Project Case Study: Integrated Power Cube Solution for a Large-Scale Factory in Al Dhafra

—45-Day Delivery, Building a Highly Reliable, Maintenance-Free Core Power Hub for the Factory

I. Project Background and Challenges

Client: A large-scale metal processing and manufacturing factory in Al Dhafra
Project Background: To support new high-precision production lines and automated control systems, the client urgently needed to establish a new, independent, and highly reliable power distribution center within the plant. Traditional decentralized electrical room construction faced issues like long lead times, complex interfaces between multiple vendors, and uncontrollable on-site installation quality, failing to meet the client's urgent need for rapid production commencement.

Core Challenges and Requirements:

1. Extremely Tight Timeline: Production line equipment was already ordered. Complete power integration and stable supply had to be achieved within 45 days to ensure new line installation and commissioning.

2. Harsh Environmental Adaptation: The Al Dhafra region's high temperatures, humidity, and sand/dust demanded stringent protection ratings and thermal management for outdoor electrical equipment.

3. Extremely High Reliability Requirements: Powering critical loads for continuous production required exceptional system availability with seamless, uninterrupted transfer capabilities.

4. Limited On-Site Technical Expertise: The site lacked high-level electrical integration engineers, necessitating a "plug-and-play," pre-commissioned, standardized packaged solution.

5. Space and Aesthetic Constraints: The new facility required a small footprint, a clean appearance, and harmony with the modern factory environment.

II. The Solution: Fully Integrated, Factory-Prefabricated "Power Cube"

As the EPC (Engineering, Procurement, Construction) Designer and Systems Integrator, we innovatively proposed the "Power Cube"—a solution that highly integrates medium-to-low voltage power transformation/distribution, reactive power compensation, uninterruptible power supply, and output feeders into a single, factory-prefabricated, standardized module.

1. Core Design Philosophy:

• Holistic Integration: Moving beyond the traditional "equipment stacking" model, the dry-type transformer, low-voltage compensation panel, modular UPS, and low-voltage output panel were designed as a unified system for electrical, structural, and thermal performance.

• Full Factory Prefabrication: The entire Power Cube was assembled, with all busbar connections and secondary wiring completed, and underwent comprehensive testing in a controlled factory environment.

• Full Busbar Connection: Internal primary power connections utilized custom-fabricated copper busbars instead of traditional cables, achieving minimized connection impedance, maximized reliability, and optimized heat dissipation.

• Productized Delivery: Upon arrival on-site, only external cable terminations and basic commissioning were required, drastically reducing on-site work risks and time.

2. Power Cube Core Configuration & Integration Highlights:

III. Project Execution: The 45-Day Rapid Delivery Record

We successfully achieved the remarkable feat of only 45 days from contract signing to on-site energization and handover. The core enabler was the fundamental restructuring of traditional workflows by the "Power Cube" productized model.

1. Three-Phase Efficient Execution Process:

• Phase 1: Concurrent Design & Factory Prefabrication (Days 1-30)

  • Days 1-7: Finalized site technical details, performed rapid detailed design based on the standardized Power Cube platform, and concurrently locked in all equipment procurement.

  • Days 8-25: Core Manufacturing Period. Concurrent fabrication of enclosure, assembly of all electrical equipment, and custom busbar work in the factory. Key processes like busbar joint surface preparation and bolt torque verification were completed.

  • Days 26-30: Comprehensive Factory Acceptance Testing (FAT) on the fully integrated Power Cube, including: dielectric withstand tests, protection function tests, UPS transfer tests, and monitoring system integration, ensuring "zero defect" delivery.

• Phase 2: Rapid Transport & On-Site Placement (Days 31-35)

  • Days 31-32: The complete Power Cube module was delivered to the Al Dhafra site via specialized transport.

  • Days 33-35: The Power Cube was lifted and placed onto the pre-prepared concrete foundation using cranes, followed by leveling and anchoring. On-site work during this phase was exceptionally clean and simple.

• Phase 3: Connection, Commissioning & Handover (Days 36-45)

  • Days 36-40: Connection of external HV cables, LV output cables, and communication lines. Workload was significantly reduced as the interior was fully pre-integrated.

  • Days 41-43: Site Acceptance Testing (SAT), including load bank testing and system interaction tests to validate overall performance.

  • Days 44-45: Client engineer training on operation and maintenance, submission of complete as-built drawings and technical documentation, and formal project handover.

2. Project Outcomes:

• Record-Setting Speed: Delivered on the 45-day promise, securing the timeline for the client's production line installation.

• Exceptional Reliability: The full busbar design reduced overall system impedance by approximately 15%, with temperature rise significantly better than standard, resulting in exceptionally stable measured operation.

• Minimal Operational Costs: The "maintenance-free" busbar connections and modular UPS design reduced long-term maintenance workload by over 60%.

• Optimized Space & Efficiency: Footprint was 40% smaller than a traditional setup. The high-efficiency transformer and dynamic compensation reduced system losses, maintaining power factor above 0.98.

• Enhanced Client Experience: Clear single-point responsibility; the client avoided coordinating multiple vendors, receiving a perfect "turnkey" experience.

IV. Client Value & Industry Significance

For this large-scale factory, the Power Cube is not merely a distribution asset but a strategic energy infrastructure ensuring production continuity.

1. Solved the Delivery Deadline Dilemma: Compressed a traditional multi-month electrical project into 45 days, securing invaluable market lead time for the client's capacity expansion.

2. Guaranteed Core Production Continuity: The highly reliable integrated design and UPS backup protected precision manufacturing equipment from grid fluctuations and outages, directly safeguarding output and product quality.

3. Enabled "Foolproof" Operations: High integration and intelligent monitoring allowed regular plant electricians to grasp the overall status after brief training, reducing dependency on highly specialized personnel.

4. Optimized Total Cost of Ownership (TCO): While the initial investment might be slightly higher, the savings in time-to-market, reduced operational costs, lower energy losses, and avoided production downtime resulted in a significantly superior TCO.

5. Set a New Industry Benchmark: This project successfully validated the immense value of the "Integrated, Prefabricated Power Module" concept in the industrial sector, providing a perfect reference for global industrial clients facing similar rapid deployment and high-reliability demands.

V. Conclusion