Offshore Wind Cable Monitoring Panels for Renewables Project
Sector: Renewables/Offshore Wind
Scope: Electrical Design & Manufacture of 111 HV Cable Monitoring Panels
Technology: EPLAN Pro Panel, Push-In Terminals & Plug-and-Socket Connections
Impact: Optimised Panel Manufacture & Reduced Offshore Installation Requirements
Project Overview
In January 2026, a customer in the renewables sector approached us with a concept schematic and an in-house prototype for a high-voltage (HV) cable monitoring system.
The prototype had been installed in an offshore wind turbine and was designed to monitor HV cable temperatures and screen currents to detect faults in underwater cabling.
Following the successful proof of concept, the customer received approval to extend the system across a further 27 turbines. This required the manufacture of 107 panels, comprising 27 main monitoring panels and 80 smaller satellite panels.
The Challenge
With tight project deadlines and a limited offshore installation window, the panels needed to be manufactured and delivered efficiently while maintaining the required quality standards.
To meet these requirements, our team was tasked with developing an optimised electrical design that would streamline panel manufacture and minimise installation time offshore.
Our Solution
Our engineering team developed a revised electrical design incorporating several features to improve manufacturing efficiency and simplify offshore installation.
Key design features included:
Larger enclosures: Providing an improved component layout and sufficient space for cable routing.
Push-in terminals: Incorporated across 95% of components to speed up production and minimise routine terminal tightness checks in the offshore environment.
Plug-and-socket connections: Used for all field cabling to reduce on-site installation requirements.
Pre-manufactured field cables: Fully tested prior to delivery.
Pre-terminated field devices: PT100 sensors and current transformers (CTs) pre-terminated into the satellite panels to minimise installation time on site.
Our in-house EPLAN Pro Panel capabilities played an important role in streamlining the design and manufacturing process. Using EPLAN, our engineers were able to export detailed manufacturing data, including core numbers, cable lengths and cable routing information. This enabled the efficient and consistent batch manufacture of the different panel types. 3D renders were also produced to provide the customer with an accurate representation of the panels before production began.
Testing and Delivery
Following manufacture, the panels underwent thorough testing and pre-commissioning activities at our workshop to verify field device functionality and software operation.
The completed panels were then delivered to the customer in batches, using a custom packaging solution to ensure safe transportation.