ELECTRICAL SYSTEM STUDIES FOR LARGE PROJECTS EXECUTED AT MULTIPLE ENGINEERING CENTRES

Issue Date: December 2009 AbstractElectrical system studies are carried out to verify that major electrical equipment is adequately rated, determine the conditions for satisfactory and reliable operation, and highlight any operational restrictions required for safe operation. The system studies for the Jamnagar Export Refinery Project (JERP) presented unique challenges because of the sheer size of the captive power generation (with a new 800 MW power plant operating in parallel with an existing 400 MW power plant), the plants extensive power distribution network, and the engineering work distributed amongst various Bechtel engineering centres and non-Bechtel engineering contractors around the world. The large number of system study cases (particularly transient stability analysis studies) to be evaluated also made the task challenging. This paper presents an overview of system study execution on the complex JERP electrical network, along with a brief report on the various studies conducted as part of this project. Keywordsanalysis, electrical system studies, Electrical Transient Analysis Program (ETAP), Jamnagar Export Refinery Project (JERP)

INTRODUCTION

lectrical system studies are carried out to verify that major electrical equipment is adequately rated, determine the conditions for satisfactory and reliable operation, and highlight any operational restrictions required for safe operation. The various units within the Jamnagar Export Refinery Project (JERP) were engineered at Bechtel engineering centres (London, Houston, Frederick, Toronto, and New Delhi), the Bechtel/ Reliance Industries Limited joint venture (JV) office in Mumbai, and the sites of non-Bechtel engineering contractors. The core Electrical group based in Bechtels London office (the London core group) was tasked with preparing a combined model of the electrical system and with conducting the system studies. The system studies for this project presented unique challenges because of the sheer size of the captive power generation (with a new 800 MW power plant operating in parallel with an existing 400 MW power plant), the Jamnagar plants extensive power distribution network, and the engineering work distributed amongst various Bechtel engineering centres and non-Bechtel engineering contractors around the world.

System studies are normally conducted on a selected set of study cases, and their results are used to determine the system behaviour under all operating conditions. For this project, it was difficult to select the cases to simulate and study because of the large number of possible operating configurations for such a complex industrial electrical network. The system studies themselves were a challenge because so many study cases (particularly transient stability analysis studies) had to be evaluated. This paper presents an overview of system study execution on the complex electrical network of the JERP, along with a brief report on the various studies conducted as part of this project.

OVERVIEW OF THE JERP

Rajesh Narayan Athiyarath

rnaraya1@bechtel.com

eliance Industries operates the Jamnagar Domestic Tariff Area (DTA) oil refinery and petrochemical complex located in Gujarat, India. The complex processes 650,000 barrels per stream day (650 kbpsd) of crude oil and produces liquefied petroleum gas (LPG); naphtha; gasoline; kerosene; diesel; sulphur; coke; polypropylene; and numerous aromatic products, including paraxylene, orthoxylene,

2009 Bechtel Corporation. All rights reserved.

ABBREVIATIONS, ACRONYMS, AND TERMS

AVR BSAP automatic voltage regulator Bechtel standard application program (a software application that Bechtel has determined to be suitable for use to support functional processes corporate-wide) captive power plant Domestic Tariff Area discipline work instruction electrical distribution management system energy management system Electrical Transient Analysis Program (a BSAP) front-end engineering and design gas turbine generator high-voltage direct current interconnecting transformer International Electrotechnical Commission Institute of Electrical and Electronics Engineers individual harmonic distortion Jamnagar Export Refinery Project joint venture load management system liquefied petroleum gas low voltage main receiving station medium voltage on-load tap changer personal computer refinery service transformer special economic zone steam turbine generator total harmonic distortion variable-speed drive

and benzene. The original project, which Bechtel designed and constructed, was the worlds largest grassroots single-stream refinery. The complex includes a captive power plant (CPP) designed to produce 400 MW of power (backed up by a 132 kV grid supply) to meet the refinerys power demands. The JERP comprises a new export-oriented refinery located in a special economic zone (SEZ) adjacent to the DTA site. The project aims to almost double the capacity of the Jamnagar refinery to more than 1,200 kbpsd; add crude distillation, associated secondary conversion facilities, and an 800 MW CPP; and modify the existing refinery to ensure the efficient operation of both it and the new refinery. On completion of the JERP, the Jamnagar complex will be the worlds largest refinery, surpassing Venezuelas 940 kbpsd Paraguana refining complex.

CPP DTA

The key task of conducting overall system studies on the JERP and DTA electrical networks was handed over to the London core group.

DWI EDMS EMS ETAP FEED GTG HVDC ICT IEC IEEE IHD JERP JV LMS LPG LV MRS MV OLTC PC RST SEZ STG THD VSD

ENGINEERING THE JERP

he JERP required approximately 6 million engineering jobhours within a short and challenging project schedule. Hence, project engineering was split up amongst the various Bechtel offices, headed by the London core group (Figure 1). The key task of conducting overall system studies on the JERP and DTA electrical networks was handed over to the London core group.

POWER GENERATION AND DISTRIBUTION

simplified depiction of the JERP power generation and distribution system is portrayed in Figure 2. JERP Power System As the JERP power source, the CPP consists of six 125 MW, 14.5 kV gas turbine generators (GTGs), with space allocated for three future GTGs. The GTGs are connected to the 220 kV switchyard bus via their dedicated 14.5/231 kV, 161 MVA step-up transformers. Eight 220/34.5 kV, 174 MVA refinery service transformers (RSTs) connected to the 220 kV switchyard feed the JERP plant substations through 33 kV switchboards in two main receiving stations (MRS-1 and MRS-2). Two 11 kV, 25 MW steam turbine generators (STGs) are connected to the switchboards in MRS-1 via 11/34.5 kV, 38 MVA step-up transformers. Finally, a pair of 220/132 kV, 107 MVA autotransformers are provided as the interconnecting

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BECHTEL FREDERICK BECHTEL LONDON

DTA Expansion Group DTA Revamp FEED FCC Group FCC/VGO Units Captive Power Plant (CPP)

BECHTEL NEW DELHI

Captive Power Plant (CPP)

BECHTEL HOUSTON/ SHANGHAI

CFP, Crude & Alkylation Units

BANTREL TORONTO

BECHTEL LONDON CORE FUNCTIONS

Aromatics Unit CNHT/KHT Units

BECHTELRELIANCE JV MUMBAI
Offsites & Utilities CFP, Crude & Alkylation Units (Balance)

THIRDPARTY AND LICENSOR OFFICES JAMNAGAR ENGINEERING OFFICE (JEC) JAMNAGAR (SITE)
Merox, ATU, SWS, PRU Units FCC/VGO Units (Balance) DTA Revamp Coker (FWHouston) Sulphur & TGTU (BVPIKansas City) Sulphur Granulation Hydrogen (LindeMunich) Acid Regeneration (MECSSt. Louis)

System studies is the generic term for a wide range of simulations conducted on a model of an electrical system under various operating conditions encountered or anticipated during operation of the network.

ATU CFP CNHT CPP

amine treating unit clean fuel plant cracked naphtha hydrotreater captive power plant

DTA FCC FEED FW

Domestic Tariff Area fluid catalytic cracker front-end engineering and design Foster Wheeler

JEC Jamnagar Engineering Office KHT kerosene hydrotreater Merox (mercaptan oxidation process) PRU propylene recovery unit

SWS TGTU VGO

sour water stripper tail gas treatment unit vacuum gas oil

Figure 1. Project Execution Locations

transformers (ICTs) between the JERP and DTA electrical systems. The JERP electrical system incorporates an energy management system (EMS) that comprises an electrical distribution management system (EDMS) to control and monitor the electrical network and a load management system (LMS) to carry out load shedding, if required, within the JERP and DTA electrical networks. DTA Power System The DTA CPP consists of nine 28 MW GTGs and six 25 MW STGs that feed the five 33 kV switchboards, from which power is further distributed to the DTA plant substations.
Captive Power Plant (Six 125 MW GTGs)

220 kV Switchgear (1 Breaker Scheme)

Interconnection to DTA

Two 25 MW STGs

Four Sets 33 kV Main Receiving Switchgear

ELECTRICAL SYSTEM STUDIES

ystem studies is the generic term for a wide range of simulations conducted on

6.6 kV/415 V Distribution Network for Each Unit

Figure 2. JERP Power System Generation and Distribution

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a model of an electrical system under various operating conditions encountered or anticipated during operation of the network. System studies analyse the behaviour of the electrical network components under various steady-state, dynamic, and transient conditions, and the results are used to predict the networks behaviour under actual operating conditions. System studies are conducted at different stages of a project. The results of system studies performed during the front-end engineering and design (FEED) and detailed engineering stages enable proper selection of equipment ratings, identification of the electrical system loading and operational modes for maximum reliability and safety, and selection of the control modes for major equipment. These early system studies can also assess the ability of the electrical network to meet present and future system energy demands. System studies conducted after the power system network is operational generally study the feasibility or effects of system expansion, check conformance with any changes in codes and standards, or analyse system behaviour to identify the underlying causes of a network disturbance or equipment failure. In the case of the JERP, the electrical system is planned to operate in parallel with the existing DTA electrical system and the grid supply from the local electricity utility. The JERP electrical system also has to be adequate for the addition of future units and high-voltage direct current (HVDC) links to the local electricity utility supply. Hence, this combination of large-scale greenfield project/major expansion of an existing network becomes a special case for system studies. The sheer size of the JERP and DTA electrical networks (with a combined power generation of 1.2 GW), the extensive power distribution network within the JERP and DTA plants, and the crucial need to ensure reliability of the power supply under all operating conditions make it important to conduct reliable and accurate system studies. Further, the study results can help in the design of a reliable electrical system suitable for the projects present and future requirements. Three key elements are at the heart of a proper system study: A dependable and versatile system study software program A reliable model of the electrical network Selection of studies to be conducted and study cases to be simulated

ELECTRICAL SYSTEM STUDY SOFTWARE PROGRAMS

ystem studies entail the analysis of the interactions amongst the various components of the electrical network to determine the power flows between elements and the voltage profile at the various buses in the network. Many mathematical computations are required to analyse even a small network, precluding the use of manual calculation techniques to conduct any but the most rudimentary system studies. These circumstances have led to an effort since the late 1920s to devise computational aids for network analysis. From about 1929 to the 1960s, special analogue computers in the form of alternating current network analysers were used for system studies. These network analysers contained scaled-down versions of the network components, such as power sources, cables, transmission lines, and loads, that were interconnected using flexible cords to represent the system being modelled. Although limited in scope and complexity, the network analysers were used to study power flows and voltage profiles under steady-state and transient conditions. The next stage in the evolution of system study software programs was the use from the late 1940s of digital computers to conduct system studies. These programs were initially limited in scope due to the programming methods used (punched-card calculators). However, the availability of large-scale digital computers from the mid-1950s gave a boost to the use of computer programs for system studies. Although these programs originally required mainframe computing power and specialised programming techniques, the growth in the computing power of desktop PCs and laptops has seen these programs become an essential tool for the electrical engineer. Current system study programs offer flexible and easy-to-use techniques for system modelling, analysis, and presentation.

The sheer size of the JERP and DTA electrical networks, the extensive power distribution network within the JERP and DTA plants, and the crucial need to ensure reliability of the power supply under all operating conditions make it important to conduct reliable and accurate system studies.

One of the more commonly used system study software programs is Operation Technology, Inc.s (OTIs) Electrical Transient Analysis Program (ETAP), which has been qualified as a Bechtel standard application program (BSAP). The offline simulation modules of ETAP 6.0.0, the most current release at the time of project execution, were used to conduct the JERP power system studies.

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MODEL OF THE JERP ELECTRICAL NETWORK he various Bechtel and third-party engineering centres prepared models of the electrical networks for the individual JERP units. The London core group integrated these various submodels into a composite model of the overall plant electrical network. It was necessary to ensure that all the engineering centres used uniform modelling principles to prepare the individual models, to speed the process of integrating them. The London core group issued specific discipline work instructions (DWIs) to the engineering centres and held a series of conferences to explain the modelling principles to be followed to ensure uniformity. These work instructions covered key points such as model structure, division of responsibility for preparing and using the model, key data required, instructions for dealing with cases of incomplete/missing data related to network or equipment required for the model, and use of library data (accompanied by a common library database to be used to populate the model). The major items modelled were the GTGs/STGs along with their control systems (governors, exciters, and power system stabilisers), plant loads, and interconnecting power cables. The modelling of certain complex portions of the GTG control system required software such as Simulink, a specialised program used to model and simulate dynamic control systems. OTI constructed the models, which were later integrated with the overall model.

used International Electrotechnical Commission (IEC) standards as the basis for evaluating the results of all studies except harmonic analysis. Load Flow Analysis Once the refinery is commissioned and fully operational, the electrical system is expected to operate in a stable condition. Load flow analysis is a steady-state analysis that calculates the active and reactive power flows through each element of the network and the voltage profile at the networks various buses. A balanced load flow analysis is adequate because the vast majority of loads in the refinery are inherently balanced (e.g., three-phase motors). Load flow analyses help identify any abnormal system conditions during steady-state operation that can be harmful for the system in the long run. They also provide the initial basis for other detailed analyses such as motor starting and transient stability. It is also to be noted that the results of the load flow analysis affect these other analyses. For example, an electrical system operating under steady-state conditions is more likely to satisfactorily survive a transient event such as the step-loading or tripping of one of the operating generators if its initial operating conditions are favourable (e.g., voltages within limits, sufficient margin in the loading of various network elements). Some of the main parameters examined in a load flow analysis are presence of overvoltage or undervoltage at any point in the electrical network, overloading of any network element, and very low system power factor. To study system behaviour at the JERP under all expected operating conditions, the London core group carried out load flow analyses under these three sets of conditions: Normal system configuration, i.e., with redundant power feeds, where available, to various plant switchboards that simulate the normal operating condition of the electrical network Loss of redundant power feed, i.e., with single power feed to the various plant switchboards (This condition of single-ended operation can occur in the electrical network under a contingency like loss of plant transformers.) No-load conditions (This study case was selected to assist in identifying any dangerous overvoltage that may occur when the network is operating under no-load or lightly loaded conditions [e.g., plant startup conditions]).

It is very important to select the study cases whose results can be used to predict the system behaviour under all operating conditions.

ELECTRICAL SYSTEM STUDIES AND STUDY CASES

wide range of system studies can be conducted on electrical networks to study the behaviour of the system under steady-state conditions as well as conditions in which it is subjected to disturbances in normal operation (e.g., step loading or load sharing amongst generators) or unplanned events (e.g., electrical fault, generators tripping). Because it is not possible to analyse every expected operating condition, it is very important to select the study cases whose results can be used to predict the system behaviour under all operating conditions. As a result, the studies are usually conducted on the most onerous conditions expected during the refinery operation. The following system studies were carried out to analyse the behaviour of the JERP and DTA electrical networks. In line with the specification requirement for the JERP, the engineering centres

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The results of these analyses revealed some instances in which the bus voltages exceeded the acceptable limits. The London core group recommended that the tap settings of the upstream transformers associated with these switchboard buses be changed to bring the voltages within the specified limits. The core group also highlighted cases of potential overloading of transformers under loss of redundant power feed (second case) for observation during actual plant operation.

A short circuit condition imposes the most onerous short-time duty on the system electrical equipment.

Short Circuit Analysis A short circuit condition imposes the most onerous short-time duty on the system electrical equipment. This fault condition arises as a result of insulation failure in the equipment or wrong operation of the equipment (e.g., closing onto an existing fault or closing circuit breakers when the associated earth switch is closed), leading to the flow of uncontrolled high currents and severely unbalanced conditions in the electrical system. The four main types of short circuits are: Three-phase short circuit with or without earthing (This is usually the most severe short circuit condition.) Line-to-earth (single-phase-to-earth) fault (In certain circumstances, the short circuit current for a line-to-earth fault can exceed the three-phase short circuit current.) Line-to-line (phase-to-phase) fault Double line-to-earth fault The electrical equipment has to be rated for the short circuit level of the system, which basically requires all of the following conditions to be met: The electrical equipment must be able to withstand the short circuit current until the protective equipment (relays) detects the fault and it is cleared by opening circuit breakers (i.e., thermal withstand short circuit current). The IEC standards specify a standard withstand duration of 1 second or 3 seconds. The JERP used switchgear rated for 1-second withstand time. The circuit breakers must be suitable to interrupt the flow of the short circuit current (i.e., breaking duty). The circuit breakers must be suitable to close onto an existing fault (i.e., making duty). Additionally, the protective system of the network has to be set to enable reliable detection of any short circuit condition (minimum and maximum short circuit conditions).

The calculation of the short circuit current for these conditions is made more complex by the behaviour of the short circuit current immediately after the fault. Depending on the network characteristics, behaviour of the generators in the network, and the exact instant of the fault, the short circuit current may contain significant amounts of transient alternating and direct current components, which decay to zero over time, depending on the characteristics of the network and the rotating machines. It is very difficult to account for the effects of these phenomena through manual calculation methods. This is particularly true because the presence of a large direct current component in the short circuit current imposes a very stringent breaking duty on the circuit breakers, since a natural current zero may not be achieved. The results of the short circuit analysis calculated the following various components of the short circuit current at each bus: ipPeak current in the first cycle after the short circuit IdcDirect current component at the instant the circuit breaker opened Ib sym and Ib asymSymmetrical and asymmetrical root mean square currents at the instant the circuit breaker opened IthThermal withstand short circuit current for 1-second rating These results were cross-checked with the equipment ratings to verify that the equipment short-time ratings were suitable for the short level of the system. Stability Analysis It is relevant to note the concept of stability as defined in standards such as Standard 399 of The Institute of Electrical and Electronics Engineers, Incorporated (IEEE). [1] IEEE 399 states that a system (containing two or more synchronous machines) is stable, under a specified set of conditions, if, when subjected to one or more bounded disturbances (less than infinite magnitude), the resulting system response(s) are bounded. System stability requirements can be generally categorised into steady-state stability, dynamic stability, and transient stability. [2] Steady-State Stability Analysis Steady-state stability is the ability of the system to remain stable under slow changes in system loading. The power transfer between two synchronous machines (generator G and motor

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jX

EG

EM

the first swing of the machines, generally within 1 second of the event). Also, the traditional transient stability analysis ignored the action of the machine governor, exciter, and automatic voltage regulator (AVR) because they were slow-acting compared with the duration of the analysis. This approach to transient stability analysis has been modified in recent times since the advent of governors, exciters, and AVRs based on fast-acting control systems. It has also been seen that different sections of an interconnected network may respond at different times to a transient event that sometimes may be outside the traditional 1 second window for transient analysis. Also, the behaviour of different sections of the network may be different for the same transient event. Hence, to verify whether system stability is retained, the transient stability analysis needs to be carried out for a longer duration (preferably over a range of transient events having varying severities and durations). This kind of analysis was not possible in earlier years due to the high complexity of modelling and limited computing power, but today such an analysis can be performed because of the availability of practically unlimited computing power on desktop and laptop computers, coupled with specialised computer programs such as ETAP. Hence, the dividing line between dynamic stability analysis and transient stability analysis has been virtually eliminated. A range of stability analyses was carried out on the JERP refinery system. They covered the operation of the JERP electrical network while in a standalone condition as well as in parallel operation with the DTA electrical network. The stability analyses can be broadly classified into the following categories. Transient and Extended Dynamic Stability Analysis Fault withstand study: This study entailed simulation of single-phase and three-phase faults at various locations in the electrical network. It analysed the behaviour of the power system in the pre-fault stage, during the fault, and after the fault was cleared by the systems protective devices. Load throw-off study: A load throw-off condition can cause the machines to over speed. Temporary overvoltage conditions can also occur in the system. Hence, the behaviour of the electrical system was studied for all probable cases of load throwoff in which a substantial portion of the operating load was suddenly tripped.

Figure 3. Power Transfer Between Machines

Mrefer to Figure 3) with internal voltages of EG and EM, respectively, and a phase angle of between them is represented in Equation 1: [1]

P=

EM EG sin X

(1)

The maximum power that can be transferred occurs when = 90 degrees, per Equation 2:

P max =

EM EG X

(2)

For particular values of EG and E M, the machines lose synchronism with each other if the steady-state limit of Pmax is exceeded. The steady-state stability study determines the maximum value of machine loading that is possible without losing synchronism as the system loading is increased gradually. Dynamic Stability Analysis A steady-state scenario never exists in actual operation, however. Rather, the state of the electrical system can be considered dynamic, whereby small, random changes in the system load constantly occur, followed by actions of the generator governor, exciter, and power system stabiliser to adjust the output of the machine and match the load requirement. The system can be considered stable if the responses to these small, random disturbances are bounded and damped to an acceptable limit within a reasonable time. The dynamic stability analysis of any system is only practical through specialised computer programs such as ETAP. Transient Stability Analysis Transient stability is the ability of the system to withstand sudden changes in generation, load, or system characteristics (e.g., short circuits, tripping of generators, switching in large bulk loads) without a prolonged loss of synchronism. [1] Traditionally, transient stability analysis focused on the ability of the system to remain in synchronism immediately after the occurrence of the transient event (i.e.,

Stability analyses carried out on the JERP refinery system covered the operation of the JERP electrical network in standalone condition as well as in parallel operation with the DTA electrical network.

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The results of stability analyses help define the limits of safe operation of the power system under various generation/load scenarios.

Load sharing on tripping of tie circuit breaker between JERP and DTA electrical systems: The behaviours of the JERP and DTA electrical systems were studied on disconnection of the JERPDTA tie line. This study was carried out for various combinations of operating GTGs/STGs in the JERP and DTA electrical systems (i.e., various power flow scenarios between JERP and DTA systems). When system stability could not be achieved by load sharing amongst the operating GTGs/STGs in each individual network, load shedding was simulated to try to achieve a stable system. Contingency Analysis Load sharing on tripping of JERP/DTA GTG: The behaviour of the power system was studied when one or more of the operating GTGs/STGs tripped, causing a loss of generation. This study was carried out for various combinations of operating GTGs/STGs in the JERP and DTA electrical systems. When system stability could not be achieved by load sharing amongst the remaining operating GTGs/STGs, load shedding was simulated to try to achieve a stable system. Operational Analysis Step-load addition study: A sudden addition of load on operating machines can cause loss of stability. A step-load addition scenario can occur in a variety of ways in an electrical system, the most probable being loss of one of the operating machines, which can cause a sudden increase in the load demand on the other operating GTGs/STGs. The behaviour of the system was studied for all probable scenarios of step-load addition. The results of these stability analyses helped define the limits of safe operation of the power system under various generation/ load scenarios. Motor-Starting Study At the instant of starting, synchronous and induction motors draw a starting current that is several times the full-load current of the motor. In the absence of assisted starting, this starting current is typically between 600% and 720% of the normal full-load current. This high current causes a voltage drop in the upstream electrical network, as well as in the motor feeder cable. The effects of this voltage drop include: The combined voltage drop in the supply network and the motor cable reduces the

voltage available at the motor terminals during the starting period. Because the motor torque is directly proportional to the square of the applied voltage, excessive voltage drops can mean that insufficient torque is available to accelerate the motor in the face of the load torque requirement, leading to very long starting times or a failure to start. The voltage drop at the switchboard buses can affect the other operating loads, mainly in the form of nuisance tripping of other loads on the network (e.g., voltage-sensitive loads or contactor-fed loads where the control voltage for the contactor is derived from the switchgear bus). There can also be cases in which the reduction in the terminal voltage for the operating motors causes the motor-torque curve to shift downwards. This reduction in the motor torque can cause the running motors to stall. For the other operating loads, a reduction in the motor terminal voltages causes the current drawn by the motors to increase as they strive to produce the power the process demands of them. This condition exacerbates the voltage problem because the increased current gives rise to an increased voltage drop in the system. Depending on the size of the motor being started and the generating capacity available, motor starting can impose a very high short-term demand on the operating generators. Studying motor starting can help identify these voltage-drop-related problems at the design stage. Usually, the worst-case motor-starting scenario is the starting of the highest-rated motor (or the highest-rated standby motor) at each voltage level with the operating load of the plant as the standing load. However, other worst-case scenarios may require evaluation in certain situations: Motors with an unusually long supply cable circuit Motors fed from a weak power supply (e.g., starting on emergency power supplied from a diesel generator set of limited rating) Simultaneous starting of a group of motors In the event of an unfavourable outcome from the motor starting study, various improvement measures are available, including: Specifying that motors be designed with a lower value of starting current, which is particularly feasible for the larger mediumvoltage (MV) motors

Bechtel Technology Journal

 Specifying lower impedance for the upstream transformer after verifying the suitability through a short circuit analysis Starting the largest motors in the network with a reduced standing load Using larger cable sizes for the motor feeder to improve the motor terminal voltage Providing assisted starting, if required, for the larger HV/MV motors instead of direct on-line starting Using motor unit transformers to feed power to large MV motors, which ensures that the effect of the voltage drop on the rest of the electrical system is reduced Increasing upstream bus voltage temporarily (e.g., through on-load tap changers [OLTCs]) before starting large motors Various motor starting scenarios were modelled for the JERP, and the results indicated that the motors could be started satisfactorily. Transformer Energisation Studies The inrush phenomenon in transformers can inflict a very severe, albeit short-term, effect on the voltage profile at the refinerys various switchboard buses. The inrush current taken by the transformers is due to the behaviour of the magnetic circuit. The constant flux linkage theorem states that the magnetic flux in an inductive circuit cannot change suddenly. Hence, the magnetic flux immediately after energisation (t = 0+) should be equal to the magnetic flux immediately before energisation (t = 0). When a transformer is switched on, the magnetic flux immediately after energisation depends on the following factors that are essentially random: The point on the sine wave voltage waveform where the transformer is switched on, which decides the amount and direction of the flux requirement The amount and direction of the remnant flux, which depends on the point on the sine wave voltage waveform where the transformer was last switched off As explained by the constant flux linkage theorem, the magnetic flux after energisation retains a sinusoidal shape that is biased by the flux requirement at the point of energisation and the remnant flux. Depending on the design of the transformer, this condition can cause the flux requirement to be well above the knee-point voltage on the transformer magnetising curve, leading to very high excitation currents that may

reach large multiples of the full-load current of the transformer. The inrush current decays substantially within a few cycles. Although modern protection systems are wellequipped with algorithms to distinguish the transformer inrush current from the short circuit, the inrush current still causes a severe voltage dip at the other switchboards in the network. This voltage dip can cause nuisance tripping of other network loads. The London core group studied various probable transformer energisation scenarios (including group energisation of transformers) to confirm that the network voltages recover without tripping system operating loads. Because ETAP could not directly model transformer behaviour under inrush conditions, the impact of the transformer inrush current was simulated by switching a series of low power-factor loads in and out at intervals of 5 milliseconds. The load values were selected as exponentially decreasing to simulate the inrush current decay. To ensure accurate modelling, the inrush current data was based on transformer manufacturers data supplemented by the measurements recorded during site testing and commissioning. The results of the transformer energisation studies established the network conditions under which the JERP transformers can be safely energised. This finding was crucial because in certain scenarios, the JERP main transformers were to be energised from the DTA electrical system and any disruption to the DTA operating loads could lead to tripping of the DTA refinery. Harmonic Analysis The amount of periodic waveform distortion present in the power supply is one of the most important criteria for measuring power quality. Periodic waveform distortion is characterised by the presence of harmonics and interharmonics in the power supply. Harmonics are sinusoidal voltages and currents with frequencies that are integral multiples of the fundamental frequency of the system. Interharmonics are sinusoidal voltages and currents with frequencies that are non-integral multiples of the fundamental frequency of the system. For the JERP: f 1 = fundamental frequency = 50 Hz fharmonic = n x f 1 (n = 2, 3, 4, ) finterharmonic = m x f 1 (m > 0 and non-integral)

The results of the transformer energisation studies established the network conditions under which the JERP transformers can be safely energised.

(3) (4)

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Conducting system studies on a complex project such as the JERP has highlighted areas where existing Bechtel procedures can be improved or fine-tuned.

Periodic waveform distortion is caused by nonlinear loads, which are loads that do not draw a sinusoidal current when excited by a sinusoidal voltage. The non-linear loads act as sources of harmonic currents in the power system, which cause a voltage distortion at the various buses because of the harmonic voltage drops across the impedances of the network. Hence, the quantum of voltage distortion depends on the harmonic currents injected into the system and the impedance of the system (the voltage distortion in a weak system, characterised by a high system impedance, is higher). The presence of excessive harmonics can lead to premature aging of electrical insulation due to dielectric thermal or voltage stress in equipment such as motors, cables, and transformers. Other possible effects of harmonics include reduced power factors, incorrect operation of protection systems, interference with communication networks, and occurrence of series and parallel resonant conditions that can lead to excessive currents and voltages in the system. Hence, it is important to carry out a harmonic analysis wherever the non-linear load forms a significant portion of the total load. The JERP electrical network includes a large number of harmonic-generating loads, mainly 22 kW and 37 kW low-voltage (LV) variable-speed drives (VSDs) that act as sources of harmonic currents. The London core group carried out a harmonic analysis of the JERP electrical network to verify that the voltage distortion at the networks various switchboards caused by these harmonic-generating loads is within the limits specified in Table 11-1 of IEEE 519 (Table 1).
Table 1. Harmonic Limits as Defined by IEEE 519
Individual Harmonic Distortion (IHD), %
3
1.5

(GTGs and STGs) were assumed to have no harmonic distortion. As a worst-case scenario, the harmonic analysis was carried out with the minimum generation configuration under normal operating conditions because this configuration corresponds to the maximum system impedance. The results of the harmonic analysis highlighted the switchboards whose power quality needs to be monitored further during plant operation. The London core group recommended that any corrective action (such as adding harmonic filters) to reduce the harmonics at these JERP plant switchboards be undertaken after measuring the actual harmonic levels at the various 6.6 kV/415 V switchboards when the plant is operating.

CONCLUSIONS

he results of the system studies of the JERP electrical network verified the adequacy of the ratings for the systems major equipment. The results also helped determine the conditions for satisfactory and reliable system operation and highlighted any operational restrictions required for safe operation.

LESSONS LEARNT onducting electrical system studies on a complex project such as the JERP and working with execution centres and non-Bechtel engineering contractors located across the globe have highlighted three major areas, discussed below, where existing Bechtel project procedures can be improved or fine-tuned to increase operating efficiency. Distributing Work The work distribution amongst the execution centres, non-Bechtel engineering contractors, and the London core group for carrying out ETAP modelling must be clearly defined through proper DWIs. Amongst other things, the instructions should include the structure of the model, the extent of modelling required, the data required to be populated in the model, the methodology of populating the data, the use of assumptions and approximations, the common library to be used to populate the standard data in the model, and the tests that must be carried out to ensure that sections of the model meet all requirements before they are transferred to the London core group for integration into the overall model.

Rated Bus Voltage

Total Harmonic Distortion (THD), %

5
2.5

69 kV and less Greater than 69 kV up to 161 kV 161 kV and greater

1.5

For shorter periods, during startups or unusual conditions, these limits may be exceeded by 50%.

All harmonic-generating process loads were modelled in the ETAP model used for harmonic analysis. The power sources in the JERP network

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Handling Model Revisions Proper work procedures for handling ETAP model revisions need to be furnished to the execution centres/non-Bechtel engineering contractors so that the London core group can integrate the revised models or revised sections of same into the overall model without causing rework or loss of data. Identifying Study Cases To increase engineering efficiency, it is essential to optimise the types of studies to be conducted on a project and the number of cases to be analysed for each study. At the same time, it is essential to ensure that the number and types of study cases allow the engineer to determine system behaviour under all operating conditions. This opportunity is particularly valuable because the projects that Bechtel is bound to take up (in the role of engineering contractor or as a project management consultant or member of a project management team) are more likely to be of the scale of the JERP, and it is highly likely that the engineering work for such projects will be divided amongst various execution centres.

REFERENCES
[1] IEEE 399-1997, IEEE Recommended Practice for Industrial and Commercial Power Systems Analysis, The Institute of Electrical and Electronics Engineers, Inc., 1998, pp. 79, 209214, access via http://standards.ieee.org/ colorbooks/sampler/Brownbook.pdf. D.P. Kothari and I.J. Nagrath, Power System Engineering, 2nd Edition, Tata McGraw-Hill Publishing Company Ltd., 2008, Chapter 12, pp. 558560, access via http://highered. mcgraw-hill.com/sites/0070647917/information_ center_view0/.

[2]

ADDITIONAL READING Additional information sources used to develop this paper include: P.M. Anderson and A.A. Fouad, Power
System Control and Stability, 2nd Edition, IEEE Press Series on Power Engineering, John Wiley & Sons, Inc., 2003, pp. 510, access via http://www.amazon.com/ Power-System-Control-Stability-Engineering/ dp/0471238627#noop.

Systems, Controls, Embedded Systems, Energy, and Machines, The Electrical Engineering Handbook, 3rd Edition, Richard C. Dorf, ed., Chapter 5, 2006, CRC Press/Taylor & Francis Group, LLC, Boca Raton, FL, pp. 5-1 5-3, access via http://www.amazon.com/ControlsEmbedded-Machines-Electrical-Engineering/ dp/0849373476.

ACKNOWLEDGMENTS The author wishes to express his gratitude to R.H. Buckle (chief engineer), R.D. Hibbett (lead electrical engineerJERP), and David Hulme (project engineering manager) for their support and guidance during execution of the JERP system studies. The author also wishes to thank V. Shanbhag, B.S. Venkateswar, and M.A. Mujawar from Reliance Industries for their support and encouragement. BIOGRAPHY
Rajesh Narayan Athiyarath is a senior electrical engineer in Bechtels OG&C Global Business Unit. He has 16 years of experience in engineering oil and gas, petrochemical, and GTG power plant projects worldwide. During his 3 years with Bechtel OG&C (London), Rajesh has contributed to system studies and relay coordination studies on the JERP and to FEED for the Ruwais refinery expansion project. He has also acted as the responsible engineer for the energy management system and load shedding system on the JERP. Rajesh received a performance award for his work on the JERP system studies. Rajesh holds a BE from Mumbai University, India, and is a chartered electrical engineer (CEng, member of Institution of Engineering and Technology [MIET], UK). He is a Six Sigma Yellow Belt.

TRADEMARKS ETAP is a registered trademark of Operation Technology, Inc. IEEE is a registered trademark of The Institute of Electrical and Electronics Engineers, Incorporated. Merox is a trademark owned by UOP LLC, a Honeywell Company. Simulink is a registered trademark of The MathWorks, Inc.

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