Russia AGCC Project
- Project Overview
This project provides specialized explosion-proof electrical equipment and comprehensive safety solutions for the entire Amur Gas Chemical Complex (AGCC) operated by Russia’s SIBUR Corporation. As one of the world’s largest gas chemical plants, AGCC features an expansive site with densely packed process units and complex explosive hazardous environments. As the core explosion-proof product supplier for this project, Huarong Explosion-Proof delivered a complete suite of explosion-proof products meeting the highest international standards for the process plant area, utilities, pipe racks, and ancillary facilities. This ensures the intrinsic safety and stable operation of this mega-project under extreme environmental conditions.
- Customer background and challenges
Core Challenges:
— Extremely Harsh Environment: The plant site is classified as Zone 1 & 2 (equivalent to GB 3836 / IECEx standards) for explosive gas atmospheres. Winter temperatures plummet to -52°C, demanding exceptionally high explosion-proof ratings and low-temperature resistance from equipment.
——Complex Standards Framework: Must simultaneously comply with Russian CU-TR/EAC certification (GOST standards), international IEC standards, and owner technical specifications, presenting significant certification and compliance challenges.
——High Volume and Diverse Product Requirements: The entire plant requires tens of thousands of explosion-proof devices, including luminaires, light poles, control boxes, junction boxes, instrument enclosures, switchgear cabinets, and gland fittings. Suppliers must possess comprehensive product supply and integration capabilities.
——Delivery and After-Sales Service: The project’s remote location poses significant challenges for logistics timeliness, on-site technical guidance, and long-term spare parts supply capabilities.
- OurSolution
To address the specific requirements of the AGCC project, WAROM provided a customized solution centered on a “full-scenario explosion-proof safety system.” Core application products include:
—WAROM Explosion-Proof LED Lighting System:
In process plant areas and pipe galleries, WAROM brand explosion-proof LED platform lights (models: BAY51-LED, HRD91-LED series) and explosion-proof LED floodlights (models: HRD95, HRJ series) were deployed on a large scale. This series holds high-level explosion-proof certifications including 1Ex d e IIC T6 Gb/Ex tb IIIC T80°C Db, achieves IP66 protection rating, and features enhanced cold-start capability and vibration resistance.
——WAROM Explosion-Proof Electrical Control System:
For power supply and control of on-site motors, valves, and instruments, WAROM provides explosion-proof control boxes (Model: BZC8050 series) and explosion-proof distribution boards (Model: HRMD93 series). The enclosures utilize stainless steel and copper-free aluminum alloy, housing internationally branded components to achieve Ex d or Ex e explosion-proof protection.
——WAROM Explosion-Proof Wiring & Instrumentation Systems:
WAROM explosion-proof junction boxes (Model: BXJ-S, BXJ-e series) and instrument enclosures, deployed throughout the plant, provide a secure and reliable wiring environment for signal transmission and instrumentation, featuring superior sealing and corrosion resistance.
——Integrated Design and Certification Support:
WAROM’s technical team provides explosion-proof equipment selection and layout design solutions based on hazardous area classification maps. All products hold valid Russian EAC certification, accompanied by comprehensive user manuals and technical passports.
- Implementation Process &Timeline
Phase 1: WAROM Technical Service Engineers conduct interface coordination and solution design, collaborating closely with the EPC contractor’s design institute to understand hazardous area classifications and specification requirements. This phase completes the plant-wide explosion-proof equipment selection list and preliminary layout plan.
Phase 2: Product Customization, Production, and Certification Verification: Customized production based on orders, with a focus on ensuring compliance with specifications for low-temperature materials and product surface corrosion resistance. Simultaneously submit technical design proposals for all products to the client for approval.
Phase 3: Batch Delivery and Logistics Management: Utilize a mature international logistics system to safely transport products in multiple batches to the Amur Project site in Russia, providing complete documentation per shipment (packing list, certificate of conformity, instruction manual, and technical passport).
- Achievements and Data Demonstration
——Cumulatively supplied over 10,000 units/sets of explosion-proof electrical equipment for the AGCC project, achieving 100% safety coverage in relevant hazardous areas.
——All products passed 100% on-site acceptance testing (SAT) by the owner and third-party inspection agencies with zero major non-conformities.
Quality and Reliability Achievements:
——During the project’s two-year installation, commissioning, and initial operation phase, WAROM explosion-proof products started normally and operated stably in extreme low-temperature environments down to -52°C, with a failure rate below 0.5%.
Unified “WAROM” branded products enhanced standardization and maintainability of explosion-proof equipment across the entire plant.
Service Achievements:
——Established a rapid response mechanism covering the entire project lifecycle, with critical consultation response times within 4 hours.
- Customer Feedback
The Electrical Lead for the SIBUR AGCC Project stated: “WAROM is our reliable partner. They provide not only top-tier products but also comprehensive solutions. Their products fully meet our stringent explosion-proof and climatic requirements, come with complete certifications, and are delivered on time. Their exceptional performance in extreme cold environments particularly demonstrates the dependable quality of their products.” The EPC procurement manager also commented: “WAROM demonstrates the international competitiveness of China’s high-end manufacturing. Their comprehensive product portfolio and professional technical support services have provided strong assurance for the smooth progress of our project.”
- Experiences Summary & Insights
——Proactive product certification is key to international market access: Preemptively securing authoritative certifications like EAC and IECEx for target markets serves as the “passport” for participating in high-end international projects.
——Deep understanding of operating conditions enables precise solutions: Only by fully grasping a project’s environmental characteristics (e.g., extreme cold), process hazards, and local regulations can we deliver truly tailored explosion-proof solutions not mere product replacements.
——A comprehensive product portfolio builds core competitiveness: Offering a full range of solutions covering lighting, control, wiring, and more enables one-stop service for customers, significantly reducing their procurement and management costs while creating strong competitive advantages.
——Evolving from “product supplier” to “solution partner”: By delivering full-value-chain services—including pre-project design support, mid-project logistics assurance, and post-project on-site services—we forge deep partnerships with users and EPC contractors, establishing long-term trust relationships.
