In the chemical industry, power distribution systems have never been merely a means of supplying electricity; they are the core line of defense for safe production. The unique operating conditions of chemical plants-including continuous operation, flammable and explosive materials, high temperatures and humidity, and dense corrosive dust-place far stricter demands on switchgear than those found in ordinary industrial and mining environments, particularly regarding insulation stability, protection ratings, explosion-proof capabilities, and operational safety. Over the past decade, we have accompanied a major chemical enterprise through every stage-from the commissioning of a single workshop, to capacity expansion, to campus expansion, and finally to intelligent upgrades-witnessing the complete evolution of its power distribution system from a crude, makeshift setup prone to frequent failures to a precise, controllable system with intelligent self-healing capabilities. From the initial commissioning of the first switchgear unit to the current deployment of nearly 100 units across the entire park-and the successive iterations of 12 kV switchgear, air-insulated switchgear (AIS), and metal clad switchgear-this journey precisely reflects the decade-long evolution of safety standards for chemical power distribution.
Ten years ago, this chemical industrial park was in its early stages of development. Power distribution design focused on "meeting basic power supply needs," with equipment selection leaning toward cost-effective configurations, resulting in low system redundancy and weak protection standards. Over the past decade, as safety production regulations have been upgraded, production capacity has continued to expand, and intelligent operation and maintenance have been implemented, the enterprise has gradually phased out outdated equipment, restructured its system architecture, and upgraded core equipment. Through multiple rounds of upgrades and iterations, 12 kV switchgear has taken on the primary power supply role in the medium-voltage distribution network. Air-insulated switchgear (AIS) provides stable power output for conventional operating conditions, while metal-clad switchgear-with its higher protection rating-is deployed in high-risk explosion-proof workshops. The tiered deployment and coordinated operation of these three types of equipment have established a power distribution system tailored to all scenarios in the chemical industry.
I. The First Decade: An Extensive Power Distribution Layout Sows Hidden Hazards in Chemical Production
In 2015, during the project's early stages, the chemical industrial park had only two production units in operation. The power distribution system was designed simply, with limited equipment options, and the industry's requirements for sophisticated protection in chemical power distribution had not yet become widespread. At that time, enterprises installed only a small number of economical switchgear units, prioritizing the provision of basic power for production; the system had virtually no safety redundancy.
At that time, the park's core power distribution relied entirely on standard 12 kV switchgear. The first-generation cabinets featured thin sheet metal, conventional insulation configurations, and low protection ratings. Affected by corrosive gases in the chemical workshops and condensation caused by diurnal temperature fluctuations, the equipment suffered year-round from issues such as insulation contamination, partial discharge, and overheating of terminal blocks. At the same time, a large number of simple air-insulated switchgear (AIS) units were widely used on-site, relying on natural air insulation and heat dissipation. Although these units were simple in structure and inexpensive, in a chemical environment filled with dust and corrosive media, they were highly prone to accelerated insulation aging and insufficient arc protection. During the rainy season and periods of high-load production, tripping, abnormal noises, and overheating failures occurred frequently.
During this phase, the enterprise's power distribution operations and maintenance were in a state of "emergency repairs and reactive troubleshooting." There was no systematic, tiered deployment of equipment, nor had high-protection metal clad switchgear been introduced. The reliance on a single type of equipment, outdated protection standards, and an unsystematic O&M model became the greatest obstacles to the enterprise's safe production and clearly defined the direction for subsequent systematic upgrades and renovations.
II. Five-Year Iteration: Capacity Expansion Drives Equipment Upgrades, and a Tiered Power Distribution System Takes Shape
From 2018 to 2020, the company entered a period of rapid expansion. Three new production units were successively commissioned, doubling production capacity and causing a rapid expansion in the scale of the power distribution system. As new safety regulations for the chemical industry took effect, the hidden risks of the existing cost-effective equipment became fully apparent; frequent power outages and equipment aging severely impacted continuous chemical production. The company officially launched the first round of large-scale upgrades to its power distribution system, embarking on a path of refined retrofitting characterized by tiered equipment and scenario-specific adaptations.
In the park's main power distribution networks and general workshop areas, the company carried out a bulk replacement of standardized 12 kV switchgear. Upgrades included vacuum arc-extinguishing mechanisms, reinforced insulation configurations, and optimized dehumidification and heat dissipation systems to accommodate the park's routine high-load operating conditions. This thoroughly resolved the core issues of the first-generation equipment-overheating, tripping, and insulation aging-and solidified the main defense line of the medium-voltage power distribution network.
In auxiliary workshops, office power distribution areas, and low-risk load zones, the park retained and optimized air-insulated switchgear (AIS) equipment-which offers greater adaptability-by installing dust-proof and corrosion-resistant components, upgrading insulation baffles, and optimizing ventilation structures. These measures addressed the environmental limitations of air-insulated equipment, meeting routine power supply needs through a low-cost, highly adaptable approach that strikes a balance between cost-effectiveness and stability.
The most critical upgrade breakthrough involves the large-scale introduction of metal-clad switchgear in high-risk explosion-proof areas such as reaction workshops, tank farms, and hazardous chemical processing facilities. Its fully enclosed, independent compartment structure, high-strength arc protection, and comprehensive mechanical interlocks effectively isolate corrosive media and prevent arc leakage, making it perfectly suited for high-risk chemical explosion-proof environments. This approach thoroughly mitigates major safety hazards-such as electrical fires and arc explosions-at the hardware level.
As a result, the company has established a three-tier power distribution architecture consisting of "armored equipment providing a safety net in high-risk areas, medium-voltage equipment supporting the main power grid, and air-insulated equipment supplementing conventional areas." This has led to a qualitative leap in power distribution stability, completely eliminating the need for reactive emergency repairs in operations and maintenance.
III. A Decade of Dedication: Implementing Smart Operations and Maintenance, with Comprehensive and Precise Control Over 100 Units of Equipment
After a decade of iterative development, the total number of power distribution units in this chemical industrial park has now exceeded 100, forming a modern power distribution network that covers the entire park, all operating conditions, and all levels. Three categories of core equipment each fulfill their specific functions and operate in coordination, forming the core power infrastructure for the enterprise's safe production. At the same time, leveraging intelligent monitoring technology, the system has evolved from merely ensuring "equipment availability" to achieving "system controllability, status visibility, and fault predictability."
Among the park's more than 100 power distribution units, standardized 12 kV switchgear accounts for over 60 percent. These units reliably carry the core loads of the entire chemical plant. Through multiple rounds of parameter optimization, structural modifications, and condition verification, they have achieved years of operation with zero major failures, becoming the backbone of the power distribution system. Air-insulated switchgear (AIS) units, having undergone upgrades for corrosion and dust protection as well as interlocking systems, serve reliably in low-risk auxiliary areas. Thanks to their ease of operation and maintenance and high cost-effectiveness, they continue to deliver value as part of the supporting power supply infrastructure.
Meanwhile, all metal clad switchgear in core high-risk areas is connected to online partial discharge, temperature monitoring, and condition-based early warning systems, enabling 24-hour uninterrupted monitoring. Relying on the high reliability and robust protection of metal-clad equipment, the park has eliminated electrical safety incidents for many consecutive years, perfectly aligning with the chemical industry's production requirements of "zero hazards, zero downtime, and zero accidents."
Over the past decade, the evolution of the company's power distribution system has long transcended mere equipment replacement; it has become a comprehensive system upgrade encompassing scenario adaptation, hierarchical coordination, intelligent control, and safety safeguards. From the early days when a single piece of equipment operated while faulty to the current state where hundreds of units are fully controllable across the entire facility, each equipment iteration has corresponded to an upgrade in safety production standards.
IV. A Decade of Evolution: The Core Rationale Behind Power Distribution Upgrades in the Chemical Industry
Looking back on the evolution of power distribution systems over the past decade, this chemical company's upgrade path serves as a microcosm of power distribution renovations in many domestic chemical industrial parks, providing the industry with replicable, practical experience.
First is scenario-based equipment selection, rejecting a one-size-fits-all approach. For general operating conditions, air-insulated switchgear (AIS) with an excellent cost-performance ratio is preferred; for main power distribution, stable and reliable 12 kV switchgear is relied upon; and for high-risk explosion-proof scenarios, high-protection metal-clad switchgear must be installed. This tiered selection and precise matching ensures a balance between safety and cost.
Second is a phased, incremental approach rather than blind, wholesale replacement. Aligned with the pace of production capacity upgrades, the company phased out outdated equipment, upgraded existing systems, and optimized the overall infrastructure in stages. This approach avoids large-scale, one-time shutdowns for retrofitting, thereby maximizing the continuity of chemical production. Finally, the focus extends from hardware upgrades to system-wide improvements-going beyond simply replacing equipment to simultaneously optimizing protection logic, operations and maintenance systems, and monitoring systems, thereby ensuring full control over the power distribution system's entire lifecycle.
Conclusion
Over the past decade, this chemical company's power distribution system has evolved from a single rudimentary switchgear unit barely capable of supplying power to 100 smart devices providing comprehensive protection across the entire facility. This evolution serves as a microcosm of the safety upgrades in China's industrial power distribution sector. The successive iterations of 12 kV switchgear, air-insulated switchgear (AIS), and metal-clad switchgear represent not merely simple upgrades in equipment models, but a comprehensive advancement in industrial safety concepts, power distribution technical standards, and operations and maintenance management systems. In the future, as intelligent and digital power distribution technologies continue to be implemented, chemical industry power distribution systems will continue to evolve toward greater safety, efficiency, and intelligence, building a robust and long-lasting power safety barrier for high-risk industrial environments.
About us
Zhejiang Lvma Electric Co., Ltd. was established in 2018, carrying forward 17 years of specialized experience in the electrical manufacturing industry. As an ISO 9001:2015-certified company, our core product portfolio includes advanced switchgear systems, complemented by high-performance oil-immersed and dry-type distribution transformers. These solutions are trusted by clients across Europe, the Middle East, South America, Southeast Asia, and Africa.
With over 40 patents held by our R&D team, we are transitioning from conventional production to intelligent, eco-friendly power solutions. By deploying smart monitoring technology and fully digitalized manufacturing processes, we ensure that every product delivers exceptional safety, reliability, and operational efficiency.