Power Systems Design for the Oil &
Gas Industry
Key Study Modules
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.
Developing the load list
1.
2.
3.
6.
Continuous
Intermittent
Stand-By
The Distribution System
1.
2.
7.
Developing/Updating the One-line
Circuit arrangement selection
Equipment Selections
1.
2.
3.
4.
5.
6.
8.
Generators
Transformers
Cables & Cable Support
Switchgear Systems
Electric Motors
Lighting Systems
Performer System Studies
1.
2.
9.
10.
11.
12.
Greenfield
Brownfield
Hand Calculation
Software Tools
Selecting Protective Devices
Grounding Systems
Hazardous Areas
Stand-by Power Systems
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INTRO
Course Objectives
Content development guideline
Assumptions
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Power Systems in Industrial Facilities
Power Generation
and distribution
systems are a critical
part of many
petrochemical
facilities worldwide
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Power Systems in Industrial Facilities
The primary objective of any industrial plant is to produce
consistently and economically. The ability to produce is
dependent to a large degree on the adequacy
and continuity of the electrical service. In many cases, the
cost of service interruptions can be evaluated directly in
terms of lost production. This cost may exceed the cost of
the physical damage to the electric equipment that caused
the interruption.
Therefore, it is of prime importance that the electrical
system be designed to serve continuously, reliably, and
hopefully unnoticed. Since no two plants have identical
requirements, a standard electrical distribution system is
not universally applicable. Therefore, it is essential to
analyze the specific requirements of each process
system and then design an electrical system which will
most adequately meet these
requirements.
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Power Systems in Industrial Facilities
Power Systems are typically designed to provide
reliable and sufficient electric power to an array of
equipment and infrastructure hence the capacity,
arrangement and operation of the power systems is
dictated by the peculiar requirements of each plant
facility
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Power Systems in Industrial Facilities
In its simplest form a power generation & distribution
system would comprise of some form of electric
power generator or incoming utility feeder, distributive
switch-gear, cables & and equipment terminating
panels
Power Cables
Power Cables
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Power Systems in Industrial Facilities
A One-line representation of More Complex Systems
Acrobat Document
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The role of the Power Systems design engineer
After Due consideration of peculiar project
requirements and constraints the PSE is required to
design a reliable, cost effective and constructible
power generation and distribution systems.
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Bio-Slide: Shola Daley
Electrical/Electronics OAU
89
Shell Petroleum Warri E/I Engineer(Field)
90-92
Chevron Oil Escravos Facilities Engineer
92-95
Mobil Producing Qua Iboe Terminal Electrical Eng 95-96
Data Communications & Control SouthBank UK
96
Sandersons Construction Company , UK
97-99
Atlas Oil Company Consultant
2000-01
Amazon Energy Limited
2001-03
Ipgrupp Engineering Technical Director
2003-
44B Ajanaku Str Opebi, Lagos
08023036794
www.IPgruppEngineering.com
018984028
Approaching the design process
Basic Design Considerations
Safety
Reliability
Maintenance
Flexibility
Simplicity of Operation
Voltage Regulation
Cost
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Approaching the design process
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;
Is the plant a new, green field plant?
How long will the plant exist e.g. 10, 20, 30 years?
Is the plant old and being extended? (Brownfield)
Is the power to be generated on site, or drawn from an external utility, or a combination of
both?
Does the owner have a particular philosophy regarding the sparing of equipment?
Are there any operational or maintenance difficulties to be considered?
Is the power factor important with regard to importing power from an external source?
If a generator suddenly shuts down, will this cause a major interruption to the plant
production?
Are there any problems with high fault levels?
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Developing The Load List Summary
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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Developing The Load List
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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Developing The Load List
Running Load
The actual electrical load of the facility during operation. Running load is
used to size utility service, generators, transformers, feeders, motor
control centers, circuit breakers, and uninterruptible power supplies. To
determine running load, individual loads must be identified as either
continuous, intermittent, or spare. Running load is the sum of all
continuous loads, including planned future continuous loads. Intermittent
loads are included on a percentage basis; spare loads are not included
in running load calculation.
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Developing The Load List
Continuous load : Defined as a load that is expected to operate
continuously for 3 hours or more.
Intermittent loads: are loads that operate continuously for periods
of less than 3 hours.
Spare loads: are operated only when other loads are not operating.
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Developing The Load List
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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Developing The Load List
Stand-by loads should be identified on the load summary to enable the electrical
system designer to design the stand-by power system. Typically, stand-by loads
include critical loads that cause damage to the process or product if power is interrupted,
loads required for black start-up of a generator (e.g., jacket water heaters and
pumps), selected plant lighting and HVAC loads, and sewage pumps.
Emergency loads deemed essential for personnel safety (e.g., building egress
lighting) and UPS loads that require clean uninterrupted power (e.g., computers and
certain electronic instrumentation) should also be identified on the load summary.
Typically, emergency loads are powered from unit equipment separate from the
stand-by system because of the more stringent requirements of emergency systems.
Refer to Sections 124 and 1300 for more information on stand-by, emergency, and
UPS power systems.
As the design evolves, load estimates should be updated constantly. It is important
to coordinate with other design disciplines to ensure that up-to-date data are used.
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Developing The Load List
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Developing The Load List
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The Distribution System
Selecting a Power Distribution Arrangement Scheme
Once the load layout has been developed and areas of high load concentrations have
been identified, a power distribution scheme can be selected. A system should be
selected that will distribute power to the load centers by the most economical and
reliable means possible that meets the particular facility requirements.
The primary distribution voltage can be distributed to the load centers economically
and reliably with the following systems:
Radial
Primary selective
Primary loop
Secondary selective
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The Distribution System
Radial System
In the radial system, one primary service feeder supplies power from a distribution
transformer to the loads (at utilization voltage) from a load center.
This system is simple in operation, and expansion is accomplished easily.
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The Distribution System
Primary Selective Distribution - A distribution system philosophy where equipment
such as Ring Main Units (RMU's), Switchgear, Load / Motor Control Center, and/or
Transformers are connected to two separate primary feeders through switching
equipment to provide a normal and an alternate source. Upon failure of the normal
source, the equipment can be switched to the alternate source.
Figure - Primary Selective System Example
(IEEE Std. 141-1993 Figure 2-2)
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The Distribution System
Primary Open Loop Distribution - A distribution system philosophy where equipment
such as Ring Main Units (RMU's), Switchgear, Load / Motor Control Center, and/or
Transformers are connected through a number of tie circuits forming a loop. In this
configuration there are two routes which any point on a loop feeder can receive power.
The loop is considered "Open" when one of the series switches is open. See Figure
3.
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The Distribution System
Secondary Selective System
If two unit substations are connected through a normally open secondary tie circuit
breaker, the result is a secondary selective system.
If the primary feeder or a transformer
fails, the main secondary circuit breaker on the affected transformer is
opened and the tie circuit breaker closed. Operation may be manual or automatic.
Maintenance of primary feeders, transformers, and main secondary circuit breakers
is possible with only momentary power interruption (or no interruption if the
stations can be operated in parallel during switching). Complete station maintenance
will require a shut down. With the loss of a primary circuit or transformer, the
total substation load can be supplied by one transformer. To allow for this condition,
one or a combination of the following features should be considered.
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The Distribution System
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Selecting The System Voltage
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
Gas Turbine Generators
Ipgrupp Engineering
Equipment Selection
Equipment Sizing & Selection
The Gas Turbine Generator
Prime power generation in remote Oil
& Gas facilities are normally provided
using Diesel or Gas fuelled
reciprocating engine generator
packages or gas turbine generators.
Diesel Generators
Gas Turbine Generators
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Equipment Selection
Equipment Sizing & Selection
The Gas Turbine Generator
Gas turbines can be classified in several ways, common forms are:-
Aero-derivative gas turbines.
available in single unit form for power outputs from about
8 MW up to about 25 MW. These outputs fall conveniently into the
typical power outputs required in the oil and gas production industry,
such as those on offshore platforms.
Light industrial gas turbines.
Easier maintenance is achieved by designing the combustion
chambers, the gas generator and compressor turbine section to be
easily removable as a single modular type of unit. The ratings of
machines in this category are limited to about 10 MW.
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Equipment Selection
Equipment Sizing & Selection
The Gas Turbine Generator
Heavy Industrial gas turbines.
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 Sizing & Selection
Selecting the Generator
Step 1. Determine the generator power requirements, Pg (in kilowatts). It is
recommended that Pg for primary power generators equal running
load plus known future running load plus 10 to 20% spare capacity.
For stand-by and emergency generators, it is recommended that Pg
equal total connected load plus known future connected load plus 10
to 20% spare capacity.
Step 2. Select a standard generator rating (PG) equal to or greater than Pg. It
is recommended that the generator rating be based on a NEMA Class
B temperature rise. The generator should be specified with NEMA
Class F (or Class H) insulation so that it will operate below its insulation
temperature rating during normal operating conditions. This
design reduces the stress on the insulation and increases generator
life. The generator will also be able to operate in overload conditions
for short periods of time and still remain below the allowable temperature
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Equipment Selection
Equipment Sizing & Selection
Selecting the Generator
Step 3. Determine the generator voltage drop during starting of the largest
motor. Usually a 15 to 20% voltage drop is acceptable if the motor is
not started often. The designer should refer to the generator
manufacturers motor starting applications data. As a rule of thumb, if
the
generator rating (in kW) is at least five times the numerical value of
the horsepower of the largest motor, the voltage drop will not be
greater than 15% with the generator already loaded to 50 to 75%.
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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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Developing The Key One-Line Diagram
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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Developing The Key One-Line Diagram
Contents
1.
Overall One-LineDiagram
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Developing The Key One-Line Diagram
Contents
1.
Overall One-LineDiagram
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Developing The Key One-Line Diagram
Contents
1.
Overall One-LineDiagram
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Performing Systems Studies
Contents
1.
Perform System Studies
1. Hand Calculation
2. Software Tools
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Selecting Protective Devices
Contents
1.
2.
3.
4.
Selecting Protective Devices
Grounding Systems
Hazardous Areas
Stand-by Power Systems
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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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Stand-By Power Systems
Contents
1.
Stand-by Power Systems
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Electrical Design Process Summary Overview
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Electrical Design Process Phase Deliverables
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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
Adhering strictly to applicable
International design codes and
regulations help to reduce the
risk of this hazard
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Typical Body response to Current
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Arc Flash
Current flowing through the air
Produces temperatures above
35,000 degrees F
Statistics show upwards of
2000 persons a year suffer
mild to serious injury from this
hazard
IT Can Kill You!!
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Electrical Hazards
Adhering strictly to applicable International design
codes and regulations help to reduce the risk of
this hazard
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Major Standards Used for Power System Design
OSHA Occupational Safety and Health Administration
NFPA 70-2005 NEC
NFPA 70E Electrical Safety in the Workplace
IEEE Recommended Practices
IEC
International Electro-Technical Commission
BS
British Standards
U.L. Underwriters Laboratories
ANSI American National Standards Institute
Client Preferred Design Instruction Guides
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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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The Institute of Electrical and Electronic Engineers(IEEE)
Publishes Technical Standards.
The colored books
Categorized into 13 colored books
Blue Book is IEEE Std 1015-2006
Bronze Book is IEEE Std 739-1995
Brown Book is IEEE Std 399-1997
Buff Book is IEEE Std 242-2001
Emerald Book is IEEE Std 1100-2005
Gold Book is IEEE Std 493-2007
Gray Book is IEEE Std 241-1990
Green Book is IEEE Std 142-2007
Orange Book is IEEE Std 446-1995
Red Book is IEEE Std 141-1993
White Book is IEEE Std 602-2007
Violet Book is IEEE Std 551-2006
Yellow Book is IEEE Std 902-1998
www.IEEE.org
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General Design Considerations
Coordination with other engineering disciplines( Process,Piping, Structural)
Plant Operating Considerations ( Onshore/Offshore?-Remote-Plant?)
Green Field/Brown Field Facility??
Plant Maintenance Considerations( Accessibility, By-Pass & redundancy)
Economic Considerations (Cost of Equipment Failure/ Start-Up Cost??)
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Key Study Modules Chapter 2
Electrical Load List Development
Power Supply and Distribution Selection
One-Line Diagram Development
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Electrical Load-List Development
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Electrical Load-List Development
Process Requirements
Utility Requirements
Electrical Code/Safety Specific
Requirements
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Electrical Load-List Development
P & ID
PUMP CALCULATION SHEET
Client
Project
Calc No
Name
Date
Equipment Number
Fluid Pumped
NGC
Fire Water Pump
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
Electrical Load-List Development
Rule Of Thumb: Matching Load HP to Motor Hp
Driven machine
power rating (kW)
Up to 15
16 to 55
56 and above
Margin of motor rating
above
the machine rating multiplier
1.25
1.15
1.10
Select 60HP(45KW) motor as your load
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Electrical Load-List Development
Select for Arial Lighting
Plot Plan
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Power Supply & Distribution Selection
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Power Supply & Distribution Specification
Power Distribution Types
Voltage Selection
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Radial Distribution Systems
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Primary Selective Distribution Systems
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Secondary Selective Distribution Systems
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Network Distribution Systems
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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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Develop Preliminary One-Line Diagram
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One-Line Diagram Development
Graphic representation of all the loads, their
supply feeder cables, the protective devices
on the feeders and termination switchgear
equipment
The preliminary load list is a key input
document required to develop single line
diagrams along with derived feeder circuit
protective devices.
One drawing can typically be produced to
depict just a few devices in simple load to
feeder representation or up to hundreds of
devices as required to capture whole sections
of the distribution network.
Requires the engineers to have good
knowledge of standards graphical symbols
used to represent power circuit components
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One-Line Diagram Development
Typical Graphical Symbols employed
Naturally the preliminary load list is a key
input document required to develop single line
diagrams along with derived feeder circuit
protective devices.
One drawing can typically be produced to
depict just a few devices in simple load to
feeder representation or up to hundreds of
devices as required to capture whole sections
of the distribution network.
Requires the engineers to have good
knowledge of standards graphical symbols
used to represent power circuit components
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Develop Preliminary Single Line Diagram
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Key Study Modules Chapter 3
Equipment Selection, Sizing and Specification
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Equipment Sizing/Selection
Motor
Feeder Cables
Transformers
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The majority of the electrical loads within
the process areas of a Oil & Gas plant
are motors.
Correct sizing of these equipment to
match the load is essential stage of the
electrical design.
Recall earlier example of fire water
pump
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Several other factors, Standards and
electrical Code requirements need to be
taken into consideration prior to selecting
the motor for your application
Article 430.4 Part winding Motors
Article 430.7 Markings on Motors
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Key Study Modules Chapter 4
System Studies
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System Studies
Short Circuit Analysis
Load Flow & Voltage Drop
Protective Relay Coordination
Harmonic Analysis
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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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Design of Electrical Systems For the Oil & Gas Industry
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