2 MW Petrochemical Power System Cost Breakdown (Q3 2026 China Supplier Pricing)
2 MW Petrochemical Power System Cost Breakdown (Q3 2026 China Supplier Pricing) — itemized bill of materials and FOB pricing for a typical configuration.
Estimated total (FOB): $382,021 · 2000 kVA transformer
Bill of materials
| Item | Specification | Qty | Price (USD) |
|---|---|---|---|
| HV incoming panel (KYN28A-12-630-315) | 630 A / 31.5 kA · vacuum | 2 | $4,896 |
| HV bus-tie panel (KYN28A-12-630-315) | 630 A / 31.5 kA · vacuum | 1 | $2,448 |
| Main transformer (each) (S13-M-2000/10) | 2000 kVA · Oil-Immersed · Copper · S13 | 2 | $44,662 |
| LV incoming panel (GGD-3150) | 3150 A busbar · In 2887 A | 2 | $14,450 |
| LV bus-tie panel (GGD-3150) | 3150 A busbar | 1 | $7,225 |
| LV feeder panel (×2) (GGD-3150) | distributes 10 circuits | 2 | $14,450 |
| Cable branch box (LV) (DFW-0.4) | 1-in / 4-out · 0.4 kV · 630 A | 2 | $1,260 |
| Busway trunking (LV main feeder) (Busway 4000 A) | 4000 A · Cu/Al busway · 80 m · $1329/m | 1 | $106,320 |
| Feeder cable — Process feeder 1 (×10) (YJV 150 mm²) | 150 mm² Cu · 304 A · ΔU 1.6% · $86.0/m | 10 | $68,800 |
| Branch trunk cable (LV → branch box 1) (YJV 240 mm² ×3) | 3× 240 mm² Cu · 1215 A · ΔU 1.3% · $123.0/m | 3 | $29,520 |
| Branch trunk cable (LV → branch box 2) (YJV 150 mm² ×2) | 2× 150 mm² Cu · 608 A · ΔU 1.6% · $86.0/m | 2 | $13,760 |
| Main busbar (Cu) (Cu 125×10) | 125×10 · 2500 A rating · ref $147.8/m | included | POA |
| Grounding electrode (Φ20mm × 2.5m rod) | R₁ 39.6 Ω → 13 rod(s) ≤ 4 Ω | 13 | $125 |
| Detuned PFC capacitor bank (221 kvar) | automatic · 7% detuned · 0.4 kV | 1 | $3,300 |
| Series detuning reactor (7%) (15.5 kvar) | 189 Hz tuning · below 5th harmonic | 1 | $804 |
| Explosion-proof (Ex) distribution board (Ex d Zone 2) | Flameproof enclosure · IEC 60079 · quoted per project (POA — not included in estimate) | 1 | POA |
| Ex-rated motor control center (MCC) (Ex d Zone 2) | Ex motor starters + VFD for pumps/compressors · IEC 60079 (POA — not included in estimate) | 1 | POA |
| Emergency / standby diesel generator (1000 kVA) | life-safety / standby power · 600 kVA required | 1 | $70,000 |
Single-line diagram
How it was calculated
- Continuous process load = 2,000 kW (N-1 continuity)
- Redundancy N+1 → 2 transformers + bus-tie (100% backup)
- Rectifier harmonic source: 400 kW · THDi 25% → Ih = 770 × 25% = 192 A
- Detuned filter: Qc = 400 × (tanφ₁ − tanφ₂) = 221 kvar · 7% reactor (f_res 189 Hz)
- Resonance check: 5th harmonic 250 Hz above 189 Hz → detuned (safe)
- Loads: P=2,000 kW, PF 0.95, 10 circuits
- Demand: 2,000 × 0.85 = 1,700 kW
- PFC: Qc = 1,700 × (0.329 − 0.329) = 0 kVAR → 0 kVAR bank
- Transformer: S = 1,700 ÷ 0.95 = 1789.5 kVA → 2,000 kVA standard
- Loading: 1,789 ÷ 2,000 = 89% (good range)
- Voltage regulation: 89% × 4% × sinφ ≈ 1.1% at full load
- HV: In 115.5 A, Isc 28.9 kA → KYN28A-12-630-315
What drives the cost
- Equipment — the transformer/switchgear/inverter is the largest single line item.
- Storage (where applicable) — batteries are the biggest swing factor.
- Copper & freight — copper-linked cabling and freight shift landed cost ±5–10%.
Frequently asked questions
What does Ex-proof / explosion-proof zoning mean for electrical equipment?
Hazardous areas are zoned by the likelihood of explosive gas (Zone 0/1/2 per IEC 60079) or dust (Zone 20/21/22). Electrical equipment in Zone 1/2 must carry Ex certification (e.g. Ex d, Ex e, Ex n) matched to the gas group and temperature class. Choosing the right Ex rating adds 20-50% to switchgear cost; the calculator lets you select the zone and flags Ex-rated BOM.
Why do petrochemical plants need dual power supply?
Continuous process plants (refineries, ethylene, ammonia) cannot tolerate supply loss — a restart can take days and cost millions. They use dual independent feeds with automatic transfer (ATS) and N+1 or 2N redundancy for critical loads per GB 50052 load classification. The calculator models redundancy level and sizes the emergency/standby path accordingly.
How are rectifier harmonics managed in petrochemical plants?
Electrolyser and plating rectifiers inject 5th, 7th, 11th harmonics. If total harmonic distortion exceeds IEEE 519 limits (5% THD at the PCC for most systems), a detuned capacitor bank (7% series reactor) or an active harmonic filter (APF) is added. The calculator sizes compensation with a 7% detuning factor when THDi exceeds ~15-20%.
What transformer impedance is typical for petrochemical MV/LV units?
Distribution transformers in petrochemical plants usually have 6% impedance (uk) for LV networks, sometimes 8% for large motors to limit fault current. Higher impedance reduces short-circuit current but raises voltage regulation; 6% balances both for a 10/0.4 kV, 1000-2500 kVA unit. The calculator applies standard uk values when computing fault levels.
What load classification does GB 50052 define for continuous processes?
GB 50052 classifies loads into first, second and third class. Continuous petrochemical process units are first-class loads requiring two independent supplies; critical safety loads (emergency shutdown, fire pumps) are 'first-class important' loads needing an additional emergency source such as a diesel generator or EPS. The calculator's redundancy and emergency-power options map to these classes.
How is the process load demand factor set for a refinery?
Refinery process loads run near-continuously, so demand factor is high at 0.8-0.9 for main units, while utility and auxiliaries run 0.6-0.7. A 2000 kW connected process load with 0.85 demand and 0.95 pf needs about 1790 kVA, so select a 2000 kVA transformer. The calculator uses these factors to avoid both oversizing and undersizing.
Size your own configuration
Run the calculator for your exact load and get a full BOM + FOB price.
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