La Chalupa Wind Farm Substation ADSS Fiber Restoration

Acciona Energía operates one of the largest renewable energy portfolios in Texas, including the La Chalupa Wind Farm Substation in Cameron County. During a scheduled outage, a damaged 48-strand ADSS fiber line was discovered, disrupting communication between wind turbines, the substation, and critical control systems.

NCS was rapidly engaged to restore the fiber communication network, protect substation operations, and complete all work within a tight outage window—ensuring minimal impact on power generation and system reliability.

About the La Chalupa Wind Farm

The La Chalupa Wind Farm is the largest wind energy project in Acciona Energía’s North American portfolio. The site includes 63 utility-scale wind turbines and plays a vital role in supporting more than 1 GW of Acciona’s U.S. wind generation capacity.

Reliable fiber communications at the substation are essential for turbine monitoring, system performance, and operational safety. When the ADSS fiber supporting these systems was compromised, immediate restoration became critical to maintaining production integrity and grid reliability.

NCS Scope of Work

NCS was responsible for restoring the communication pathway by rebuilding the damaged ADSS fiber segment and ensuring long-term performance of the network.

Fiber Installation & Certification

• Pre-certified a 1,600-ft spool of 48-strand single-mode ADSS fiber

• Installed new ADSS fiber from Dead-End Structure 69 to Structure 71

• Fusion spliced the new fiber into the existing network

• Removed the damaged fiber segment

• Re-fastened fiber at Pole 6 to ensure long-term reliability

Hardware Installed

• Dome splice enclosures

• Splice case defenders

• Splice trays

• Slack loop storage brackets

• Banding kits

• Dielectric dead-end grips

• Downlead clamps

Challenges & Field Adaptability

Difficult road conditions made structure access challenging, but NCS adapted quickly to maintain progress. During the outage, the client requested an additional aerial support repair, requiring the team to work through the weekend to stay within the fixed timeline.

After returning to Houston, Acciona identified another issue. NCS rapidly sourced materials and mobilized back to the site the next day, resolving the issue without impacting operations.

Collaboration Built on Technical Expertise

NCS provided on-site technical guidance rooted in deep field experience, including a critical consultation regarding fiber tensioning:

• The client initially requested increased tension on the ADSS fiber

• NCS advised against it due to long-term fiber integrity risks

• Specifications were reviewed collaboratively on-site

• Acciona agreed with NCS’s recommended tension levels

This collaborative, specification-driven approach reinforced trust and led Acciona to request further system evaluations and future repair planning support.

Ensuring Reliable Operations and Client Success

This project delivered immediate and long-term value for Acciona Energía by restoring reliable communication across its wind generation assets and protecting ongoing operations. NCS’s ability to respond quickly, adapt to scope changes, and execute within a strict outage window ensured the client could return the La Chalupa Wind Farm to full operation with confidence.

• Restored reliable communication between wind turbines and substation control systems, allowing normal monitoring, control, and safety operations to resume
• Completed all work within the approved outage schedule, even as additional requests were added, helping the client avoid extended downtime or production risk
• Provided trusted technical guidance that supported long-term fiber integrity and reduced future maintenance concerns
• Strengthened Acciona Energía’s confidence in NCS as a responsive, knowledgeable partner for future renewable energy and substation projects
• Supported the long-term reliability of one of Texas’s most important renewable energy assets

By delivering precise fiber restoration and dependable field execution, NCS helped Acciona Energía safeguard system performance, maintain operational continuity, and protect the long-term value of the La Chalupa Wind Farm.