800 kW / 800 kVA Petrochemical Power: Ex Zone 2 + 200 kW ESP VFD + 1000 kVA Diesel Deep-Read
2×S13-M-800/10 N+1 · 200 kW ESP VFD · Ex Zone 2 · 1000 kVA diesel (600 kW standby)
1 · TL;DR Conclusion
Conclusion: this 800 kW petrochemical plant uses 2×S13-M-800/10 oil transformers (N+1) + a 200 kW ESP VFD (Ex Zone 2) + a 1000 kVA (600 kW standby) emergency diesel — configurator total ≈ $585,247, 84% N-1 loading, THDi 25% (needs APF/SVG), SH15 amorphous upgrade pays back in 3.3 yr (feasibility-level).
- •2×800 kVA S13-M-800/10 oil transformers (N+1), 84% loading after one-unit loss (pass), 640 kW demand
- •200 kW ESP on VFD — 1.7% start dip vs 8.1% DOL; Ex Zone 2 → Ex d board + Ex MCC (IEC 60079)
- •Emergency diesel 1×1000 kVA (600 kW standby) covers grade-1 400 kW + fire 150 kW = 550 kW (V9 pass), 20 ft container, 3-day autonomy
- •THDi 25% over limit → detuned reactor + APF/SVG active filtering (V6 warn)
- •Economics: $585,247 total; SH15 amorphous upgrade saves $410/yr, 3.3 yr payback; losses 248,596 kWh/yr ≈ $29,832
2 · Solution Overview
A petrochemical plant is a hazardous-area, grade-1-heavy load: fire water, emergency lighting and DCS control must never lose power, while ESP pumps and process motors are harmonic-rich VFD loads. This scheme pairs N+1 oil transformers with Ex Zone 2 distribution, a VFD-driven ESP, and an emergency diesel for fire + critical process.
| Source | Role | Share kW | Share |
|---|---|---|---|
| Grid 10 kV | base | 640 kW | 100% |
| Diesel 600 kW | backup | 0 kW | 0% |
Petrochemical Power System Calculator
Size and configure a high-reliability dual-source power distribution system for continuous petrochemical processes - redundancy level, explosion-proof equipment, BOM and single-line diagram.
3 · Design Process & Rationale
1. Requirement identification
800 kW petrochemical unit: grade-1 400 kW (fire 150 + emergency/control + critical process 250), critical process 250 kW, 200 kW ESP VFD, Zone 2, ≤15 s allowed outage.
2. Load & grading
Fire 150 + emergency/critical → grade-1 400 kW; ESP/process → grade-2 250; general → grade-3 150. Grade-1 + fire = 550 kW sets the diesel size.
3. Source & mix
10 kV grid (base) + 600 kW standby diesel. Diesel covers grade-1 + fire 550 kW (V9 pass 109%), transfer ≤15 s.
4. Transformer sizing
640 kW demand ≈ 674 kVA → 800 kVA tier; N+1 → 2×S13-M-800/10 oil (outdoor, fire-separation), 84% loading after one-unit loss.
5. Explosion-proof & ESP
Ex Zone 2 → Ex d board + Ex MCC (IEC 60079); 200 kW ESP on VFD (1.7% dip vs 8.1% DOL); detuned reactor + APF for 25% THDi.
6. Protection & secondary
MV 31.5 kA / LV 36 kA breaking; 104 protocol + secondary schematic + DC auxiliary; selectivity 11.9×.
7. Reliability & emergency
Diesel ATS auto-transfer + fire end-transfer, 3-day fuel autonomy; N-1 keeps 84% loading after one-unit loss.
Pain Points → Solution → Evidence
A stray spark in a hazardous area can ignite gas
Ex Zone 2 equipment per IEC 60079: Ex d board + Ex MCC, equipotential earthing
V14 zone2 Ex d; grounding + surge-protection drawings
Fire pumps must run on total grid loss
Dedicated fire feeder + end-transfer ATS + 1000 kVA diesel
V11 dedicated circuit; V9 pass (600 ≥ grade-1 400 + fire 150); 3-day autonomy
ESP VFDs inject harmonics that overheat the transformer
Detuned reactor + APF/SVG active filtering
V6 THDi 25% over limit → APF/SVG recommended
4 · Key Parameter Deep-Read
| Parameter | Value | Basis | Impact & Boundary |
|---|---|---|---|
| Transformer capacity | 800 kVA ×2 (S13-M) | 674 kVA → 800 tier; N+1 → 2 oil units | 84% loading; outdoor oil for fire separation above ~850 kVA demand, step to 1000/1250 |
| Demand factor | 0.8 → 640 kW | installed 800 kW × Kd 0.8 | sizes transformer & cable at real demand verify Kd against process schedule |
| ESP start | 200 kW VFD, 1.7% dip | VFD kst 1.3 vs DOL 6.5 | no sag on other process; DOL would be 8.1% confirm downhole cable & braking resistor |
| Hazardous zone | Zone 2 | gas/vapor present only under abnormal conditions | Ex d board + Ex MCC, higher cost (POA) Zone 1 → stricter Ex ia/ib, more cost |
| Emergency diesel | 1×1000 kVA (600 kW standby) | covers grade-1 400 + fire 150 = 550 kW | 3-day autonomy, 75% load, <15 s auto-start full-site backup needs ≈950 kW |
| Harmonics | THDi 25% | nonlinear 200 kW / 800 kW | needs APF/SVG; detuned reactor alone won't clear APF target THDi ≤8% |
5 · Drawing Deep-Read
The following drawings are shown for reference (full set in the configurator “View design document”):
6 · Operation Demo (Deep-Read)
Reliability & availability
N+1 84% after one-unit loss + diesel auto-transfer ≤15 s + fire end-transfer, covering grade-1 400 + fire 150 kW; series availability ≈99.9% class.
Fault & protection
MV 28.9 kA / LV 27.8 kA, breaking MV 31.5 kA / LV 36 kA (1.1–1.3× margin); selectivity 11.9×, a downstream fault trips only its feeder.
Power quality
THDi 25% over limit, detuned reactor + APF/SVG; ESP VFD start dip 1.7% (DOL 8.1%), bus voltage 0.983 pu.
Economics
$585,247 total; SH15 amorphous upgrade 3.3 yr payback ($410/yr); losses 248,596 kWh/yr ≈ $29,832.
Other views (shown): LCC (life-cycle cost) · Power quality & harmonics · Voltage profile · Scheme features · Environmental derating
7 · Economics & Payback
Equipment total ≈ $585,247 (2×S13-M-800/10 + Ex Zone 2 distribution + 200 kW ESP VFD + 1000 kVA diesel + 104 SCADA). No PV/BESS in this scheme, so economics = capex + losses + transformer TCO: upgrading S13→SH15 amorphous saves ≈3,416 kWh/yr (≈$410/yr), 3.3 yr payback; annual transformer+line losses ≈248,596 kWh (≈$29,832/yr). Diesel is standby-only — running cost applies only on grid outage.
8 · FAQ
What transformer for an 800 kW petrochemical plant?
How is the hazardous area handled?
Does the ESP need a VFD?
How big a diesel generator?
How are harmonics handled?
What happens on grid loss?
What's the payback on a better transformer?
Why oil-type not dry-type?
Is the price final?
Special Considerations
- THDi 25% exceeds the limit — a detuned reactor alone won't clear it; add APF active filtering (V6 remedy).
- 600 kW diesel covers grade-1 400 kW + fire 150 kW = 550 kW (V9 pass); full-site 800 kW backup needs ≈950 kW.
- Ex Zone 2 equipment (Ex d board + Ex MCC) is quoted per project (POA); final Ex certification per IEC 60079 to be confirmed.
- The 200 kW ESP VFD is the largest motor; confirm downhole cable and braking resistor for the submersible pump.
- Feasibility-level estimate; drawings pending a licensed design institute; confirm grid Ssc (500 MVA assumed).
Turn this into your project
Open this exact scenario pre-loaded in the Power System Configurator, then generate the full design document or the operation & techno-economic assessment.
Open in Power System Configurator →Related Scenarios
One-Stop Supply of Conventional & Solar Power Equipment
From power distribution system design to solar energy — transformers, switchgear, substations and solar equipment, sized and quoted in one place. Use our calculators to get a complete bill of materials and FOB price.