Egypt Benban Solar Park Utility-Scale PV Cable System Configuration

When the Benban Solar Park officially commenced operations in November 2019, this monumental installation in Egypt's Western Desert marked a turning point for renewable energy across the African continent. As a 1.8-gigawatt utility-scale photovoltaic facility spanning 37.2 square kilometers and comprising 41 individual generating plots, the park delivers clean electricity to over 350,000 households annually while eliminating approximately 2 million tons of CO₂ emissions each year.
Behind this landmark achievement, however, lay formidable cable system configuration challenges that tested the engineering capabilities of every supplier involved. As a cable provider for this ambitious undertaking, we understood that in the extreme environment of Egypt's western desert, the cable infrastructure needed to withstand relentless heat, intense UV radiation, and abrasive sandstorms while maintaining optimal power transmission efficiency across a 25-year operational lifespan.
The client's core pain points crystallized around three critical dimensions during the initial project phase. First, standardization complexity—how to achieve consistent voltage drop control across the entire 1.8GW chain from individual modules to the main substation. Second, certification compliance—as a project financed by multilateral institutions including the European Bank for Reconstruction and Development (EBRD) and International Finance Corporation (IFC), all electrical equipment had to meet stringent IEC/EN international standards. Third, delivery urgency—simultaneous construction across 41 plots demanded supply chain responsiveness that few manufacturers could match.
Solution Architecture: End-to-End Cable System Design
Drawing upon comprehensive analysis of Benban's technical specifications and the harsh desert environmental conditions, we engineered a complete cable solution spanning DC generation, AC conversion, and medium-voltage evacuation.
PV DC Cables (Generation Side): Precision Connectivity at Module Level
For the DC side of the photovoltaic arrays, we deployed TÜV-certified solar cables specifically the H1Z2Z2-K series. This selection was driven by the model's exceptional performance under extreme climatic stress—its dual-layer insulation structure (cross-linked polyolefin inner insulation combined with specialized UV-resistant outer sheathing) provides robust protection against ground temperatures reaching 70°C and intense ultraviolet exposure characteristic of Egypt's desert regions.
For short-distance connections from modules to combiner boxes, we specified H1Z2Z2-K 1×6 mm² cables to handle individual string currents. For array configurations requiring higher current capacity, we utilized H1Z2Z2-K 2×4 mm² and H1Z2Z2-K 2×6 mm² variants. Notably, the H1Z2Z2-K 2×6 mm² configuration found extensive application throughout the project for high-power module parallel connections. Its 6mm² conductor cross-section effectively minimizes line losses in parallel branches, while the twin-core structure significantly simplifies on-site wiring complexity.

Main DC Cables: Optimized Long-Distance Transmission
For the critical long-distance DC transmission runs from combiner boxes to inverters, voltage drop management became the design priority. We selected large-section H1Z2Z2-K cables in 1×10 mm², 1×25 mm², and 1×35 mm² specifications, deploying them differentially based on transmission distance and current load. The 10mm² variant served medium-distance runs up to 150 meters, while 25mm² and 35mm² configurations were installed on main lines exceeding 300 meters, ensuring total DC-side voltage drop remained below 1.5%—well within the 3% limit specified by IEC standards.
Low-Voltage AC Cables: Efficient Inverter Output Handling
For AC output from inverters to step-up transformers, we specified YJV/XLPE power cables, selected to balance current-carrying capacity with mechanical durability for low-voltage AC transmission. Our supply included 3×120 mm², 3×185 mm², and 3×240 mm² configurations, with the 185mm² and 240mm² variants primarily deployed at high-capacity central inverter outputs. Their copper conductor cross-sections and XLPE insulation layers effectively manage harmonic currents and thermal loading from inverter operations.
Additionally, for battery interconnections within the storage system, we provided H07V-K flexible cables in 1×25 mm², 1×35 mm², and 1×50 mm² specifications. Their fine-stranded copper conductor construction ensures flexibility and reliability for internal battery cabinet wiring.
Medium-Voltage Cables: Critical Power Evacuation Infrastructure
As the power evacuation backbone of the entire system, the 22kV medium-voltage transmission from pad-mounted transformers through the collection system to the main substations required medium-voltage XLPE insulated cables conforming to IEC 60502 standards. We supplied 1×185 mm² and 1×240 mm² single-core copper configurations, which established reliable underground cable networks among the park's four on-site substations, enabling power aggregation and delivery to the 220kV transmission grid.
Safety Assurance: TÜV Certification and IEC Standard Quality Control Systems
A decisive factor in the client's selection of our company over competing suppliers was our comprehensive international certification portfolio. All cables supplied for the Benban project carried TÜV certification, conforming to EN 50618 and IEC 62930 standards for photovoltaic cables, as well as IEC 60502 for medium-voltage applications. These certifications satisfied not only the mandatory requirements of project financiers but also provided quality assurance for long-term stable operation under harsh desert conditions.
Our manufacturing processes operate under strict ISO 9001 quality management protocols, with complete traceability from copper rod drawing and conductor stranding through insulation extrusion to final product testing. Specifically addressing Benban's environmental challenges, we implemented additional sand penetration resistance testing and high-temperature aging verification, ensuring cable sheathing would not crack or degrade under Egypt's extreme diurnal temperature variations.

Delivery Execution: Supply Chain Coordination at Scale
Confronting the massive material requirements of simultaneous construction across 41 plots, we established a dedicated project service team. From contract execution to first cargo arrival at Alexandria Port, we compressed the total delivery cycle to 60% of industry standard lead times. This achievement stemmed from our mature production capacity—exceeding 500 kilometers monthly of specialized PV cables—coupled with flexible scheduling mechanisms enabling batch deliveries precisely aligned with construction progress.
During peak project execution, we maintained steady shipments of two 40-foot high-cube containers weekly, ultimately supplying over 2,000 kilometers of various cable types to the Benban complex. All shipments included complete factory inspection reports and third-party certification documentation, clearing Egyptian customs and project supervision verification without complication.
Results Validation: Performance Data and Client Feedback
Since achieving full commercial operation in November 2019, the Benban Solar Park has maintained stable performance for over five years. According to monitoring data from the project operator, the 41 generating units served by our cable systems have achieved average DC-side line losses below 1.2% and AC-side losses under 0.8%—significantly outperforming design projections. The zero-failure record of our cable systems under extreme climate conditions directly supports the park's exceptional annual generation exceeding 4 billion kilowatt-hours.
In subsequent communications regarding follow-up cooperation opportunities, project developers identified three decisive factors in their original supplier selection: "The complete certification portfolio eliminated financing bank concerns, the comprehensive product range reduced multi-supplier coordination complexity, and the delivery speed ensured critical construction paths remained on schedule." This feedback validates our integrated service capabilities in large-scale renewable energy developments.
Partnership Value and Industry Insights
The successful implementation of the Benban project established a benchmark case for our presence in African and Middle Eastern utility-scale solar markets. This development demonstrated that in mega-scale renewable energy projects, cable system value extends beyond the physical products to encompass the supplier's deep understanding of international standard frameworks, specialized knowledge of extreme environment applications, and precise control of complex supply chain logistics.
For developers and EPC contractors currently planning similar projects, selecting a cable supplier with a comprehensive product matrix and complete international certification means eliminating technical compliance risks during project financing, achieving more efficient material security during construction, and reducing maintenance costs across the 25-year operational lifecycle.
Contact Us Today
If you are developing utility-scale photovoltaic projects or require IEC/EN-compliant comprehensive solar cable solutions, contact us for customized technical proposals and competitive quotations.
Dongguan GERITEL Electrical Co., Ltd.
Tel/WhatsApp/WeChat: +86 135 1078 4550 / +86 136 6257 9592
Email: manager01@greaterwire.com