Turnkey Solution for Sanmu Liquefied Air Separation Project's Intelligent Power Distribution System

I. Project Overview

(A) Project Background

The Sanmu Liquefied Air Separation Project, invested and constructed by Dalian Sanmu Liquefied Air Co., Ltd., represents a total investment of RMB 350 million. Spanning 27,700 square meters of land with a construction area of 9,000 square meters, the project specializes in the production of industrial and medical gases—including liquid oxygen, nitrogen, and argon—and bottled gas filling, with an annual design capacity of 150,000 tons of liquid gas. Serving high-end industries such as chemical synthesis, new material manufacturing, medical cold chain, food preservation, metal smelting, and precision welding, the production process demands an exceptionally safe, stable, and intelligently managed power supply. Critical equipment—such as cryogenic liquefaction units, deep-cooling air separation plants, and filling systems—operates 24/7, highlighting shortcomings in traditional power distribution systems, including delayed overload protection, slow fault response, and coarse energy management, which emerged as key bottlenecks to efficient operations.

(B) Customer Requirements

As a high-risk chemical manufacturer, Sanmu Liquefied Air outlined three core requirements for its power distribution system:

1. Essential Safety Assurance: Compliance with explosion-proof electrical standards in hazardous areas, paired with a full-link fault warning and rapid response mechanism to eliminate production safety accidents caused by power failures;
2. Energy Efficiency Optimization: Dynamic load regulation and energy-saving control for high-power loads (e.g., air separation compressors, cryogenic pumps) to reduce power consumption per ton of gas;
3. Digital Operation Upgrade: Integration of real-time power distribution monitoring, equipment lifecycle management, and a data visualization platform to enhance maintenance efficiency and support data-driven decision-making.

II. MEYGO Electrical’s Turnkey Solution

Liaoning MEYGO Electrical Automation Equipment Co., Ltd., leveraging its end-to-end capabilities in industrial power distribution, was selected as the general contractor for the project’s power distribution system from among dozens of competitors. The solution integrates "hardware products + system integration + full-cycle services" to deliver a comprehensive turnkey offering:

(A) Intelligent Power Distribution System Design

1. Core Hardware Deployment for Medium/Low Voltage Systems

• Intelligent Distribution Panels: Customized explosion-proof medium/low voltage panels equipped with digital air circuit breakers (10kA breaking capacity). Integrated current/voltage/temperature sensors monitor over 20 electrical parameters—including three-phase unbalance and harmonic distortion—with fault warning responses within ≤200ms;
• High-Efficiency Variable Frequency Control: Vector-controlled frequency converters for air compressor systems utilize built-in PLC PID algorithms to achieve closed-loop constant-pressure gas supply, delivering 35% energy savings compared to traditional mains-frequency operation and elevating motor efficiency to ≥96%;
• Explosion-Proof Compliance: All electrical equipment meets ATEX certification (II 2G Ex db IIC T6 Gb), suitable for Zone 2 explosive gas environments. Epoxy-resin 灌封 (encapsulated) terminals achieve IP66 protection, ensuring reliability in low-temperature, high-humidity production environments.

2. Digital Monitoring System Integration

• Energy Management Platform: A SCADA data acquisition system collects real-time power distribution data via MODBUS TCP, enabling 3D visualization of equipment status, 180-day historical data retrieval, and load trend prediction. Multilevel alarms (audio-visual + SMS) trigger instantaneously for abnormal parameters;
• Equipment Lifecycle Management: IoT-based digital twin models for critical devices (circuit breakers, converters) monitor health indicators—such as mechanical life and insulation status—generating intelligent maintenance plans (e.g., circuit breaker contact replacement prediction error ≤5%), shifting from reactive to predictive maintenance.

(B) Full-Procedure Turnkey Services

1. Project Management & Execution

• A cross-functional team—encompassing electrical design, automation engineering, and safety management—oversaw the entire process, from detailed construction drawing design and third-party equipment procurement (30+ brands) to on-site installation and commissioning. Adherence to ISO 45001 safety standards ensured zero safety incidents during construction;
• The innovative "prefabricated power modules + rapid on-site integration" technique reduced on-site construction time by 40% by shifting panel assembly and cable termination to factory prefabrication, minimizing disruptions to active production areas.

2. Full-Cycle Technical Support

• 7×24 remote maintenance via encrypted VPN enables real-time fault diagnosis and parameter configuration;
• An emergency spare parts warehouse (3 sets of core modules) guarantees a 2-hour response to on-site technical requests and 4-hour arrival at fault sites, limiting production downtime to ≤30 minutes.

III. Project Outcomes

(A) Industry-Leading Safety Enhancement

• A three-level safety system—"front-end explosion-proof protection + mid-end intelligent control + back-end rapid response"—reduced power distribution failure rates by 85%, successfully passing national safety facility acceptance (AQ/T 3073-2022 compliance);
• Digital circuit breakers achieved short-circuit interruption in ≤40ms—60% faster than conventional models—effectively preventing accident escalation.

(B) Dual Optimization of Energy Efficiency & Maintenance

• Variable frequency control reduced power consumption of air separation units to 0.68kWh/m³ per ton of gas, resulting in annual electricity savings exceeding RMB 4.2 million (at full capacity);
• Digital monitoring reduced on-site inspection frequency from 4 to 1 time daily, shortened fault handling time by 70%, and cut annual maintenance costs by 55%.

(C) Digital Transformation Value

• The energy management platform enabled real-time plant-wide electricity data visualization, assisting the client in obtaining the local government’s "Green Factory" certification;
• Equipment health management extended the service life of core devices (circuit breakers, converters) by 25%, reducing unplanned downtime losses by over RMB 2 million annually.

IV. Customer Testimonial

"MEYGO Electrical not only provided high-performance power equipment but also delivered end-to-end value through their turnkey model—from design to operation. Their customized explosion-proof solutions and digital maintenance system completely addressed our concerns about power safety and efficiency in high-risk environments. In three years of operation, the power system has seen zero major failures, with their technical team maintaining industry-leading response speeds. They are a trusted long-term partner."—Zhang Xudong, Director of Equipment, Dalian Sanmu Liquefied Air Co., Ltd.

V. Project Insights

The success of the Sanmu Liquefied Air Separation Project validates the application value of "intelligent hardware + integrated services" in high-risk industrial sectors. As a general contractor, MEYGO Electrical integrates technology R&D, engineering execution, and maintenance services to provide holistic solutions—from single devices to system architecture—setting a new benchmark for "safety, efficiency, and digital empowerment" in industrial power distribution. Moving forward, the company will deepen its focus on energy chemicals, advanced manufacturing, and other industries, driving intelligent upgrades of traditional power systems through technological innovation.