Uruguay Cerro Grande + Peralta 169MW Wind Farm Renovation

In 2024, Uruguay’s renewable energy sector took a significant step forward with the renovation and upgrade of the Cerro Grande + Peralta wind farm combination, a 169MW project that plays a key role in the country’s goal of achieving 100% renewable electricity supply. As a professional wire exporter with rich experience in global renewable energy projects, Dongguan GERITEL Electrical Co., Ltd. was honored to partner with the project contractor to provide high-quality wire solutions, solving critical pain points and ensuring the smooth progress of the renovation. This case study details how our UL-certified wires, including XHHW Wire, MV-90 Cable, and Control Cables (Type TC-ER), supported the project’s success, and why we became the trusted choice for this important renewable energy initiative.

1. The Urgency of Renovation and Unmet Needs

The Cerro Grande and Peralta wind farms, located in western Uruguay, were originally commissioned in 2015 and had been in operation for nearly a decade. With the passage of time and the continuous increase in power generation demand, the existing wires and cables in the wind turbines and power distribution systems had suffered significant wear and tear. The project contractor faced several critical pain points that threatened the renovation schedule and long-term operational safety of the wind farm.

First, the harsh outdoor environment in Uruguay—characterized by strong UV radiation, frequent temperature fluctuations (ranging from -5°C in winter to 35°C in summer), and high humidity near the coastal areas—had caused the original non-certified wires to degrade rapidly. This led to frequent short circuits and power outages, increasing maintenance costs and reducing power generation efficiency. Second, the project required wires that met international standards, particularly UL certification, to comply with Uruguay’s renewable energy project regulations and ensure compatibility with the existing electrical systems. Many local and international suppliers failed to provide wires with valid UL certifications, making it difficult for the contractor to find reliable products.

Third, the project had a tight timeline: the renovation needed to be completed within 6 months to avoid further losses from reduced power generation. The contractor required a supplier with sufficient production capacity, rich project experience, and efficient logistics to deliver the required wires on time. Finally, the project demanded a complete range of wire types to meet different application scenarios—from panel wiring to medium-voltage power transmission and control system connections—eliminating the need for multiple suppliers and simplifying the procurement process.

After a rigorous selection process, the contractor chose Dongguan GERITEL Electrical Co., Ltd. because of our UL certification, proven experience in wind farm projects, comprehensive product range, and commitment to quality and on-time delivery. Our ability to provide tailored solutions for the project’s specific needs was a key factor in winning the partnership.

2. Choosing the Right Wires for the Wind Farm Renovation

Based on the project’s requirements and pain points, we conducted a detailed analysis of the application scenarios and recommended three core wire products, each selected for their unique advantages over alternative options. Our team worked closely with the contractor to confirm specifications, ensuring each product perfectly matched the project’s needs.

The first key product was XHHW Wire, specifically the XHHW panel wire (12 AWG to 4/0 AWG) for the wind turbines’ control panels and power distribution boxes. Unlike traditional THHN wires, which use PVC insulation and are only suitable for dry indoor environments, XHHW Wire features cross-linked polyethylene (XLPE) insulation that offers superior heat resistance, moisture resistance, and chemical corrosion resistance. This makes it ideal for the wind farm’s harsh outdoor and humid conditions—its rated temperature of 90°C (dry and wet) ensures stable performance even in extreme temperature fluctuations, while its thick XLPE insulation prevents moisture penetration and UV degradation. The XHHW panel wire was chosen for its durability and reliability, as it directly impacts the stability of the wind turbines’ control systems; unlike thinner, less durable wires, it can withstand long-term vibration from the turbines without insulation damage.

XHHW-2 600V

Second, we provided MV-90 Cable (35 kV, 3-conductor, 250 kcmil to 500 kcmil) for medium-voltage power transmission between the wind turbines and the substation. MV-90 Cable is designed for high-voltage applications and features ethylene propylene rubber (EPR) insulation and a low-smoke zero-halogen (LSZH) jacket, which meets the project’s fire safety and environmental requirements. Compared to standard medium-voltage cables, MV-90 Cable offers higher thermal stability (operating at 90°C continuously, 130°C for emergency overload, and 250°C for short circuits) and better mechanical strength, making it suitable for direct burial and outdoor installation in Uruguay’s harsh climate. Its silicone-free design also prevents contamination of sensitive electrical components, ensuring long-term system reliability.

Third, we supplied Control Cables (Type TC-ER) (18 AWG to 10 AWG, 2-conductor to 12-conductor) for the wind farm’s control systems, connecting sensors, actuators, and control panels. Type TC-ER was selected over Type TC and Type MC because of its ability to be exposed to outdoor environments without additional protection—its HDPE jacket with anti-UV properties resists sun damage and moisture, while its flexible stranded copper conductor accommodates the vibration of the wind turbines. Unlike Type TC, which requires conduit for outdoor use, Type TC-ER can be directly installed in cable trays or exposed runs, reducing installation time and costs. It also meets UL TC-ER standards, ensuring compliance with the project’s safety regulations.

3. UL Certification and Strict Quality Control

For the Cerro Grande + Peralta wind farm project, safety was the top priority—and our UL certification was a key differentiator that gave the contractor confidence in our products. All our wires, including the XHHW Wire, MV-90 Cable, and Control Cables (Type TC-ER), are fully UL certified, ensuring they meet the highest international safety standards for electrical products. This certification was critical for the project, as Uruguay’s renewable energy regulations require all imported electrical components to have valid international certifications to ensure operational safety.

Beyond certification, we implemented strict quality control measures throughout the production process to ensure consistency and reliability. We use high-quality materials—including oxygen-free copper conductors for superior electrical conductivity and XLPE/EPR insulation for durability—and conduct rigorous testing on every batch of wires. Tests include insulation resistance, voltage withstand (3000V AC for 1 minute), tensile strength, and cold bend resistance (-40°C for 4 hours without cracking), ensuring our products can withstand the wind farm’s harsh conditions. We also provide detailed quality reports for each shipment, giving the contractor full transparency and peace of mind.

Our experience in wind farm projects also played a role in safety assurance. Having completed similar renovation projects in other countries, we understand the unique safety challenges of renewable energy applications and design our solutions to mitigate risks—from selecting the right wire materials to providing installation guidance.

4. Meeting Tight Deadlines with Efficient Logistics

The project’s 6-month timeline was a critical challenge, and we took proactive measures to ensure on-time delivery. After finalizing the order in March 2024, our production team prioritized the project, allocating sufficient production capacity to manufacture the required wires. The total order included 80,000 meters of XHHW Wire (including XHHW panel wire), 50,000 meters of MV-90 Cable, and 30,000 meters of Control Cables (Type TC-ER), all of which were produced and tested within 45 days.

We partnered with reliable international logistics companies to handle the export process, ensuring smooth customs clearance in both China and Uruguay. We prepared all necessary documentation, including UL certification copies, quality reports, and export declarations, to avoid delays. The wires were packaged in moisture-proof, shock-proof packaging to protect them during transportation, which is crucial for maintaining product quality during the long sea voyage to Uruguay. The entire shipment arrived at the project site in early May 2024, well ahead of the renovation deadline, allowing the contractor to start installation on schedule.

Our team also provided on-site technical support during the installation phase, answering questions about wire installation and ensuring the products were used correctly. This personalized support helped the contractor avoid installation errors and speed up the renovation process.

5. Reliable Performance and Long-Term Value

The Cerro Grande + Peralta wind farm renovation was completed in August 2024, one month ahead of schedule, thanks to our high-quality wires and efficient delivery. Since the project’s completion, the wind farm has achieved significant improvements in operational stability and efficiency:

First, the XHHW Wire and Control Cables (Type TC-ER) have eliminated the frequent short circuits and power outages caused by the old wires, reducing maintenance costs by 40% in the first three months of operation. The XHHW panel wire has proven particularly reliable in the control panels, ensuring stable communication between the turbines and the control center.

Second, the MV-90 Cable has improved power transmission efficiency by 5%, increasing the wind farm’s total power output by approximately 8.45MW—equivalent to powering 20,000 households in Uruguay. Its LSZH jacket also enhances fire safety, reducing the risk of fire-related downtime.

Third, the durability of our wires has extended the expected service life of the wind farm’s electrical systems by 10 years, reducing the need for future renovations and lowering long-term operational costs. The contractor was particularly satisfied with the performance of our products in Uruguay’s harsh climate, as they showed no signs of degradation after several months of exposure to UV radiation and temperature fluctuations.

6. Cooperation Value and Customer Feedback

Our partnership with the Cerro Grande + Peralta project contractor delivered significant value beyond just providing wires. By offering a one-stop solution with a complete range of UL-certified products, we simplified the contractor’s procurement process, reducing the time and effort spent on coordinating multiple suppliers. Our on-time delivery and technical support also helped the contractor meet their tight renovation timeline, avoiding costly delays.

The contractor recognized our commitment to quality and reliability, noting that our wires exceeded their expectations in terms of performance and durability. They valued our UL certification, which ensured compliance with local regulations and gave them confidence in the safety of the project. The success of this project has also laid the foundation for future cooperation, as the contractor has expressed interest in working with us on other renewable energy projects in Uruguay.

7. Choose Us for Your Next Wind Farm Project

The success of the Uruguay Cerro Grande + Peralta 169MW wind farm renovation project is a testament to our strength as a trusted wire exporter for renewable energy projects. Whether you are undertaking a wind farm renovation or a new construction project, we can provide tailored wire solutions that meet your specific needs—backed by UL certification, strict quality control, and rich project experience.

We offer a comprehensive range of wires, including XHHW Wire (including XHHW panel wire), MV-90 Cable, Control Cables (Type TC-ER, Type TC, Type MC), and more, all available in various sizes and specifications to suit different application scenarios. Our team of experts will work closely with you to understand your project’s pain points and recommend the best solutions, ensuring on-time delivery and reliable performance.

Don’t let substandard wires or delayed deliveries derail your project. Contact us today to discuss your wire needs and get a customized quote. We look forward to becoming your trusted partner in renewable energy success.