medium-voltage collection cables delivered in batches according to step-up station and box transformer construction progress, reducing on-site storage pressure.
All cables use wooden drum packaging with outer waterproofing for ocean and desert storage conditions. We prepared complete certificates of origin, packing lists, commercial invoices, and certification copies in advance to ensure smooth customs clearance. For desert construction conditions, we optimized cable drum specifications to accommodate limited on-site lifting equipment.
Seven Years of Stable Operation Proving Reliability
Since 2018 commissioning, Noor IV has operated continuously and stably, contributing clean power to Morocco's national grid. Our cable systems demonstrate excellence in: 
Weather Resistance Verification: After seven-plus years of intense UV and sand exposure, cable sheaths show no significant aging or cracking, validating XLPO materials and UV-resistant formulations for long-term reliability.
Stable Electrical Performance: Aluminum core cables in the medium-voltage collection system operate well at 33kV, with line losses within design ranges and no cable-related outages.
Controllable O&M Costs: Extremely low cable failure rates mean the project operator has incurred virtually no cable-related maintenance costs during operation, effectively supporting LCOE targets.
From Supplier to Long-Term Technical Partner
Through Noor IV collaboration, we established a long-term partnership based on technical trust and delivery reliability. Clients particularly valued:
Technical Response Speed: During project preparation, we provided detailed technical selection advice for Morocco's desert environment, helping the EPC team optimize cable specifications and avoid cost waste from over-design.
Certification Support Capability: Complete and authoritative certification packages (TÜV, UL, etc.) passed financier and Moroccan grid company audits without compliance issues.
Delivery Flexibility: Phased delivery models perfectly matched desert construction schedules, with no impact on critical milestones even under constrained logistics.
This success case also established our foundation for subsequent participation in Moroccan and broader North African solar projects.
Cable Experts for Desert Solar Projects
In extreme application scenarios like desert solar plants, cables are not mere commodities but critical infrastructure affecting project lifecycle returns. Choosing GERITEL provides:
Field-Proven Desert Environment Solutions—Noor IV and similar projects' successful operation proves our product reliability under extreme climates
Complete International Certification System—TÜV and UL dual certification meeting multilateral financing and grid connection requirements
Flexible Aluminum and Copper Configurations—Optimal conductor material solutions based on project budget and performance needs
End-to-End Delivery Support from Factory to Site—Professional logistics planning and documentation ensuring on-time delivery
25-Year Lifetime Design—XLPO insulation, UV-resistant sheathing, and high-weatherability materials reducing long-term O&M costs
Take Action Now: Start Your Project Partnership
If you are planning solar projects in Morocco, the Middle East, or other desert regions, contact our technical team for customized cable selection proposals and quotations.
Dongguan GERITEL Electrical Co., Ltd.
Tel/WhatsApp/WeChat: +86 135 1078 4550 / +86 136 6257 9592
Email: manager01@greaterwire.com
We look forward to becoming your reliable cable partner for your next renewable energy project.