DP30A

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

1 of 76

Date December, 1999 Changes shown by ➧

CONTENTS Section

Page

SCOPE ............................................................................................................................................................ 4 REFERENCES ................................................................................................................................................ 4 DESIGN PRACTICE ............................................................................................................................... 4 INTERNATIONAL PRACTICES.............................................................................................................. 4 OTHER LITERATURE ............................................................................................................................ 4 BACKGROUND .............................................................................................................................................. 4 DEFINITIONS.................................................................................................................................................. 4 POWER SOURCE REQUIREMENTS............................................................................................................. 8 CAPACITY .............................................................................................................................................. 8 NUMBER OF GENERATORS .............................................................................................................. 10 PURCHASED POWER ................................................................................................................................. 10 RELIABILITY......................................................................................................................................... 10 NUMBER OF CIRCUITS FROM UTILITY............................................................................................. 11 VOLTAGE AND REGULATION ............................................................................................................ 11 SHORT CIRCUIT LEVEL...................................................................................................................... 11 POWER FACTOR REQUIREMENTS ................................................................................................... 12 PARALLELING OF CIRCUITS.............................................................................................................. 12 NEUTRAL GROUNDING ...................................................................................................................... 13 FREQUENCY LIMITS ........................................................................................................................... 13 RELAYING............................................................................................................................................ 13 SURGE PROTECTION......................................................................................................................... 13 METERING ........................................................................................................................................... 13 POWER CONTRACT BILLING (TARIFF) ............................................................................................. 13 SPACE REQUIREMENTS .................................................................................................................... 13 DEMARCATION OF RESPONSIBILITIES............................................................................................ 14 GENERATED POWER IN PARALLEL WITH UTILITY ................................................................................ 14 POWER FOR EXPANSION OF EXISTING FACILITIES .............................................................................. 15 PURCHASED POWER......................................................................................................................... 15 GENERATION ONLY............................................................................................................................ 15 PURCHASED POWER PLUS GENERATION ...................................................................................... 15 MAIN SUBSTATION DESIGN ...................................................................................................................... 15 GENERAL............................................................................................................................................. 15 BUSBAR ARRANGEMENT .................................................................................................................. 16 TRANSFORMERS ................................................................................................................................ 16 SWITCHGEAR...................................................................................................................................... 17

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

2 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

CONTENTS Section

Page

REACTORS .......................................................................................................................................... 17 PROTECTIVE RELAYING .................................................................................................................... 17 TRANSFORMER SECONDARY CIRCUITS ......................................................................................... 18 LOCATION AND SPACING .................................................................................................................. 18 CONTROL AND INDICATION .............................................................................................................. 18 SURGE PROTECTION ......................................................................................................................... 18 ENVIRONMENT.................................................................................................................................... 19 MAIN SUBSTATION AUXILIARIES ...................................................................................................... 19 DESIGN PROCEDURE – ELECTRICAL DESIGN SPECIFICATION GUIDE............................................... 19 INTRODUCTION................................................................................................................................... 19 PLANNING AND DESIGN BASIS ENGINEERING ............................................................................... 19 HOW INFORMATION IS PROVIDED TO THE CONTRACTOR ........................................................... 20 INFORMATION NEEDED TO WRITE A DESIGN SPECIFICATION .................................................... 20 Writing A Design Specification ........................................................................................................... 21 COMPUTER PROGRAMS ............................................................................................................................ 23 GUIDANCE AND CONSULTING .......................................................................................................... 23 AVAILABLE PROGRAMS ..................................................................................................................... 24 APPENDIX A SAMPLE PLANNING DOCUMENTS ..................................................................................... 47 SITE SURVEY QUESTIONNAIRE........................................................................................................ 47 Power Supply ..................................................................................................................................... 47 Public Utility Power............................................................................................................................. 47 General Electrical Information ............................................................................................................ 47 Questionnaire for Public Utility to Obtain Definitive Planning Data. ...................................................... 48 Brighton Synthetics Plant and Troup Lignite Mine................................................................................. 49 APPENDIX B SAMPLE DESIGN SPECIFICATION 94-1 ............................................................................. 54

TABLES Table 1 Table 2 Table 3 Table 3-1 Table 3-2 Table A-1

Offsite DBM Recommended Design Factors ............................................................. 27 Power Transformer Ratings ....................................................................................... 28 Design Specification Check List Of International Practice Asterisk Items .................. 29 Summary of Distribution Loads and Transformer Sizes............................................. 61 Substation Motor List ................................................................................................. 62 Brighton Synthetics Plant and Troup Lignite Mine Electrical Requirements............... 50

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

3 of 76

Date December, 1999

CONTENTS (Cont) Section FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure A-1 Figure A-2 Figure A-3

Page

Application of Load Growth and Reserve Capacity Factors......................................... 36 Symbols for Figures..................................................................................................... 37 Duplicate Feeders (No Breaker) .................................................................................. 38 Line Tee-Off One Switch Substation (Quarter Breaker) .............................................. 38 Duplicate Feeders (Half Breaker) ................................................................................ 38 Line Tee-Off Two Switch Substation (Half Breaker) .................................................... 38 Three Switch Substation (Three Quarter Breaker) ...................................................... 39 Four Switch Substation (One Breaker) ........................................................................ 39 Five Switch Substation (One and One Quarter Breaker) ............................................. 39 Ring Bus (One Breaker) .............................................................................................. 39 Ring Bus (One Breaker) .............................................................................................. 40 Ring Bus With Two Pairs of Transformers (One Breaker) ........................................... 41 Ring Bus With Two Pairs of Transformers (Two-Thirds Breaker) ................................ 41 Breaker and Half.......................................................................................................... 42 Double Bus single Breaker (One Breaker)................................................................... 43 Double Bus Double Breaker (Two Breaker)................................................................. 43 Double Circuit Tee-Off (No Breaker) ........................................................................... 44 Double Circuit Tee-Off (Third of a Breaker) ................................................................. 44 Double Circuit Tee-Off With Two Pairs of Transformers (Three Quarter Breaker) ...... 45 Synchronizing Bus Bar ................................................................................................ 46 Operational Power Requirements Approximate Load Growth Profile Proposed Brighton Synthetics Project ......................................................................................... 51 Peak Construction Power Requirements Approximate Load Growth Profile Proposed Brighton Synthetics Project ......................................................................... 52 Utility Substation Simplified One-Line Diagram Proposed Brighton Synthetics Project ......................................................................................................................... 53 Revision Memo 12/99

This revision is a rewrite of Section XXX-A. The changes are covered below by subsection. Also S purpose codes added and revisions marked with an arrow. REFERENCES – Titles of IPs updated. ANSI / IEEE Standard 141 replaced by latest revision 1993-12-02 rev. POWER SOURCE REQUIREMENTS – Implications of partial loss of power on plant overpressure protection added. Application of LGF clarified. Calculation added of Adjusted Maximum Demand and Firm Capacity. PURCHASED POWER – Application of Variable Frequency Drive Systems for power factor correction added. MAIN SUBSTATION DESIGN – Deleted example of basic spacing requirement and reference only made to DP-XV-G. DESIGN PROCEDURE - Additional information on design specifications for Front End Loaded projects added. The General Instructions and Information (GII) added to the list of vehicles by which information can be provided to contractors. Title of the document, and references to it, updated to: The Exceptions and Additions to the International Practices. DESIGN SPECIFICATION CHECKLIST OF INTERNATIONAL PRACTICES ASTERISK ITEMS – This section has been revised inline with IP revisions. SAMPLE PLANNING DOCUMENTS – Q8 of Questionnaire for Public Utility to Obtain Definitive Planning data "item 1" corrected to "item 7" COMPUTER PROGRAMS – Addresses and Contacts updated. Product code added for AST. Available Programs section updated to reflect present nomenclature and available programs.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

4 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

SCOPE This section covers the main source(s) of electric power for refineries, chemical plants, and other large industrial users of electric power where a reliable supply is required. These sources are generally sized 10 MVA and upwards The sources are either a public utility (purchased power) or in-plant generation, or a combination of the two.

REFERENCES DESIGN PRACTICE Section XV

Safety in Plant Design

INTERNATIONAL PRACTICES IP 4-3-1, IP 4-3-2, IP 16-1-3, IP 16-2-1, IP 16-4-1, IP 16-6-1, IP 16-10-1, IP 16-11-1, IP 16-12-1, IP 16-12-2, ➧

Plant Buildings for Operation and Storage Blast Resistant Buildings Protection of Electrical Equipment in Contaminated Environments Power System Design Grounding and Overvoltage Protection Substation Layout Power Transformers Neutral Grounding Resistors Switchgear, Control Centers, and Bus Duct Control of Secondary Selective Substations With Automatic Transfer

OTHER LITERATURE ANSI / IEEE (Institute of Electrical and Electronics Engineers) Standard 141-1993-12-02, IEEE Recommended Practice for Electrical Power Distribution for Industrial Plants. (IEEE Red Book) ANSI / IEEE Standard 142-1991, Recommended Practice for Grounding of Industrial and Commercial Power Systems. (IEEE Green Book) ANSI / IEEE Standard 242-1986, Recommended Practice for Protection and Coordination of Industrial and Commercial Power Systems (IEEE Buff Book).

BACKGROUND Nearly all refineries and chemical plants are wholly dependent on electric power for operation. Hence, for any refinery or chemical plant consisting of several continuous process units, a reliable power supply is of paramount importance. While the steam generation facilities in Exxon plants are capable of operation without power, the mechanical drive steam turbines provided are only capable of maintaining a safe condition and are not able to keep process units on stream. In addition to the loss of throughput due to a power failure, there are two other major concerns: 1. Safety of process operations due to the dependence on all the shutdown facilities operating correctly. 2. Damage to equipment caused by thermal shocks. The loss of the main power source is one of the incidents that can shutdown the whole site, and as the power distribution network is generally one integrated system, great care must be exercised over the main power source installation in order to maintain the integrity of the entire system. Therefore, the main power source is required to be as, or more, reliable than the supply to individual process units.

DEFINITIONS Adjusted Maximum Demand Based on Firm Load Data The demand equal to 1.0 times maximum demand. Adjusted Maximum Demand Based on Non-Firm Load Data The demand equal to 1.05 times estimated maximum demand.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

5 of 76

Date December, 1999

DEFINITIONS (Cont) Back-Up Protection A form of protection that operates independently of specified components in the primary protective system and that is intended to operate if the primary protection fails or is out of service. In Exxon designs, it usually has the latter function and consists of a time / current graded protection scheme backing up either a unit protection scheme or a downstream time / current graded circuit. Base Load The minimum load over a given period of time. Demand The load integrated over a specified interval of time expressed in kilowatts, kilovolt-amperes, kilovars, amperes, or other suitable units. Demand Factor The ratio of the maximum demand of a system, or part of a system, to the total connected load of the system. The demand factor of a part of the system may be similarly defined as the ratio of the maximum demand of the part of the system to the total connected load of the part of the system under consideration. Design Basis Memorandum (DBM) This memorandum provides the selected design which has evolved from a number of designs studied and cost estimated in the planning (pre-DBM) stage of a project. The DBM design is the basis for the design specification. The DBM is issued together with an Investment Basis Memorandum (IBM) which provides the necessary equipment and system data required by the cost engineers. Distance Protection Protective relays in which the response to the input quantities is primarily a function of the electrical circuit distance between the relay location and the point of fault. Diversity Factor The ratio of the sum of the individual maximum demands of the various subdivisions of a system to the maximum demand of the whole system. Double Circuit Two independent circuits run overhead supported by common towers or poles. Firm Capacity Total installed capacity minus standby or spare capacity provided for scheduled and unscheduled outages. Firm Load Load data derived from actual equipment performance characteristics and duty cycles. First Line Protection The protective relay or device which is intended to operate first to trip a circuit or apparatus when a fault or other abnormal condition occurs. Sometimes referred to as “primary protection.” FOW Rating The output rating of a transformer having its core and coils immersed in oil and cooled by the forced circulation of this oil through external oil-to-water heat exchanger equipment utilizing forced circulation of water over its cooling surface. General Instructions & Information (G.I.I.) The Design Specification in each Job Specification which states characteristics of utilities, meteorological design conditions, etc. Items included are voltages and frequency available, the break point between medium voltage and low voltage motors, whether oil mist lubrication is to be applied, etc.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

6 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

DEFINITIONS (Cont) High Voltage System In Exxon practice, equipment with a normal operating voltage in excess of 34.5 kV. Island Operation The operating condition in which parts of a system which normally are connected and operate as one system are disconnected and split into separate operating entities. This includes separation of plant generating busses from public utility supplied busses, separation of stub busses from a synchronizing bus, etc. Load Factor The ratio of the average load over a designated period of time to the peak load occurring in that period. Load Growth Factor (LGF) An Exxon term which represents the actual amount by which the load is expected to increase as the design is firmed (excluding major basis changes). This increased load can result from many diverse reasons. Perhaps the most significant reason is the increased amount of basic engineering which is applied as the project is developed. Other less significant reasons are lower than expected driver or driven equipment efficiencies, revised process requirements during design development, and revised normal / spare driver designations. If the correct load growth factor is used, the capacity of the system should not change as the design progresses from the planning stage to start-up. Load Shedding The process of deliberately removing preselected loads from a power system in response to loss of power source(s) in order to maintain the integrity of the system. Low Voltage System In Exxon practice, equipment with a normal operating voltage of 1,000 volts or less. Maximum Demand See “8 Hour Maximum Demand" and “15 Minute Maximum Demand." Medium Voltage System In Exxon Practice, equipment with a normal operating voltage in the range 1001 to 34,500 volts. Normal Operating Load The power consumption at process design throughput under design operating conditions. OA Rating The output rating of a transformer having its core and coils immersed in oil and cooled by the natural circulation of air over the cooling surface. OA / FA / FOA Rating The output rating of a transformer having its core and coils immersed in oil; the self-cooled (OA) rating is obtained by the natural circulation of air over the cooling surface such as integral cooling tubes or fins, the forced-air-cooled (FA) rating is obtained by the forced circulation of air over this same cooling surface, and the forced-oil-cooled (FOA) rating is obtained by the forced circulation of oil over the core and coils and through to this same cooling surface over which the air is being forced-circulated. Operation in Synchronism The connection and operation of two or more power sources, either generating units or purchased power sources, at the same voltage and frequency to share real power and reactive power loads as determined by turbine governor and voltage regulator settings. Pilot Wire Protection Protection in which a control circuit is used as the communicating means, between relays at the circuit terminals.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

7 of 76

Date December, 1999

DEFINITIONS (Cont) Reactive Power The product of voltage and the component of alternating current that is in quadrature (90° out-of-phase) with the voltage. Its rate is expressed in kilovars (kvar). Real Power The rate of generating, transferring, or using energy expressed in kilowatts (kW). It is the product of voltage and the in-phase components of alternating current. Reclosure Practice The practice by public utility companies of re-energizing an overhead open-wire line after the initial clearing of a short circuit by circuit breaker trip. A specified number of reclosures are made with the time delay after each trip specified. Since many openwire line short circuits are line-to-ground and are not sustained short circuits, this practice provides quick re-establishment of voltage if the fault has cleared itself. Reserve Capacity Factor (RCF) An Exxon term which represents the incremental capacity provided to cover sudden load swings and small increases in load which result from changes made by the Owner after start-up to accommodate revised plant running plans. This incremental capacity is intended to be intact at initial plant start-up. It is usually provided in utilities sources and their support facilities only. Secondary-Selective Substations Substations having two busses, each supplied by a normally-closed incoming line circuit breaker and connected together by a normally-open bus tie circuit breaker. The term “secondary-selective" is applicable to dual fed substations with or without transformers. The dual sources normally divide the load in non-parallel operation. Upon failure of one source, the substation is isolated from the failed source and the de-energized bus section is connected to the source remaining in service. This “transfer" of load may be manual or automatic. Source Impedance The impedance presented by a source of energy to the input terminals of a device or network. Spot Network Substations Substations supplied from two or more sources which normally divide the substation load in paralleled operation. Upon failure of one source, the substation is isolated from the failed source by automatic operation of directional overcurrent relaying. This relaying senses current flow from the remaining source back into the failed source and trips the appropriate circuit breakers. Spot-network substations provide high order of supply continuity in the event of faults, but impose higher fault interrupting duty than secondary-selective substations with sources of the same capacity. Stability Limit A condition of a linear system or one of its parameters that places the system on the verge of instability. This expression defines the maximum fault clearing time that will permit the generators to remain in parallel with each other and/or the utility, following fault clearing. See also Section XXX-B, System Stability. Subtransient Reactance (X′′d) This reactance is the apparent reactance of the generator stator winding at the instant a short circuit occurs, and it determines the current flow during the first few cycles after short circuit. Although the current decreases continuously, it is assumed to be steady for these few cycles. The subtransient reactance approaches armature leakage reactance, differing only by the leakage of damper windings. Synchronous Reactance (Xd) This reactance determines the current flow after the transient reactance period when a steady-state condition is reached. It is effective after the transient reactance period. This is assumed usually to be several seconds after the short circuit occurs. The current excludes the effect of the automatic voltage regulator and the turbine or engine governor.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

8 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

DEFINITIONS (Cont) Transformer Reactance For OA / FA transformers, the reactance is usually expressed as a percentage of the transformer OA rating base. For OA / FA / FOA and FOW transformers, the reactance is usually expressed as a percentage of the FOA or FOW rating. Transient Reactance (X′d) This reactance is the apparent initial reactance of the stator winding if the effect of all amortisseur or damping windings is ignored and only the effect of the field winding is recognized. This reactance determines the short circuit current for the period between the subtransient and steady-state conditions. The transient reactance is effective up to one-half second to two seconds depending on the design of the generator. Unit Protection A protection circuit associated with a particular “unit' of the electrical network that will not operate for faults other than on its unit, e.g., differential protection, transformer Buchholz, motor resistance temperature detectors (RTDs). Zones of Protection The parts of the electric system or the apparatus which are protected by a specific protective relay. Most commonly used in conjunction with differential type relays in which the zone limits are the locations of the current transformer sets supplying the differential relays. For other types, the zone limit is the most electrically distant point for which the relay will operate on short circuit or other abnormal condition. 8-Hour Maximum Demand The greatest root-mean-square value the load can take during any 8-hour period. It is the equivalent thermal aging load. 15-Minute Maximum Demand The greatest average load which can occur for a 15-minute period. Switchgear continuous ratings are based on this demand.

POWER SOURCE REQUIREMENTS Before a utility company can be requested to provide power, or an in-plant generation design finalized, the following must be determined: ➧

CAPACITY The capacity required from the power source is obtained from the process, offsites, and utilities load data lists which summarize the electrical load on the overall system and on system components. The load data is used to establish the capacity requirements for the various elements of the system. Load data summaries for the plant's normal and abnormal operating conditions will show which condition is determining. The process and offsite designers provide the load data that is the basic input for the electrical system design. The data lists each individual motor load for all processing units and offsite facilities and any other electrical load such as heaters, etc. These data will be “normal" operating loads, unless there are specific operating conditions that substantially increase or decrease the plant load. In this case, as many sets of input load data are required as there are operating conditions. The various operation conditions should be evident from load data provided by process and offsite designers. Computer programs are available for computation of load data. A program may be used early in the design specification stage on major plant designs and is usually required during the detailed engineering phase by the contractor. Load Growth Factors (LGF) are applied to the input load data and should be adjusted during the course of the design to reflect the changes in the quality of the load data being used. These are applied because, historically, loads tend to increase as the project is better defined. A Reserve Capacity Factor (RCF) is also applied to provide margin at start-up in power source facilities, for operating flexibility, and small load increases. The following are the rules for applying the LGF factors to the input load data received by the electrical designer. 1. Load growth factors are applied to load data for process facilities. 2. Load growth factors are not normally applied to load data for offsite and utilities facilities. The factors should have already been applied by the offsite designer in arriving at the required capacity of the specific offsite or utilities system. You should confirm that this is the case. For example a motor associated with a cooling tower will already have LGF applied as part of the sizing of the cooling tower by the offsite designer. However an offsite's pump may not have had LGF applied.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A

9 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

POWER SOURCE REQUIREMENTS (Cont) The following load growth factors should be used for equipment sizing, if other factors have not been established for the project. LOAD GROWTH FACTORS LOAD BASIS PRE-DBM Firm Load

10%

DBM 0

DESIGN SPEC 0

CONTRACTOR'S OFFICE 0

Duplicate of Existing Major Drive

10%

5%

0

0

Non-Firm Load

30%

15%

5%

5%

A 10% reserve capacity factor is used at all the stages of a project. It is applied for sizing source facilities, such as generation capacity or purchased power substation capacity, and is intended to provide 10% reserve capacity margin at start-up. Note that this is the reserve required in normally operating units. It should not be confused with reserve capacity provided to cover forced and scheduled outages of generating units. The application of load growth and reserve capacity factors for the overall utilities requirements of a coal gasification project is illustrated in Figure 1. The selection of the load growth factors for design basis memorandum (DBM) engineering for the same plant is shown in Table 1. Note the majority of the facilities are non-firm loads and one facility's load is sufficiently uncertain to require a 20% LGF. The use of Load Growth and Reserve Capacity Factors is an effort to improve the accuracy and provide a consistent basis for maximum demand estimates. Before planning and design of main power source facilities can be finalized, the following must be determined: 1. Two values of load should be calculated: the Normal Operating Load and the 15 Minute Maximum Demand. The normal operating load is calculated by applying a Load Factor in the order of 0.5 to 1.0 to the 15 Minute Maximum Demand. The Load Factor depends on the process units, their interdependence, and the proportion of load for non-process facilities. 2. Basic load data for determining required source capacity is obtained from process, utilities, and offsites load lists, and includes the following: a. Planning or design estimates of new electrical loads (considered Non-Firm Load) b. Maximum demand of existing operating loads (considered Firm Load) c. Maximum demand of estimated future loads for which the project will pre-invest (Non-Firm Load). Note: If load data indicates a higher load for an alternative operating condition, the higher load should be used if it coincides with the timing of maximum demand on the power source. 3. Adjusted Maximum Demand and Firm Capacity for a main power source are determined from load data as follows: a. Start with basic load data (above) and determine all of the loads that operate simultaneously to contribute to the 15-minute and 8-hour periods of maximum demand on the main power source. b. Add Load Growth Factors (LGF) to the basic load data, in accordance with the LGF table above. LGF accounts for the historical growth in loads from screening through detailed design and startup. With the exception of basic load data, the terms "Load" and "Demand", as used herein, include LGF. c. Calculate Adjusted Maximum Demand by multiplying the sum of all non-firm loads by 1.05, and add the result to the sum of any firm loads. The adjustment factor of 1.05, applied to non-firm load, provides a safety margin in the size of the source above the known historical load growth. If the adjusted load varies significantly with time over 15 minutes or over 8 hours, see below. d. The Firm Capacity required from main power source equipment is the Adjusted Maximum Demand (per above) plus 10% Reserve Capacity Factor (RCF).

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

10 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

POWER SOURCE REQUIREMENTS (Cont) If load varies significantly over an 8-hour period, transformers can be sized to meet the "average" load instead of the maximum load. This and other load variation and equipment sizing considerations are discussed below: 1. Use "Adjusted 8-Hour Maximum Demand" plus 10% RCF to size main transformers. This 8-hour demand is a root-meansquare (rms) quantity which can be closely approximated as follows: a. Break the eight-hour period of maximum adjusted-demand into eight one-hour intervals b. Estimate the average adjusted load magnitude (kVA, MVA, A, etc.) for each hour c. Square each magnitude d. Obtain the mean by summing the 8 squared magnitudes and dividing by 8 e. Take the square root. f. The result is approximately the effective heating (rms) 8-hour maximum demand in kVA, A, etc. 2. Transformer switchgear and source feeders are rated to meet the larger of maximum transformer rating or Adjusted 15Minute Maximum Demand plus 10% RCF. 3. In the absence of dedicated source transformers and generators, use Adjusted 15-Minute Maximum Demand plus 10% RCF to size main buses and incoming cables. Adjusted 15-Minute Maximum Demand is typically taken to be the same as Adjusted Maximum Demand (i.e., maximum simultaneous adjusted load). If there is a short duration peak load, use the average adjusted load over the 15-minute interval of maximum demand. 4. For generators, use Adjusted Maximum Demand plus 10% RCF without time averaging. 5. When a minimum firm-sources configuration consists of generators and transformers, the generators are base-loaded with non-time-averaged load. The transformer load curve then consists of the top portion of the total load duration curve with the base loading of the generators removed. The minimum required capacity the transformers is then the adjusted 8-hour maximum demand of this modified load curve. Remember to check the adjusted 15-minute maximum demand of the remaining load for the transformer switchgear and source feeders. The "Firm Capacity" of up to five power sources is generally taken to be the capacity of the sources remaining when the largest source is out of service. For 6 to 10 sources, the two largest sources would generally be considered out of service. However, if the load varies with time and there is a combination of transformers and generators, the firm source capacity verse effective load may have to be tested in more than one configuration.

NUMBER OF GENERATORS The number of generators required for an in-plant generation system is covered in Section XXX-B.

PURCHASED POWER ➧

RELIABILITY A reliable electric power system is essential for continuous process plants and, in some cases, for non-continuous processes where power interruptions can result in unacceptable safety or product loss risks (see Design Practices Section XV-C). The most critical component in overall power system reliability is the power supply source. Assuming reliable purchased power is available, the decision to purchase power or install in-plant power generation is an economic decision based on comparison of alternatives having adequate but not necessarily equal reliability levels. In determining the level of reliability that is adequate, the following factors are assessed: (1) Frequency and duration of total or major potential power outages. This is the most important of the factors and covers the “forced" outage which occurs without warning and causes either a total plant shutdown or a major plant upset; (2) Frequency and duration of power supply conditions which tend to reduce reliability and capability to meet load demands. Typical conditions are more than normal maintenance outages on supply circuits or reduced reserve capacity caused by lower than normal generation availability; and (3) Frequency, magnitude, and duration of voltage dips caused by faults on other customer’s circuits which share busses or circuits supplying the plant. No single maximum forced outage rate sets the minimum acceptable reliability level. The minimum acceptable level is established by process plant type and complexity, cost of lost production and ability to make up lost production, likelihood that the total outage causes immediate or progressive equipment damage, and the complexity of emergency facilities required to provide satisfactory safety and equipment protection levels. In designing the electrical distribution system, the implications of a partial loss of power on the plant overpressure protection facilities should also be considered. This should be discussed with the process design specialist assigned to the project. Refer to the NUMBER OF CIRCUITS FROM UTILITY and RELAYING sections on the following pages for other factors affecting reliability.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

11 of 76

Date December, 1999

PURCHASED POWER (Cont) From experience, some general statements on reliability level can be made: 1. Public utility power supplies which have experience or calculated data showing a frequency of failure (total or serious disturbance) in the 1 in 3 yr. to 1 in 5 yr. range provide satisfactory reliability levels even for the large complex facilities. Generally, additional investment cannot be justified to improve reliability above this level. 2. Public utility power supplies which have failure rates for total or serious disturbances in the 1 per year to 1 in less than 3 year range are probably marginal for the large complex facility but acceptable for smaller less complex facilities. However, these power supplies should be carefully investigated to determine whether improvements could be made at an acceptable investment level. 3. Public utility power supplies which have total failure or serious disturbance rates exceeding 1 per year are generally not acceptable for large complex facilities. The improvements required to the supply to improve its reliability and their cost should be determined. Also, the economics of providing in-plant generation should be investigated. 4. Voltage dips due to faults in the utility grid should be cleared in the instantaneous to 5-6 cycle range. The voltage drop at the plant main bus should not exceed about 10%. This limit may be difficult to meet when other circuits are electrically close. In such cases, the utility should provide estimates of frequency and magnitude of dips. This data should be assessed for effect on the plant and whether the conditions can be accepted without change.

NUMBER OF CIRCUITS FROM UTILITY Where the plant is totally dependent on the utility company, a minimum of two incoming circuits is required. These should, where possible, be independent of each other, i.e., come from different busses in the utility grid and be routed independently on separate towers for overhead lines or in separate trenches for buried cables. However, we are often forced to accept two circuits from a utility substation bus supplied from opposite sides of a normally closed tie breaker that are run overhead on common towers (double circuit) to our facilities. We should endeavor to avoid such supply arrangements, but when no other is possible, at least ensure that there are protective relays to open the utility tie breaker, and that a common pilot cable is not used to run control and/or protection circuits. It is usual to carry out maintenance of one circuit of a double circuit overhead line with the other in service, but this point should be confirmed. When there is in-plant generation, one incoming circuit from utility may suffice. This will depend upon the firm generating capacity and the normal maximum generating capacity. Generally, the design of the utility supply should be based on the largest in-plant generator being out-of-service while operating the plant at maximum demand. In some cases, a two generator outage may be considered, e.g., one on maintenance and a fault on another, if maintenance periods are frequent or of long duration. However, it is more normal to accept load shedding for a two-generator outage, or a financial penalty resulting from exceeding an agreed maximum demand from the utility.

VOLTAGE AND REGULATION The utility companies have standard voltages and will generally offer the supply from the lowest voltage they have locally with adequate capacity. This voltage in kV may vary from 1 to 10 times the capacity requested in MVA, with the higher loads having a factor nearer unity. This is based on the power being transmitted over one circuit. Unless incoming transformers can be avoided, the higher the voltage (within reason) the better, as the short circuit level will be higher and also the reliability will be higher. Variations in utility supply voltage, inplant load variations, and system configuration changes (such as loss of a main transformer) normally lead to the need for an automatic on-load tap changer (LTC) on utility supply transformers. Even where inplant power generators normally control system voltage, a utility-tie transformer usually has an LTC to regulate voltage upon loss of inplant generation or to control power factor. Thus any design that would omit LTC's on main transformers must be carefully evaluated to ensure that voltage and power factor variations are within acceptable limits.

SHORT CIRCUIT LEVEL Once the supply voltage level is defined, we have little control over the short circuit level of the utility supply. The short circuit level must be high enough to: 1. Avoid excessive voltage drops when starting large motors. 2. Permit large steps of motor re-acceleration after an automatic transfer or supply outage. 3. Provide selectivity and fast clearing times for the back-up protective relaying. 4. Help prevent instability of in-plant generators and synchronous motors.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

12 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

PURCHASED POWER (Cont) Within the limits determined by switchgear availability and cost, a higher short circuit level has advantages over a substantially lower level for large motor starting and for the overall motor re-acceleration system. Typical values of fault levels in MVA and corresponding typical interrupting ratings for switchgear are:

SYSTEM VOLTAGE

SYSTEM OPERATING RANGE OF FAULT LEVEL (MVA) Min

Max

SWITCHGEAR RANGE (MVA) Min (MVA)

Max (MVA)

10–15 kV

150

1000

300

20–69 kV

500

5000

500

1000 5000

90–150 kV

500

10,000

5000

20,000

160–240 kV

750

15,000

5000

25,000

The system minimum short circuit level is used for stability and voltage profile studies and the maximum short circuit level for equipment rating. When selecting equipment short circuit ratings, the motor contribution from the load should be added to the utility maximum contribution to a short circuit. A computer program should be used both to determine the maximum short circuit for specifying the switchgear and the minimum short circuit level required for stability and voltage profiles.

POWER FACTOR REQUIREMENTS

➧

There may be little incentive to improve the inherent power factor of the plant unless the public utility insists, or there is a financial incentive in the power contract, or from sizing of equipment such as generators. Without any correction, a power factor in the range 0.8 to 0.86 lagging can be expected for a load consisting of squirrel cage induction motors operating between half to full load. This can be improved by any of the following: 1. In-plant generation operating in parallel at a low power factor (generating more vars by increasing the excitation). 2. Synchronous motors operating at increased excitation (unity or leading power factor). 3. Application of capacitors. 4. Application of Variable Frequency Drive Systems. (Care should be taken not to induce excessive current or voltage harmonics). When correction is required, we generally use banks of capacitors connected to the main busbars. This is the most economical solution when there are no large generators or synchronous motors, but has the following disadvantages: 1. No benefit to equipment capacities downstream. The technically ideal location for capacitors is at each individual load so that they are switched with the load and reduce the currents in the upstream cables and transformers to a minimum. However, this solution is costly and it requires locating most capacitors in classified areas. 2. Requires switching off the capacitors during certain conditions such as an automatic transfer to assist in a rapid voltage decay. 3. Can cause harmonics and over voltages on the network. Public utility contracts may include any of the three following requirements: 1. No requirements at all regarding power factor. 2. Power factor to be always “X" lagging or better (X may be any value between 0.8 and 0.95). 3. kVA maximum demand charge. For Item 1: We would not correct the power factor unless correction could be justified for energy conservation reasons. For Item 2: We would correct to the value required. For Item 3: Calculate the optimum value of capacitors to be installed if any. This may mean correction to 0.95 or even 0.98 lagging.

PARALLELING OF CIRCUITS The utility may not permit paralleling of their two incoming circuits, either because they could at times be out of synchronism, or to avoid circulating currents. This will determine whether spot network substations can be used and the need for check synchronizing relays on the secondary-selective substations. Often the utility will permit momentary parallel operation but not continuous operation. This allows momentary paralleling during manual transfer operations for secondary-selective substations. However, whether such momentary paralleling is acceptable must be checked with the utility.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

13 of 76

Date December, 1999

PURCHASED POWER (Cont) NEUTRAL GROUNDING Most public utility transmission networks have the system neutral solidly grounded, as there are considerable savings in insulation and lightning arrester costs. Also, high ground fault current levels are acceptable on transmission systems since there are no motors or generators directly connected to such systems. The actual method of neutral grounding should be requested from the utility and stated in the Design Specification.

FREQUENCY LIMITS On large utility systems, the frequency can be expected not to vary more than about 0.5%, except when there is a major upset. It is the major upset that concerns us, so records of the utility frequency variations during upsets should be obtained. Frequency relays are not used in our plants unless we have in-plant generation. They are used to separate the generators from the utility to permit running part or all of the plant in island operation (see Section XXX-B). Frequency relays are also used as part of the protection scheme of synchronous motors. If the utility has frequency relays, to either break their network into smaller areas or to load shed, their settings should be obtained. The settings should be given in the Design Specification and used to determine the setting of plant frequency relays.

RELAYING The settings of all the relays in the utility substation at the voltage we receive power are required for three reasons: 1. The plant will be subjected to a loss of voltage for faults on the utility system until they are cleared by the protective relaying. These clearing times are needed for computer studies which are made to check stability under these conditions. 2. To ensure that plant back-up protection coordinates with the utility relaying. 3. Relays that separate the in-plant generation from the utility substation should coordinate where possible with upstream relays in the utility system on feeders to other loads. Whenever possible, unit zone protection (such as differential) should be applied to the feeders to our plant and ideally for all the utility network at the supply voltage and higher. This improves stability and relay coordination on the plant system. As a general rule, any bus to which an in-plant generator is connected and the feeders from that bus should have instantaneous protection in order to ensure stability of the generators. (See Section XXX-E for more details on relaying.)

SURGE PROTECTION Surge protection, e.g., lightning arresters, should be provided at the termination of the utilities overhead lines at the plant substation. The arrester rating and class should conform to the arresters used by the utility on their system that supplies the plant. Depending on the physical arrangement at the main substation, these same arresters may be used to protect the substation’s main transformers.

METERING Metering for billing purposes is usually designed and installed by the utility. This metering usually requires separate current transformers and possibly a dedicated voltage transformer. Ratio, class, and fusing for these transformers should all be shown on the one-line diagram in the Design Specification.

POWER CONTRACT BILLING (TARIFF) The details of the proposed power contract with the utility, including tariffs, should be known and tentatively agreed upon during the planning stage of the project. However, as the project progresses, more details are known about the load. The contract should be reviewed again to ensure that the project basis is still sound and to determine the effects of any changed terms. For expansions at existing sites, it is usual for the Owner to carry out all negotiations with the utility.

SPACE REQUIREMENTS The incoming substation should be located near the perimeter fence at least 150 ft (45 m) from any process units. Refer to Section XV-G for equipment spacing. Dimensions and spacing requirements for any equipment to be provided by the utility company should be established and covered in the Design Specification.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

14 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

PURCHASED POWER (Cont) DEMARCATION OF RESPONSIBILITIES Location of the utility incoming lines, a list of all equipment supplied by the utility, and/or equipment which must be provided by the Owner should be established. The demarcation between utility and plant responsibility should be clearly defined in the Design Specification.

GENERATED POWER IN PARALLEL WITH UTILITY The complexity of a system deriving power from a utility, together with in-plant generation, is much greater than either source on its own for the following reasons: 1. Systems fed entirely by purchased power do not have any relaying to trip distribution circuit breakers for loss of voltage, except in special situations. (The automatic transfer scheme is no exception as it only trips an incoming breaker on low voltage if the alternate supply is healthy. If both in-feeds are lost, neither incoming breaker trips so that no breaker closing is necessary when power is restored.) However, when there is in-plant generation operating in parallel, it is unacceptable to force the generation to shutdown due to a failure of the utility. Therefore, a failure of the utility has to be detected and relaying included to effect separation of the generation and plant load from the utility. 2. The power and var flows can reverse direction in parts of the system. 3. Control of the generator power and var output will be required. 4. Fault levels will change considerably depending on the number of generators connected to the busbars or shutdown for turnaround. 5. Faults on the system should not cause the generator(s) to slip out of synchronism. Whereas a synchronous motor may be switched off during a system disturbance and re-accelerated later, a generator is required to remain on-line whenever possible to provide power to the load. The design, therefore, should include the following: 1. Relaying to separate generation from the utility when the utility fails. 2. Relaying which senses direction of current flow at specific locations in the system. 3. Control and metering for quantity and direction of power and var flow and bus voltage control. 4. Instantaneous (unit or differential) protection on all circuits operating at the generator voltage that do not have any appreciable reactance such as a transformer or reactor between them and the generator. 5. Synchronizing facilities wherever it is required to connect the generation to the utility or other generators. 6. An event recorder, to enable analysis after faults on the system, is highly recommended. 7. Load shedding facilities to avoid a complete blackout when the load exceeds the generator capability either due to outage of generator(s), loss of utility, or segregation of parts of the network. In designing to meet the above requirements, some of the points to consider are: 1. Where the point of separation between the utility and in-plant generation should be. 2. What relaying should initiate separation. Generally, a combination of breaker logic, undervoltage relays, and frequency relays are used. See Section XXX-E for more details. 3.

4. 5. 6.

7.

Where and how the watt and var flows should be measured and controlled. Either a combination of a four quadrant power factor meter with watt or ammeter or one instrument that will indicate watts, vars, kVA and power factor can be used for measurement. Factors affecting control are generators' excitation systems capability, range of utility tie transformer tap changers, and the extent to which automatic control will be used. Transformers with on-load tap changers may require a larger tap changer range in order to control var output from the generator(s). Impedance between the generation and utility should be low for stability, but may intentionally need to be high to avoid excessive voltage drops in the plant for faults on utility network. If purchased power is very reliable, consideration can be given to connecting generator(s) to the utility at the point of supply (as if they were generators belonging to the utility), thereby simplifying the tie-ins and relaying but losing the capability of running in island. Power flow through reactors should be minimized.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

15 of 76

Date December, 1999

POWER FOR EXPANSION OF EXISTING FACILITIES Tie-in of expansions should be so arranged that the reliability of the existing plant is not impaired. The target should be to arrive at a design identical to that which would exist if the existing plus expansion were installed at the same time as a grass roots plant. The simplest arrangement is almost certainly the most reliable; also what may appear at first to be a more economical design with reactors and sophisticated switching sequences could prove to be very expensive in the final design and lower in reliability.

PURCHASED POWER Where there are business incentives, plant expansions may be constructed to be completely independent of the plants existing facilities. However, it is more normal to tie-in expansions such that the final outcome is one integrated system. As far as the tariff is concerned, it is nearly always advantageous to limit the power contract to one supply (which could consist of several circuits with summation metering), thereby taking advantage of the diversity factor and any energy rate reductions. If additional transformer capacity is required there are alternatives to expand the capacity: 1. Use available capacity at higher temperature ranges of existing transformers, if rating and design permit. 2. Replace existing transformers. 3. Add new transformers in pairs. 4. Add new transformer(s) on radial basis with common spare for existing and additional transformers.

GENERATION ONLY A new generator will automatically increase the infeed fault level to the switchgear to which it is connected in proportion to the size of the generators. Therefore, reactors may be required, either between generator busses, or to add new stub busses to a synchronizing bus arrangement. (See Section XXX-B for full details.)

PURCHASED POWER PLUS GENERATION This is the most difficult system expansion, be it expanding a system already consisting of purchased power plus generation, adding generation to an existing purchased power system, or adding a purchased power supply to an existing generation system. With the increased complexity, great care and much more engineering effort are required to maintain reliability. One exception is where the design for the plant prior to expansion included provision for the future facilities and included them in the network studies. For details, see Section XXX-B and the section above on GENERATED POWER IN PARALLEL WITH UTILITY.

MAIN SUBSTATION DESIGN GENERAL The purchased power supply components are the busses and switching equipment at the public utility supply substations, the supply circuits from the utility substation to the plant, and the switching equipment and step-down transformers at the plant main substation. Usually the supply circuits are part of the public utility system. The switching equipment and step-down transformers at the plant main substation may be owned by either the public utility or the plant, depending on the power contract. When the supply voltage is in the 10 to 36 kV range approximately, the supply facilities may be: 1. Either overhead open-wire (bare wire) or insulated underground cable supply circuits. 2. Outdoor air-insulated overhead busses and switches, and individual power circuit breakers or grouped metal clad switchgear either outdoors or in a substation building. When the supply voltage is above the 36 kV level, the supply facilities are: 1. Normally overhead open (bare) wire. In specific situations where space limitations or other unique circumstances dictate, insulated cable circuits may be used. 2. Outdoor air-insulated overhead busses and switches with individual power circuits breakers. The breakers may be SF6 (Sulfur Hexaflouride), air blast, or bulk oil. 3. SF6 circuit breakers and busses, and associated switches and potential and current transformers. The SF6 equipment can be used outdoors or in a building. Use of SF6 equipment in main substations continues to grow and, where space is limited, can be the only suitable type. A typical space ratio is 1 to 30 favoring SF6 over outdoor air-insulated at 500 kV.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

16 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

MAIN SUBSTATION DESIGN (Cont) Other ancillary components of purchased power supply facilities are the protection, control and metering voltage and current transformers, and associated protective relays, control devices and meters. The protective relays, control devices and meters are located so they are convenient both for operation and maintenance. Control and metering circuits can be extended to permit operation from locations such as main substation buildings, power plant or process plant central control rooms. The main power supply transformers reduce the public utility supply voltage down to the plant distribution system medium voltage level. Type and application information on these transformers are covered in the section on transformers.

BUSBAR ARRANGEMENT A typical design would consist of two incoming circuits, two transformers and a secondary-selective (as detailed in IP 16-12-2) or a spot-network substation. Another bus arrangement which is common for larger systems with generation is a synchronizing bus. Other arrangements, particularly for large capacity purchased power substations, are ring bus, double breaker, and breaker-anda-half. (See Figures 3 through 20.)

TRANSFORMERS Transformer sizing should be based on the plant 8 hour Maximum Demand plus reserve capacity. Where transformers are spared by another power source, the forced cooled rating should be used with fans and/or oil pumps running whether integral or not. If there are good reasons to believe that there will be a future expansion of the plant, consideration should be given to preinvesting, with the Owner's approval, in a larger transformer or provision of additional forced cooling stages. In any calculations, one must take into account the fact that any increase in power demand will have to come from these transformers, and the very large difference in cost between larger units now as compared with replacement units in the future. Some of the points to consider are: 1. How would capacity be expanded. 2. Land availability. 3. Would larger transformers require changing the secondary switchgear. 4. Downtime to tie-in expansion. 5. Financial incentives for pre-investment, e.g., tax rules, interest rates. 6. Probability of extra capacity being used in the near future. 7. Cost benefit of providing transformer capacity to permit fully utilizing main secondary circuit breaker and bus capacity since this equipment has finite continuous current rating steps. The main power supply transformers may be supplied by the utility. However, in cases where we own the transformers it is often advantageous to purchase to the utility company specification at one of their standard ratings, as they may do the maintenance and there is always the possibility that they will provide a replacement in the event of an emergency. The initial design should include on-load tap changers to compensate for variations in the utility supply voltage and cater for the build up of load, especially on the larger transformers where the reactance will be higher. During the final stages of Design Specification preparation or during engineering in the contractor's office, the need for the on-load tap changers should be reviewed. There are costly items, but it is very rare to purchase a main source transformer without an on-load tap changer. An exception would be if the source is a closely regulated distribution voltage and the voltage profile shows acceptable voltage range at utilization voltage levels. On-load tap changers in the Americas are generally equipped with 33 positions connected to 16 taps above nominal voltage and 16 below; each step being 5/8 percent of the transformer voltage. In Europe and countries following European practice, 21 taps is more normal. Usually ten below and ten above nominal voltage each step being in the range of one to two percent. This will vary with the reactance of the unit. On-load tap changers may be connected to either the high or low voltage winding. Outside the Americas, the changers are usually on the HV winding up to 150 kV. In the Americas, they may be in either winding. Manufacturers prefer to have the tap changers in a wye (star) winding for several technical reasons. Transformers with tertiary windings or double secondary windings present voltage regulation problems. The tap changer on the primary winding controls the voltage on the other two windings, thus voltage control is not as good as with a two winding transformer. A second on-load tap changer can be added to a secondary winding, but this can prove costly, thus nullifying the economy of the third winding. Exxon plants require close voltage regulation on the main substation transformer’s secondary, because normally there are no onload tap changing transformers downstream of the main incoming transformers.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

17 of 76

Date December, 1999

MAIN SUBSTATION DESIGN (Cont) Transformer reactance should preferably be the manufacturers standard if it is suitable for the short circuit duty rating of equipment downstream, stability, and motor re-acceleration needs. If a lower reactance than standard is required and costs extra, it may be better to spend the money on larger transformers. This will achieve the same result and give some additional capacity for future loads. The secondary voltage will usually be in the range of 5 to 36 kV for supply voltages in the range 30 to 300 kV. These secondary voltages are at a level that is economical for distribution and can be used to power large motors either directly or via a dedicated (captive) transformer. Voltages for motors are preferably below 10 kV, but may go up to about 15 kV as a maximum. Transformer size will be limited by the maximum current rating obtainable for the secondary switchgear. This typically is 3 kA. Transformer connections (vector reference) should be shown on the one-line diagram together with the system grounding arrangements. Often we use the same transformer connections as the local utility for standardization. Before finalizing the connections, the following points, which conflict with each other, should be considered: 1. A delta / wye (star) connection is preferred. 2. A wye (star) primary has the advantages that the on-load tap changer, if it happens to be on the primary, will be lower cost than on a delta winding, and it is possible to ground the neutral. 3. A wye (star) secondary permits access to the neutral for grounding. 4. The wye / wye (star / star) connection should be avoided. 5. If the utility insists on the primary being wye (star) connected, then the secondary should preferably be delta and a grounding transformer can be connected to the secondary, which will both provide a neutral for grounding and a power source for the substation. Preferred USA power transformer ratings are listed in Table 2. Preferred ratings and method for listing maximum capacity differ in other countries.

SWITCHGEAR The incoming circuits from the utility may or may not be equipped with circuit breakers at the plant end. It may be difficult to justify these breakers for smaller installations, but they should be included whenever possible. One exception is when the circuit to each transformer is supplied from its own dedicated circuit breaker in the utility substation and the utility agrees to a unit protection zone covering the transformer and its feeder cable. The main substation transformers can be double banked, i.e., connect two transformers to one primary breaker. However, only one transformer per primary breaker is preferred, as the protection and switching maintenance are simplified, thus resulting in higher reliability. The secondary switchgear usually consists of metal clad compartments with drawout circuit breakers installed indoors. Operation with the tie breaker open (secondary selective) rather than closed (spot network) is more usual. This reduces the range of maximum to minimum short circuit level, which is beneficial for motor re-acceleration and may permit use of lower interrupting rated switchgear. Switchgear continuous current rating should be suitable for the transformer rating including any overload capacity. When operated with spot networks, transformers must be matched in size and impedance, and their on-load tap changers must be equipped for cross compensation control.

REACTORS Reactors are used to limit short circuit levels but should be avoided whenever possible. Where they are used, they preferably should interconnect networks to permit transfer of power under abnormal conditions rather than be in series with a main power circuit where all power to the load flows through them in normal operating conditions. Alternatives are to use pairs of transformers with no interconnection between the secondary of each pair, or current limiting explosive fuses between sections of busbars that split up the network when a fault occurs. Reactors may be of the air cored or oil immersed type. The advantages of the air cored type are that they are less expensive and lighter. On the other hand, the oil-immersed units are less susceptible to contaminants in the atmosphere, do not require special construction features to avoid steel work in the vicinity, and do not require an additional enclosure around them. Both types have been used in Exxon plants with the air core type being more common.

PROTECTIVE RELAYING All incoming circuits, main transformers, and secondary switchgear should each be protected by instantaneous differential (unit) protection plus time and over-current graded back-up protection.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

18 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

MAIN SUBSTATION DESIGN (Cont) In some instances, the utility company will not provide instantaneous differential (unit) protection on their feeders to the main substation (see PURCHASED POWER – RELAYING above). However, differential (unit) protection should still be provided on the main transformers and secondary switchgear for fast clearance of faults in this equipment. The back-up protection should coordinate with the utility relaying. A separate room may be required to locate the transformer primary breaker relays and sometimes the secondary switchgear relays. This arrangement may be required by the utility company and can be useful where there are many relays that would require some extra dummy panels on the switchboard and/or mounting relays at high level and on the rear of the switchgear. Protective relaying requirements are more fully covered in Section XXX-E.

TRANSFORMER SECONDARY CIRCUITS These usually consist of metal enclosed bus duct or cables, either single core or multicore, and either armored or unarmored. Where cables are used, they must be well protected especially if unarmored. They may be run in conduit, cable trays, direct buried, or laid in a concrete trough finished flush with grade, or cable bus in air. Bus duct is only used when distances are short enough to make it economical. ➧

LOCATION AND SPACING Space must be provided at the boundary fence for the incoming circuit(s). Equipment at the boundary fence may consist of incoming circuit breakers only, or may include the transformers, or all the foregoing plus the secondary switchgear. This will depend on the magnitude of the load and distances to the bulk of the load. The final decision is one of economics plus availability of space. Whatever arrangement is used, all the equipment mentioned above should meet the spacing guidelines listed in Section XV-G of the Design Practices. Dual circuits should be spaced to avoid a single fault affecting both of them. This applies to power cables and control / protection cables. Consideration should also be given in the layout of switchgear and transformers to provide adequate isolation to avoid total loss of power due to a single fault.

CONTROL AND INDICATION Open and closed indication of all the transformer primary and secondary breakers, plus any interconnecting circuit breakers, is required in either the plant utilities control room and/or the main process control room. Control of breakers may be required also. One example is when generation is involved. All the breakers with synchronizing facilities will be controlled from a control room unless automatic synchronizing is employed and Owner does not require control at the control room. Transformer primary breakers are units in the overall utility transmission or distribution system. As such, the utility may require prior notice before any switching can be done by plant operators or may not permit such operations in normal circumstances. Also, these breakers may be part of the utility systems for status, control, and data acquisition (SCADA) with operating control by the system controller only. These details must be specified in detail in plant operating procedures. Indicating meters should be provided in the control room where the remote control is located to give the operator an appraisal of the electrical power situation. Types of meters usually provided are voltmeters, ammeters, watt, and var meters. In some cases, much more metering is required depending on the tariff, whether there is in-plant generation and Owner preference. These indicators and control devices are often incorporated into a mimic panel that represents the main components of the network or more recently into a microprocessor-based system.

SURGE PROTECTION If the incoming circuits from the utility consist of uninsulated overhead wires, surge protection will be required at the substation to protect the transformers and equipment downstream. This protection consists of surge diverters (lightning arresters) mounted outdoors connected to the incoming lines upstream of all the substation equipment. The arresters look like post insulators and consist of the outer insulation and weather protection, with a terminal at the top for connection to the line and mounting base at the bottom which also serves as the other terminal for connection to ground. The arresters may be either: 1. Valve type consisting of a gap (spark gap) unit in series with a non-linear resistance valve element. This combination offers very high impedance at normal-voltage, low-surge current conditions, but very low impedance to high-surge current, overvoltage conditions. 2. Metal oxide (zinc oxide or gapless) type which has sufficient non-linearity that a series gap is not required to provide the high impedance-low impedance characteristics.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

19 of 76

Date December, 1999

MAIN SUBSTATION DESIGN (Cont) ENVIRONMENT A clean environment is required for the protection relays and the contacts on switches and interposing relays. Combinations of hydrogen sulfide contamination, d-c circuits, humidity, silver migration along phenolic surfaces of relays, etc. have resulted in failure to operate and false trip events at various locations. Use of solid state protective relays is widespread and programmable controllers are also being used in substations. While this equipment avoids some of the problems associated with induction disc and similar mechanical relays, they impose their own requirements for a clean and sometimes temperature controlled environment. As a result, air filtration or air conditioning will be needed if ambient air is likely to be contaminated with H2S, dusts, or other contaminants. If air is treated for contamination only, it may be difficult to justify two 100% units since the problem is time related. However, if air conditioning is required to maintain a controlled ambient temperature for equipment, at least two units sized for 50 to 100% of the duty should be provided.

MAIN SUBSTATION AUXILIARIES A reliable low voltage power supply will be required for substation auxiliary loads which may include the following: 1. Battery chargers. 2. Tap changers. 3. Transformer cooling fans and oil pumps. 4. Air conditioning. 5. Lighting. This power supply can be obtained from a small tertiary winding on each main transformer, or small transformers connected, with suitable protection, between the main transformers low-voltage terminals and the switchgear. Exxon installations usually use a pair of transformers supplied from the main switchgear if there is no reliable low-voltage supply available from a nearby substation.

DESIGN PROCEDURE – ELECTRICAL DESIGN SPECIFICATION GUIDE INTRODUCTION This guide is intended to help new electrical engineers in the preparation of electrical Design Specifications. In the past, the electrical engineer simply went to a previous Design Specification and used it as a guide. Although this assured the continuation of some good features of electrical design, it did not necessarily insure evaluation of certain alternatives which should be considered every time a Design Specification is written. This guide lists pertinent paragraphs from the International Practices which should be checked by the engineer to insure that all alternatives have been considered. ➧

PLANNING AND DESIGN BASIS ENGINEERING Design is a real time dynamic work process which leads to the detailed specification of equipment and facilities. The Basic Design Specification (BDS) covers the critical engineering aspects and unique equipment engineering (e.g. mechanical, rotating equipment, etc.) requirements in sufficient detail so that the Front-End-Loading (FEL) or Engineering, Procurement and Construction (EPC) Contractor can complete the remainder of project definition / detailed engineering. Three levels of Exxon Engineering BDS definition are typically recognized, reflecting differing levels of detail required based on such factors as the nature of the project, technology employed, contracting strategy etc. 1. Full Basic Design Specification 2. Abbreviated Basic Design Specification 3. Duty Specification Selection of the type of BDS will be client and job specific. Protection of proprietary information and know-how for competitive advantage will need to be balanced versus job cost and schedule. The contractor would then use the BDS to produce a FrontEnd Engineering Package (FEEP). Additional information on FEL and FEEP is contained in Exxon Engineering Work Processes Manual. This guide describes the electrical section of a Full Basic Design Specification.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

20 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

DESIGN PROCEDURE – ELECTRICAL DESIGN SPECIFICATION GUIDE (Cont) The Full Electrical Design Specification engineering is preceded by engineering work done during the planning and Design Basis Memorandum (DBM) stages of a project. Appendix A provides a Sample Site Survey questionnaire to assist in the planning process. The DBM provides the details of the system design selected from the results of the planning and DBM engineering. The DBM provides a technically feasible and economically viable design to serve the electrical loads of the project. It contains a one-line diagram, load list, equipment lists, system and equipment performance criteria, and results of studies carried out during the engineering. It may also contain specific conditions requiring further attention during the Design Specification engineering. The equipment list details together with the investment curves references, where appropriate, comprise the IBM which is intended to provide the cost engineers with the information needed to prepare the project cost investment estimates. Many times, in the absence of a major basis change, the DBM design will essentially be reflected in the Design Specification. It is recommended that the Owner make a detailed review of the DBM in order to understand the basis of the facilities to be provided. ➧

HOW INFORMATION IS PROVIDED TO THE CONTRACTOR There are four vehicles by which we provide information to the contractor: 1. The Design Specification. 2. The General Instructions and Information (GII) Specification. 3. The International Practices. 4. The Exception and Additions to the International Practices. In an ideal situation, a contractor should be able to produce a detailed electrical design using a set of the electrical International Practices. Practically, however, this is not the case. There are still too many decisions left by the International Practices which the contractor cannot or should not make. These decisions are either made for him in the Design Specification or he is directed to perform studies which will result in a decision. Exceptions and additions to the International Practices indicate to the contractor areas where the International Practices are superseded. These usually occur for plant expansions where equipment and/or design are intended to match existing facilities, or sometimes affiliates have their own standards which conflict with specific International Practice requirements. These discrepancies are also covered by the exceptions. Ideally, there should be no exceptions to the International Practices, but the affiliates' preferences and requests may take precedence. The Design Specification brings together the International Practices, the exceptions and additions, affiliates' preference and requests, and the most up-to-date Exxon Engineering thinking on plant electrical systems. Efforts should be made to include in the Design Specification only those items which are not covered by the International Practices.

INFORMATION NEEDED TO WRITE A DESIGN SPECIFICATION The Design Specification should include all the features of the prepared design and should resolve as many of the alternatives described by the International Practices as possible. The items marked with an asterisk in the International Practices require a decision. Table 3 provides a check list of International Practice Asterisk items for consideration in preparing an Electric Power Facilities Design Specification. The specification writer is responsible for determining affiliate preferences on these items and for specifying them in either the Design Specification or in IP exceptions. Decision on the remaining items will be made during detailed design. In addition to resolving the asterisked items, the following information should be available prior to writing an electrical system Design Specification: 1. Power Source Characteristics (see POWER SOURCE REQUIREMENTS). 2. 3. 4. 5.

Affiliate Preferences on Design Features. Load Description. DBM Design Features. Engineering Survey Data.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

21 of 76

Date December, 1999

DESIGN PROCEDURE – ELECTRICAL DESIGN SPECIFICATION GUIDE (Cont) Writing A Design Specification It should be noted that all the items below may not be necessary. For example, if lighting requirements conform to the International Practices, then it would not be necessary to include a section of lighting in the specification. On the other hand, the above items should not preclude any additional items which a Design Specification writer might deem necessary. The use of sections with only statements to the effect that the requirements of the International Practices should be met is to be avoided. That the requirements of the International Practices be fulfilled is covered adequately in the Design Specification SCOPE. The function of the Design Specification is to supplement the International Practices, not repeat the requirements of the International Practices. THE DESIGN SPECIFICATION SHOULD INCLUDE ONLY THOSE ITEMS THAT ARE NOT COVERED IN OTHER DOCUMENTS. BE COMPLETE BUT DO NOT BE REPETITIVE. IF SOMETHING HAS BEEN MENTIONED IN THE INTERNATIONAL PRACTICES, IT SHOULD NOT BE MENTIONED IN THE DESIGN SPECIFICATION. The Design Specification should contain enough detail to enable a contractor to engineer facilities that are flexible, reliable, and require the minimum of maintenance. The International Practices contain most details of our requirements for process substations, their power supply, and all facilities downstream. Intermediate distribution systems (say 36 kV), incoming substations receiving power from the utility, and power generation are not completely covered by the International Practices; therefore, more details of these upstream facilities, including all relaying and protection, should be included in the Design Specification. During preparation of the Design Specification, it may not be known if the contract will be “Fixed Price" (Lump Sum) or “Cost Reimbursable." If this is the case, it should be assumed that the contract will be “Fixed Price" and the Design Specification should clearly define the specification scope, with no omissions, and include enough definition to avoid “extras" to the contract. The specification should clearly define contractor, utility, and Owner responsibilities. When more than one contractor will be used, split of responsibilities and interfaces must be stated and checked carefully to avoid overlaps and to insure all electrical facilities, functions, and studies are assigned. All of this must conform to the overall project split of responsibilities. The term “Owner" should be used in Design Specifications when referring to Exxon / Esso or the customer, not “Owner's Engineer” as used in the International Practices. The following apply to respective sections of SAMPLE DESIGN SPECIFICATION 94-1 included as Appendix B in this Design Practice. 1. Scope The scope describes in a broad sense what the specification covers and lists any exclusions. 2. Design Basis Generally, the items in the Design Basis are determined during the planning and DBM phases of the project and are not part of the Design Specification effort. These items include: a. Purchased or generated power. b. Pre-investment philosophy. c. Estimated peak demand of the refinery or project and the basis for estimate. d. Voltage levels (may be determined as part of Design Specification effort rather than specified in Design Basis). e. Any atmospheric conditions which might affect design. 3. General This section points out how the contractor is expected to use the information supplied to him in the Job Specification. It specifies who is responsible for construction power (if not in GII) and directs the contractor to other sources of information, i.e., to the Owner for details of existing equipment. 4. Power Source This section describes the power source and provides the source characteristics at the distribution system source bus. These characteristics include the following: a. For Generation Source 1) Generator rating (kVA, PF, MW, kV, Hz), and requirements for excitation system, enclosure, etc. 2) Subtransient, transient, and synchronous reactance. 3) Generator bus configuration. 4) Location and contractor responsibilities at the interface. 5) Generator bus grounding details. 6) Special relaying, clearing times for stability, load shedding, and proposed method of voltage and var control. EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

22 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

DESIGN PROCEDURE – ELECTRICAL DESIGN SPECIFICATION GUIDE (Cont) b.

5.

6.

7.

For Purchased Power Source 1) System nominal voltage and frequency. 2) Present minimum and future maximum short circuit levels at the source bus. 3) Is source bus neutral effectively grounded? 4) Source bus configuration and number of incoming circuits. 5) Level at which circuits can be paralleled. 6) Voltage regulation at source bus. 7) Limiting kVA of supply (transformer or incoming line). 8) Location of source bus. 9) Power factor correction. 10) Specify contractor and Owner responsibilities at the source bus interface. Distribution System This section gives substation designations, locations, and types but does not repeat system information given on the one-line diagram. It describes any unusual features, such as three winding transformers, capacitor banks, and special bus configurations. If the project is an addition to or an expansion of an existing facility, specify the contractor's responsibilities at any tie-in points. Based on the source bus information above and the load information (POWER SOURCE REQUIREMENTS), the design for the distribution system can be developed by determining the following features: a. Location of refinery load centers (refer to load summary). b. Determination of the simultaneous maximum demand at each load center. c. Determination of the type of service required by each load center (radial, primary selective, secondary selective), and which loads can be served from a common bus, i.e., operate and turnaround together. d. Selection of substation locations as close as possible to the load centers being served. e. Selection of distribution and utilization voltage levels and distribution method to each substation (tapped feeder, individual feeder, loop feeder, or series substation). f. Selection of sectionalizing devices (breakers, links, load break switches, disconnect switches). g. The writer usually will have to prepare several system one-line diagrams for cost and reliability comparison before the optimum distribution system can be selected. Load Description The load description should include the simultaneous maximum demand at each load center, substation load center assignments, and an electrical load summary by substation. The load summary should include the following: a. Voltage level. b. Substation type (secondary selective, radial, etc.). c. Substation transformer rating. d. Load centers served by substation, identified by process or offsite facility or area supplied. e. Maximum simultaneous demand on each substation in kW and kVA. The load description should also include all assumptions used in formulating the load summary, such as contingencies, assumed power factors, and medium / low voltage horsepower split. Protection and Control The International Practices specify most of what is usually required for protection and control. Sometimes affiliate preferences will require specifying motor controller types and relaying methods. Also, the relaying and metering on main incoming substations, any special reacceleration control, or load shedding requirements are often specified. Differential protection must be specified where required.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

23 of 76

Date December, 1999

DESIGN PROCEDURE – ELECTRICAL DESIGN SPECIFICATION GUIDE (Cont) 8.

9.

Equipment and Construction Procedures This section specifies any special design features or affiliate preferences dealing with the following: a. Power cabling methods and materials. b. Transformers, motors, and other electrical equipment. c. Substation building type and layout. d. Electrical equipment test requirements. e. Turnaround power center locations. f. Welding and convenience outlets. Lighting Lighting is adequately covered by IP 16-5-1 except for affiliate preferences and whether or not to invoke the security lighting IP 16-5-2.

10. Instrument and Essential Services Power Supply Instrument power supply systems are covered by the International Practices except for affiliate preferences, such as expansion or duplication of an existing system. There are two key asterisk items in IP 16-8-1 that will set the basis for the design configuration for the instrument and essential services power supplies. Par. 3.5 requires the designer to determine which operating units (or group of units) are critical and independent from other units. Following identification of all groups of critical and independent units, and the site selection of all control centers and remote instrument buildings, the instrument and essential services power supply configuration can be determined from IP 16-8-1, Pars. 8.1, 9.1, and 9.2. This will require preparation of one or more one-line diagrams for inclusion into the Design Specification. Par. 6.2 requires the designer to determine whether or not a standby power generator is required, and for which units/loads. The power source configuration can then be designed per IP 16-8-1, Figure 1. This will require preparation of one-line diagrams for the power sources and essential services switchgear configurations. 11. Communications Communications systems are not covered by the International Practices. Depending on the complexity of the system, communications equipment can be covered as a separate specification or as part of the distribution specification. In general, consultation with the affiliate will be necessary before the specification can be written. The general communications systems covered include: a. Telephone, facsimile, and electronic mail systems, type, whether purchased or rented, etc. b. Ship-to-shore radios. c. Intra-refinery communications systems (two-way radios, sound powered phone loops, etc.). d. Fire and accident reporting systems. 12. Diagrams This section should include a one-line diagram and any other diagrams which may not be covered by the International Practices, such as an existing distribution system or an unusual instrument power supply systems.

COMPUTER PROGRAMS GUIDANCE AND CONSULTING

➧

For up-to-date information on available programs and how to use them, affiliate personnel should get in touch with their Affiliate Library Contact. Exxon Research and Engineering personnel should consult either the Exxon Engineering Section responsible for the technology involved and/or the Technical Computing Group of Exxon Engineering Technology Department (EETD). The Application Technology Set (AST) Catalog is a data base of the technical and engineering applications used by Affiliate and ER&E Engineers. The prime delivery mechanism for the ATS Catalog is the Windows “help” file format. To request a copy of Windows “help” file version, contact: ER&E Manual Distribution OUTLOOK: AMERICAS(MANUAL) Exxon Research and Engineering Company

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

24 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

COMPUTER PROGRAMS (Cont) AVAILABLE PROGRAMS The applicable programs available at the time of this writing are listed below: PROGRAM 3317

TITLE AND DESCRIPTION MAGNET Version 9 This is a program for calculating motor acceleration, generator performance, and network component duties. The type of calculations which can be performed are: STEADY-STATE CALCULATIONS Steady-State Load Flow - “Load flow” based on a specified utility source voltage and/or voltages at generator busses. Steady-State Optimum Taps - Same as Steady-State Load Flow, with automatic selection of best transformer taps to achieve desired voltages at load busses. Steady-State End of Transient - With in-plant generation, a calculation of the bus voltages and generator excitation values which will result from a given set of generator automatic voltage regulator settings V(Ref), but with a load situation which may be different from that for which the V(Ref) settings were established. 3-PHASE FAULT CALCULATIONS Fault Bus XXX IEC - Classical short circuit study, giving voltages and currents at “time zero,” half cycle, and steady-state (for switchgear duty and relay coordination). Dynamic Fault Bus XXX - A dynamic calculation of generator contribution and/or large motor deceleration during a short circuit of specified duration on a specified bus. Generator terminal voltage and phase angle can also be plotted for stability checks. REACCELERATION OF MOTORS IN GROUPS (STEPS) Automatic calculation of the maximum groups of motors which can be reaccelerated, in steps, based on specified priorities (and/or step assignments) and minimum allowable voltages. DYNAMIC NON-FAULT STUDIES (SUCH AS LARGE MOTOR STARTING AND REACCELERATION) Dynamic General - General purpose calculation, starting from specified initial speeds of motors (and initial conditions of generators, if any). Dynamic Loose - A modification of Dynamic General with reduced calculation time, especially for plants with no generation. Dynamic Tight - A modification of Dynamic General with difficult-to-solve networks. CABLE SIZING OR CHECKING Cable Select - Selects, from available cables specified by user, the smallest acceptable for motors (SMPL MTR BLOCK) and loads such as heaters and lighting (LOAD BLOCK); alternatively, checks those selected by user. For LV loads, calculates ground fault current with 40 V arc drop. Operating Environments: MVS, VM, TSO. Documentation/References: MAGNET User's Manual, Version 9, September 1983.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

25 of 76

Date December, 1999

COMPUTER PROGRAMS (Cont) ➧

PC Magnet

PCMagnet is a personnel computer program version of MAGNET. The preprocessor function in MAGNET is provided by a database application written in Microsoft Access 97. This provides a convenient tool for manipulating MAGNET data sets including exchanging data with other applications. PCMagnet runs within a window and is a batch calculation process. It has the same calculation types as MAGNET except that it does not allow for database manipulation of Static Var Compensators, Induction Generators and Generator / Synchronous motor change cards. These are placed in a text file for manual handling. Input / Output: Input is via tables in a Microsoft Access Database. Output is text based in 132 column format. When a dynamic calculation is run PCMagnet produces a comma-separated-value file which is plotted by a companion Microsoft Excel 97 based program called MagGraph. Operating Environments: WIN, WIN95/NT Documentation / References: Help file provided with PCMagnet, Magnet User's manual.

PSS/E

PSS/E Version 20 or later, (Power System Simulator) This is a system of programs and structured data files designed to handle the basic functions of power system performance simulation work, namely:

• Data Handling, Updating, and Manipulation • Power Flow • Fault Analysis • Dynamic Simulation • Equivalent Construction ➧

SKM

SKM Power*Tools for Windows. SKM Systems Analysis Inc have developed the Power*Tools for Windows in order to migrate their existing DOS based programs within the Windows environment. SKM currently offer the following modules: DAPPER, CAPTOR, A_FAULT, IEC_FAULT, HI_WAVE and I*SIM. I*SIM Program

➧

The I*SIM program is specifically designed to simulate the electro-mechanical dynamic behavior of power systems. I*SIM can simulate all types of balanced network disturbances including: isolation from the utility; fast transfer switching; motor starting, tripping, and reclosing; loss of generation; loss of excitation; blocked governors tie-line oscillations; load rejection; load shedding; and system splitup. I*SIM can be used to simulate small or large power systems. The I*SIM program provides record keeping capabilities which permit the updating of studies and reports as the power system is revised or upgraded. CAPTOR: Computer Aided Plotting for Time Overcurrent Reporting Version 3.5 This program aids in the plotting of the time current relationship of protective devices and equipment in electrical power systems. Specification of variables by the user for each piece of equipment in the study. Program displays the results of the specifications directly on the monitor. The program may be additionally used as a tool in the study of transformer damage, cable heating, and time simulation of motor starting. Program uses a hardware key to run. Input / Output – User specifies variables associated with a variety of power system devices and equipment. The program has a library with the most common pieces of equipment but specific parameters of each are selected by the user. Results of the user specifications are displayed on the computer monitor. Reports may be requested for printing which include the time current curve (TCC) drawings, reports for each device setting, and a simple single line drawing depicting the electrical arrangement of the equipment displayed on the TCC. Operating Environments: WIN, WIN95/NT Documentation / References: Power Tools User's Manual, SKM Systems Analysis, Inc.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

26 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

COMPUTER PROGRAMS (Cont) ➧

DAPPER: Dist. Analysis for Power Planning, Evaluation and Reporting Version 3.5 Part of a suit of programs in Power Tools. Performs steady-state and short circuit calculations on arbitrary distribution systems. Add-on modules do ANSI fault calculations (A-fault) and IEC 909 fault calculations (IEC-fault). Primary uses include load flow and short circuit analysis, synchronous and induction machine modeling, transient motor starting analysis, and equipment sizing. Input / Output: Input is done by creating a one-line diagram using a component toolbar and by entering database information into dialog boxes in the "Component Editor". Output is displayed in reports and may be displayed on a one-line diagram, if that form of output is selected. Operating Environments: WIN, WIN95/NT Documentation / References: Power Tools User's Manual, SKM Systems Analysis, Inc.

➧

EASYPOWER

The Graphical Solution for Power System Analysis Performs steady-state and short circuit calculations on any interconnected electrical system. Used for load flow and short circuit analysis, and for "impact" motor starting where the starting motor is modeled as a constant impedance (see User Manual), requires a hardware key. Input / Output: Input is done in a session window by creating a one-line diagram using an "equipment palette" and by entering data base information into dialog boxes which appear by doublechecking on each piece of equipment in the one-line diagram. Output is displayed on the one-line diagram, with the option of having detailed results sent to text windows. Operating Environments: WIN Documentation / References: Easypower User's Manual, Electrical Systems Analysis, Inc.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

27 of 76

Date December, 1999

TABLE 1 OFFSITE DBM RECOMMENDED DESIGN FACTORS LGF (%) LOAD GROWTH FACTORS (LGF) AREA

STEAM

COOLING WATER

BFW

COMPRESSED AIR

15

—

10

15

10

10

—

—

10

15

15

10

—

15

—

15

15

15

15

Refrigeration(1)

—

—

10

10

—

—

Gas Liquid Separation

15

—

15

15

—

—

Phenosolvant

15

—

15

15

—

—

Gas Liquid Stripping

15

—

15

15

—

—

Sulfur Recovery

15

—

15

15

15

—

CO2 Incineration

—

0

15

—

0

—

Product Gas Compression(1)

—

0

15

—

0

—

Fractionation

20

0

20

20

0

20

Oxygen Plant(1)

10

—

—

10

—

—

CONDENSATE

PRODUCT

Gasification

10

10

Lock Gas Recompression(1)

—

—

Gas Cooling

—

Gas Purification

ELECTRIC POWER

Note: Item shown may be either steam turbine or electric motor driven. Reserve Capacity Factors (RCF) A reserve capacity factor (RCF) of 10% will be added to all utilities supply equipment.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

28 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

TABLE 2 POWER TRANSFORMER RATINGS The following 3-phase transformer ratings are USA preferred per ANSI C57.12.00 Table 2 and C57.12.10 Table 2. Other countries differ but the following table will give an idea: KVA 65°C SELF-COOLED (OA)

65°C SELF-COOLED (FA)

65°C FORCED OIL FORCE AIR COOLED (FOA)

≤500

–

–

750

862

–

1,000

1,150

–

1,500

1,725

–

2,000

2,300

–

2,500

3,125

–

3,700

4,687

–

5,000

6,250

–

7,500

9,375

–

10,000

12,500

–

12,000

16,000

20,000

15,000

20,000

25,000

20,000

26,667

33,333

25,000

33,333

41,667

30,000

40,000

50,000

37,000

50,000

62,500

50,000

66,667

83,333

60,000

80,000

100,000

> 75,000

See Manufacturer

Note: Temperature rise above a 24-hour average ambient of 30°C (40°C maximum). Transformers may be specified 55°C/65°C temperature rise to permit limiting temperature rise to 55°C at 100% name plate rating. For these transformers, 65°C is 112% of 55°C rating.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

➧

Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

29 of 76

Date December, 1999

TABLE 3 DESIGN SPECIFICATION CHECK LIST OF INTERNATIONAL PRACTICE ASTERISK ITEMS IP PAR. NO. S

16-1-1

(NOTE)

ITEM

Area Classification and Related Electrical Design for Flammable Liquids, Gases or Vapors 5.3

16-1-2

Specify if the "additional" 50 ft x 2 ft high classified zone can be waived.

Area Classification and Related Electrical Design for Combustible Dust 4.2

16-1-3

(3)

Specify values for the dust being classified

Protection of Electrical Equipment in Contaminated Environments

16-2-1

2.2

Specify if plant location is tropical.

2.4

Specify if insulators require protection.

2.9

Specify if equipment will be exposed to dust from neighboring facilities.

Power System Design 2.3

Specify additional or equivalent standards of design to be used.

4.14

Specify the relay coordination computer software to present the coordination curve results.

4.19

Specify contractor participation in technical review meetings with Utility supply company.

5.3

Specify if buses need to be maintainable with plant in service.

5.4 5.5

Specify if buses need to be extendable with plant in service. (2)

5.7

Specify if a single large motor may be supplied from a captive transformer

5.8 c, d

Specify if high resistance grounding is to be used.

5.16

Specify secondary protection if primary protection differs.

5.24

Specify if fault pressure relaying (63) is to be used.

5.27 5.30 c

Specify if differential relaying is to be used. (2)

6.4

S

Specify if radial substation to be designed to be convertible to secondary selective. Specify Transformer impedance requirements to limit fault currents

6.22

Specify design basis for short circuit withstand for cables at 1000 v and below, and feeders to motors above 1000v.

7.5

Specify lighting Transformer voltage taps.

7.6

Specify if outdoor switchgear is to be used.

7.9

Specify individual motor controllers or otherwise.

7.17

Specify motor starter disconnect device type.

8.1

Specify if additional or redundant switchgear control power source is required.

8.14

S

Specify design basis for sub-bus feeders.

6.6 c

8.6 S

Specify process priorities for motor re-acceleration.

(1)

Specify minimum design ambient temperature. Specify if start-stop control stations are required to be lockable in the stop position.

8.16

Specify the electric motor valve actuators that are type C or D.

8.21

Specify plant standard design of control station.

10.8

Specify if a power system disturbance recorder is required.

11.11

Specify requirement for motor alarms.

12.2

Specify welding terminal box requirements for outside Process units.

12.5

Specify if welding outlets are required.

13.1

Specify convenience outlet requirements for outside Process units.

13.2

Specify convenience outlet voltage.

13.4 c

16-3-1

Provide details of existing convenience plugs.

Wiring Methods and Material Selection 4.2 d

Specify if aluminum sheath is acceptable.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

30 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

TABLE 3 (Cont) IP PAR. NO. S

16-4-1

16-5-1

(NOTE)

Grounding and Overvoltage Protection 6.5

Specify if a sand filled pull pit is required, location of any below grade pull pits and their design requirements.

4.3

Specify if bonding and grounding conductors are to be bare stranded medium-hard-drawn copper and if their minimum size is to be increased.

4.4

Specify if common ground return conductors are to be used.

5.2

Specify if insulated conductor between neutral and the grounding point in the switchgear is required.

7.9

Specify if one or more conductors may serve as ground return path for a group of circuits in direct buried cable systems.

Lighting 9.11

Specify if additional provisions are required to protect against overvoltages.

3.3 3.8

S

Specify any lighting requirements in areas not covered by IP's. (2)

Specify extent of gauge glass lighting.

3.19

Include information necessary where Owner's standardized poles are to be used.

3.20

Specify automatic or remote control of lighting for areas not continuously attended.

3.26

Specify if electronic type controllers are required for Control room lighting.

3.27e

Specify areas requiring emergency lighting above IP minimum, and identify power source, as necessary.

16-5-2

Security Lighting of Plants

1.2, 1.3 S

6.1

16-6-1

S

ITEM

Specify if backup (emergency generators) power is required.

Substation Layout 2.2

Specify the extent of use of IP 4-3-2, Blast Resistant Buildings.

4.9

Designate "critical" facilities (other than those defined by IP under 20% rule.)

5.1 (3), 16.1 16.2

S

Specify if IP is to be used on project, and if so, the applicable areas.

Specify if substation building is blast resistant.

6.4

Specify if substation is to be at grade or elevated above grade.

6.6

Specify if chain link fencing is required.

6.7

Specify if supplemental heating is required.

6.9, 6.10

Specify substation cooling design alternatives.

8.5, 8.6

Specify if spare conduits are required.

S

9.2 10.1 a

Specify if an alternative material for substation doors is required. Specify weight limitation of draw out voltage transformers and low voltage motor controllers that require permanent handling facilities.

E

12.5

E

12.7

Specify the extent of facilities around transformer yards.

12.8

Specify if fire walls are required.

13.1

Specify if a floor space allowance is required.

13.5

Specify if greater clearances are required.

15.2

Specify Owner's receptacle and plug details.

17.1 b S

16-7-1

Specify the extent of the oil retention system.

Specify if area around captive transformer will meet requirements for "Transformer Yards".

18.1

Specify if a breaker test and inspection station is required.

18.2

Specify safety and maintenance equipment.

Motor Application 2.1

Specify motor standards applicable outside the USA.

4.2

Specify any special conditions.

4.4

Specify if local standards require specially designed motors such as "increased safety".

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

31 of 76

Date December, 1999

TABLE 3 (Cont) IP PAR. NO.

16-8-1

(NOTE)

Instrument and Essential Services Power Supplies 3.1

Specify essential instrumentation and controls.

3.2

Specify other essential services to be fed from the instrument and essential services power supply.

3.5

(2)

Specify each unit or group of units considered critical and independent., (also see Par. 8.1, 8.2 and 9.1).

5.2

(2)

Specify tolerable outage time for each d-c instrument power load.

6.2 b2

(2)

Specify units which require continuous operation during main power supply failure.

6.5

S

S

ITEM

Specify if other than diesel generator driver.

6.6

Specify location of power generator controls.

8.8

Specify if ground fault location facilities are required for d-c systems.

10.2

(2)

Specify minimum design ambient temperature for battery sizing.

12.4

Specify of other than lead-acid or nickel-cadmium batteries are to be used.

12.13

Specify if load test terminals are required.

12.14

Specify if other than static type inverters are to be used.

12.15, 12.25 12.26 Figure 2 (d)

16-9-1

Specify tolerable limits of the loads served. Note 7: specify if transfer switches are required.

Low Voltage A-C Motors Up To 200 HP (150 kW)

2.1, 2.2, 2.3, 4.2

16-9-2

Specify power factor range and crest factor for performance characteristics. Specify ambient temperature extremes.

Specify list of practice and standards to be used.

3.1

Specify motor data

3.2

Specify if test reports are required.

4.3

Specify if motor insulation is not class F with class B temperature rise.

4.4

Specify if motors are not grease lubricated.

5.1

Specify if motors are not to be TEFC.

A-C Motors: Medium Voltage and Low Voltage Over 200 HP (150kW) 1.1

2.2,2.3,2.4 4.1, 4.2

Specify if this IP is to be used for low voltage motors in sizes 200 HP(150kW) and below. Specify practices and publications to be used. Specify if inspection is required and if reports are required for low voltage motors.

4.5

Specify L10 rated life.

5.1

Specify if motor insulation is not class F with class B temperature rise and if it requires an alternative insulation systems.

5.3 b

Specify if an epoxy resin VPI system is not to be used.

5.3 d

Specify if surge tests are required.

5.6 c

Specify if pure mist for anti-friction bearings lubrication system is to be used.

5.7 e

Specify the type of grease fittings.

5.15

Specify if motor half couplings are required.

5.20 h

Specify equipment number for nameplate.

5.22

Specify if winding temperature detectors are required.

5.23

Specify if air filters or provision for air filters are required.

5.24

Specify if air filters are to be disposal type.

5.25

Specify if a differential pressure switch is to be provided.

5.27

Specify voltage to be used if space heaters are required.

5.28

Specify if the motor is for a Class 1 Division 1 or 2 use.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

32 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

TABLE 3 (Cont) IP PAR. NO.

(NOTE)

ITEM

16-9-2 (Cont) 6.1 6.1 a 6.2

S

Specify if vibration-monitoring systems are required. Provide probe size and other necessary mounting dimensions. Specify extent of SPM adapters or space for attachment of vibration transducers.

7.1

Specify drive motors required to meet Pars 7.2 - 7.6

7.5

Specify if a rotor dynamic analysis is required.

8.1

Specify enclosure type.

8.12

Specify environment.

8.15

Specify motors for use in Class 1 Division 1 locations.

8.17

Specify tube material, and cooling water inlet temperature and fouling factor.

8.18

Specify if purchaser or motor vendor supplies water flow indicator.

8.19

Specify area classification of motor location.

9.5

Specify if motor winding heaters are required.

10.1

Specify if a more severe starting duty is required.

11.4

Specify if a complete motor rotor dynamic analysis is required.

11.5

Specify if a study is to be performed of the axial vibration dynamic response of the motor-coupling-driven load system.

11.8

Specify if a shorting device is required.

11.12

Specify if self-balancing type is not to be used.

11.13

Specify if surge protection is required.

11.14

Specify if a lower locked rotor current is required.

11.16

Specify the application for starting performance and duty design.

12.2

Specify if a motor is to be inspected.

12.5

Specify if a complete test is required.

12.7

Specify if a submerged test is required.

12.10

Specify if surge testing is required.

16-9-3

Synchronous Generators 3.2

Specify if IEC 85 is to be used

3.4

Specify applicable standards of manufacture and test.

5.3

Specify if neutral leads do not need to be brought out.

5.5 5.8 d

Specify capability of excitation system. Specify cooling water piping entry.

5.8 f

Specify cooling water type, and water inlet temperature and pressure conditions.

5.9

Specify materials if saltwater service.

5.12 6.5 b 2 6.9

Specify if an open-ventilated air-cooling system design is to be proposed as an alternative. Specify if load break switches are to be provided. Specify if devices are to be mounted on Purchaser's control panel or metal enclosed freestanding enclosure furnished by generator vendor.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

33 of 76

Date December, 1999

TABLE 3 (Cont) IP PAR. NO.

16-10-1

(NOTE)

ITEM

Power Transformers 2.2 2.3

3.1 g

Specify additional or equivalent standards to be used. Specify if IP 20-1-1 is to be used. Specify if fans are required.

5.4

Specify if transformer design shall take into account the harmonic currents associated with the loads.

5.5

Specify if load-tap-changing required and tap size.

5.6

Specify if the transformer is to be used as a captive transformer and the characteristics of its load.

5.7

Specify if lightning arresters are required to be mounted on or within a few feet of the transformer.

5.8

Specify if fault pressure relays are required.

5.9

Specify type of termination.

5.10

Specify each winding with neutral brought out.

5.11

Specify if double primary cable entrance required.

S

5.12

Specify if switch location is Class 1 Division 2.

S

5.15

Specify momentary duty of switch.

S

5.16

Specify if primary fuses are required.

5.17

Specify if primary current transformers are required.

5.19

Specify if a current transformer for ground fault protection is required and its CT ratio.

5.23

Specify electrical area classification for transformer accessories.

5.23 c

Specify if alarm contacts are required.

5.23 e

Specify if bleeder device and gauge required.

5.24

Specify if space heaters are required and their voltage, source of power and methods of control.

6.2

Specify tests to be witnessed.

6.3 i, j, k 6.4

16-11-1

16-12-1

S S

Neutral Grounding Resistors 2.1

Specify or otherwise standard to be used.

4.2

Specify period for carrying maximum system ground fault current.

Switchgear, Control Centers and Bus Duct

1.3 a

Specify type of switching device

1.3 b

Specify type of circuit breaker

1.3 c

Specify relaying for other than motor branch circuits.

2.1

Specify codes and standards to use.

6.1

Specify if arc resistant switchgear is not required.

6.2 6.8, 7.1

S

S

6.13, 6.14, 7.3, 10.3

Specify available current and relay time. Specify name or equipment numbers. Specify if main bus neutral required and its current rating.

6.22

Specify switchgear control power voltages.

7.11

Specify if control power transformers are required.

7.18

Specify latched switching devices control power source.

8.4

Specify if re-acceleration is required, if it is to be by fixed time steps or voltage-controlled steps. Specify if a PLC control system is required and a functional specification for it.

8.5 b 1 8.7 d S

Specify if impulse, temperature and regulation tests required. Specify if certified copies required.

Specify time for memory timer. Specify if ground fault relays are required.

8.8

Specify ambient compensated overload relays.

8.9

Specify thermal overload alarm relay.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

34 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

TABLE 3 (Cont)

IP PAR. NO.

(NOTE)

ITEM

16-12-1 (Cont) 8.14

Specify type of differential relay protection and responsibility to supply.

8.15 8.19

Specify locked rotor damage time and type of relay. (2)

Specify if remote meters are required.

S

8.21

Specify controllers requiring contact for space heater control and space heater voltage and watt rating.

S

8.22

Specify controllers requiring motor off alarms and alarm voltage.

9.1, 9.4

S

Specify voltage, power source and method of control for space heaters.

10.5

Specify fault current magnitude.

11.2

Specify tests to be witnessed.

16-12-2

Control of Secondary Selective Substations With Automatic Transfer

1.2. 3.3

Specify design modifications to the control system for manual transfer.

3.3, 3.4 3.6

S

Specify if sources are not synchronized. (1)

Specify inter-tripping with the source substation to initiate automatic transfer.

3.8

Specify transformer protection.

3.14

Specify if there are any modifications to the Figure 5 circuit for substations supplied from sources which can not be synchronized.

16-13-1

16-14-1

Field Installation and Testing of Electrical Equipment 6.1

Specify if separate grounding conductors are required.

9.3

Specify if step by step procedures are required.

9.6

Specify or otherwise tests to be witnessed.

Standard LV Variable Frequency Drives

14.6 b 2.2 3.2, 5.2, 5.6, 5.11, 5.21, Table 1

Specify if primary injection testing is required. Specify standards to be used. Specify VFD data.

4.1

Specify classification of location of VFD.

4.4

Specify installation and interlocking details.

4.8

Specify control features required.

4.16

Specify if an electrical bypass is required.

5.12

Specify if more restrictive current harmonics required.

5.13

Specify if a lower harmonic voltage distortion is required.

7.1

Specify if factory tests are to be witnessed.

7.2

Specify VFD input current harmonics.

7.3

Specify if VFD and motor tests required.

7.4

Specify if complete string test required.

16-14-2

Engineered Variable Frequency Drive Systems 2.3

4.1, 5.43

Specify standards to be used. Specify if a converter bypass is required and the motor speed at power frequency.

5.1

Specify if VFD motor and transformer not to be suitable for outdoor installation.

5.5

Specify if modules not to be designed for indoor location.

5.14

Specify if the VFD is required to communicate with external PLC or process computer and if data logging is required.

5.19

Specify if fluid-cooling system required.

5.38

Specify if liquid filled reactors required.

6.1

Specify continuous operation and idle period duties.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

35 of 76

Date December, 1999

TABLE 3 (Cont) IP PAR. NO.

(NOTE)

ITEM

16-14-2 (Cont) 6.3

Specify if redundant EVFD auxiliaries are required and if a standby generator is required.

6.13

Specify if VFD speed output not required to be within 1% of any given set point.

6.17

Specify if harmonic distortion values are not to be to IEEE 519 and any existing background harmonic levels.

6.18

Specify if six pulse system required.

6.19 S

Specify if a torsional vibration analysis is not required.

6.10

6.20 e

Specify if measurement of existing harmonic distortion required. Specify if independent overspeed protection required.

7.2

Specify if the alarms are to be powered from an UPS.

8.1

Specify if a converter bypass is required.

10.5

Specify additional tests to be performed.

11.1, Table 1

Specify power system data.

Notes: (1) (2)

Not marked with an (✶) in the IP, but still comes under the intent of a DESIGN SPECIFICATION CHECK LIST. Process design decision required.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

36 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

FIGURE 1 APPLICATION OF LOAD GROWTH AND RESERVE CAPACITY FACTORS Ash Handling Equipment

Ash Rate Process Coal Requirement

Process Steam Requirement

Coal Handling Equipment

Coal Requirements

X(1 + LGF)

Steam Balance

X(1 + RCF)

Process BFW Requirements

X(1 + LGF)

Boiler Size

Balance

+(1 + RCF)

X(1 + RCF)

+(1 + RCF) Process Electrical Requirement

Electric Power Requirements

X(1 + LGF)

X(1 + RCF)

Power Supply Facilities Purchased or Generated

+(1 + RCF)

Oxygen Requirements

O2 Plant Air & O2 Comp Power

X(1 + LGF)

Process Design

Process Water Requirements

Process Cooling Water Requirement

X(1 + LGF)

X(1 + LGF)

Water Requirements

Cooling Water Requirements

X(1 + RCF)

X(1 + RCF)

Water Supply Equipment

Cooling Water Equipment (towers, pumps)

+(1 + RCF)

DP30AF1

NOTES: 1. LGF is load growth factor (applied to utilities only). 2. RCF is reserve capacity factor (applied to utilities only). 3. Compressed air is treated in the same manner as cooling water.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

Boiler Fans, Deaerator, BFW and Fuel Pumps FGDS BFW Treat Equipment

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

FIGURE 2 SYMBOLS FOR FIGURES

Circuit Breaker - CLOSED During Normal Operation.

Circuit Breaker - OPEN During Normal Operation.

Isolator - CLOSED During Normal Operation.

Isolator - OPEN During Normal Operation.

Two Winding Transformer.

Reactor

Alternator

Exxon Secondary Selective Switchboard as per IP16-12-2.

Counting of Circuit Breakers - Each incoming line and each transformer feeder count as a circuit. Therefore one circuit breaker in a line from the utility to an Exxon transformer counts as a "Half Breaker" system i.e. one circuit breaker for two circuits.

37 of 76

Date

DP30AF2

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

38 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

FIGURE 3 DUPLICATE FEEDERS (NO BREAKER)

DP30AF3

FIGURE 4 LINE TEE-OFF ONE SWITCH SUBSTATION (QUARTER BREAKER) a

b

DP30AF4

FIGURE 5 DUPLICATE FEEDERS (HALF BREAKER)

DP30AF5

FIGURE 6 LINE TEE-OFF TWO SWITCH SUBSTATION (HALF BREAKER) a

b

DP30AF6

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

EXXON ENGINEERING

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

FIGURE 7 THREE SWITCH SUBSTATION (THREE QUARTER BREAKER) a.

b.

c.

DP30AF7

FIGURE 8 FOUR SWITCH SUBSTATION (ONE BREAKER) a.

b.

DP30AF8

FIGURE 9 FIVE SWITCH SUBSTATION (ONE AND ONE QUARTER BREAKER) a.

39 of 76

Date

b.

DP30AF9

FIGURE 10 RING BUS (ONE BREAKER)

DP30AF10

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

40 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

FIGURE 11 RING BUS (ONE BREAKER) a. Preferred Layout for Expansion

b.

c.

DP30AF11

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

EXXON ENGINEERING

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

41 of 76

Date December, 1999

FIGURE 12 RING BUS WITH TWO PAIRS OF TRANSFORMERS (ONE BREAKER)

DP30AF12

FIGURE 13 RING BUS WITH TWO PAIRS OF TRANSFORMERS (TWO-THIRDS BREAKER)

DP30AF13

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

42 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

FIGURE 14 BREAKER AND HALF a. Preferred Layout For Expansion

b .

c .

DP30AF14

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

EXXON ENGINEERING

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

43 of 76

Date

FIGURE 15 DOUBLE BUS SINGLE BREAKER (ONE BREAKER)

DP30AF15

FIGURE 16 DOUBLE BUS DOUBLE BREAKER (TWO BREAKER)

DP30AF16

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

December, 1999

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

44 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

FIGURE 17 DOUBLE CIRCUIT TEE-OFF (NO BREAKER) a.

b.

DP30AF17

FIGURE 18 DOUBLE CIRCUIT TEE-OFF (THIRD OF A BREAKER)

DP30AF18

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

FIGURE 19 DOUBLE CIRCUIT TEE-OFF WITH TWO PAIRS OF TRANSFORMERS (THREE QUARTER BREAKER) Chatham Substation

Morristown Substation

DP30AF19

45 of 76

Date

Basking Ridge Shale

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

46 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

FIGURE 20 SYNCHRONIZING BUS BAR

Synchronizing Bus

Stub Bus

Stub Bus

Stub Bus

Notes: • No breakers connected to synchronizing bus which permits very high fault levels. • No isolators shown, as circuit breakers are at generation voltage which is low enough for metalclad not shown for clarity. switchgear which is withdrawable. Withdrawable feature DP30AF20

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

Stub Bus

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

47 of 76

Date December, 1999

APPENDIX A SAMPLE PLANNING DOCUMENTS SITE SURVEY QUESTIONNAIRE Power Supply Public Utility Power 1.

2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

14.

15. 16. 17.

Amounts available: kW. The following questions, 2 through 17, apply if the amount of public utility power available is sufficient to permit considering purchasing of power: Characteristics: Phase Hertz Volts What is the minimum and future maximum short circuit level MVA at the source and/or the plant? Provide a one-line diagram of the source showing equipment sizes/capacities, impedances, and short circuit ratings. Submit rate schedule, including any fuel adjustment or low power factor clauses, and present cost of fuel. Dependability (outages per year, length of outages, % voltage variation, frequency, magnitude and duration of voltage dips, etc., based on past records). What is the distance from plant limits to substation or substations from which utility would supply the power? How many feeders would utility install from substation or substations to the plant limits? What would be feeder characteristics as to construction method (underground or overhead) and insulation level? If two feeders are provided and carried overhead, would they be carried on separate poles? Would plant have exclusive use of feeder or feeders? If feeder voltage is too high for plant use, would the cost of this substation be borne by the utility or the plant? If refinery substation is provided, what would transformer characteristics be: a. Number and capacity of each. b. Method of operation (parallel or single). c. Internal connections. d. Grounding method. e. Impedance. What would substation characteristics be on basis of 11: a. Secondary bus operation (split or single bus). b. Secondary bus short circuit duty. c. Secondary bus voltage regulation. d. Metering and relaying. e. Number of feeder positions provided for refinery use. f. If load tap changing provided, number and range of taps. If voltage variation on secondary bus exceeds 5%, would utility provide voltage regulators or load tap changers? On what date could permanent power be available? Are there any limitations on imposing sudden loads on the utility system, such as starting a large motor or a group of motors after a voltage interruption?

General Electrical Information The following questions, 18 through 27, concern general electrical equipment and construction methods that are used. 18. What are normal voltages for the following equipment? a. Lighting. b. Small motors (below 200 hp). c. Large motors (up to 5000 hp). d. Large motors (above 5000 hp). 19. What are the local nominal standard secondary distribution voltages in the range of 380 volts to 36,000 volts? EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

48 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

APPENDIX A (Cont) 20. Applicable mandatory regulations or accepted practices and published data with respect to: a. Grounding methods. b. Use of explosion-proof equipment in hazardous areas. c. Circuit and equipment protection. d. Wiring, cable construction, etc. within hazardous areas. e. Safety precautions in general. f. Copies of any applicable safety codes. 21. Information on locally used wiring materials with respect to: a. Conduit types (i.e., galvanized, fiber, PVC, etc.) b. Standard conduit sizes and thread types. c. Cable insulation and sheath types. d. Conduit fittings. 22. Standard practice for underground cable installations: a. Construction method. b. Type of cable insulation. c. Standard conductor size. 23. Local power distribution equipment. a. What are the characteristics of locally used power transformers: 1) Voltage ratings and sizes in the 300 kVA to 10,000 kVA range? 2) Impedance of various sizes and ratings? b. What are characteristics of locally used switchgear: 1) Standard voltage ratings in the 380 volt to 36,000 volt range? 2) Continuous current, interrupting current, and momentary current ratings of various size circuit breakers? c. Information on protective relays used locally for switchgear: 1) Relay types (overcurrent, undervoltage, etc.). 2) Calibration curves on all relays showing time vs. current or voltage vs. time. Curves should show all available time characteristic types. 3) Data on relay amperage and voltage ranges. 4) Data on standard instrument transformer ratios. d. Information on motors. Should include the following: 1) Standard horsepower rating. 2) Voltage available. 3) Enclosures available. 4) Minimum speeds available for squirrel cage induction motors. 5) Limitations, if any, on full voltage starting. 6) Maximum size of explosion-proof (weather-proof) motors available. 7) Prices. 24. Regulations as to minimum allowable lighting intensities on streets and areas in a refinery? Is security lighting required? 25. Standard type of distribution used locally for street lighting circuits (i.e., low voltage parallel, high voltage series, etc.). 26. Will public utility provide power during construction? At what voltage? What quantity? What date? 27. Procure all available manufacturer's literature showing equipment available with prices.

QUESTIONNAIRE FOR PUBLIC UTILITY TO OBTAIN DEFINITIVE PLANNING DATA. The following provides a specific example of a questionnaire for a public utility company, requesting them to provide definitive data for a project that has reached the planning stage.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

49 of 76

Date December, 1999

APPENDIX A (Cont) BRIGHTON SYNTHETICS PLANT AND TROUP LIGNITE MINE. 1. 2. 3. 4. 5. 6. 7.

8. 9. 10. 11. 12. 13.

14. 15. 16.

17.

18.

19.

Schedule for implementation, including securing rights-of-way, construction of facilities, etc. Date when a firm load commitment is required in order to have power available for construction in 1995 and for plant / mine operation in 1998. Anticipated reliability of separate rights-of-way for the two incoming double-circuited lines. Confirmation that the supply will be looped in from the 138 kV Stryker - S. E. Tyler lines. Space requirements for the 138 kV substation proposed to supply load requirements shown in Table A-1. When can a proposed layout sketch be provided? Plan for supply of construction power requirements shown in Table A-1 beginning in 1995. Short circuit levels at the proposed Brighton 138 kV substation and the conditions under which they occur. a. Minimum. b. Maximum. c. Future maximum (if different than current switchgear short circuit rating). Utility system X/R ratio for the short circuit conditions in Item 7, above. MVA limitation for future load additions to the Brighton 138 kV substation. Details of the facilities which would be installed and owned by the utility. What other customers are served from the S. E. Tyler-Stryker 138 kV lines? Supply a one-line diagram of the utility system showing equipment capacities and impedances and the distances from generation sources to the Brighton 138 kV substation. Reliability data: Chronological listing of voltage interruptions on the S. E. Tyler-Stryker 138 kV lines and substations, including for each listing: a. Date of outage. b. Cause of outage. c. Length of outage. d. Frequency, magnitude and duration of voltage dips. Note: Data should cover most recent 5 years as a minimum. If not sufficient data on these circuits, please provide data on similar 138 kV circuits. Voltage regulation expected at the Brighton 138 kV substation. Frequency regulation expected on the 138 kV system. Circuit breaker operation at S. E. Tyler-Stryker substations. a. Reclosing practice. b. Single-pole switching operation. c. Relaying philosophy and settings. Are there any limitations on imposing sudden loads on utility system? a. Large motors. b. Draglines and other excavators. c. Automatic restarting of the plant by reaccelerating groups of motors following a voltage interruption. What utility standards will apply to the 138 kV facilities? a. 138 kV system grounding. b. Main transformer winding connections. c. Typical relaying for breaker-and-a-half configuration involving customer generation connected to 138 kV bus via unit transformers. d. Will metering be on primary or secondary side of main transformers? Would it be possible to have two sets of meters: one for the plant and one for the mine?

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

50 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

APPENDIX A (Cont) TABLE A-1 BRIGHTON SYNTHETICS PLANT AND TROUP LIGNITE MINE ELECTRICAL REQUIREMENTS The following planning design basis items are provided for the Brighton electrical system. This design has been based on the information obtained during the site survey, responses from the utility company to questionnaires, and on additional planning engineering for the project. 1. Transmission Voltage: 138,000 volts, three-phase. 2. Circuits: Two separate independent circuits. (Possibility exists of having each circuit on its own right-of-way). 3. Operational Power Requirements: The plant / mine complex will require power beginning the first quarter of 1998 with an ultimate capacity of 220 MW by 2008. The load growth profile is shown on Figure A-1. Included in this requirement is the base case operation of ultimately ten draglines, of which eight will be operating at any one time. A diversity factor of 70% was assumed for the operation of eight draglines. Figure A-1 also shows an alternate case for the mine using draglines and bucketwheels. 4.

Construction Power Requirements: Beginning in early 1995, construction power will be required with a maximum of 12 MW needed during 1998. Figure A-2 shows the load growth for construction power.

5.

Proposed Site information: The mine located in northeastern Sussex County with the proposed plant site roughly in its center. Utility access through the mine area is through the “western corridor" to the utility substation located near the Southwest corner of the proposed plant site. Substation Configuration and interface for Operational Power: A simplified one-line diagram of the utility substation is shown in Figure A-3. The utility company would be responsible for all materials and construction upstream of, but excluding, the four main 138 kV transformers. Space for expansion to two additional bays should be provided. Major equipment provided by the utility company would include: a. Two (2) three-phase 138 kV transmission circuits. b. Two (2) 138 kV dead-end structures with necessary switches, bussing, insulation, etc. c. Twelve (12) 138 kV three-pole oil circuit breakers, 1200 A continuous rating. d. Twenty-four (24) 138 kV three-pole disconnect switches. e. Four (4) sets of CTs per OCB, 2 on each OCB bushing for relaying. f. Four (4) 138 kV three-pole disconnect switches (motor operated) for transformers. g. Twelve (12) lightning arresters on the transformer primaries. h. Four (4) PTs, one on each transformer 138 kV line, and one on each mine area 138 kV line. Incoming line and 138 kV bus PTs will be specified by the utility.

6.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

51 of 76

Date December, 1999

APPENDIX A (Cont) FIGURE A-1 OPERATIONAL POWER REQUIREMENTS APPROXIMATE LOAD GROWTH PROFILE PROPOSED BRIGHTON SYNTHETICS PROJECT 220

200

Alternate Load Profiles (Based on Mine Operation of Draglines Plus Bucketwheels)

180

160

Electric Power, Megawatts

140

Instantaneous Peak Load

120

100

80

60

40 Maximum 15-Minute Demand

20

0

DP30AFA1

1998

1999

2000

2001

2002

2003

2004

2005

2006

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

2007

2008

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

52 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

APPENDIX A (Cont) FIGURE A-2 PEAK CONSTRUCTION POWER REQUIREMENTS APPROXIMATE LOAD GROWTH PROFILE PROPOSED BRIGHTON SYNTHETICS PROJECT 22

20

18

16

Electric Power, Megawatts

14

12

10

8

6

4

2

0

DP30AFA2

1994

1995

1996

1997

1998

1999

2000

2001

2002

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

2003

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A

53 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

APPENDIX A (Cont) FIGURE A-3 UTILITY SUBSTATION SIMPLIFIED ONE-LINE DIAGRAM PROPOSED BRIGHTON SYNTHETICS PROJECT

Exxon

S. E. Tyler 138 KV Supply

Utility Co.

Stryker 138 KV Supply

To Mine Area

Utility Co. 45/60/75/ MVA 138-13.2-13.2 KV

Typical of Four To Brighton Indoor Main Substation (Typ.)

Exxon

Legend Outdoor Oil Circuit Breaker Disconnect Switch Lightning Arrester

DP30AFA3

3-Winding Delta-Wye Power Transformer With Automatic On-Load Tap Changer

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

54 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

APPENDIX B SAMPLE DESIGN SPECIFICATION 94-1

EXXON RESEARCH AND ENGINEERING COMPANY TECHNOLOGY DEPARTMENT

DESIGN SPECIFICATION NO. 94-1 COVERING ELECTRICAL POWER FACILITIES FOR THE BURBANK FUELS PROJECT BURBANK REFINERY

CAUTIONARY NOTICE This specification contains technical information that is the property of Exxon Research and Engineering Company. It is furnished to the recipient strictly for use in connection with the unit concerned and is to be held proprietary. By: Joe Grouphead John Engineer

Date: July 29,1994

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

55 of 76

Date December, 1999

APPENDIX B (Cont) D.S. 94-1 BURBANK FUELS PROJECT DESIGN SPECIFICATION NO. 94-1 ELECTRIC POWER FACILITIES TABLE OF CONTENTS

GENERAL .............................................................................................................................................................................................3 SCOPE OF SPECIFICATION ................................................................................................................................................................3 DESIGN BASIS .....................................................................................................................................................................................3 CONTRACTOR RESPONSIBILITIES ....................................................................................................................................................3 CONTRACTOR WORK IN EXISTING SUBSTATIONS ..........................................................................................................................4 AREA CLASSIFICATION.......................................................................................................................................................................5 SECTION 1 - POWER SOURCE .......................................................................................................................................................100 SECTION 2 - DISTRIBUTION SYSTEM ............................................................................................................................................200 •

12 kV Feeders.........................................................................................................................................................................200

•

Main Switch House .................................................................................................................................................................200

•

New 480 V Substations 36 & 37..............................................................................................................................................200

•

New 480 V Substation 38........................................................................................................................................................200

SECTION 3 - LOAD DESCRIPTION ...........................................................................................................................................300-302 •

General ...................................................................................................................................................................................300

•

Table 3-1 Summary of Distribution Loads and Transformer Sizes ..........................................................................................300

•

Table 3-2 Substation Motor List..............................................................................................................................................301

SECTION 4 - PROTECTION AND CONTROL ............................................................................................................................400-402 •

General ...................................................................................................................................................................................400

•

Philosophy ..............................................................................................................................................................................400

•

Main Switch House .................................................................................................................................................................400

•

12 kV Feeders.........................................................................................................................................................................400

•

Utilization Substations.............................................................................................................................................................401

•

Transformer Protection ...........................................................................................................................................................401

•

Motor Protection......................................................................................................................................................................401

•

Substation Alarms and Metering .............................................................................................................................................402

SECTION 5 - MODIFICATIONS TO EXISTING FACILITIES..............................................................................................................500 •

General ...................................................................................................................................................................................500

•

Substations 3 & 30 ..................................................................................................................................................................500

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

56 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

APPENDIX B (Cont) D.S. 94-1 BURBANK FUELS PROJECT DESIGN SPECIFICATION NO. 94-1 ELECTRIC POWER FACILITIES TABLE OF CONTENTS (Cont)

SECTION 6 - EQUIPMENT......................................................................................................................................................... 600-601 •

General................................................................................................................................................................................... 600

•

New Substation Construction .................................................................................................................................................. 600

•

Programmable Controller ........................................................................................................................................................ 600

•

Variable Frequency Drive Units............................................................................................................................................... 601

•

Emergency Generator............................................................................................................................................................. 601

•

Generator Distribution Panel ................................................................................................................................................... 601

•

Generator Load Bank.............................................................................................................................................................. 601

SECTION 7 - LIGHTING AND COMMUNICATIONS.......................................................................................................................... 700 •

Lighting, Welding, and Convenience Outlets ........................................................................................................................... 700

•

Fiber Optic and Telephone Communications........................................................................................................................... 700

SECTION 8 - INSTRUMENT POWER SUPPLY ................................................................................................................................ 800 •

Instrument Power.................................................................................................................................................................... 800

•

Analyzer Systems ................................................................................................................................................................... 800

•

Emergency Diesel Generator .................................................................................................................................................. 800

SECTION 9 - SYSTEM STUDIES ...................................................................................................................................................... 900 SECTION 10 - DRAWINGS .................................................................................................................................................... 1000-1003 •

Electrical One-Line Diagram ................................................................................................................................................. 1001

•

Plot Plan - Existing and New Substations.............................................................................................................................. 1002

•

Instrumentation Power - Simplified One-Line Diagram .......................................................................................................... 1003

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

57 of 76

Date December, 1999

APPENDIX B (Cont)

Page 3 D.S. 94-1 BURBANK FUELS PROJECT DESIGN SPECIFICATION NO. 94-1 ELECTRIC POWER FACILITIES

GENERAL Any conflict between sections of this specification or between this specification and local codes shall be resolved with the Owner. SCOPE This specification covers the design requirements of the Electric Power Facilities for the Burbank Fuels Project (BFP). General Instructions and Information, Design Specification No. 94-99 also applies and should be considered an integral part of this specification. This specification is intended to supplement the information contained in Section 16 of the International Practices (IPs) and modifications in Section 16 of the Burbank Refinery Regional Practices (BRRP). DESIGN BASIS The electric power requirement of BFP, approximately 14 MVA, will be supplied by the local utility, PG&E, at 230 kV via the existing refinery 230/12.47 kV main transformers and 12 kV distribution system. No modification to the PG&E facilities is required. The existing 12 kV main switch house has been expanded prior to BFP by a “Third 12 kV Main Feeder Project” which is outside the scope of this Specification. New medium voltage onsite loads will be supplied from existing Substation H, which is located south of the new process block. Two new low voltage Substations (36 and 37) will be housed in a common building to be constructed in the northeast side of the Clean Fuels process block, and will supply the new onsite low voltage loads. (See attached Plot Plan, Page 1002.) New and uprated hydrogen plant LV loads will be supplied from new Substation 38 which will be built on the north side of the hydrogen plant block. Offsite loads will be supplied by way of expansions to existing substation. CONTRACTOR RESPONSIBILITIES The Contractor shall purchase and install all electrical facilities required for BFP. The Contractor’s scope of work for the project shall include, but not be limited to, the following: •

The three new distribution substations (36, 37 and 38).

•

Modifications to existing IPs; utilization Substations H, 3, 9, 10, 16, 29, 30, and related downstream electrical equipment.

•

•

Relay coordination of the 12 kV and downstream facilities including: -

PG&E interface relaying (if required).

-

12 kV substation feeders to the new substations.

Relay coordination study update for all existing utilization substations where Contractor makes load additions or modifications, including the Emergency Diesel Generator.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

58 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

APPENDIX B (Cont)

Page 4 D.S. 94-1

•

Computer studies of the complete Refinery electrical system. Only the portion affected by the Fuels Project needs to be analyzed in detail, however, the existing refinery must be modeled. -

Load flow and motor reacceleration.

-

Short circuit.

-

Dynamic simulations (motor starting/transient stability) for C-302D (response to PG&E faults, etc.).

•

Overall area classification drawings.

•

Decommissioning and physical removal of existing 175 kW emergency STG.

•

Installation and tie-in of new emergency diesel-generator.

•

Instrument power distribution, including fuse coordination.

•

Connection of all project substation alarms and metering.

•

All construction power required for the project including cooling, heating, and lighting in Contractor areas and Exxon PMT offices.

•

Control and interlocking circuitry required by electrical drives.

•

Facilities required for normal and emergency area lighting.

•

All field investigations necessary to check the tie-in points, verify the feasibility of his design, and obtain any additional information.

•

Coordination of the construction work program with operation of existing facilities including scheduling of shut downs required to complete the job. A schedule shall be submitted for Owner’s approval.

CONTRACTOR WORK IN EXISTING SUBSTATIONS The following is a brief outline of work in and around existing refinery substations. The list is not meant to be comprehensive, but is provided here to give the Contractor a feel for field construction requirements and the Refinery procedures that must be followed. Upon request, the Owner will provide the Contractor with detailed work requirements for carrying out electrical work in and around existing substations. •

Schedule with Contractors estimate of time required to complete each stage of the work, including the estimated time the substation must operate single-ended and the time required for MCC outages.

•

Complete, detailed list of equipment to be modified and new equipment to be added. Contractor shall coordinate work such that all new equipment is assembled before starting an outage.

•

One-line diagram marked up to show the proposed work.

•

Complete set of construction drawings for work to be done in that substation.

•

When an outage of a power bus is necessary, a list of all existing operating equipment that could be affected by the outage.

These packages shall be submitted to the Owner for review at least four (4) weeks prior to the scheduled start of the work. Refinery safety practices must be followed for all work and Contractor’s personnel must be familiar with the Refinery electrical safety practices. The Refinery electrical work permit system is in effect when the Contractor is performing work in the refinery. AREA CLASSIFICATION Contractor shall prepare an area classification study in accordance with BRRP 16-1-1 for the new facilities. Equipment installed within existing units can be added to existing Unit Area Classification Drawings.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

59 of 76

Date December, 1999

APPENDIX B (Cont)

Page 100 D.S. 94-1 SECTION NO. 1 POWER SOURCE

The 230 kV PG&E substation supplies power to the refinery via three, refinery-owned, 230/12 kV transformers; a short length of doublecircuit underground cable; and a three-circuit, three conductor-per-phase, overhead line section which feeds the refinery 12 kV switch house. Except for remote areas (pier and waste water treatment plant), the entire plant is supplied from the 12 kV switch house. The transformers are rated 30/40/50 MVA (OA/FA/FA). The two incoming transformers/circuits have sufficient capacity to supply the entire plant load, including the BFP loads. The main switch house is provided with a 12 kV automatic transfer scheme to assure continuity of supply to the three main switchgear busses in the event of loss of one incoming feeder or transformer. The present three-phase symmetrical short circuit level at the PG&E 230 kV bus is 9,118 amperes with both incoming circuits in service and a minimum of 4,337 A when fed from a single 230 kV circuit. The 12 kV transformers are connected delta-wye with the neutral point grounded via an 800 A resistor. Backup power for critical loads will be supplied by a new emergency diesel-generator, in conjunction with the existing UPS system. Both are covered in Sections 600 and 800 of this specification.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

60 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

APPENDIX B (Cont)

Page 200 D.S. 94-1 SECTION NO. 2 DISTRIBUTION SYSTEM

Refer to the attached one-line drawing, Page 1001, which illustrates the new electrical distribution facilities to be installed as part of BFP. Approximate geographical locations of the substations are shown on the attached plot plan, Page 1002. 12 kV FEEDERS Contractor shall design the cable routing for the new 12 kV feeder to C-302D, as well as extensions or modifications to existing 12 kV circuits. Power cables shall be installed using direct burial methods as detailed in BRRP 16-3-1. MAIN SWITCH HOUSE One new 12 kV circuit breaker, appropriate auxiliary panel, and field excitation equipment shall be installed in the existing main switch house to supply the new hydrogen compressor C-302D. An empty breaker cubicle has been installed for this purpose by the Third 12 kV Main Feeder project. The cubicle contains the necessary fixed parts of the switchgear such that it will not be necessary to de-energize the main bus to connect the new motor. An additional cubicle for C-302D field excitation equipment shall be installed, if required. A new 12 kV power cable shall be installed from the new 12 kV breaker along 10th Street to the motor. A captive transformer, if used, will be located near the compressor motor, in the hydrogen plant block. Excitation and control cabling shall be installed as required. Digital and analog signals from the new breaker shall be connected tot he existing PLC monitoring system. NEW 480 V SUBSTATIONS 36 & 37 Two new grass roots 480 V low voltage substations will be built for the onsites portion of the project. Both substations will be located in a common building located near existing Substation 24 (see attached Plot Plan). 15 kV rated, transformer feeder cables will be extended from existing Substation 29 to supply these new substations. Load assignments for services to be supplied from these substations are shown in Section 3 of this specification. Certain of these loads may require over-sized feeder cables to meet BRRP voltage drop requirements. One turnaround power center (TAPC) will be built in the Substation 36/37 building and shall be supplied from Substation 36, with a “backup” feeder from existing Substation 11. NEW 480 V SUBSTATION 38 A new 480 V LV substation will be built north of the existing hydrogen plants, between existing Substations 9 & 10. The 12 kV feeder cables from the main switch house to existing Substation 29 run along 10th Street past the location of new Sub 38. These cables will be redirected “through” the new Sub 38 location so that these feeders “9” and “10” supply new Sub 38, existing Sub 29, new Sub 36 and new Sub 37, in that order. A turnaround power center will be built in the Sub 38 building and shall be supplied from Substation 38, with a “backup” feeder from existing Substation 9.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

61 of 76

Date December, 1999

APPENDIX B (Cont)

Page 300 D.S. 94-1 SECTION NO. 3 LOAD DESCRIPTION

GENERAL Table 3-1 summarizes the electrical loads expected on the new substations reflecting a 5% load growth factor for process loads. Substation designations, voltage levels, and transformer sizes are shown. Table 3-2 lists the individual loads for each substation, including replacements for existing loads in existing substations. The design specification number, service, duty, estimated operating kW, and reacceleration requirements are also shown.

TABLE 3-1 SUMMARY OF DISTRIBUTION LOADS AND TRANSFORMER SIZES

Substation Designation

Nominal Voltage (V)

Design (kW)(2)

Total kVA(1)

Transformer kVA (OA)

S/S 36

480

910

1138

1500

S/S 37

480

965

1206

1500

S/S 38

480

277

345

1000(3)

Notes: (1)

Total kVA based on 0.8 power factor 480 V loads.

(2)

Design kW reflects Onsite D.S. operating load multiplied by a load growth factor of 1.05.

(3)

Minimum transformer size for 480 substations is 1000 kVA per BRRPs.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

62 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

APPENDIX B (Cont)

Page 301 D.S. 94-1 SECTION NO. 3 (Cont) LOAD DESCRIPTION

TABLE 3-2 SUBSTATION MOTOR LIST (Typical: Not all substations are shown in sample, but should be included in actual Design Specification) Main Switch House (12 kV) D.S.

Number

Service

Duty

D.S. kW

Reacc

94-18

C-302D

Hydrogen

N

7814

C

D.S.

Number

Service

Duty

D.S. kW

Reacc

94-23 94-23 94-13 94-13 94-14 94-21 94-21

C-1704A/B P-1864A/B P-4409A/B P-4421A/B P-4441A/B P-4460A/B B-4460

Refrigeration Tank Blending HCN T90 Distillate HSU Feed LCN Feed Hot Oil Circulation Hot Oil ID Fan

N/I N/S N/S N/S N/S 2N/S N

270 185 170 148 352 649 140

A C A A A A A

Substation H (4.16 kV)

Total (Incl. LGF)

2,010 Substation 36 (480)

D.S.

Number

Service

Duty

D.S. kW

Reacc

94-21 94-12 94-12 94-12 94-12 94-21 94-12 94-12 94-12 94-12 94-12 94-12 94-12 94-21 94-22

B-4701A/B E-4404A/B E-4414A E-4414B E-4416A/B E-4460 E-4403A-V P-4401A/B P-4403A/B P-4408A/B P-4410A/B P-4411A/B P-4412 P-4461 P-4471A

TAPC NH3 Air Inject. (ven. pkg) Heartcut SS Cooler HCN T90 Cond. HCN T90 Cond. (VFD) HCN T90 Bottoms Cooler Hot Oil Cooler Heartcut Condenser Heartcut Reflux/Distillate Heartcut Bottoms HCN T90 Reflux HCN T90 Bottoms H/C Feed C5/C6 Split Dist. to H2 Plant Hot Oil Inventory MRU Slop Oil Pump

I N/S 2N N N 2N I 22N N/S N/S N/S N/S N/S N I I

50 5 21 22 22 22 7 460 70 17 5 30 55 31 19 31

C B A A A A C A A A A A A A C C

Total (Incl. LGF)

910

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

63 of 76

Date December, 1999

APPENDIX B (Cont)

Page 302 D.S. 94-1 SECTION NO. 3 (Cont) LOAD DESCRIPTION

Notes for Table 3-2: (1)

Duties: N = Normal, S = Spare, I = Intermittent

(2)

Electric power requirements for new equipment are estimated. Final values are to be determined by the Contractor.

(3)

Reacceleration requirements: A = Necessary, B = Desirable, C = Unnecessary (or non-applicable).

(4)

D.S. kW shown in each line is the total Normal Operating Load from the referenced D.S. Individual operating loads are the load shown divided by the number of normally-running motors.

(5)

Load summations, where shown, include a Load Growth Factor (LGF) of 1.05 for Onsite loads and OM&S.

(6)

Number of exchanger and condenser drivers have been estimated. Actual equipment may differ.

(7)

Replacements for existing equipment are indicated by an asterisk (*) after the equipment number.

(8)

Restart, if any, determined by compressor controls. Compressor itself is not reaccelerated.

(9)

Load split between Subs 36 and 37 based on flare loading considerations and should not be changed without consulting Owner’s Safety Engineer.

(10)

MOV load for planning purposes. Exact size to be determined by detailed engineering.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

64 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

APPENDIX B (Cont)

Page 400 D.S. 94-1 SECTION NO. 4 PROTECTION AND CONTROL

GENERAL Contractor shall perform relay coordination studies for all electrical facilities installed with the project. Contractor shall review the relay coordination requirements of all substations where a design change is made. Contractor shall verify that the results meet the requirements of BRRP 16-2-1 and this specification. Contractor shall furnish the Owner with relay data for each adjustable relay or other protective device on the same relay forms used at present by the Owner. Contractor shall provide, install, and set all the relays required in the different substations. Contractor shall provide, install, and terminate the required control wiring from the 12 kV main switch house to the new Substations 36, 37, and 38. Contractor will verify functioning of the control circuits. Description of relay protection contained in this section is intended to compliment the requirements of BRRP 16-2-1. Details of existing relay types and settings records are available from the Owner. PHILOSOPHY The protective relaying scheme described in the subsequent sections features conventional circuit breaker, selective tripping, and automatic transfer circuitry in accordance with the standard Exxon secondary-selective automatic-transfer design. A new 12 kV power cable shall be installed from the new 12 kV breaker along 10th Street to the motor. A captive transformer, if used, will be located near the compressor motor, in the hydrogen plant block. Excitation and control cabling shall be installed as required. Digital and analog signals from the new breaker shall be connected to the existing PLC monitoring system. MAIN SWITCH HOUSE The main 12 kV switch house is secondary-selective and equipped with automatic-transfer circuitry activated by inter-tripping with the utility’s 230 kV substation supply breakers. Protection for bus faults consists of three 50/51 relays on the incoming feeders. The 51 relay and the automatic transfer blocking relay 50 have been set as described in the substation protective relaying section. 12 kV FEEDERS The 12 kV feeders leaving the main substation are bifurcated to supply downstream secondary-selective and some radial substations, including the new substations being added by the Contractor. The 12 kV feeders are to be protected against phase and ground faults by instantaneous and time delayed overcurrent relays as follows: •

Phase fault protection consists of three instantaneous and time delay overcurrent relays 50/51 connected to trip the 12 kV feeder breaker. The 50 relays are set above the maximum transformer secondary asymmetrical fault current on the largest transformer and above the sum of magnetizing inrush currents of all connected transformers. The 51 feeder relays are set to coordinate with the transformer secondary 51 relays but not necessarily with transformer primary 51 relays. The minimum pickup of the 51 relays is 1.25 times the FA rating of all connected transformers.

•

Ground fault protection consists of a residually-connected 51N relay. The 51N relay shall be set high enough to avoid false operation caused by current transformer unbalance during maximum inrush conditions.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

65 of 76

Date December, 1999

APPENDIX B (Cont)

Page 401 D.S. 94-1 SECTION NO. 4 (Cont) PROTECTION AND CONTROL

Backup protection for tapped feeders is provided by the main Substation 51 relays on the incoming 12 kV feeders. Any required changes to the protective relays scheme described above shall be brought to the attention of the Owner. Contractor shall review the setting ranges of the protective relaying installed, and propose to the Owner any modifications that are considered necessary for correct coordination of relaying in the system. UTILIZATION SUBSTATIONS The new secondary-selective Substations 36, 37, and 38 shall be equipped with automatic-transfer circuitry per BRRP 16-12-2. Inter-tripping with the main switch house 12 kV feeder breakers shall be provided. The substations shall be protected against phase and ground faults by overcurrent relays, as follows: •

Phase overcurrent protection shall consist of 50/51 and 50N/51N relays on the incoming feeders. The transfer blocking relay 50 should ideally block transfer for all values of fault current that would pick up the under-voltage transfer relay 27. However, the 50 relay must be set above the motor back feed so as not to block transfer for faults on the transformer secondary bus duct. The 51 relay shall coordinate with the highest set outgoing feeder phase fault protection and shall be set to provide transformer through fault protection. The relays shall be set to permit successive groups of motors to reaccelerate without tripping the main incoming breaker. This may require setting the pick-up of the 51 relay above the maximum reaccelerating current of the substation. The 51 relay should preferably be set to coordinate with the 27 relay such that the 51 relay operates before the 27 relay initiates transfer.

•

Secondary-selective substations shall have ground fault relaying consisting of a 50N/51N relay on each incoming feeder. The 51N relay shall be set to coordinate with the outgoing feeder ground fault protection. The 51N relay shall be set no lower than 10% of the available ground fault current. The 50N relay is used for transfer blocking and can usually be set on its minimum tap but at least 10% below.

TRANSFORMER PROTECTION Transformers supplying secondary-selective substations shall have the following protective relays: •

Transformers fed from tapped feeders, and having a rating too small to be adequately protected by the 12 kV feeder relays as defined in BRRP 16-2-1, shall be protected by time delayed overcurrent relays 51 driven from current transformers located on the transformer primary bushings. These relays shall coordinate with the secondary breaker phase fault relays.

•

Each transformer 500 kVA and larger shall be provided with a sudden pressure relay, device 63, connected to trip the main substation feeder breaker via the 86T relay.

•

Medium voltage (4.16 kV) transformers have their secondaries low resistance grounded and shall have a time delay ground overcurrent 51G relay connected in the neutral ground connection. The 51G relay shall coordinate with the 51N relay on the substation incoming feeder.

•

Low voltage transformers (480 V) are solidly grounded, and shall have a time delay ground overcurrent 51G relay in the neutral. The 51G relay shall coordinate with 51N relay on the transformer secondary breaker.

MOTOR PROTECTION Low and medium voltage motor protection shall be as detailed in the BRRPs. Motor control equipment shall be provided with reacceleration provisions required for the reacceleration categories listed in Table 3-2. Type of reacceleration relays and motor control circuitry shall be reviewed with Owner prior to placing the equipment order. Contractor shall be responsible for the overall reacceleration system and shall provide all data to the Owner. Section 600 of this specification covers the PLC control for reaccelerated loads supplied from new Substations 36 & 37.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

66 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

APPENDIX B (Cont)

Page 402 D.S. 94-1 SECTION NO. 4 (Cont) PROTECTION AND CONTROL

SUBSTATION ALARMS AND METERING Contractor shall be responsible for providing and installing all the equipment in the substations required for metering and substation alarms. Contractor shall install circuits from the new substation building for transmission of common substation alarms to the control center. Contractor shall terminate the wiring on the terminal strips for further connection by the in-house Contractor. The substation alarms required are detailed in BRRP 16-2-1.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

67 of 76

Date December, 1999

APPENDIX B (Cont)

Page 500 D.S. 94-1 SECTION NO. 5 MODIFICATIONS TO EXISTING FACILITIES

GENERAL The new Substations 36 and 37 shall be supplied from existing 12 kV main switch house. The project also includes other new medium and low voltage loads, and reused existing electrical drives, that shall be supplied from other existing substations. These existing substations include: H (4.16 kV), 3 (480 V), 9 (480 V), 10 (480 V), 16 (480 V), 21 (480 V), 29 (480 V), 30 (480 V), and others a may be required during the development of the project. Contractor has complete responsibility for the design, field construction, and testing of all modifications to existing facilities as specified herein. Owner believes that sufficient physical space exists in the above substations for the proposed additional loads. However, Contractor shall be responsible for investigating the spare compartments and space in the above-mentioned substations. In most cases, additional vertical sections will be required. In the case of older gear, transition sections will be required to interface to new equipment. Where transition sections are required, a “top hat” type construction shall be used, if available from the manufacturer. Contractor shall be responsible for sizing starters and insuring that each service is provided with the proper protection meeting the guidelines and requirements of the job specification and as specified herein. Contractor shall coordinate with the Owner all substation investigation work, and shall obtain Owner’s agreement for any proposal to re-assign services should this be deemed beneficial. Unless otherwise directed by the Owner, existing installed spare starters are not to be used for BFP although vacant spaces in MCCs may be reclaimed if not presently designated for a specific use. Contractor shall check with the Owner prior to planning the use of any existing equipment. SUBSTATIONS 3 & 30 Existing loads P-707A/B/C shall be removed from Substation 3 and shall be supplied from Substation 30. These services shall utilize cables and motor starters which have been previously installed as existing Substation 30 for this purpose.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

POWER SOURCES

Page

XXX-A

ELECTRIC POWER FACILITIES

68 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

APPENDIX B (Cont)

Page 600 D.S. 94-1 SECTION NO. 6 EQUIPMENT

GENERAL Technical acceptance of equipment is based on meeting the requirements of the Job Specification, the BRRPs, and the applicable design specifications. Because of the detail contained in the above documents, the subsections on various major equipment items usually contained in Section 6 of this specification have been eliminated. In cases where requirements are not specifically covered in the Job Specification, Contractor shall consult with the Owner for the purpose of judging the technical acceptability of the equipment in question. Outdoor electrical equipment shall be designed for service industrial environment. POWER CABLES All 12 kV feeder cables shall be paper-insulated, lead-covered type, rated for 15 kV operation. BRRP 16-3-1 provides details on cable construction for 4160 V and 480 V cables. NEW SUBSTATION CONSTRUCTION New substations built for the project will be evaluated-type buildings constructed in such a way to be able to accept direct buried power and control cables entering through the floor. The building construction shall match the existing Burbank standard design that is basically a concrete floor/foundation with an insulated, metal-enclosed building mounted on it. Package substations with steel floors mounted on concrete piers are also acceptable. Details of this type of construction are contained in BRRP 16-2-1. Because of the corrosive nature of exhaust products from the near-by Tail Gas/Stretford Units, consideration shall be given to using aluminum conduit, aluminum or fiberglass boxes, and filtered air for Substations 36 & 37 in the new process block. Contractor shall review his proposed methods/designs with the Owner prior to finalizing the design. PROGRAMMABLE CONTROLLER Motor reacceleration in Substations 36 & 37 shall be performed by a Programmable Logic Controller (PLC) system using software already designed and tested by Exxon. Provisions in the PLC wiring shall be provided for future control of the substation’s automatic transfer feature. Requirements for the PLC/switchgear interface are outlined in sample Specification No. 1583. The PLC will be integrated with the switchgear and MCCs in the substation vendor’s plant and tested before shipment to site. Substation 38, due to its small size and location in the existing plant area, shall utilize hardware control logic for reacceleration and automatic transfer. VARIABLE FREUENCY DRIVE UNITS Process design specifications have designated certain air-cooled heat exchangers whose motor drives shall be controlled by variable frequency drive (VFD) units. All VFD units shall be located in the substation building containing the MCC equipment supplying the motors. All VFDs shall be provided with a manual bypass feature so that the VFD unit can be maintained while the motor remains in service on fixed speed. It will not be necessary for the bypass to be made with the motor running; de-energized switching is sufficient.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

69 of 76

Date December, 1999

APPENDIX B (Cont)

Page 601 D.S. 94-1 SECTION NO. 6 (Cont) MODIFICATIONS TO EXISTING FACILITIES

In the interest of proper converter cooling, and to allow for maintenance, it is expected that the VFD units will be one-high design and mounting. If another philosophy is proposed, Contractor shall demonstrate that the units will be properly cooled, and that maintenance of one unit can be safely performed, with other units in service. EMERGENCY GENERATOR In addition to the IPs and BRRPs, the following references shall be used when preparing the Emergency Generator purchase specification. •

NFPA 37, Stationary Combustion Engines and Gas Turbines

•

NFPA 110, Emergency Standby Power Systems

•

NFPA 110-A, Stored Electrical Energy, Emergency, and Standby Power Systems

Emergency generator shall be brushless, a-c synchronous type, self-cooled, and enclosed in a fully guarded housing suitable for the environment specified. The stator winding configuration, voltage, and number of phases shall be as specified. Total harmonic distortion shall be less than 5 percent. The vendor shall specify the capabilities of the generator and its excitation system, while under automatic voltage regular control, for the following: •

The percent of generator rated current that can be maintained for a minimum of two seconds for any type of short circuit at the generator terminals.

•

The percent of generator rated current that can be maintained for a minimum of 30 seconds when supplying a load with a power factor of 20 percent lagging.

Voltage regulation shall be by means of an electronic regulator, preferably installed in the generator control panel. Generator instruments, controls, and indicators, readily accessible for maintenance and identified with permanently affixed engraved nameplates, are required as follows: •

Output voltmeter and ammeter (with phase selector switches if three-phase).

•

Frequency meter with high and low alarm contacts.

•

Generator output voltage control adjuster.

•

Battery charger, d-c voltmeter, and ammeter.

•

Alarm annunciator.

GENERATOR DISTRIBUTION PANEL A 480 V generator distribution panel shall be installed in the new generator building. It shall be in a separate room from the diesel-generator. The MCC shall have two vertical sections initially, with building space provided for expansion to a total of 4 vertical sections. The 480 V circuit breaker used to supply the generator load resistor shall be in addition to the above requirements and may be included in the same line-up. The building shall also be sized to accommodate the future installation of two ASCO automatic transfer switches, in addition to the controls and panel(s) required for the new generator. GENERATOR LOAD BANK A load bank shall be permanently installed in the generator building, to be used for periodic exercising of the diesel generator. This load bank shall be capable of loading the generator to its full nameplate rating for at least one hour. In consideration of the heat produced, the load resistor may need to be mounted in a separately ventilated room or shelter. The Contractor shall review his preliminary design with the Owner. The design shall be submitted for Owner’s approval, prior to finalizing construction details.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

70 of 76

Date December, 1999

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON ENGINEERING

APPENDIX B (Cont)

Page 700 D.S. 94-1 SECTION NO. 7 LIGHTING AND COMMUNICATIONS

LIGHTING, WELDING, AND CONVENIENCE OUTLETS Lighting for the new Fuels unit shall be supplied at 480 volts from the new Substation 36/37 turnaround power center, TAPC. Lighting contactor(s) with Hand-Off-Auto switch shall be mounted in the substation and shall supply the unit lighting at 480 volts directly. In addition to the normal 60 A welding receptacles required by the International Practices, two 200 A welding receptacles shall be supplied; one at each end of the new Fuels unit. Contractor shall make note of the requirements of BRRP 16-2-1. Field convenience outlets shall be powered from transformer supplied 120/240 V panel boards, both of which will be mounted in the Fuels unit process block. Power supply for this transformer shall be from the TAPC located in Substation 36/37. FIBER OPTIC AND TELEPHONE COMMUNICATIONS A fiber optic and telephone communications shall be installed in each new substation. A telephone and circuit for a computer terminal shall be installed in the operator’s shelter that will be built near new Substation 36/37. Fiber optic cables shall be extended to new Substation 36/37 from a junction box near existing Substation 11, and to new Substation 38 from existing Substation 9. A fiber optic/coax cable termination cabinet shall be installed in new Substations 36/37 and 38.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

71 of 76

Date December, 1999

APPENDIX B (Cont)

Page 800 D.S. 94-1 SECTION NO. 8 INSTRUMENT POWER SUPPLY

INSTRUMENT POWER Two 120/208 V, 3-phase UPS panel boards shall be installed in the new Fuels Unit to supply the instrument power requirements of the onsite area. One panel board shall be supplied at 480 V from UPS No. 1 in the Control House and the other panel board from UPS No. 2, also in the Control House. Critical instrument loads that require normal and backup power shall be supplied, one from UPS No. 1 and the other from UPS No. 2. Other critical instrument loads not requiring backup shall have their supplies balanced equally from UPS No. 1 and UPS No. 2, consistent with the existing distribution scheme. Non-UPS instrument loads, such as the advanced process managers (APMs), shall be fed from either of two existing panels, 51 PL-EH or 51 PL-EJ, located in the Annex Room of the Control House. The Contractor shall investigate the voltage tolerance of this equipment and reconcile his design with the expected voltage drop during the starting of C-302D connected to Main Switch House 12 kV Bus 1 and, if necessary, shall install the hardware required to provide regulated power to the instrumentation. ANALYZER SYSTEMS A Continuous Emissions Monitoring (CEM) System and Stack Gas Analyzer (for F-446) require instrument power as well as lighting and utility outlets. Refer to D.S. 94-19. EMERGENCY DIESEL-GENERATOR To supply incremental power requirements of the Fuels Unit and improve reliability of power supply to the Control Center, the existing 175 kW steam-driven emergency generator shall be replaced with a 500 kW diesel-generator. Refer to Page 1003 of this specification for the simplified instrumentation power one-line diagram that provides general guidance on the new generator power distribution arrangement. A new building is required to house the generator and associated 480 V generator distribution panel. The generator building shall be located northeast of existing Substation 12, adjacent to the existing Substation 12 building. The new 480 V distribution panel will be located in the generator building but in a separate room from the generator. The generator shall start automatically upon loss of normal power supply to Substation 12, picking up the loads served from existing distribution panels MCC 12-4-1 and MCC 12-4-2. The present feeder from MCC 12-4-1 and 12-4-2 to the existing emergency generator shall be re-routed and extended to the new generator distribution panel. Requirements for the new generator are provided in Section 6 of this specification. The Contractor shall use this information to prepare a detailed purchase specification for the Owner’s review. The new generator distribution panel and load resister are also specified in this section. All existing functions presently available on the mimic panel in the UPS Room for the existing generator shall be maintained for the new emergency diesel-generator.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

DESIGN PRACTICES Section

ELECTRIC POWER FACILITIES

POWER SOURCES

Page

XXX-A

72 of 76

Date

PROPRIETARY INFORMATION - For Authorized Company Use Only

December, 1999

EXXON ENGINEERING

APPENDIX B (Cont)

Page 900 D.S. 94-1 SECTION NO. 9 SYSTEMS STUDIES

The Contractor shall perform a computer analysis of the overall BCP electrical system including effects on electrical facilities in the existing plant. Load flow, short circuit, and motor starting analysis for C-302D shall be done using SKM Dapper program. The analysis required for the project includes the following: •

Load flow study.

•

Short circuit study.

•

Motor re-acceleration study (using ER&E Computer Program 3317, MAGNET).

•

Motor starting analysis for C-302D.

•

Dynamic simulation for C-302D (stability, transient torque, etc., using MAGNET).

•

12 kV Bus 1 voltage drop, when starting C-302D, and its effect on instrument loads.

The Contractor shall provide the Owner with all the data related to the electrical facilities that are required to perform the computer studies. These data shall include the following: •

One-line diagram complete with all the information required by BRRP 16-2-1, Paragraph 3.1.

•

Transformer data:

•

•

•

•

-

kVA rating.

-

%R and %X on transformer kVA base.

-

Rated primary and no load secondary voltage.

-

Tap size in % of primary voltage.

-

Number of positive/negative tap steps.

Switchgear data: -

Nominal voltage rating.

-

Bus continuous current rating.

-

Circuit breaker continuous current rating.

-

Circuit breaker short circuit momentary and interrupting ratings.

Motor control center data: -

Same as switchgear data.

-

Listing of all motors and static loads supplied from each MCC.

Motor feed cables: -

Number of conductors per phase.

-

Conductor size and capacity.

-

Short circuit rating.

-

Length in kilometers and AC resistance in ohm/kft.

-

Reactance at 60 hertz in ohm/ft.

Motor data: -

Rated voltage.

-

Rated kVA.

-

Rated power factor.

The Contractor shall provide the Owner with the computer study results. The Contractor is responsible for the proper engineering of the electrical facilities to meet system design and operating requirements determined by the computer studies. The Contractor shall verify that the correct input data has been used and that the results are acceptable.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

ELECTRIC POWER FACILITIES

POWER SOURCES EXXON ENGINEERING

DESIGN PRACTICES Section

Page

XXX-A PROPRIETARY INFORMATION - For Authorized Company Use Only

73 of 76

Date December, 1999

APPENDIX B (Cont)

Page 1000 D.S. 94-1 SECTION NO. 10 DRAWINGS

The drawings contained in this Design Specification are intended to specify the intent of the electrical system design. Sizes shown are preliminary and must be confirmed by the Contractor except where, and equipment size is specifically stated in this specification to be the required size for the reason given. Burbank drawings referenced in this specification, and other drawings required for the Contractor’s detailed design, are available from the Owner.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J.

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J. New Substation 37

JULY 29,1994

SIMPLIFIED ONE-LINE DIAGRAM BURBANK FUELS PROJECT

EXXON RESEARCH AND ENGINEERING CO.

PROPRIETARY INFORMATION - For Authorized Company Use Only

1000 /1750kVA 480 V

Substation 16 1000 kVA 480 kV

POWER SOURCES

12 kV Cable Splice

Existing Facilities New Equipment

New Substation 36 From SS 11

TAPC

1000 /1750kVA 480 V

Existing Substation 29

1000 /1150kVA 480 V

Substation 24 1000 kVA 480 kV

Substation 27 1000 kVA 480 kV

74 of 76

DP30AP1

Legend

Substation 4 1000 kVA 480 kV

Substation 3 1000 kVA 480 kV

New Substation 38 From SS 9

Substation H 7500 kVA 4.16 kV

FDR 3

12kV

December, 1999

TAPC

1000 /1150kVA 480V

FDR 10

BUS 3

Page

Substation 6 1000 kVA 480 kV

Substation 1 1000 kVA 480 kV

FDR 4

12kV

Date

C-302D

M

FDR 9

BUS 2

XXX-A

BUS 1

PAGE 1001 D.S. 94-1

Section

12kV

MAIN SWITCH HOUSE

DESIGN PRACTICES ELECTRIC POWER FACILITIES EXXON ENGINEERING

5th St Sub #3

Sub #4

Substations H & #27

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J. 10th St

JULY 29,1994

PLOT PLAN EXISTING AND NEW SUBSTATIONS BURBANK FUELS PROJECT

XXX-A

DP30AP2

Main Switch House

Substations #1

Avenue G

Substations #9

New Sub #38

Substations #10

PROPRIETARY INFORMATION - For Authorized Company Use Only

EXXON RESEARCH AND ENGINEERING CO.

H2 Plant

New Emerg Gen Loc Sub #12

Existing UPS Gen

Section

ONLY SUBSTATIONS MENTHIONED IN DS 94-1 SHOWN

Sub K

Sub #6

Substations #29

Sub #11

Control House

POWER SOURCES

NOTES: THIS DRAWING SHOWS APPROX. LOCATIONS ONLY CONTRACTOR TO VERIFY

100 Ft.

Scale

Sub #16

Fuels Process Area New Substation #36 & #37 Shelter Substations #24

8th St

Avenue J

9th St

EXXON ENGINEERING

4th St

PAGE 1002 D.S. 94-1

ELECTRIC POWER FACILITIES DESIGN PRACTICES Page

Date 75 of 76

December, 1999

EXXON RESEARCH AND ENGINEERING COMPANY - FLORHAM PARK, N.J. ~ UPS No.1

~

480V

UPS No.2

Static Switch

~

~

JULY 29,1994

SIMPLIFIED ONE-LINE DIAGRAM INSTRUMENT POWER SUPPLY BURBANK FUELS PROJECT

EXXON RESEARCH AND ENGINEERING CO.

480-120/208V

MCC 12-4-1

PROPRIETARY INFORMATION - For Authorized Company Use Only

120/208V PNL 51PL-E

~

PNL 51PL-F

~

=

=

BUS 1

POWER SOURCES

120/208V PNL 51PL-E

~

PNL 51PLD

~

=

Static Switch

~

480 V

76 of 76

DP30AP3

480V

ALL EQUIPMENT SHOWN IS LOCATED IN CONTROL HOUSE INVERTER ROOM EXCEPT AS NOTED.

SEE DESCRIPTION IN SECTION 8 OF THIS SPECIFICATION FOR DETAILS OF THE UPS SYSTEM

=

BUS 2

December, 1999

~

480 V

~ ~ Future

Date

NO DISTINCTION MADE BETWEEN NEW AND EXISTING EQUIPMENT

BUS 2

Load Resistor

480 V

Page

NOTES:

MCC 12-4-2 480 V

BUS 1

XXX-A

BUS 2

Substation 12

PAGE 1003 D.S. 94-1

Section

500kW Gen

Emergency Generator Building

DESIGN PRACTICES ELECTRIC POWER FACILITIES EXXON ENGINEERING