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Petrochemical Refineries and Chemical Production

Petrochemical refineries and chemical production plants are critical facilities that must be managed with energy-intensive processes and high-security standards. In this sector, due to the flammable and explosive properties of the materials used, safety measures must be at the highest level. Energy continuity in these facilities is crucial not only for the uninterrupted progress of production but also for safety. Power outages can lead not only to the halt of production processes but also to an increase in security risks.

The large machinery and complex production lines used in petrochemical facilities require energy efficiency and secure energy management. These facilities typically operate 24/7, necessitating that energy distribution systems function reliably at all times. Additionally, sensitive data management systems are used to monitor and manage chemical processes. Continuous data communication plays a critical role in both production efficiency and safety.

Petrochemical facilities typically operate under harsh environmental conditions. Therefore, energy distribution systems must be durable, resistant to high temperatures, humidity, and corrosion. Additionally, maintenance-friendly systems are required for quick intervention in case of failures. Interruptions in production processes can lead to significant financial losses. For this reason, systems that provide quick intervention and repair capabilities with flexible and modular solutions are among the most critical needs in the industry.

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The Need for Forming for High Security:

The safe operation of panels is crucial for this sector. Therefore, it is recommended to form the electrical panels.

The process of forming or internal separation, also known as compartmentalization in electrical panels, aims to enhance safety measures within the panel, ensuring both personnel and equipment safety. This process ensures that faults (such as fires) are confined to a specific area and prevents technical staff from coming into contact with live parts during intervention, maximizing safety.

There are different levels of forming in electrical panels. These levels define the internal structure of the panel and how the compartments are separated. The highest level of internal separation is called Form 4b. Form 4b means that all compartments inside the panel are completely separated from each other, providing the highest level of safety.

Panels with Form 4b forming are preferred, especially in high-risk environments and critical applications. These panels prevent the spread of faults, ensuring both personnel and equipment safety. Additionally, they provide a safe working environment during maintenance and repair operations.

Panels with Form 4b forming typically also feature a sectional cover application. Sectional covers make it easier to access only specific parts of the panel, while maintaining the safety of the compartments.

In summary, forming or internal separation is an important practice to enhance safety in electrical panels. Different forming levels offer solutions tailored to various needs and risk levels. To provide the highest level of safety required by this industry, Form 4b forming and sectional cover applications are recommended.

You can click here to access our related blog post to learn more about formatting.

Need for High Corrosion Resistance:

The need of this sector is to provide corrosion resistance, and all EAE Electrotechnical products stand out with high corrosion resistance under harsh environmental conditions.

Corrosion is the process of wear and deterioration of metals or metal alloys due to oxidation or other chemical effects. Electrical panels need to be protected from these corrosive effects depending on the environmental conditions they are exposed to.

• Paint application on cold-rolled steel (DKP sheet): This method provides limited protection against corrosion. While external environments may be more corrosive, similar corrosive effects can occur over time in internal environments as well. For this reason, the corrosion resistance achieved by applying paint to cold-rolled steel should not be preferred for use in internal environments.

• Galvanized steel or paint application on galvanized steel: This method, commonly used in industrial environments, provides effective protection against corrosion. It should generally be preferred for both internal and external applications. When evaluated in terms of price and performance, it is quite advantageous.

In all EAE Electrotechnical products, even if they are the second option of painted, pre-galvanized steel is used. This feature, as explained above, enhances the products' resistance to corrosion under harsh environmental conditions.

Need for Seismic Resistance:

Being located in Turkey's earthquake zone makes it mandatory for structural non-load-bearing products, such as electrical panels and rack cabinets, to be produced with seismic resistance. To ensure energy continuity during an earthquake and to protect human safety, it is crucial to use products with independent seismic certification and strictly follow the manufacturer's installation instructions.

Seismic certification demonstrates that electrical panels and rack cabinets can maintain their structural integrity and functionality during an earthquake. Additionally, these certifications prove that the products have been tested according to international standards and are designed to withstand a specific level of earthquake intensity.

Proper installation of seismic-certified products on-site directly impacts the product's performance and safety. Failure to adhere to the manufacturer's installation guidelines can reduce the seismic resistance of the product and may even cause damage during an earthquake.

At EAE Electrotechnical, we place great importance on seismic resistance. Our products have been tested according to international standards and are seismic certified. Additionally, we have prepared detailed installation instructions for our products to ensure that our customers can perform a safe and accurate installation.

The Need to Correctly Determine the IP Protection Rating:

The protection of electrical panels against environmental factors, including protection against solid and liquid objects, is ensured through tests defined under the IEC 60529:1989 standard. These tests are represented by numbers (IP code) that indicate the level of protection the panels provide.

In the IP code, the first digit indicates the level of protection against solid objects, while the second digit represents the level of protection against liquids.

A high IP rating does not necessarily provide sufficient assurance for outdoor use, meaning that panels with a high IP level do not automatically indicate that they are suitable for EXTERNAL use!

There is a common misconception in the market that products with a high IP protection rating can be used outdoors.

Even though products with a high IP protection rating are defined as dust and water-resistant, their exposure to corrosion in outdoor environments is generally shorter. Additionally, the effects of solar radiation must also be considered. These factors are not accounted for in the IP classification.

Additionally, as the IP rating increases, the heat inside the panel also rises, which can reduce the current-carrying capacity of the products. Therefore, it is important to determine the optimal IP value for the panel, neither too high nor too low.

The Need for Proper Ventilation:

Temperature increase directly affects the performance of devices inside panels or rack cabinets. Temperature rise tests, which are as critical as short circuit tests in panel-type assessments, are essential for the safe and efficient operation of devices. Since temperature rise reduces current-carrying capacity, the temperature inside the panel/rack cabinet must be regulated to an ideal level through proper ventilation.

The temperature inside the panel/rack cabinet rises due to the ambient temperature and the heat-emitting devices inside (such as circuit breakers, busbars, servers, etc.). This temperature increase is calculated by considering the electrical loss power values provided in the catalogs of each device used.

The IP protection rating also contributes to the temperature increase by preventing heat from escaping. Therefore, selecting the correct IP level, rather than a high one, is crucial for the panel/rack cabinet. A high IP protection rating does not always mean better protection, and an incorrect choice can lead to excessive temperature rise, potentially damaging the devices.

Once the temperature rise has been determined, the panel or rack cabinet can be cooled using the following methods:

• Natural Ventilation
• Cooling with a Fan
• Cooling with Air Conditioning

As EAE Electrotechnical, you can use our PanelTemp thermal software for cooling calculations inside panels up to 1600A. To learn more about PanelTemp, click here. You can also access our blog post on cooling with a fan here. For air conditioning solutions, please contact your Customer Representative.

Additionally, you can read our related blog post on cooling with a fan by clicking here.

The Need for High Durability with the Correct IK Rating:

Additionally:
In addition, the infrastructures solutions used in petrochemical refineries and chemical production facilities should not only provide reliable energy management but also be integrated with real-time data management and monitoring systems. As EAE Electrotechnical, our solutions enable operations to run seamlessly and securely, while also helping to quickly detect and resolve potential faults.

PanelMaster Low Voltage Type-Tested Panel Systems provide high security and durability for use in petrochemical refineries and chemical production facilities. In these facilities, where energy continuity and maintenance safety are critically important, our systems are equipped with type test certificates from internationally accredited laboratories with high technical values. Additionally, they support Form 4b applications, ensuring operational safety.

You can click here to explore our PanelMaster Panel System in more detail.

PanelMaster Low Voltage Drawer-Type Type-Tested Panel Systems; are widely used in these projects as they are designed to meet the high security, flexibility, and easy maintenance requirements for power circuits and motor starting circuits.

• IEC 61439-1-2 Type Test Standard
• IEC 60068 Seismic Test Standard
• IEC 61641 Internal Arc Test Standard

You can click here to explore our PanelMaster Drawer-Type Panel System in more detail.

E-Cabinet Type-Tested Empty Panel Systems; offer solutions with a wide range of products to meet the needs of control, command, and various applications in both internal and external environments of petrochemical refineries and chemical production facilities, including 304-316 stainless steel options. E-Cabinet panel products, with their international accredited standards, provide durable and long-lasting use, making them suitable for the challenging working conditions of refineries and chemical production plants.

• IEC 62208 Type Test Standard for Empty Panels
• IEC 60529 Protection Rating in Panels
• IEC 62262 Protection Against External Mechanical Impacts

For this sector, E-Cabinet solutions that stand out could be Stainless Steel and External Solutions.

E-Cabinet Stainless Steel Series Panels:

Our products can be manufactured in 304 or 316 quality upon request. Based on the standard product design, size modifications, material thickness adjustments, and desired hole processing can be applied.

Additionally, manufacturing in desired RAL colors or with varnish coating is possible. If preferred, instead of the standard high-chemical-resistance pendulum latch system, a lock system made from 316-grade stainless steel can be selected.

All internal accessories such as mounting profiles, mounting plates, front cover systems, etc., used in all E-Cabinet series can also be used for stainless steel products.

Thanks to our manufacturing techniques, welding bolts used for various door components are applied in a way that leaves no marks on the outside of the door. This ensures a clean and smooth surface appearance.

You can click here to explore our stainless steel panels in more detail.

E-Cabinet External Panels:

The external factors that panels are exposed to in outdoor environments are much more significant than those in internal environments, such as snow, rain, dust, mud, sand, etc. The panel must maintain its structural integrity and continue to function despite these factors. Therefore, external panels should be designed accordingly.

One of the most important accessories in these products is the roof. It needs to be properly designed to prevent accumulated water from entering when the door is opened. Additionally, it should prevent water leakage or water run-off from the reverse angle.

There is a common misconception in the market that a high IP protection rating automatically means suitability for outdoor use. However, a high IP protection rating does not necessarily mean the product is suitable for external environments. Although the relationship between dust and water is defined for products with high IP ratings, the exposure to corrosion is shorter in outdoor environments. Additionally, the effects of solar radiation must be considered, which are not taken into account in the IP protection rating. Corrosion resistance is one of the most important factors in external panels. You can find our article on corrosion resistance above.

E-Cabinet H Series external panels are designed for outdoor environments, available in either modular or monoblock configurations. You can click here to explore our E-Cabinet external panel series.

You can click here to explore our entire E-Cabinet product portfolio in more detail.

KabinPLUS IT Infrastructure Solutions provide sustainable systems for every building and facility where data and communication are involved. These solutions are designed to be environmentally suitable, durable, modular, long-lasting, highly secure, aesthetic, and user-friendly.

You can click here to explore our KabinPLUS products in more detail.