Experience – Petro-Chemical  Industry

  • Design review and Expert witness of failure investigation of several oil type transformers rating 16 MVA – 30 MVA for adjustable speed drive applications.
  • Conducted complex investigations into utility power failure resulting in shutdown of two major oil refineries.
  • Conducted motor starting analysis and computer modelling for 13.8 kV, 25000 HP synchronous motor under normal and abnormal utility conditions for a large chemical plant in Ontario. Prepared a report with recommendations.
  • Completed a complex electrical failure analysis and field measurements of three slow speed 17500 HP, 13.8 KV brushless Synchronous motors driving reciprocating compressors.  All failures were rotor related that made predicting the failures very challenging. The first motor suffered a cracked shaft that had to be replaced. The second experienced arcing amortisseur bars and the third shorted field winding.
  • Conducted complex investigation to address incompatibly issues of 12 km, nine conductors sub sea umbilical cable connecting three offshore 1500 HP adjustable speed drives to electrical submersible pumps (ESP) for oil drilling application.
  • Reviewed the impact of adding 50 MVAR, 138 KV capacitor bank on existing plant operation with and without a co-generation plant.
  • Investigated field excitation failure for slow speed 25000 HP brushless synchronous motor for compressor application in a chemical plant.  
  • Conducted comprehensive review of implementation plan, justifications, methodology and overall cost for replacing obsolete electrical equipment in a large Petro-Chemical plant involving over 10 substations. The work includes installing multifunctional relays and modern switchgear – to be carried out during scheduled process unit shutdown.
  • Conducted failure analysis, protection review and system engineering of a 25,000 HP Adjustable Speed Drive for starting and speed control of three synchronous motors for compressor applications. This IGBT based ASD rating was considered the first of its kind at 11KV directly connected to synchronous motor.
  • Conducted investigation into operating history, repair work of magnetic wedges, motor protection and field measurements of three slow speed induction motors each rated 5400 HP for reciprocating compressor application.
  • Selection and implementation of the 19000 HP, 7200 V, IGBT based ASD for compressor application and this to date is still considered the largest IGBT ASD drive ever build and placed in service in the world.
  • Carried out design, specification and implementation of the largest medium voltage induction motor ASD for extruder application (7500 HP) in Petro-Chemical industry in North America. Also, worked on the first retrofit project of replacing eddy current clutch (ECC) with ASD rated 2500 HP for extruder.
  • Completed comprehensive study of users and manufacturers experiences of medium voltage ASDs in North America, which was sponsored by a large electrical utility. This study was considered the first of its kind when conducted in 1995. Key recommendations were provided to the manufacturers to address the performance and reliability of ASDs as well as produced engineering specification to purchase medium voltage ASD for induction motor.
  • Prepared specifications, selection, implementation and testing of the largest LCI drive in the world (1986) for retrofit compressor application. The system consisted of two 22000HP, 6000 rpm LCI with two brushless synchronous motors having 6-phase stator winding located in class1, division1 hazardous area. The key challenges included selecting design parameters to improve the performance and availability of drive train, design input filter to meet very stringent Hydro Quebec harmonic guidelines at 138 KV supply and torsional vibration when running at super synchronous speed.
  • Conducted Plant wide computerized harmonic study for a 125 MW Petro-Chemical plant in Alberta having ASD type load to ensure compliance to harmonic guidelines of TransAlta/System Administrator and to IEEE 519-1992 standard. Also, conducted harmonic field measurements.
  • Provided technical expertise for a very large Petro-Chemical project in Alberta. This involved 400 MW Co-generation plant, specification and selection of 5 Medium Voltage ASDs.
  • Performance evaluation and testing of two 5000 HP MV ASDs for gas pumping station.
  • Engineering specification and selection of 13000 HP motor for a mixer application.
  • Selection and implementation of (2×2500 HP, 2×1500 HP) medium voltage ASDs for compressor and pump applications.
  • Plant wide automatic re-acceleration system for 150 motors using PLC system.
  • Rehabilitation of 10 MVA main substation.