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Company: Project: Engineering Contractor:

OFFSITES ENGINEERING WORKS


FOR THE ERBIL REFINERY
40,000 B/D EXPANSION PROJECT

Contract no.: 10J01762-01


Company doc. no.: Job no.: 10J01762 Engineering doc. no.:
N/A Sheet 1 of 12 10J01762-ELE-SP-000-001

OFFSITES ENGINEERING WORKS FOR THE


ERBIL REFINERY 40,000 B/D EXPANSION PROJECT

POWER SYSTEM STUDIES

D0 27/09/2011 Issued for Construction Caldarigi Caputi Cilia


C0 30/06/2011 Issued for Company Approval Caldarigi Caputi Cilia
REV. DATE REVISION TITLE PREPARED CHECKED APPROVED

File name: 10J01762-ELE-SP-000-001_D0.doc


OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
Power System Studies
Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 2 of 12 10J01762-ELE-SP-000-001

INDEX

1 GENERAL ....................................................................................................................................3
1.1 Scope of the Document .........................................................................................................3
1.2 Definitions ..............................................................................................................................3
1.3 Codes and Standards ............................................................................................................4
1.4 Project Documentation...........................................................................................................4
1.5 Abbreviations .........................................................................................................................4
2 POWER DISTRIBUTION OVERVIEW ..........................................................................................4
3 POWER SOURCE ........................................................................................................................5
3.1 Power Source ........................................................................................................................5
3.2 Power Cables ........................................................................................................................5
3.3 Power transformers ...............................................................................................................6
3.4 Motors ...................................................................................................................................6
3.5 Basis......................................................................................................................................6
3.6 General Note for Simulation ...................................................................................................7
3.7 Single Line Diagrams .............................................................................................................7
4 LOAD FLOW CALCULATION .......................................................................................................9
4.1 General..................................................................................................................................9
4.2 Configurations .......................................................................................................................9
4.2.1 Load Flow Results ........................................................................................................10
5 SHORT CIRCUIT CALCULATION ..............................................................................................11
5.1 Configurations .....................................................................................................................11
5.2 Short Circuit Current Calculation Results .............................................................................11
6 ANNEXES ..................................................................................................................................12

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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
Power System Studies
Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 3 of 12 10J01762-ELE-SP-000-001

1 GENERAL

1.1 Scope of the Document


This report is dedicated to the Power Study for the electrical system dedicated to OSBL loads
to be implemented for offsites engineer works for Erbil Refinery 40,000 B/D expansion project
Scope of this report is to study the network behavior during normal configuration and motors
starting time, so to guarantee that switchgears, circuit breakers, transformers and all power
transmission equipment are correctly sized and capable of withstanding the effects of short
circuit currents and voltage arising during running system.
The following studies have been performed:

- Load Flow
- Short Circuit

The above studies and all simulation have been performed with software ETAP

1.2 Definitions

The following terms will be used in all documents issued during the execution of the project:

Project: Off-sites Engineering Works inherent to the Erbil Refinery 40,000 B/D
Expansion Project.

Company: KAR Engineering & Construction (KAR)

Engineering: ENERECO Qatar Engineering and Consulting, the engineering


contractor nominated by the Company to perform the Off-sites
Engineering Works (OSBL) inherent to the Erbil Refinery 40,000 B/D
Expansion Project.

Ventec: It’s the interface Contractor responsible for the design of the new
Refinery Plant, the so called In Site Battery Limit (ISBL)

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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
Power System Studies
Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 4 of 12 10J01762-ELE-SP-000-001

1.3 Codes and Standards


Reference standard codes and specifications for this calculation report are:

IEC 60038 IEC Standard Voltages


IEC 60909 Short Circuit Current Calculation in three phase AC systems.

1.4 Project Documentation


The documents listed below form an integral part of the Power System Study:

The documents in the following table are indicated in order of precedence:

Item Number Description


1 10J0176-ELE-DW-000-002 Key Single Line Diagram
2 10J0176-ELE-DW-000-003 S.L.D. Relaying and Metering for MCC 0.40/0.23 kV
3 10J0176-ELE-LS-000-001 Electrical Load Summary
4 10J0176-ELE-LS-000-002 List for Power, Control and Earthing Cables
5 10J0176-ELE-DS-000-003 Data sheet for 6.6/0.40kV Power Transformer
6 10J0176-GEN-SP-000-001 Basic Engineering Design Data (B.E.E.D.)
33kV O/H Line from Ministry of Electricity (MOE) Single Line
7 -
Diagram

1.5 Abbreviations
The following abbreviations are used in this document:

A.C. or a.c. Alternating current


CB Circuit breaker
FLC Full Load Current
FLT Full Load Torque
DOL Direct on Line Start Motor
LV Low Voltage
MCC Motor Control Center
MV Medium Voltage
NER Neutral Earthing Resistor
OSBL Off-Site Battery Limit (of the refinery process area)
PH Phase

2 POWER DISTRIBUTION OVERVIEW

The electrical power system, dedicated to OSBL Loads, will be supplied by two circuit
breakers on MV Switchgears: MVS-04A & MVS- 04B. (to see ref. doc. - 33kV O/H LINE from
Ministry of electricity (MOE) Single Line Diagram).

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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
Power System Studies
Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 5 of 12 10J01762-ELE-SP-000-001

MV Switchgear no.2 C.B. number XXX at 6.6kV, 3 Ph, 50 Hz Switchgear, provided by


Ventech.

For supply the OSBL loads, multicore cable, 3x240mm2 will be used with EPR insulation, steel
armour, PVC sheath (EPR/SWA/PVC).

The 6.6kV cable length has been considered equal to 100 m. Length has been finalized
according to final cable routing.

The OSBL Loads shall include no.2 step-down transformer, from 6.6kV to 0.40kV, 630 kVA.
The transformer is provided with off-load tap-changer.

The 400V Motor Control Center shall be provided with no.two main incomer from 6.6/0.40kV
Transformer and one bus tie and outgoing feeders for LV electrical consumers, according to
the Load List doc no. 10J01762-ELE-LS-000-001.

3 POWER SOURCE

3.1 Power Source

Rated Voltage 6.6 kV


Frequency 50 Hz
Max. short circuit value S’’k=260MVA (data provided by Client)
X/R 10 Assumption
Neutral System TN- S

3.2 Power Cables


The major cables used for study are listed in the following table:
Max
current
carryng
Maximum Phase
To capacity
Voltage DC reactance Length
Cable Type From Cross section in
(Uo/Um) resistance 50Hz
ground
at 20°C approx
(T 20°°C,
depth 1
m)
6.6/0.4kV
EPR/CU/SWA/PVC 6.6kV MV MCC – Transformer 0,0754 0,09
6/10 kV 3x240sqmm 495 A 100 m
Multicore MVS-04A – Ω/km Ω/km
TR-03 A
6.6/0.4kV
EPR/CU/SWA/PVC 6.6kV MV MCC – Transformer 0,0754 0,09
6/10 kV 3x240sqmm 495 A 100 m
Multicore MVS-04A – Ω/km Ω/km
TR-03 B

6.6/0.4kV LV MCC
EPR/CU/AWA/PVC Transformer – 0.4/0.23 kV 0,0470 0,24 100
0.6/1kV 4x(3x1x400)+N+PEsqmm 645 A
Singlecore Ω/km Ω/km
TR-03 A MCC - 020

6.6/0.4kV LV MCC
EPR/CU/AWA/PVC Transformer – 0.4/0.23 kV 0,0470 0,24 100
0.6/1kV 4x(3x1x400)+N+PEsqmm 645 A
Singlecore Ω/km Ω/km
TR-03 B MCC - 020

Fuel Oil
LV MCC 0.4/0.23 Transfer
EPR/CU/SWA/PVC kV Pump – 0,0966 530m
0.6/1kV 2 (3x185)+PEsqmm 0,07Ω/km 500 A
Multicore Ω/km
MCC - 020 P-2315
A/B/C

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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
Power System Studies
Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 6 of 12 10J01762-ELE-SP-000-001

NOTE:
Data according to Manufacturer Catalogue
Cable sizing is finalized

3.3 Power transformers


The characteristic of the transformers are listed in the following table:

Short Circuit Tapping on


Item Rated Power Rated Voltage Group Type Air Cooled
Voltage windings
off load tap
6.6/0.40kV Transfomer change
630 KVA 6.6/0.40 KV Dyn 11 Dry type 4% AN/AN
(note b) TR-03(*) 2x2.5%
± 5%

Note:
(*) description according to Cyme diagram
a) Neutral directly grounded.

3.4 Motors
The characteristic of the motors are listed in the following table:

Efficiency
Item Rated Power Rated Voltage Power factor

P-2315 A/B/C _Fuel Oil Transfer Pump 75kW 0.4kV 0.87 94.0%

3.5 Basis

Loads are in accordance with Load List, see reference document [2] where following duty
factors are considered:

- Continuous loads 100%


- Intermittent loads 30%
- Stand-by loads 10%

For steady state mode all consumers of the power system are assuming in running condition
according to Load List.
For LV Switchgear, the loads have been represented on the diagrams by four equivalents; two
equivalent for dynamic load and two equivalent for static load with summary power according
to Load List.

The Electrical system shall be subject to the following limits on cable voltage drop, as a percent
of nominal voltage:

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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
Power System Studies
Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 7 of 12 10J01762-ELE-SP-000-001

Description Maximum Volt Drop

MV circuits between MV switchgear and incoming 2.5%


terminals on primary side of power transformers

Bus-duct or cable between transformer secondary and 2.5%


switchgear

Main feeders to downstream switchboards/MCCs 2.5%


installed inside same substation

Main feeders to downstream switchboards/MCCs 2.5%


installed in different substation or process area

Motor Feeders to motor terminals at full load 5%

Motor Feeders to motor terminals during starting (1) 15%

Lighting circuits (up to the farthest lighting fixture) 2.5%

DC supply circuits 2.5%

AC UPS circuits 2.5%

(1) During motor starting, the voltage drop at the bus bar of the switchboard that supplies the
motor shall be -10% maximum.

3.6 General Note for Simulation

Bus 2 and Bus 7 are not “real” bas bar but indicates only connection between 6.6kV power
cable and 6.6/0.4kV power transformer.
Bus 8 and Bus 11 are not “real” bas bar but indicates only connection between 6.6/0.4kV
power transformer and 0.4 kV power cable
Bus 4, Bus 5, Bus 13 are not “real” bas bar but indicates only motor terminals

3.7 Single Line Diagrams

The single line diagram used in the software calculation is represented in the following
page.

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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
Power System Studies
Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 9 of 12 10J01762-ELE-SP-000-001

4 LOAD FLOW CALCULATION

4.1 General
Load Flow Calculations are intended to check/define:

• voltage profile at the different network buses should remain confined between -5% +10%;
• equipment sizing: each equipment should not be loaded above 95% of its rating;
• TAP Changer position;

Load Flow Analysis has been performed to provide the better condition during normal
operation of the electrical system. The following Cases:
- Case no. 1 (Attached no. 1)
- Case no. 2 (Attached no. 2)

As a safety condition, a positive tolerance on transformers impedance value has been


applied.

4.2 Configurations

With reference to the loads described at prf. 3, the following cases have been analysed:

6.6 MV SWG 0.4 kV MCC


CASE # Load Participation (1) Network Configuration(2)
(% of Rated Value) (% of Rated Value)

1 100% Double Ended 100% 100%

2 100% Single Ended 100% 100%

3 100% Single Ended 100% 105%

(1)
Peak Load, as per Load Summary document
(2)
Double ended: both incoming closed and tie breaker open; Single ended: one incoming and tie breaker closed,
the other incoming open

o In case 1 tap changer for MV/LV transformer is 0%

o In case 2 tap changer for MV/LV transformer is 0%

o In case 3 tap changer for MV/LV transformer is in LV side is +2.5%.

Configurations 1,2 have been performed to verify normal load service conditions.

Configurations 3 has been performed to reduce the voltage drop on secondary bus bar

Newton-Raphson Method has been used to be perform Loaf Flow Analysis. Flat Profile
condition has been considered in starting condition.

Newton-Raphson Method:

 ∆P   J 1 J 2   ∆δ 
∆Q  =  J ×
J 4  ∆V 
   3
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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
Power System Studies
Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 10 of 12 10J01762-ELE-SP-000-001

Where:

∆P = Real Power Mismatch Vector


∆Q = Reactive Power Mismatch Vector
J 1 J 2 J 3 J 4 = Jacobian Matrix
∆δ =Bus Voltage Angle
∆V =Bus Voltage Magnitude

Flat Profile: IVI=1.0 p.u., δ = 0

After load flow resolve, the voltage drop value shown in tables results has been calculated with
the following formula:

VNo min al − VActual


∆Vd % = × 100
VNo min al

where:

∆Vd % =voltage drop percent

V Actual =voltage load flow solution

VNo min al = VBase

The VBase , considered on bus bars, is shown on tables related at each studies.

4.2.1 Load Flow Results

The following tables summarize main load flow results.

Switchgear Vn [kV] In [A] Case #1 Case #2 Case #3


%V A %V A %V A
MV –SWG - BUS A 6.6 100 100 100
MV –SWG - BUS B 6.6 100 100 100
MCC-020 BUS A 0.4 1000 98.6 482.01 97.3 872.5 99.7 871.2
MCC-020 BUS B 0.4 1000 98.6 390.51 97.3 392.7 99.7 398.2
BUS 4 0.4 128 96.7 132.61 95.2 134.7 97.6 131.3
BUS 5 0.4 128 96.5 132.87 95.2 134.7 97.6 131.3

o In case #1 the voltage drops on the bus bars remain confined in limits imposed in prf
3.5 (to see table).
o In case #2 the voltage drops on the bus bars don’t remain confined in limits imposed in
prf 3.5 (to see table).
o In case #3 (modifying the tap-changer on LV side Power transformer) the voltage drops
on the bus bars don’t remain confined in limits imposed in prf 3.5 (to see table).

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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
Power System Studies
Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 11 of 12 10J01762-ELE-SP-000-001

5 SHORT CIRCUIT CALCULATION

Short Circuit Calculations are intended to evaluate the maximum three phase short circuit currents to
check/define the electrical characteristics of electrical equipments. Results shall be considered
acceptable if SCC result will not be higher than 95% of equipment rating.

Calculations have been performed according to IEC 60909-0 Standard First Edition 2001-07 using the
following assumptions:

• for the duration of the short circuit there is no change in the type of short circuit
involved;
• for the duration of the short circuit there is no change in the network involved;
• the impedance of the transformers is referred to the tap-changer in main position,
including the negative tolerance;
• arc resistances are not taken into account;
• all line capacitances and shunt admittances and non-rotating load are neglected;
• voltage factor “c” as per IEC60909 has been used as follows:

Rated Voltage Voltage Factor


V rated cmax
Low Voltage
1.1
Up to 1000 V
Medium/High Voltage
1.1
> 1 kV

• cmax for LV transformer Z adjustment = 1.10;


• The short circuit current peak value has been calculated according to method “c” of the IEC
60909-0 Standard;
• The network is always considered in single radial configuration.

5.1 Configurations

The following cases have been analysed:

(1) (2)
CASE # Load Participation Network Configuration
1 100% Single Ended
(1)
Peak Load, as per Load Summary document, plus largest spare on each bus
(2)
Single ended: one incoming and tie breaker closed, the other incoming open

5.2 Short Circuit Current Calculation Results

The following table summarizes short circuit current calculation results for main busses.

Switchgear Vn [kV] Ik_rated Ip_rated Case #1


[A] [A] I”k (kA) ip (A)
MCC-020 0.4 50 105 27.4 43.9

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OFFSITES ENGINEERING WORKS FOR THE ERBIL REFINERY 40,000 B/D EXPANSION PROJECT
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Company doc. no.: Rev.: C0 D0 Engineering doc. no.:
N/A Sheet 12 of 12 10J01762-ELE-SP-000-001

6 ANNEXES

1) Load Flow ETAP Reports and Diagrams (ANNEXES 1-6)


2) Short Circuit ETAP Report and Diagrams (ANNEXES 7-8)
3)

File name: 10J01762-ELE-SP-000-001_D0.doc