Petrochemical plants are typical high-risk industrial sites characterized by flammable and explosive gas atmospheres, high-temperature operating environments, and corrosive media. The reliability and safety of power supply equipment directly determine the stable operation of production lines and the safety of personnel and property. As a core component of the power distribution system, transformers in petrochemical plants must withstand harsh working conditions while eliminating potential explosion risks. To address these stringent requirements, Hubian Electric has developed an explosion-proof dry-type transformer specifically designed for petrochemical scenarios. This product integrates advanced explosion-proof technology, high-temperature resistance, and corrosion protection design, fully complying with global petrochemical safety standards. It provides a reliable power guarantee for petrochemical production and has become a trusted choice for major petrochemical enterprises worldwide.
1. Product Overview: Core Design for Petrochemical Harsh Environments
Hubian Electric's explosion-proof dry-type transformer is mainly applicable to hazardous areas (such as Zone 1 and Zone 2) in petrochemical plants where flammable gas and vapor atmospheres may occur. The product covers voltage levels of 10kV-35kV and capacity ranges of 100kVA-2500kVA, and can be customized according to the specific process requirements and load characteristics of petrochemical plants. Unlike conventional dry-type transformers, this product adopts a "multi-layer protection" design concept, focusing on solving key problems such as explosion prevention, high-temperature resistance, corrosion resistance, and dust prevention in petrochemical environments.
The core design of the product revolves around explosion-proof performance. It adopts an integral flameproof enclosure structure, which is made of high-strength carbon steel plates through precision welding. The enclosure has undergone strict pressure-bearing tests, capable of withstanding the pressure generated by internal gas explosions and preventing the spread of flames to the external flammable atmosphere. The joint surfaces of the enclosure adopt a labyrinth seal design with a reasonable flameproof gap, which can effectively cool the flame and block the transmission of explosive gases. In addition, all external leads and control interfaces of the transformer are equipped with explosion-proof cable glands and connectors, ensuring that the entire equipment meets the flameproof grade requirements of Ex d IIC T4, which is suitable for most flammable gas environments in petrochemical plants, such as methane, ethylene, and propane.
In response to the high-temperature environment in petrochemical production workshops (the ambient temperature can reach 40℃-60℃), the transformer adopts a high-efficiency cooling system combined with natural air cooling (AN) and forced air cooling (AF). The enclosure is designed with optimized heat dissipation fins, which increase the heat dissipation area by 30% compared with conventional products. When the ambient temperature is too high, the forced air cooling system can be automatically activated to reduce the winding temperature by 15℃-20℃, ensuring that the transformer operates stably within the rated temperature range. At the same time, the windings are made of H-class insulation materials, which have a maximum allowable temperature of 180℃, significantly improving the product's high-temperature resistance.
2. Core Explosion-Proof and Safety Design Advantages
Hubian Electric's explosion-proof dry-type transformer has formed a complete set of safety protection systems through in-depth research on the safety risks of petrochemical plants, with significant advantages in explosion-proof reliability, fault early warning, and anti-interference performance.
In terms of explosion-proof reliability, in addition to the integral flameproof enclosure, the product also adopts an intrinsic safety design for key electrical components. The temperature sensor, current sensor, and other monitoring components used are all intrinsically safe type (Ex ia IIC T4), which will not generate sparks or high temperatures that may ignite flammable gases during operation. The transformer's winding is cast with epoxy resin through vacuum pressure impregnation technology, forming a dense insulation layer that not only improves insulation performance but also prevents dust, moisture, and corrosive media from invading the winding, avoiding insulation breakdown and short-circuit faults that may cause explosions. According to the test results of authoritative third-party institutions, the product can maintain stable explosion-proof performance even in the environment of 95% relative humidity and 50ppm corrosive gas (such as hydrogen sulfide).
In terms of intelligent fault early warning, the product is equipped with a dedicated online monitoring system for petrochemical scenarios. This system can real-time monitor key parameters such as winding temperature, core temperature, load current, and enclosure pressure. When the parameters exceed the preset threshold, the system will immediately send an alarm signal through multiple channels such as the on-site sound and light alarm, remote monitoring platform, and mobile APP. For example, if the winding temperature exceeds 150℃, the system will first activate the forced air cooling system; if the temperature continues to rise to 170℃, it will issue an overload alarm and automatically cut off the power supply after a delay to prevent fire and explosion accidents. The monitoring system also has a data recording and traceability function, which can store the operation data of the past 5 years, providing a basis for the safety risk assessment and maintenance of petrochemical plants.
In terms of anti-interference and stability, the product adopts electromagnetic shielding design to resist the electromagnetic interference generated by large-scale petrochemical equipment (such as motors, pumps, and compressors). The enclosure is grounded through multiple points, which not only reduces electromagnetic radiation but also prevents static electricity accumulation. At the same time, the transformer's iron core adopts a fully laminated structure and is clamped with high-strength bolts, which reduces vibration and noise, and avoids sparks generated by friction between components. The product has passed the 168-hour continuous operation test under simulated petrochemical harsh conditions, with an operation stability rate of 99.9%.
3. Adaptability to Diverse Petrochemical Application Scenarios
With its excellent explosion-proof performance and environmental adaptability, Hubian Electric's explosion-proof dry-type transformer is widely applicable to various key areas of petrochemical plants, including oil refining workshops, chemical reaction zones, storage tank farms, and loading and unloading stations. It has been verified in many actual petrochemical projects and has performed outstandingly.
In oil refining workshops, where there are a large number of flammable and explosive gases such as gasoline vapor and diesel vapor, and the ambient temperature is high, the explosion-proof dry-type transformer's flameproof design and high-temperature resistance ensure the safe operation of the power supply system. For example, in a large petrochemical refinery project in East China, Hubian Electric provided 24 sets of 10kV explosion-proof dry-type transformers. During the one-year operation period, the product operated stably under the conditions of ambient temperature up to 58℃ and frequent load fluctuations, without any safety accidents. The online monitoring system accurately predicted 3 potential faults (such as abnormal temperature rise of windings), and the maintenance personnel handled them in a timely manner, ensuring the continuous operation of the refining production line.
In chemical reaction zones, where corrosive media such as acid mist and alkali vapor exist, the transformer's anti-corrosion enclosure and epoxy resin cast windings can effectively resist the erosion of corrosive substances. A chemical plant in South China produces ethylene oxide, and the reaction zone has a high concentration of corrosive gas. After using Hubian Electric's explosion-proof dry-type transformer, the product maintained good insulation performance and explosion-proof performance after 2 years of operation, which is far superior to the traditional oil-immersed transformer used before (which needed to be replaced every 1.5 years due to corrosion).
In storage tank farms and loading and unloading stations, where the risk of flammable gas leakage is high, the transformer's intrinsic safety design and multi-channel alarm system can quickly respond to potential risks. When a gas leakage occurs, the monitoring system can link with the plant's emergency system to cut off the power supply of the transformer in time, preventing the occurrence of explosion accidents. The product's compact structure also makes it suitable for installation in narrow spaces of storage tank farms.
4. Compliance with Global Petrochemical Safety Standards and Certifications
To ensure the smooth application of products in global petrochemical projects, Hubian Electric's explosion-proof dry-type transformer has passed a number of international and domestic authoritative certifications, fully complying with the safety standards of the petrochemical industry.
Internationally, the product complies with IEC 60079 (Explosive Atmospheres) series standards, including IEC 60079-0 (General Requirements), IEC 60079-1 (Flameproof Enclosures "d"), and IEC 60079-7 (Increased Safety "e"). It has obtained ATEX certification in the European Union, UL certification in the United States, and IECEx international explosion-proof certification, which can meet the safety access requirements of petrochemical projects in different countries and regions. For the Middle East market, which has strict requirements on petrochemical safety, the product also complies with the SASO 2870 standard and has obtained the relevant certification of the Saudi Arabian Standards Organization.
Domestically, the product complies with GB 3836 (Explosive Atmosphere Electrical Equipment) series standards and GB/T 10228 (Dry-Type Power Transformers) standards, and has passed the CQC explosion-proof product certification and energy efficiency certification, reaching the level 2 energy efficiency standard. It also meets the requirements of the "Chemical Park Safety Risk Investigation and Governance Guidelines", which can effectively support the safety risk assessment and control of chemical parks. The product labels and operation manuals are provided in multiple languages such as Chinese, English, Arabic, and Spanish, and are marked with clear explosion-proof signs and safety warnings, facilitating the installation, operation, and maintenance of petrochemical enterprises.
5. Service Guarantee and Market Prospects
Petrochemical plants have high requirements for the reliability and after-sales service of power equipment. Hubian Electric provides a full range of customized services and reliable after-sales guarantees for explosion-proof dry-type transformers, solving the worries of customers.
Before sales, the professional technical team of Hubian Electric conducts on-site surveys of petrochemical plants, analyzes the hazardous area classification, ambient temperature, corrosive medium type, and load characteristics of the site, and provides personalized product design and selection suggestions. For special process requirements, the team can customize the transformer's explosion-proof grade, cooling method, and monitoring function to ensure that the product is fully matched with the actual application scenario.
During sales, the company dispatches engineers with rich experience in petrochemical projects to the site to guide the installation and commissioning of the transformer, ensuring that the installation process meets the explosion-proof requirements and safety regulations. The team also provides professional training for the customer's operation and maintenance personnel, covering product structure, explosion-proof precautions, and monitoring system operation.
After sales, Hubian Electric has established a 24-hour emergency service hotline and a global after-sales service network, with localized service centers in major petrochemical industry clusters such as the Middle East, Europe, and Southeast Asia. For any faults or problems during the operation of the transformer, the after-sales team can arrive at the site within 48 hours (for domestic projects) or 72 hours (for international projects) to carry out maintenance work. The company also provides a long-term supply of spare parts, ensuring that the spare parts needed for maintenance can be delivered in a timely manner. The product has a 5-year quality guarantee period, during which the company regularly conducts return visits and preventive maintenance to ensure the long-term stable operation of the transformer.
With the continuous improvement of global petrochemical safety regulations and the acceleration of the transformation and upgrading of petrochemical enterprises, the demand for high-performance explosion-proof dry-type transformers is growing rapidly. According to industry forecasts, the global petrochemical explosion-proof electrical equipment market size is expected to reach 12.8 billion US dollars by 2030, with a compound annual growth rate of 6.5%. The Asia-Pacific region and the Middle East, which have a large number of petrochemical projects under construction and renovation, are the main growth markets. Hubian Electric's explosion-proof dry-type transformer, with its excellent explosion-proof performance, strong environmental adaptability, and perfect service guarantee, has broad market prospects.
Looking to the future, Hubian Electric will continue to increase investment in technological research and development, focusing on the integration of intelligent technologies such as digital twins and AI into explosion-proof dry-type transformers. It will develop more intelligent, efficient, and safe products to realize real-time simulation of transformer operation status and accurate prediction of faults. At the same time, the company will strengthen cooperation with global petrochemical enterprises and research institutions, actively participate in the formulation of international petrochemical explosion-proof electrical equipment standards, and contribute more to the safe and green development of the global petrochemical industry.
In conclusion, Hubian Electric's explosion-proof dry-type transformer is a high-quality power equipment customized for the harsh environment of petrochemical plants. With its advanced explosion-proof design, reliable safety performance, compliance with global standards, and perfect service guarantee, the product effectively solves the safety risks of power supply in petrochemical plants. In the context of increasing emphasis on industrial safety, Hubian Electric is willing to work with customers around the world to promote the safe and stable development of the petrochemical industry and create greater value for society and customers.
