The presentation discusses improving electrical system reliability in petrochemical facilities through establishing a goal of zero power failures and fastest recovery times. It emphasizes getting all employees onboard to save costs from shutdowns. The presentation also highlights common hazards petrochemical facilities face like explosions, fires, and hurricanes and provides solutions to address aging infrastructure, safety systems, and area classification.
August 2010 - Michigan Energy Forum - Jay MurdochAnnArborSPARK
Ähnlich wie Zero Policy = maximize profits; Clients (Refineries and petrochemical Facilities) will maximize profits if they develop a zero policy. (20)
4. Reference Data
• Long term optimization of asset replacement in energy
infrastructures; Ype C. Wijnia, Martijn S. Kom, Saskia Y. de Jager,
Paulien M. Herder 2006
• Refinery power failures: causes, costs and solutions; Patrick J
Christensen, William H Graf and Thomas W Yeung Hydrocarbon
Publishing Company 2013
• Integrating Advanced Relays On Medium Voltage Switchgear Safety
Instrumented Systems (P66 and BMcD) IEEE PCIC 2013.
• OSHA 1910.119 Process safety management of highly hazardous
chemicals
• Arc Flash Mitigation in a Chemical and Refining Facility Using IEC
61850 (CPChem/BMcD IEEE PCIC 2012)
• Many, many papers and studies published by IEEE.
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
4
35. Case study
• A facility (refinery/petro‐chemical facility up north), was down from 28 October to
20 November 2012 due to SuperStorm Sandy.
• According to the company, the expenses related to the storm were $56 million
before tax.
• This loss did not include missed production for over three weeks.
• Based on the refinery’s nameplate gasoline production capacity of 145 000 b/d
and distillate production capacity of 115,000 b/d,
• a utilization rate of 85% and average spot market prices of gasoline of $2.812/gal
and $3.084/gal for distillates in New York Harbor during the shutdown period,
estimated revenue loss was over $650 million.
• Net profit loss ranged from $5.3 million for cash margins of $1/bbl to $26.5 million
for cash margins of $5/bbl.
• US refineries outside the East Coast should expect a bigger financial impact, since
East Coast refiners are known to have much lower refining margins than their
peers in other parts of the country.
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
35
41. Crisis Management
• When a problem does arise, the second part
of the strategy — crisis management — comes
into play.
• This involves the recovery technologies that
allow for safe shutdown and continued
operation, and the restart methods that will
not lead to the same problem that caused the
previous failure.
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
41
54. Power independence
• Onsite power generation via combined heat and
power (CHP) units and microgrids are worth
consideration.
• The latest CHP and microgrid technologies can be
incorporated into the design of a new
refinery/petro‐chemical facility power grid that
can be combined with other renewable energy
generation units as a way to improve power
supply security and reduce plant carbon
footprint.
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
54
56. Major Equipment In Electrical Systems
• Generators
• Motors
• Power & control cables
• Transformers
• UPS
• Battery chargers
• Battery banks
• Switch gear & control gear
• Panels
• Lighting
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
56
78. Inadequate Lightning Protection
• In Port Arthur, Texas, facility experienced lightning that led to a power
outage and also stated a fire. The lightning caused a crude unit, two
hydrotreaters and a delayed coker to shut down.
• Unlike the above experience, in July 2009, a refinery/petro‐chemical
facility in Pasadena, Texas, experienced a lightning strike that disabled all
power to the Tank farm, which resulted in loss of feed to the refinery’s
crude unit. The feed was restored with a backup generator, and the
refinery was able to run using backup power and keep operations online
despite the loss of power to the tank farm.
• A facility in Los Angeles CA experienced a power surge caused by lightning,
which caused the hydrocracking unit to trip. Emissions of sulphur dioxide
and hydrogen sulphide were released during the flaring caused by the
shutdown.
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
78
97. What we have found during site visits
• Mis‐coordination of circuit breakers and fuses.
• Undersized equipment (voltage or current).
– Cannot withstand the short circuit current
– Cannot withstand the continuous current.
– I have heard CEO’s say: we don’t have this problem in our
facility do we? (radial feeds to critical process units? Can’t
be). It is our jobs to inform our supervisors, they trust the
line managers, the maintenance crews, etc.. To inform
them of safety and reliability issues.
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
97
100. Long Range Plan Theories
• Long Range Plan Theories
– Equipment Consolidation
– Equipment Modernization
– Equipment Maintainability
• Long term goal, add substations as new load
dictates
– Existing study must show that limited existing capacity
exists
– New load must be required
– Envision one substation per area
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
100
102. Master plan should clearly
• List code related issues.
• List grounding issues.
• List lighting issues.
• List area classification issues.
• List maintenance department and operator complaints,
confirm these complaints.
• List bad actors.
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
102
112. Understand the Power Requirements
• Total Connected Load
• Running Load
– Rule of thumb in industrial facilities 90% of load
rotating and 10% of load static.
• Utility Required Power Factor
• Utility Required Harmonic Distortion
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
112
114. Understand the Internal Electrical
Distribution
• Routing Power Cables in the Facility
– Cable Tray
– Duct Bank
– Air Insulated Conductors
• Unit Substation Size
– 25‐MVA max for 15‐kV
– 15‐MVA max for 5‐kV
– 2.5‐MVA max for 480‐V
• Unit Substation Voltage Levels
– 15‐kV
• 7.5‐kV
– 5‐kV
• 2400‐V
– 480‐V
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
114
116. Understand the Power Centers
• Locating
– Classified Area
– Blast Zone
• Prefab
– Elevation
– Shipping Issues
• Site Built
– Building Penetrations
– Equipment Access
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
116
117. Understand the Transformers
• Transformer Sizing
– Connected Load
– Running Load
• Transformer Impedance
– Short Circuit
– Arc Flash
• Transformer Grounding
– High Resistance Grounding
• 5‐kV
• 2400‐V
• 480‐V
– Low Resistance Grounding
• 15‐kV
• 27‐kV
• 38‐kV
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
117
120. Understand the Electrical Loads
• Motors
– Pump
– Compressors
– Fans
• Variable Frequency Drives
• Other Loads
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
120
121. Understand Your Motors
• Motors
– Medium Voltage Motors
• Induction
• Synchronous
– Low Voltage Motors
• <250‐hp
IEEE/AiChE Joint Presentation April 9, 2015
Rev. 0 For Educational, Safety, and Process
Improvement Purposes Only
121