Oil & Gas Hazardous-Area Power Solutions in Egypt

On an oil & gas site classified Zone 1 for hydrogen hazard, KPS engineered and deployed a fully certified solar power system designed to run unattended, indefinitely, without exposing personnel or equipment to ignition risk.

Generation and Collection

Power generation begins with a high-performance, ATEX-certified solar field built from Pharos Marine SPEX panels, configured to the client’s load and site layout. The array is wired through dedicated Solar Array Junction/Combiner Boxes, which consolidate the incoming energy into a single main DC feed ahead of the conversion stage.

Conversion and Regulation

Energy conversion and regulation is handled by Victron SmartSolar MPPT charge controllers, each housed in a cast-aluminum Ex d (flameproof) enclosure rated IP66 and T5 — certified for continuous operation in Zone 1 hydrogen environments. Each charger runs a programmed charge profile with a maximum charge current of 100A, regulating energy flow into the battery bank.

Storage and Central Coordination

Energy is stored in a battery bank built from OPzV gel cells, distributed across dedicated battery boxes for thermal and physical separation. A Central Power Hub serves as the system’s master protection point: a DC MCCB protects the main battery trunk, while individual MCBs isolate each charger — so a single fault never takes the whole system down.

Monitoring and Alarm Logic

System intelligence runs on a Victron Cerbo GX paired with a GX IO-Extender, continuously evaluating 12 critical functions — including State of Charge thresholds at 70%, 40%, and 10%, high-voltage battery alerts, and regulator failure signals. These are mapped to dry contact outputs for local panel indication and full Remote Terminal Unit (RTU) integration, so site status is visible both on-site and remotely, with no need to enter the hazardous zone to check it.

The result is a power system engineered around the site’s real constraint: in a hazardous, often unmanned location, power failure is not an option. Certified hardware at every stage, paired with remote visibility from day one, is what makes that reliable.