Project:: 2Mw Electrolysis Pilot Plant

Project:
2MW ELECTROLYSIS PILOT PLANT
Title:
Cable Sizing Calculation and Criteria
Document No.: 092-556-F-E-01006 Issue 2
Purpose of issue: Information Date: 2023-06-30
Prepared: AJI
Reviewed: ALB
Approved: VPA
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2 2023-06-30 INFORMATION AJI ALB VPA
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CUSTOMER (OWNER) PROJECT

CLIENTE (PROPIETARIO) PROYECTO
2MW Electrolysis Pilot Plant

Sines Refinery
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PETROGAL, S.A.
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2MW Electrolysis Pilot Plant

Sines Refinery
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Date of Printing: 20/02/24
AUTHOR: AJI
DOC.: Cable sizing calculation and criteria
SIZE: A4 LANGUAGE: English ED: 2 REV: 1
INDEX
Page No.
1. PURPOSE...................................................................................................................
1.1 APPLICABLE CODES AND STANDARDS................................................................
2. LIST OF DOCUMENT INPUT DATA...........................................................................
3. STARTING DATA......................................................................................................
3.1 DESING TEMPERATURES AND GROUND DATA.................................................
3.2 CABLE LINES...........................................................................................................
3.2.1 MEDIUM VOLTAGE CABLES................................................................
3.2.2 LOW VOLTAGE CABLES......................................................................
3.3 CABLE CHARACTERISTICS AND CORRECTION FACTORS...............................
3.3.1 MEDIUM VOLTAGE CABLES................................................................
3.3.2 LOW VOLTAGE CABLES......................................................................
4. ASSUMPTIONS.........................................................................................................
4.1 MEDIUM VOLTAGE CABLES..................................................................................
4.2 LOW VOLTAGE CABLES.........................................................................................
5. METHODOLOGY AND CRITERIA FOR THE DETERMINATION OF
THE CABLE SECTION..............................................................................................
5.1 SIZING OF MEDIUM VOLTAGE CABLES...............................................................
5.1.1 SHORT CIRCUIT CURRENT.................................................................
5.1.2 MAXIMUM CURRENT-CARRYING CAPACITIES.................................
5.1.3 VOLTAGE DROP...................................................................................
5.2 SIZING OF LOW VOLTAGE CABLES......................................................................
5.2.1 SHORT CIRCUIT CURRENT.................................................................
5.2.2 MAXIMUM CURRENT-CARRYING CAPACITIES.................................
5.2.3 VOLTAGE DROP...................................................................................
6. SUPPORTING CALCULATIONS...............................................................................
6.1 THREE PHASE LINES FROM QE-57-1-1 (6B1) AND QE-51-2-1
(5A1).........................................................................................................................
6.2 THREE PHASE LINES TO/FROM QE-91-3-01........................................................
6.3 LINES TO/FROM QE-UPS-91-4-01..........................................................................
Este documento es propiedad de DF y deberá ser gestionado bajo las This document contains proprietary information of DF and is subject to Page 6 of 32
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AUTHOR: AJI
1. PURPOSE
The purpose of this Technical Report is to justify by means of calculations the minimum
section of the different Medium and Low voltage cables in the 2MW ELECTROLYSIS PILOT
PLANT that PETROGAL, S.A. will install in Sines (Portugal). The criteria to be used in the
calculation of the medium and low voltage cables are also defined.
This document is mandatory for all engineering and design activities related to the
development of the Hydroelectric Power Plant project.
2. APPLICABLE CODES AND STANDARDS
Unless otherwise expressly indicated, the cables and components to be supplied shall be
designed, manufactured and testedconclusions and calculations shown in this document
have been done in compliance with the codes and regulations listed below, always
considering the latest edition on the award date of the order.
 IEC 60502-1 Power cables with extruded insulation and their accessories for
rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV) -
Part 1: Cables for rated voltages from 1 kV (Um = 1,2 kV) up to 3
kV (Um= 3,6kV)
Part 2: Cables for rated voltages from 6 kV (Um =7,2 kV) up to 30
kV (Um = 36kV)
Part 4: Test requirements on accessories for cables with rated
voltages from 6 kV (Um = 7,2 kV) up to 30 kV (Um = 36 kV)
 IEC 60228 Conductors of insulated cables
 IEC 60287 Electrical Cables – Calculation of the Current RatingIEC 60287

Electrical Cables – Calculation of the Current Rating
 IEC 60364-5-52 Low-voltage electrical installations - Part 5-52: Selection and erection
of electrical equipment - Wiring systems
 IEC 60364-4-41 Low voltage electrical installations - Part 4-41: Protection for safety -
Protection against electric shock
 IEC 60364-4-43 Low voltage electrical installations - Part 4-43: Protection for safety -
Protection against overcurrent
AUTHOR: AJI
Part 1: Cables for rated voltages from 1 kV (Um = 1,2 kV) up to 3

kV (Um= 3,6kV)
Part 2: Cables for rated voltages from 6 kV (Um =7,2 kV) up to 30
kV (Um = 36kV)
 IEC 60865 Short-circuit currents - Calculation of effects
 IEC 60028 International standard of resistance for copper
 IEC 60331-11 Test for electric and optical cables under fire conditions. Circuit
integrity – Part 11. Apparatus. Fire alone at a flame temperature of
at least 750°C.
 IEC 60332-1-2 Test on electric and optical fibre cables under fire conditions – Part
1-2: Test for vertical flame propagation for a single insulated wire or
cable – Procedure for 1kW pre-mixed flame.
 IEC 60332-3 Test on electric cables under fire conditions – Part 3: Test for
vertical flame or vertically-mounted bunched wires or cables –
Apparatus
 IEC 60332-3-24 Test for vertical flame spread of vertically-mounted bunched wires
or cables – Category C.
 IEC 60364 Low-voltage electrical installations
 IEC 60702 Mineral insulated cables and their terminations with a rated voltage
not exceeding 750 V.
 IEC 61034-2 Measurement of smoke density of cables burning under defined

conditions – Part 2: Test procedure and requirements.
 IEC 60754-1 Test on gases evolved during combustion of materials from cables –
Parte 1: Determination of halogen acid content
 IEC 60754-2 Test on gases evolved during combustion of materials from cables –
Parte 2: Determination of acidity and conductivity
 IEC 61442 Electric cables - Test methods for accessories for power cables with
rated voltages from 6 kV (Um=7,2 kV) up to 30 kV (Um=36 kV)
 IEC 60793-1 Optical fibres - Part 1-1: Measurement methods and test procedures
 IEC 60794-1-1 Optical fibre cables - Part 1-1: Generic specification – General
 IEC 61156 Multicore and symmetrical pair/quad cables for digital

communications
 2011/305/EUIEC 60909 Short-circuit currents in three-phase a.c. systems
AUTHOR: AJI
 IEC 60949 Calculation of thermally permissible short-circuit currents, taking into

account non-adiabatic heating effects
 Regulation of Construction products (CDP/CPR)
 EN 60811 Electric and optical fibre cables – test methods for non-metallic
materials
 EN 13501 Fire classification of construction products and building elements.

Classification using data from reaction to fire tests.
 EN 50575 Power, control and communication cables. Cables for general

applications in construction works subject to reaction to fire
requirements
 EN 50399 Common test methods for cables under fire conditions - Heat
release and smoke production measurement on cables during flame
spread test - Test apparatus, procedures, results
 UIC 895 OR Hydrocarbon resistant (RH)
Cables must have CE marked.
In general, all directives aimed at preserving personnel safety and health shall apply.
If any discrepancies arise between the different codes and standards or with this
Specification, the most restrictive regulation shall apply. In any other case, Engineering shall
be informed and shall decide on the applicable code or standard.
The administrative and security conditions required by the CLIENT shall be fulfilled.
[3.] LIST OF DOCUMENT INPUT DATA
No. Source document

Requirement/Data
Ord No. Rev. Title
Short circuit calculations Electrical
1 HE-16410-GEN-041 01 General characteristics
Study and Analysis
2 HE-16120-GEN-052 021 General load list General characteristics
‍
‍
‍
‍
‍
‍
‍
AUTHOR: AJI
No. Source document

Requirement/Data
Ord No. Rev. Title
‍
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‍
AUTHOR: AJI
[4.] STARTING DATA
2.1[4.1] DESING TEMPERATURES AND GROUND DATA
The cables will be designed for an ambient temperature of 40 ° C.
In the case of buried cables, a ground temperature of 25ºC is considered.
For Medium Voltage cables and Low Voltage cables, the resistivity value of 1.50 K.m/W is
selected for the calculations.
2.2[4.2] CABLE LINES
2.2.1[4.2.1] Medium Voltage Cables
The interconnection cables between the equipment will be conducted, in general, by means
of galvanized steel trays of the ladder type or by means of trenches embedded in the
ground.
For the purposes of calculating the dimensioning of Medium Voltage cables, the following
types of possible cable raceways are therefore considered:
 Channels embedded in the floor:
- Cables laid inside trenches
2.2.2[4.2.2] Low Voltage Cables
The interconnection cables between equipment and/or switchboards will, in general, be

routed through galvanized steel trays (ladder and/or mesh type), buried banks of PVC
ducts, rigid steel conduits and flexible conduits or trenches embedded in the ground.
For the purposes of calculating the dimensioning of Low voltage cables, the following types
of possible conduits are therefore considered:
 Channels embedded in the floor:
- Cables laid inside trenches.

- Cables in trays beneath a false floor.
 Air canalizations:
AUTHOR: AJI
- Cables laid on ladder trays and/or mesh trays (in general and unless some very
particular conditioning of the installation imposes it, no more than two layers of
power or lighting cables will be laid on the same tray and with no separation
between cables). A reserve of 20% will be considered for future extensions.
2.3[4.3] CABLE CHARACTERISTICS AND CORRECTION FACTORS
2.3.1[4.3.1] Medium Voltage Cables
2.3.1.1[4.3.1.1] Cable length
The lengths of the cables are measured taking as reference the layout plans of the trenches
and equipment.
2.3.1.2[4.3.1.2] General Characteristics
The Medium Voltage power cables shall comply with:
 IEC 60502.
 IEC 60228.
 IEC 60502-2.
 IEC 60332-1-2.
 IEC 60332-3-24.
 UIC 895 OR.
Cables are unipolar and multicore with a nominal insulation voltage of 3.6/6 kV and 12/20 kV
and have stranded copper conductors, class 2 (IEC 60228). All cables shall have a red PVC
outer sheath and for single-core, two Layers of aluminum helix-wound armoring (ATA) and
for multi-core cables, two layers of galvanized steel tape helix-wound armoring (STA).
The Medium Voltage power cables shall be fire and flame retardant.
The Medium Voltage power cables shall be hydrocarbons resistant according to UIC 895
OR.
The cables will be multipolar for sections smaller than 95 mm2 and unipolar for sections
equal to or greater than 95 mm2, up to a maximum limit of 300 mm2.
AUTHOR: AJI
The insulation of the conductors is resistant to humidity, heating and aging, based on
crosslinked polyethylene (XLPE).
2.3.1.3[4.3.1.3] Short circuit currents
The following table shows the values of the three-phaseriphasic short-circuit current in 10 kV
and 3 kV cabinets that have been obtained from the document “Short circuit calculations
Electrical Study and Analysis” (HE-16410-GEN-041).
CODE NAME I”k(kA) ip(kA peak) Ik(kA)

QE-57-1-1(6B1) MEDIUM VOLTAGE 10 kV 23.7313873 59.9642396 16.1896619
QE-51-2-1(5A1) MEDIUM VOLTAGE 3 kV 13.3082731 31.8755188 11.5783458
Table 1: Short Circuit Currents (Medium Voltage)
Where:
 I”k: Symmetrical initial short-circuit current.
 ip: Peak value of the short-circuit current.
 Ik: Permanent short-circuit current.
2.3.1.4[4.3.1.4] Current-carrying capacities
For single-core XLPE insulated cable conductors with U0/U = 3.6/6 kV or 12/20 kV, the
current-carrying capacities is as indicated in the following table.
Reference document: Table B.2 (buried) of IEC 60502-2 and typical manufacturer's data
(regarding external diameters, resistance and reactance at 90ºC).
No. conductors External Resistance Reactance Current buried direct

x section diameter 90ºC (Ω/km) (Ω/km) in ground (1 and 2) (A)
(mm2) (mm)
3 (1x70) 33.1 0.339 0.103 239
3 (1x95) 34.8 0.245 0.098 285
3 (1x120) 36 0.195 0.095 323
3 (1x150) 38.3 0.159 0.092 361
Table 2: Characteristic data of single-core cables 3.6/6 kV (Medium Voltage)
No. conductors External Resistance Reactance Current buried direct

x section diameter 90ºC (Ω/km) (Ω/km) in ground (1 and 2) (A)
(mm2) (mm)
3 (1x70) 28.6 0.399 0.130 239
3 (1x95) 30.1 0.245 0.125 285
AUTHOR: AJI
3 (1x120) 31.5 0.195 0.120 323

3 (1x150) 38.4 0.159 0.117 361
Table 3: Characteristic data of single-core cables 12/20 kV (Medium Voltage)
(1) Since the maximum current-carrying capacities for this type of installation are not specified in the standard,
values equal to those with trefoil formation.
(2) Ground temperature 20ºC; Depth of laying 0.8 m; Thermal resistivity of soil 1.5 K.m/W.
These ampacities will be corrected to consider the real installation and ambient conditions of
the site, according to the factors indicated in section 43.3.1.6.
2.3.1.5[4.3.1.5] Short-circuit current capacity
For XLPE insulated cable conductors with U0/U = 3.6/6 kV or 12/20 kV, the allowable short-
circuit current density is as indicated in the table below.
According to the specification of the project, the short circuit duration to be considered will be
300 ms.
Reference document: IEC 60949.
MAXIMUM ALLOWABLE SHORT CIRCUIT CURRENT, A/ mm2,

COPPER CONDUCTORS
Short Circuit Duration (s)
Cable insulation
0.1 0.2 0.3 0.5 1
XLPE 452 319 261 202 143
Table 4: Maximum short-circuit current of the cable (Medium Voltage)
2.3.1.6[4.3.1.6] Correction factors for current-carrying capacities
2.3.1.6.1[4.3.1.6.1] Temperature correction factors in buried installations
The correction factors for the current-carrying capacities for ground temperatures other than
20ºC to be applied for unipolar and three-pole cables buried directly in the ground, are those
indicated in the table below.
Reference document: Annex B of IEC 60502-2 (table B-11), for a conductor service
temperature of 90°C:
AUTHOR: AJI
Ground temperature
Correction factor
(ºC)
10 1.07
15 1.04
20 1
25 0.96
30 0.93
35 0.89
40 0.85
45 0.80
50 0.76
Table 5: Correction factors for ambient ground temperatures other than 20ºC to be
applied to the values of the current-carrying capacities for buried installations
(Medium Voltage)
2.3.1.6.2[4.3.1.6.2] Correction factor depending on the resistivity of the ground
The correction factors of the current-carrying capacities for cables unipolar (direct buried) in
terrains of resistivity different from 1.5 K.m/W, are those indicated in the table shown below.
Reference document: Annex B of IEC 60502-2 (table B-14):
Section Soil thermal resistivity

(mm2) 0.7 0.8 0.9 1.0 1.5 2.0 2.5 3.0
1x95 1.34 1.28 1.22 1.18 1.00 0.89 0.80 0.74
1x120 1.34 1.28 1.22 1.18 1.00 0.88 0.80 0.74
1x150 1.35 1.28 1.23 1.18 1.00 0.88 0.80 0.74
Table 6: Correction factors for soil thermal resistivities other than 1.5 K.m/W for direct
buried single-core cables ducts (Medium Voltage)
2.3.1.6.3[4.3.1.6.3] Correction factor for grouping in buried installations
The reduction factors by grouping for several groups of three-phase circuits of single-core
cables installed direct in the ground, are those indicated in the table shown below.
Spacing No of circuits
between
cables 2 3 4 5 6 7 8 9 10 11 12
centres (m)
Touching
0.73 0.60 0.54 0.49 0.46 0.43 0.41 0.39 0.37 0.36 0.35
(d=0)
AUTHOR: AJI
Spacing No of circuits
between
cables 2 3 4 5 6 7 8 9 10 11 12
d=0,2 0.83 0.73 0.68 0.63 0.61 0.58 0.57 0.55 0.54 0.53 0.52
d=0,4 0.88 0.79 0.75 0.72 0.70 0.68 0.67 0.66 0.65 0.64 0.64
d=0,6 0.90 0.83 0.80 0.78 0.76 0.75 0.77 0.73 --- --- ---
d=0,8 0.92 0.86 0.84 0.82 0.81 0.80 --- --- --- --- ---
Table 7: Correction factors for groups of three-phase circuits of single-core cables in

horizontal formation laid direct in the ground (Medium Voltage)
2.3.1.6.4[4.3.1.6.4] Correction factor as a function of depth in buried installations
The IEC 60502-2 standard contemplates a burial depth of 0.8 meters. When the burial depth
in our project differs from this value, the maximum current-carrying capacities of the tables
must be corrected according to the values in table B.12.
The reduction factors for single-core and three-core cables installed direct in the ground,
depending on the depth, are those indicated in the table shown below.
The correction factor will be given by the depth of burial and the type of cable. It is necessary
to estimate if the cable that we are going to use is going to be smaller or bigger than 185
mm2.
Section of cables Section of cables

Depth (m)
2
≤185 mm >185 mm2
0.50 1.04 1.06
0.60 1.02 1.04
0.80 1.00 1.00
1.00 0.98 0.97
1.25 0.96 0.95
1.50 0.95 0.93
1.75 0.94 0.91
2.00 0.93 0.90
2.50 0.91 0.88
3.00 0.90 0.86
Table 8: Correction factors for depths of laying other than 0.8 m for direct buried
cables (Medium Voltage)
We will enter an iterative process where we must check if the estimates are true. This
process should not take more than one or two iterations.
AUTHOR: AJI
2.3.1.6.5[4.3.1.6.5] Correction factor for Hazardous areas
For those cables that are installed in hazardous areas, a correction factor of 0.85 should be
applied, according to Portaria 949A/2006.
2.3.2[4.3.2] Low Voltage Cables
2.3.2.1[4.3.2.1] Cable length
The lengths of the cables are measured taking as reference the layout plans of the
trays, trenches and equipment.
2.3.2.2[4.3.2.2] General Characteristics
The conductors are made of annealed electrolytic copper of flexible type class 5 (PO-ENG-
BES-1600-101, section 5.10.7) with insulation resistant to humidity, heating and aging, based
on cross-linked polyethylene (XLPE). The outer shell will be black color and the rated
insulation voltage is 0.6/1 kV.
The Low Voltage power cables shall comply with:
 IEC 60502-1.
 IEC 60228.
 IEC 60332-1-2.
 IEC 60332-3-24.
 EN 60811.
 EN 50575.
 EN 13501.
 EN 50399.
 UIC 895 OR.
The single-core cables shall have two layers of aluminum helix-wound armoring (ATA) and
the multi-core cables shall have two layers of galvanized steel tape helix-wound armoring
(STA) and they should be hydrocarbons resistant according to UIC 895 OR standard.
AUTHOR: AJI
The cables shall be fire and flame retardant and shall comply with CPR regulation with a
classification Cca-s1b, d1, a1.
The maximum conductor temperature is 90ºC in permanent service and 250ºC in short
circuit.
The minimum sections to use in Low Voltage are:
 • Power cables 2.5 mm²
 • Lighting cables 2.5 mm²
 • Control cables 2.5 mm²
The cables will be multipolar for sections smaller than 95 mm 2 and unipolar for sections
equal to or greater than 95 mm2, up to a maximum limit of 300 mm2.
Protective devices settings and power demand will also be considered for the cable sizing.
2.3.2.3[4.3.2.3] Short circuit currents
The following table shows the values of the triphasic three-phase short-circuit current in
power centreslow voltage distribution board, and secondary boards which were obtained
from the document “Short circuit calculations Electrical Study and Analysis” (HE-16410-GEN-
041).
CODE NAME I”k(kA) ip(kA peak) Ik(kA)
QE-91-3-01 LOW VOLTAGE SWITCHGEAR 14.53633 30.53758 13.17529
Table 9: Short Circuit currents (Low Voltage)
Where:
 I”k: Symmetrical initial short-circuit current.
 ip: Peak value of the short-circuit current.
 Ik: Permanent short-circuit current.
2.3.2.4[4.3.2.4] Current-carrying capacities
For multipole conductors, the current-carrying capacities are indicated in the following table.
AUTHOR: AJI
Reference document: Table B.52.12 (air), and tables B.52.3 and B.52.5 (buried) of IEC
60364-5-52 and typical manufacturer's data (regarding external diameters, resistance and
reactance at 90ºC).
No. conductors x External diameter Resistance 90ºC Current rating (air) Current rating
section (mm2) (mm) (Ω/km) (1) (A) (buried) (A) (2)
3G2.5 9.6 10.17 36 35
3G4 10.6 6.31 49 46
3G6 12.1 4.20 63 58
3G10 14.1 2.43 86 77
3G16 17.1 1.54 115 100
3G25 20.8 0.99 149 129
3G35 23.2 0.70 185 155
3G50 26.4 0.49 225 183
3G70 30.5 0.34 289 225
4G2.5 10.4 10.17 32 30
4G4 11.5 6.31 42 39
4G6 13,2 4.20 54 49
4G10 15,4 2.43 75 65
4G16 18.7 1.54 100 84
4G25 22.8 0.99 127 107
4G35 25.4 0.70 158 129
4G50 29.3 0.49 192 153
4G70 33.8 0.34 246 188
5G2.5 12 10.17 32 30
5G4 13.2 6.31 42 39
5G6 14.8 4.20 54 49
5G10 17.7 2.43 75 65
5G16 21.8 1.54 100 84
5G25 26.2 0.99 127 107
5G35 30.6 0.70 158 129
5G50 30.6 0.49 192 153
5G70 30.6 0.34 246 188
Table 10: Characteristic data of multipolar cables (Low Voltage)
(1) Installation in tray at 30ºC.
For unipolar conductors, the current-carrying capacities is indicated in the following table.
AUTHOR: AJI
Reference document: Table B.52.12 (air), and tables B.52.3 and B.52.5 (buried) of IEC
60364-5-52 and typical manufacturer's data (regarding external diameters, resistance and
reactance at 90ºC).
No. conductors x External diameter Resistance 90ºC Current rating (air) Current rating
section (mm2) (mm) (Ω/km) (1) (A) (buried) (A) (2)
1x95 16.6 0.26 328 226
1x120 18.1 0.20 383 257
1x150 20.1 0.16 444 287
1x185 22.3 0.13 510 324
1x240 25.4 0.10 607 375
1x300 27.9 0.08 703 419
Table 11: Characteristic data of unipolar cables (Low Voltage)
(1) Installation in tray at 30ºC.
2.3.2.5[4.3.2.5] Short-circuit current capacity
For XLPE insulated cable conductors with 0.6/1 kV, the allowable short-circuit current density
is as indicated in the table below.
Reference document: IEC 60949.
MAXIMUM ALLOWABLE SHORT CIRCUIT CURRENT, A/ mm2, COPPER

CONDUCTORS
Short Circuit Duration (s)
Cable insulation
0.1 0.2 0.3 0.5 1
XLPE 452 319 261 202 143
Table 12: Maximum short-circuit current of the cable (A) for Cu conductors with
(XLPE), maximum 250 ºC in short circuit. (Icc = 143· S/√t) (Low voltage)
Where:
S: Conductor section in mm2
t: fault clearance time
143: Constant for copper conductors
AUTHOR: AJI
2.3.2.6[4.3.2.6] Correction factors for current-carrying capacities
2.3.2.6.1[4.3.2.6.1] Temperature correction factors for cables in the air
The correction factors for the current-carrying capacities for ambient temperatures different
from 30 ºC to be applied for unipolar and multipolar cables in trays, are those indicated in the
table shown below.
Reference document: IEC 60364-5-52 (table B.52.14), for a conductor service temperature of
90 ° C:
Ambient temperature
Correction factor
(ºC)
10 1.15
20 1.08
25 1.04
30 1.00
35 0.96
40 0.91
45 0.87
50 0.82
55 0.76
60 0.71
Table 13: Correction factors for ambient temperatures different from 30ºC to be
applied to the values of the current-carrying capacities for outdoor
installationsinstallations
(Low Voltage)
2.3.2.6.2[4.3.2.6.2] Temperature correction factors in buried installations
The correction factors for the current-carrying capacities for ground temperatures other than
20 ºC to be applied for unipolar and multipolar cables buried directly in the ground, are those
indicated in the table below.
Reference document: IEC 60364-5-52 (table B.52.15), for a conductor service temperature of
90 ° C:
Ground temperature
Correction factor
(ºC)
10 1.07
15 1.04
20 1.00
25 0.96
AUTHOR: AJI
Ground temperature
Correction factor
(ºC)
30 0.93
35 0.89
40 0.85
45 0.80
50 0.76
55 0.71
60 0.65
Table 14: Correction factors for ground temperatures other than 20ºC to be applied to
the values of the current-carrying capacities for buried installations (Low Voltage)
2.3.2.6.3[4.3.2.6.3] Correction factor depending on the resistivity of the ground
The correction factors of the current-carrying capacities for cables (direct buried) in terrains
of resistivity different from 2.5 K.m/W, are those indicated in the table shown below.
Reference document: Annex B of IEC 60364-5-52 (table B.52.16):
Soil thermal resistivity

Correction factor
(K.m/W)
0.50 1.88
0.70 1.62
1 1.5
1.5 1.28
2 1.12
2.5 1.00
3 0.90
Table 15: Correction factors for direct buried cables in land with resistivity different
from 2.5 K.m/W (Low Voltage)
2.3.2.6.4[4.3.2.6.4] Correction factor for grouping in free air
The reduction factors by grouping for several multipolar cables installed in the air in ladder
tray spaced 30 cm without separation between cables, are those indicated in the table shown
below.
Reference document: IEC 60364-5-52. (Table B.52.20):
Distance No of No of cables
between cables trays 1 2 3 4 6 9
Touching 1 1.00 0.87 0.82 0.80 0.79 0.78
AUTHOR: AJI
Distance No of No of cables
between cables trays 1 2 3 4 6 9
2 1.00 0.86 0.80 0.78 0.76 0.73

3 1.00 0.85 0.79 0.76 0.73 0.70
Table 16: Correction factors for grouping multipolar cables in ladder trays with
(Low Voltage)
NOTE 1: These factors apply to single layers of cables. For 2 layers of cables an additional
factor of 0.8 will be applied.
The reduction factors by grouping for several unipolar cables installed in the air in ladder tray
spaced 30 cm without separation between cables, are those indicated in the table shown
below.
Reference document: IEC 60364-5-52. (Table B.52.21):
Distance between No of Number of three phase circuits

cables trays 1 2 3
1 1.00 1.00 1.00
Touching 2 0.97 0.95 0.93
3 0.96 0.94 0.90
Table 17: Correction factors for grouping unipolar cables in ladder trays with
(Low Voltage)
NOTE 1: These factors apply to single layers of cables. For 2 layers of cables an additional
factor of 0.8 will be applied.
2.3.2.6.5[4.3.2.6.5] Correction factor for grouping in buried installations
The reduction factors by grouping for several unipolar or multipolar cables installed direct in
the ground, are those indicated in the table shown below.
Reference document: IEC 60364-5-52 (table B.52.18):
Multipolar cables/single-core cables

No of Distance between cables (m)
circuits
One cable
Touching 0.125m 0.25m 0.5m
diameter
2 0.75 0.80 0.85 0.90 0.90
3 0.65 0.70 0.75 0.80 0.85
4 0.60 0.60 0.70 0.75 0.80
AUTHOR: AJI
Multipolar cables/single-core cables

No of Distance between cables (m)
circuits
One cable
Touching 0.125m 0.25m 0.5m
diameter
5 0.55 0.55 0.65 0.70 0.80
6 0.50 0.51 0.60 0.70 0.80
Table 18: Correction factors for grouping multipolar direct buried cables (Low Voltage)
2.3.2.6.6[4.3.2.6.6] Correction factor for multiple cables per phase
The installation of several cables per phase can be considered as a special case of
"grouping".
When the current is divided into several cables per phase, there is a possibility that the
current may not be distributed exactly the same between the cables of the same phase due
to small imperfections in the same (defects or manufacturing tolerances).
To take this into account, a correction coefficient is applied that simulates a higher intensity
in all the phase cables.
In these cases, a coefficient of 0.95 will be used for runs shorter than 100 meters and 0.9 for
runs greater than 100 meters.
2.3.2.6.7[4.3.2.6.7] Correction factor for Hazardous areas
For those cables that are installed in hazardous areas, a correction factor of 0.85 should be
applied, according to Portaria 949A/2006.
3.[5.] ASSUMPTIONS
3.1[5.1] MEDIUM VOLTAGE CABLES
The following considerations will also be considered:
 The maximum conductor temperature is 90ºC in permanent service.
 It is considered that the cables are directed buried at a depth of 1 meter (otherwise the
corresponding factors will apply).
 For the dimensioning of the cables due to short-circuit, a maximum allowable tripping
time is considered:
- For the supply cable to the 10kV connection cabin (QE-57-1-1), 300 ms is
considered.
AUTHOR: AJI
- For the supply cable to the 3kV connection cabin (QE-51-2-1), 300 ms is
considered.
 The power cables to the transformers are calculated for the nominal power of the
transformer.
 The Medium voltage cables shall be design for the respective Transformer rating
power.
3.2[5.2] LOW VOLTAGE CABLES
The following assumptions will also be considered:
 The power lines to electrical panels are dimensioned with the nominal current of the
supply switch.
 The power cables to the transformers are calculated for the nominal power of the
transformer.
 The main feeder cables are dimensioned for 1.20 times their nominal current to allow
future load.
 In classified areas, the maximum allowable current for cables is reduced by 15%.
These areas will be avoided if possible.
 It is considered that the buried cables are buried directly in the ground at a depth
of 1 meters (otherwise the corresponding factors will apply).
 For the dimensioning of the cables due to short circuit, a fault clearance time is
considered not less than the times indicated below:
- Cables to final loads: 100 ms.

- Power cables to electrical panels: 100 ms.
- Power cables from transformers: 100 ms.
 The minimum short-circuit current between phase and earth must not be less than the
value of the instantaneous magnetic protection of the circuit protection switch. In this
sense and for the dimensioning of the cables under this criterion, the following values
are considered for the magnetic protections:
- For motor supply, 11 times its nominal current.

- For feeder-type supplies less than 160 A, 10 times the nominal current of the
switch.
- For feeder type power supplies between 160A and 500 A, 8 times the nominal
current of the switch.
- For feeder-type power supplies greater than 500 A, 5 times the nominal current
of the switch.
AUTHOR: AJI
4.[6.] METHODOLOGY AND CRITERIA FOR THE DETERMINATION OF THE CABLE

SECTION
4.1[6.1] SIZING OF MEDIUM VOLTAGE CABLES
The dimensioning of the section of the medium voltage cables is carried out using the criteria
of short-circuit current and maximum current in permanent regime.
Therefore, both criteria are verified and, depending on the value of the short circuit and the
cable installation conditions, the minimum section is set by the most restrictive.
In general, the voltage drops in this type of cables are not considered significant when
dimensioning the conductors, given the relationship between the length of the laying and the
voltage level used.
The disposition of the single-core conductors will be forming an equilateral triangle (trefoil
formation).
4.1.1[6.1.1] Short Circuit Current
In this case, the thermal short-circuit current is first calculated and compared with the
maximum admissible short-circuit current in the conductors for different cable sections.
The cable that supports the higher current than the thermal short circuit current is selected
for the times indicated in section 54 Assumptions.
4.1.2[6.1.2] Maximum Current-Carrying Capacities
The maximum current-carrying capacities, depending on the types of installation, the

characteristics of the cables, the correction factors, etc., mentioned above, are determined
as follows.
4.1.2.1[6.1.2.1] Installation in buried direct in the ground
The following correction factors apply to the maximum intensities of the cables defined in
section 43.3.1.6 of this document:
 Ground temperature equal to 25ºC: Correction factor 0.96.
 Soil resistivity equal to 1,5 K.m/W: Correction factor 1.
 A maximum of 4 circuits are considered and with a distance between cables of 200 mm
apart: Correction factor 0.68.
AUTHOR: AJI
 Buried at a depth of 1 meter. Correction factor 0.98.
 In the case of cables installed in hazardous areas, a correction factor of 0.85 should be
applied.
 The Medium voltage cables shall be design for the respective Transformer rating
power.
4.1.3[6.1.3] Voltage Drop
The voltage drop in this type of cables is limited to 1%.
4.2[6.2] SIZING OF LOW VOLTAGE CABLES
The dimensioning of the section of the low voltage cables is carried out using the criteria of
short-circuit current, maximum current in permanent regime, drop voltage, earth fault loop
impedance, minimum short circuit current to be protected by instantaneous protection
function and thermal overload\ withstand.
Therefore, these criteria are verified and, depending on the value of the short circuit and the
cable installation conditions, the minimum section is set by the most restrictive.
4.2.1[6.2.1] Short Circuit Current
The intensity of the short-circuit through which must be supported by the cable for the
duration of the defect will depend on the type of defect and the coordination of the system
protections.
For the short circuit sizing of cables connected to mould case circuit breakers it will be
checked that the i2t characteristic of the cable is above moulded case circuit breaker i2t.
To ensure protection in the event of a short circuit, it is checked that the passing energy of
the switch that protects the cable is always below the passing energy of the cable. This
ensures cable protection in the event of a short circuit.
The cable that supports the intensity higher than the thermal short circuit is selected for the
times indicated in section 54 Assumptions.
Additionally, it will be taken into account that the minimum short-circuit current
between phase and earth must not be less than the tare value of the instantaneous
magnetic protection of the circuit protection switch (see section 4 Assumptions).
AUTHOR: AJI
4.2.2[6.2.2] Maximum Current-Carrying Capacities
The maximum current-carrying capacities, depending on the types of installation, the

characteristics of the cables, the correction factors, etc., mentioned above, are determined
as follows.
4.2.2.1[6.2.2.1] Indoor/Outdoor tray installation
The following correction factors apply to the maximum currents of the cables defined in
 Areas with a maximum ambient temperature of 40ºC: Correction factor 0.91.
 Cables laid on ladder trays are considered with no separation between the
cables: Correction factor 0.82 for multipole cables and 0.96 for unipolar cables.
applied.
 If several cables per phase are considered, an additional correction factor of 0.95 must
be considered.
 Main feeder cables should be sized to allow for 20% future load. Correction
factor applied to the load current 1.2.
4.2.2.2[6.2.2.2] Installation in buried direct in the ground
The following correction factors apply to the maximum currents of the cables defined in
 Ground temperature equal to 25ºC: Correction factor 0.96.
 Soil resistivity equal to 1.5 K.m / W: Correction factor 1.28.
 A maximum of 4 circuits are considered and with a distance between cables of 0.25m
apart: Correction factor 0.75.
 Buried at a depth of 1 meter. Correction factor 0.98.
applied.
 If several cables per phase are considered, an additional correction factor of 0.95 must
be considered.
 Main feeder cables should be sized to allow for 20% future load. Correction
factor applied to the load current 1.2.
AUTHOR: AJI
4.2.3[6.2.3] Voltage Drop
In general, the voltage drop in the cables will not exceed the following values:
General Circuits:
 Between transformer and low voltage power centredistribution board: 1%.
 Between low voltage power centerdistribution board and motor control centres (CCM)
orand auxiliary services panel: 1%.
 Between low voltage power centerdistribution board and motors: 5%.
Lighting and Power Circuits:
 Between transformer and general lighting and power panel: 1%.
 Between general lighting and power panel and distribution lighting and power panels:
1%.
In any case, it is ensured that the maximum total voltage drop will be 8% in power circuits
and 6% in lighting circuits according to Portaria 949A/2006, clause 525. That is, in those
cases where it is not reasonable to apply the partial limits indicated above, they may be
exceeded as long as the total value of the voltage drop does not exceed the maximum
allowed values.
Also indicate that the maximum voltage drop in the motor circuits under motor starting
conditions will be 15%.
In addition, motor-operated valves will accept also 15% drops during start-up.
5.[7.] SUPPORTING CALCULATIONS
This section presents the results obtained according to the criteria defined in the previous
sections of this document.
AUTHOR: AJI
5.1[7.1] THREE PHASE LINES FROM QE-57-1-1 (6B1) AND QE-51-2-1 (5A1)
TYPE Nº
LENGT SIZE SIZE FINAL
LOAD VOLT. COS DVMAX CABLE TYPE OF
TAG EQUIPMENT POWER UNIT In (A) H k Iadm Isc SIZE ASSEMBLY
(note (V) ꬹ (%) S PER CABLE
(m) (mm2) (mm2) (mm2)
1) PHASE
Buried direct in the
HE-PSU-001 Transformer PSU (ITM) T 2405,0 kW 10000 0,95 153.86 500.00 1 0.544 95 120 1 120 1x3x(1x120mm2)
ground
Transformer New PT Buried direct in the
TR-91-3-01 T 420.0 kW 3000 0,84 101.3 670.00 1 0.544 50 95 1 95 1x3x(1x95mm2)
H2 ground
Note 1: Type of Load: T terminal loads; M Motor loads; V VFD’s, P Panels.
5.2[7.2] THREE PHASE LINES TO/FROM QE-91-3-01
Nº
TYPE
VOLT. COS LENGTH DVMAX SIZE Nº CABLES CABLES
EQUIPMENT EQUIPMENT LOAD POWER UNIT In (A) k TYPE OF CABLE ASSEMBLY
(V) ꬹ (m) (%) (mm2) PER PHASE PER
(note 1)
PHASE
LOW VOLTAGE 566.0 2x3x(1x185mm2)
QE-91-3-01 P 336.07 kW 400 0,80 8.00 0.71 1 185 2 2 Cable tray
SWITCHGEAR 4 +2x185mm2
Este documento es propiedad de DF y deberá ser gestionado bajo las restricciones detalladas en la portada This document contains proprietary information of DF and is subject to the restrictions set forth on the title page Page 30 of 32
AUTHOR: AJI
TYPE Nº
LENGT
LOAD VOLT. In DVMAX SIZE CABLE
EQUIPMENT EQUIPMENT POWER UNIT COS ꬹ H k CRITERIA TYPE OF CABLE ASSEMBLY
(note (V) (A) (%) (mm2) S PER
(m)
1) PHASE
2x3x(1x150 Buried
224.
HE-PC-001-AUX Electrolyzer BOP P 131,95 kW 400 0,80 30.00 0.73 1 150 IN 2 mm2)+2x(1x150mm2) direct in the
3
+ 1x150 mm2 ground
Buried
60,0
HE-PSU-001-AUX PSU Auxiliary Services P 36.17 kW 400 0,80 25.00 0.77 1 50 IN 1 5G50 direct in the
0
ground
Buried
HE-PM-1A Effluent water Pump 1 (PIT) M 1,10 kW 400 0.85 2.25 50,00 0.77 5 6 CC 1 4G6 direct in the
ground
Buried
HE-PM-1B Effluent water Pump 2 (PIT) M 1,10 kW 400 0.85 2,25 50,00 0.77 5 6 CC 1 4G6 direct in the
ground
IN Buried
61.1
HE-TF-4-01 Industrial power socket 1 T 36 kW 400 0,85 30.00 0.77 5 16 1 5G16 direct in the
3
ground
IN Buried
61.1
HE-TF-4-02 Industrial power socket 2 T 36 kW 400 0,85 30.00 0.77 5 16 1 5G16 direct in the
3
ground
36.0 IN
TR-91-4-01 Lighting transformer P 23.75 kW 400 0,95 4.00 0.63 1 10 1 4G10 Cable tray
9
16.9 IN
QE-91-4-02/HVAC HVAC T 10 kW 400 0,85 5.00 0.63 5 4 1 5G4 Cable tray
8
Nº
TYPE
VOLT. COS LENGTH DVMAX SIZE CRITERI CABLES TYPE OF
EQUIPMENT EQUIPMENT LOAD POWER UNIT In (A) k ASSEMBLY
(V) ꬹ (m) (%) (mm2) A PER CABLE
(note 1)
PHASE
QE-91-4-01 Lighting & Sockets Panel T 23.75 kW 400 0,95 36.09 4.00 0.63 1 10 IN 1 5G10 Cable tray
AUTHOR: AJI
5.3[7.3] LINES TO/FROM QE-UPS-91-4-01
Nº
TYPE
VOLT. COS LENGTH DVMAX SIZE CABLES TYPE OF
TAG EQUIPMENT LOAD POWER UNIT In (A) k CRITERIA ASSEMBLY
(V) ꬹ (m) (%) (mm2) PER CABLE
(note 1)
PHASE
Buried direct
QE-UPS-91-4-01 Power supply 400 V UPS network P 2.60 kW 400 1 3.75 620.00 0.77 1 25 CI-DU 1 5G25 in the
ground
Nº
TYPE
TAG VOLT. LENGTH DVMAX SIZE CABLES TYPE OF
EQUIPMENT LOAD POWER UNIT COS ꬹ In (A) k 2 CRITERIA ASSEMBLY
(V) (m) (%) (mm ) PER CABLE
(note 1)
PHASE
QE-91-3-01 Control voltage for LV Switchgear P 1,00 kW 230 1.00 4.35 8 0.63 1 2.5 MINI 1 3G2.5 Cable tray
PG-PT91-MRS-0001 Communication panel P 0,50 kW 230 1.00 2.17 6 0.63 1 2.5 MINI 1 3G2.5 Cable tray
PCI panel P 0,50 kW 230 1.00 2.17 4 0.63 1 2.5 MINI 1 3G2.5 Cable tray

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2MW ELECTROLYSIS PILOT PLANT

Cable Sizing Calculation and Criteria

Document No.: 092-556-F-E-01006 Issue 2

Purpose of issue: Information Date: 2023-06-30

EMPRESARIOS AGRUPADOS INTERNACIONAL S.A.

PRELIMINARY OR PENDING INFORMATION

2 2023-06-30 INFORMATION AJI ALB VPA

1 2023-05-04 INFORMATION AJI ALB VPA

0 2023-04-26 INFORMATION AJI ALB VPA

Rev./ Date/ Description/ Prepared/ Checked/ Approved/

CUSTOMER (OWNER) PROJECT

2MW Electrolysis Pilot Plant

EN/ES DATE/FECHA NAME/NOMBRE ÍSSUER/EMISOR

ISSUED ISSUER DOC.NUMBER/NÚMERO DOCUMENTO EMISOR

SIZE WORK NUMBER PROJECT DOCUMENT NUMBER IS REV

DF INTERNAL NUMBER/Nº INTERNO DF

2MW Electrolysis Pilot Plant

Cable Sizing Calculation and Criteria

PROJECT DOC NUMBER/ Nº DOC. PROYECTO: ED: 2 REV: 1

ISSUE FOR BIDDING

DF STAMP/SELLO DF: PREPARED BY: AJI DATE/FECHA: 2023-06-30

CHECKED BY: ALB DATE/FECHA: 2023-06-30

APPROVED BY: VPA DATE/FECHA: 2023-06-30

www.dfdurofelguera.com Page 4 of 32 APPROVED DOCUMENT BY

2. APPLICABLE CODES AND STANDARDS

 IEC 60228 Conductors of insulated cables

 IEC 60287 Electrical Cables – Calculation of the Current RatingIEC 60287

Part 1: Cables for rated voltages from 1 kV (Um = 1,2 kV) up to 3

 IEC 60865 Short-circuit currents - Calculation of effects

 IEC 60028 International standard of resistance for copper

 IEC 60364 Low-voltage electrical installations

 IEC 61034-2 Measurement of smoke density of cables burning under defined

 IEC 61156 Multicore and symmetrical pair/quad cables for digital

 2011/305/EUIEC 60909 Short-circuit currents in three-phase a.c. systems

 IEC 60949 Calculation of thermally permissible short-circuit currents, taking into

 Regulation of Construction products (CDP/CPR)

 EN 13501 Fire classification of construction products and building elements.

 EN 50575 Power, control and communication cables. Cables for general

 UIC 895 OR Hydrocarbon resistant (RH)

Cables must have CE marked.

[3.] LIST OF DOCUMENT INPUT DATA

No. Source document

2 HE-16120-GEN-052 021 General load list General characteristics

No. Source document

[4.] STARTING DATA

2.1[4.1] DESING TEMPERATURES AND GROUND DATA

The cables will be designed for an ambient temperature of 40 ° C.

In the case of buried cables, a ground temperature of 25ºC is considered.

2.2[4.2] CABLE LINES

2.2.1[4.2.1] Medium Voltage Cables

 Channels embedded in the floor:

- Cables laid inside trenches

2.2.2[4.2.2] Low Voltage Cables

The interconnection cables between equipment and/or switchboards will, in general, be

 Channels embedded in the floor:

- Cables laid inside trenches.

2.3[4.3] CABLE CHARACTERISTICS AND CORRECTION FACTORS

2.3.1[4.3.1] Medium Voltage Cables

2.3.1.1[4.3.1.1] Cable length

2.3.1.2[4.3.1.2] General Characteristics

The Medium Voltage power cables shall comply with:

 UIC 895 OR.