Chemical and electrochemical processing plants depend on stable electrical systems to avoid unplanned shutdowns, feedstock waste, and lost production. Applications such as air separation, polymer extrusion, chlor-alkali production, and hydrogen generation place heavy demands on plant power systems through large rectifiers, medium-voltage motors, VFDs, and strict harmonic performance requirements.
Addressing Critical Process Challenges
Harmonic Mitigation for Large Rectifiers & Hydrogen Electrolysis
Hydrogen electrolysis and chlor-alkali rectifiers are major non-linear loads that create IEEE 519 and IEC compliance concerns, transformer heating, and harmful system distortion. VarStec’s custom-engineered harmonic filter banks supply reactive power while filtering 5th, 7th, 11th, 13th, and higher-order harmonics to improve power factor, control THD, preclude and prevent harmonic resonance and protect critical equipment.
Voltage Sag Support for Large Motor Starting
Across-the-line starting of large 2.4 kV to 13.8 kV motors can create voltage sags that disrupt sensitive chemical processes. VarStec’s MotorVAR™ supplies reactive power locally during starting to reduce system voltage drop and improve motor starting torque. This provides a practical plant-wide alternative to VFD starters, RVSS lineups, E-Houses, and synchronous bypass switchgear where speed control is not required.
Power Factor Correction & Capacity Recovery
VarStec systems improve displacement power factor to eliminate utility penalties and improve voltage regulation. By lowering system losses, these solutions recover capacity within the existing electrical system for future process expansion and infrastructure growth.
How VarStec Helps
Detuned Filter Designs for Resonance Avoidance
In plants with significant high-pulse drive loading, harmonic distortion is often low, but not zero, so conventional capacitor banks may still present resonance concerns. VarStec applies detuned filter bank designs to move the system away from resonance while supplying the reactive power needed for power factor correction. This allows facilities using so-called IEEE 519-compliant drives to improve power factor and plant power quality without the risk associated with standard capacitor bank application.
Engineering for Corrosive & Hazardous Environments
Chemical facilities often involve atmospheres where H2S, NH3, or Cl2 are present. VarStec provides outdoor systems specifically engineered for these environments, including:
- Corrosion Resistance: Stainless steel enclosures and specialized protective coatings to ensure long-term reliability.
- Thermal Management: Sealed cooling approaches that protect internal components while reducing total installed cost.
System-Fit Engineering & Analysis
We do not offer one-size-fits-all catalog equipment. Using field measurement data or detailed system modeling, VarStec performs motor-starting, load-flow, power factor, and harmonic analysis, as well as filter design studies. These studies ensure the final solutions are technically correct, meet system objectives, and are reliable, cost-effective, and compliant with all industry and utility interconnection requirements.