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Gas Industry
1.
2.
3.
4.
Intro
Power Systems in Industrial Facilities
The role of the Power Systems design engineer
Approaching the design process
1.
2.
5.
6.
Continuous
Intermittent
Stand-By
7.
Equipment Selections
1.
2.
3.
4.
5.
6.
8.
Generators
Transformers
Cables & Cable Support
Switchgear Systems
Electric Motors
Lighting Systems
9.
10.
11.
12.
Greenfield
Brownfield
Hand Calculation
Software Tools
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INTRO
Course Objectives
Assumptions
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Power Generation
and distribution
systems are a critical
part of many
petrochemical
facilities worldwide
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Power Cables
Power Cables
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Safety
Reliability
Maintenance
Flexibility
Simplicity of Operation
Voltage Regulation
Cost
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One of the earliest tasks for the engineer who is designing a power system is to estimate the
normal operating plant load. He is also interested in knowing how much additional margin
he should include in the final design. There are no hard and fast rules for estimating loads,
and various basic questions need to be answered at the beginning of a project, for
example;
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Load Summary
A load summary is a detailed listing of all loads to be served by
the electrical distribution system. It is used to determine the
power requirements of a systemin order to properly size power
sources, distribution equipment, and feeder systems. The load
summary also aids in determining system voltages
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Load Summary
To develop a load summary, data on all loads to be served and
information about the facility processes should be collected first.
Generally, industrial facility loads are a function of the process
equipment. A list of loads must be obtained from the process and
equipment designers. The list should include nameplate ratings of
motors, brake-horsepower of electric motor-driven equipment, and
kVA and kW ratings of all other process equipment.
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Peak load, the maximum instantaneous load drawn by a system during a stated
period of time, is obtained when the facility is operating at full capacity and the
maximum instantaneous intermittent load is energized. All intermittent loads on a
system normally will not be energized at the same time. Therefore, to estimate peak
load the process must be evaluated to determine when the maximum intermittent
load will be energized. Peak load is the sum of the running load and the maximum
instantaneous intermittent load.
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Distribution Voltage
In most facilities it is necessary to
distribute power at a voltage higher
than the utilization voltages. When
choosing a distribution voltage, the
first voltage level to consider should
be the incoming utility (or generator)
voltage. If the utility supplies a voltage
in the range of 12,000 volts to 15,000
volts, it is often economical to use this
voltage as the primary distribution
voltage for the facility because
step down transformers are not
required.
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Equipment Selection
Equipment Sizing & Selection
Power Systems
Prime power generation in remote Oil & Gas
facilities are normally provided using Diesel
or Gas fuelled reciprocating engine
generator packages or gas turbine
generators.
For an individual generator that is rated
above 1000 kW, and is to be used in the oil
industry, it is usual practice to use a gas
turbine as the driving machine (also called
the prime mover). Below 1000 kW a diesel
engine is normally preferred, usually
because it is an emergency generator
running on diesel oil fuel.
On Many offshore smaller facilities it is also
common to see gas fuelled reciprocating
engine prime mover for power demands
below 1000MW
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Diesel Generators
Equipment Selection
Equipment Sizing & Selection
The Gas Turbine Generator
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Equipment Selection
Equipment Sizing & Selection
The Gas Turbine Generator
Gas turbines can be classified in several ways, common forms are:-
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Equipment Selection
Equipment Sizing & Selection
The Gas Turbine Generator
Heavy industrial gas turbines are usually to be found in refineries, chemical plants and
power utilities. They are chosen mainly because of their long and reliable running times
between major maintenance overhauls. They are also capable of burning most types of
liquid and gaseous fuel, even the heavier crude oils. They also tend to tolerate a higher
level of impurities in the fuels. Heavy industrial machines are unsuitable for offshore
applications because:-
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Equipment Selection
Equipment Sizing & Selection
.
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Equipment Selection
Equipment Sizing & Selection
Selecting the Generator
What needs to be considered in selecting the generator:
Location: onshore/offshore
Source of Fuel.
Power Demand
Maintenance
Cost
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Equipment Selection
Equipment Sizing & Selection
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Equipment Selection
Equipment Sizing & Selection
Selecting the Switchgear Assembly
What needs to be considered in selecting the generator:
Location: onshore/offshore
Source of Fuel.
Power Demand
Maintenance
Cost
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Equipment Selection
Equipment Sizing & Selection
Contents
1.
Equipment Selections
1. Generators
2. Transformers
3. Cables & Cable Support
4. Switchgear Systems
5. Electric Motors
6. Lighting Systems
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Equipment Selection
Equipment Sizing & Selection
Contents
1.
Equipment Selections
1. Generators
2. Transformers
3. Cables & Cable Support
4. Switchgear Systems
5. Electric Motors
6. Lighting Systems
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Equipment Selection
Equipment Sizing & Selection
Contents
1.
Equipment Selections
1. Generators
2. Transformers
3. Cables & Cable Support
4. Switchgear Systems
5. Electric Motors
6. Lighting Systems
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1.
Equipment Selections
1. Generators
2. Transformers
3. Cables & Cable Support
4. Switchgear Systems
5. Electric Motors
6. Lighting Systems
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1.
Overall One-LineDiagram
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1.
Overall One-LineDiagram
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1.
Overall One-LineDiagram
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1.
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1.
2.
3.
4.
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Grounding Systems
Contents
1.
2.
3.
Grounding Systems
Hazardous Areas
Stand-by Power Systems
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Hazardous Location
Contents
1.
Hazardous Areas
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1.
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Hazards of Electricity
Risk/Effects of Shock
The effects depend on the
current (not the voltage), and
the worst damage occurs along
its path from the entry to the exit
point. Causes of immediate
death are ventricular fibrillation
and paralysis of the brain's
breathing centre or of the heart
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Arc Flash
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Electrical Hazards
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BS
British Standards
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NFPA 70 - NEC
The National Electric Code was first
established in1897
Sponsored by the NFPA
Primary design codes for domestic
and commercial electrical installations
in North America
Not a Design Standard but a minimum
Code requirement for safe electrical
designs
Provides for several exemptions from
Code
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ANSI
The American National Standards
Institute established in
1918
ANSI coordinates and endorses
standards produced by accredited
standards developers
Created to avoid duplication of
standards developed from IEEE, ASME,
ASTM and many others
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IEC
Established In 1906 through leading
scientists and pioneering industrialists
from around the globe.
Ensures global standardization of
electrical apparatus and machinery.
The (IEC 60364) document provides
guidance to an authority on developing
national wiring principles that would, in
turn, serve as the basis to further
develop practices & Codes.
Predominantly used Electrical standards
in Europe
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www.IEEE.org
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Process Requirements
Utility Requirements
Electrical Code/Safety Specific
Requirements
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P & ID
NGC
By
Chk'd By
App'd By
Rev
O.U
00
4th-Jan-2006
Service
Water
1 x 100%
Duty
PHYSICA L PROPERTIES
Fluid Temperature, T
Max
30 C
40.0 C
Viscosity @T
0.797 cP
Density @T
996 kg/ m
Vapour Pressure @max T
4.247 kPaa
PUMP SPECIFICATION
Volumetric Flowrate
114 m/ h
Design Margin, Flow
10.0 %
Design Flowrate
125 m/ h
Pump Type
Centrifugal
Pump Centre Line Elevation
0.76 m
(above grade)
Pump Speed
3000 rpm
Pump Suction Impeller Type
single suction
SUCTION CONDITIONS
Suction Vessel Pressure
10.370 m
101.325 kPaa
Suction Liquid Level Elevation
2.34 kPa
1.00 m
(above grade)
Maximum Vapour Pressure
4.247 kPaa
0.435 m
Line / Fittings Pressure Drop
0.0 m
0.00279 kPa
Suction Head
103.667 kPaa
10.610 m
Available NPSH
99.42 kPa
10.175 m
NPSH Design Margin
9.77 kPa
1.00 m
Required NPSH
5.10 m
DISCHARGE CONDITIONS
Line / Fittings Press. Drop
1.044 m
10.2 kPa
Discharge Vessel Pressure
108.354 m
1058.7 kPaa
Discharge Liquid Level Elevation
0.95 kPa
0.86 m
(above grade)
Discharge Head
1069.85 kPaa
109.495 m
POWER
Differential Head
966.18 kPa
98.9 m
Flowrate
125 m/ h
Hydraulic Power
33.526 kW
Pump Efficiency
90.0%
Assumed
Estimated Power
37.251 kW
Calculated- X Inputed- X
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Plot Plan
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Voltage Selection
Usually 480Y/277 or 415Y/240
depending on National preference
Industrial loads normally supplied
through 3phase 480/415V
Lighting and low demand domestic
loads would be supplied through the
Phase to- Neutral Single phase
System 277/240
Further Voltage reduction to
208Y/120V is also employed in some
Countries to supply Light/domestic
loads
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Voltage Selection
Usually 4,160Y/2,400V, 11,000Y/6351V
13,200/7620V
Used when the load center becomes too
great or of significant distance from
source of power
11,000V/4,160V are the preferred
generating voltages for land based
facilities in the Oil industry.
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Equipment Sizing/Selection
Motor
Feeder Cables
Transformers
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System Studies
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System Studies
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Arc Flash
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General Information
This training guide was developed by Ipgrupp Engineering. Information contained in this
guide is subject to change without notice and Ipgrupp Engineering assumes no
responsibility for any damages resulting from use of the information contained herein.
The Information contained in this training guide is protected under the Federal Republic of
Nigeria copyright laws and may not be reproduced in whole or in part without written
consent by Ipgrupp Engineering
The class participant, by accepting this manual, agrees to the conditions listed on this page
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