DP30A

ELECTRIC POWER FACILITIES DESIGN PRACTICESPOWER SOURCES Section

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DateDecember, 1999

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

CONTENTSSection Page

SCOPE ............................................................................................................................................................ 4

REFERENCES ................................................................................................................................................ 4DESIGN PRACTICE ............................................................................................................................... 4INTERNATIONAL PRACTICES.............................................................................................................. 4OTHER LITERATURE ............................................................................................................................ 4

BACKGROUND .............................................................................................................................................. 4

DEFINITIONS.................................................................................................................................................. 4

POWER SOURCE REQUIREMENTS ............................................................................................................. 8CAPACITY.............................................................................................................................................. 8NUMBER OF GENERATORS .............................................................................................................. 10

PURCHASED POWER ................................................................................................................................. 10RELIABILITY......................................................................................................................................... 10NUMBER OF CIRCUITS FROM UTILITY............................................................................................. 11VOLTAGE AND REGULATION ............................................................................................................ 11SHORT CIRCUIT LEVEL...................................................................................................................... 11POWER FACTOR REQUIREMENTS................................................................................................... 12PARALLELING OF CIRCUITS.............................................................................................................. 12NEUTRAL GROUNDING...................................................................................................................... 13FREQUENCY LIMITS........................................................................................................................... 13RELAYING............................................................................................................................................ 13SURGE PROTECTION......................................................................................................................... 13METERING........................................................................................................................................... 13POWER CONTRACT BILLING (TARIFF) ............................................................................................. 13SPACE REQUIREMENTS.................................................................................................................... 13DEMARCATION OF RESPONSIBILITIES............................................................................................ 14

GENERATED POWER IN PARALLEL WITH UTILITY ................................................................................ 14

POWER FOR EXPANSION OF EXISTING FACILITIES .............................................................................. 15PURCHASED POWER......................................................................................................................... 15GENERATION ONLY............................................................................................................................ 15PURCHASED POWER PLUS GENERATION...................................................................................... 15

MAIN SUBSTATION DESIGN ...................................................................................................................... 15GENERAL............................................................................................................................................. 15BUSBAR ARRANGEMENT .................................................................................................................. 16TRANSFORMERS................................................................................................................................ 16SWITCHGEAR...................................................................................................................................... 17

Changes shown by ➧

DESIGN PRACTICES ELECTRIC POWER FACILITIES

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CONTENTSSection Page

REACTORS ..........................................................................................................................................17PROTECTIVE RELAYING ....................................................................................................................17TRANSFORMER SECONDARY CIRCUITS.........................................................................................18LOCATION AND SPACING ..................................................................................................................18CONTROL AND INDICATION ..............................................................................................................18SURGE PROTECTION.........................................................................................................................18ENVIRONMENT....................................................................................................................................19MAIN SUBSTATION AUXILIARIES ......................................................................................................19

DESIGN PROCEDURE – ELECTRICAL DESIGN SPECIFICATION GUIDE ...............................................19INTRODUCTION...................................................................................................................................19PLANNING AND DESIGN BASIS ENGINEERING...............................................................................19HOW INFORMATION IS PROVIDED TO THE CONTRACTOR...........................................................20INFORMATION NEEDED TO WRITE A DESIGN SPECIFICATION ....................................................20

Writing A Design Specification ...........................................................................................................21

COMPUTER PROGRAMS ............................................................................................................................23GUIDANCE AND CONSULTING ..........................................................................................................23AVAILABLE PROGRAMS.....................................................................................................................24

APPENDIX A SAMPLE PLANNING DOCUMENTS .....................................................................................47SITE SURVEY QUESTIONNAIRE........................................................................................................47

Power Supply .....................................................................................................................................47Public Utility Power.............................................................................................................................47General Electrical Information ............................................................................................................47

Questionnaire for Public Utility to Obtain Definitive Planning Data. ......................................................48Brighton Synthetics Plant and Troup Lignite Mine.................................................................................49

APPENDIX B SAMPLE DESIGN SPECIFICATION 94-1 .............................................................................54

TABLESTable 1 Offsite DBM Recommended Design Factors .............................................................27Table 2 Power Transformer Ratings .......................................................................................28Table 3 Design Specification Check List Of International Practice Asterisk Items ..................29Table 3-1 Summary of Distribution Loads and Transformer Sizes.............................................61Table 3-2 Substation Motor List .................................................................................................62Table A-1 Brighton Synthetics Plant and Troup Lignite Mine Electrical Requirements...............50


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CONTENTS (Cont)Section Page

FIGURESFigure 1 Application of Load Growth and Reserve Capacity Factors......................................... 36Figure 2 Symbols for Figures..................................................................................................... 37Figure 3 Duplicate Feeders (No Breaker) .................................................................................. 38Figure 4 Line Tee-Off One Switch Substation (Quarter Breaker) .............................................. 38Figure 5 Duplicate Feeders (Half Breaker) ................................................................................ 38Figure 6 Line Tee-Off Two Switch Substation (Half Breaker) .................................................... 38Figure 7 Three Switch Substation (Three Quarter Breaker) ...................................................... 39Figure 8 Four Switch Substation (One Breaker) ........................................................................ 39Figure 9 Five Switch Substation (One and One Quarter Breaker) ............................................. 39Figure 10 Ring Bus (One Breaker) .............................................................................................. 39Figure 11 Ring Bus (One Breaker) .............................................................................................. 40Figure 12 Ring Bus With Two Pairs of Transformers (One Breaker) ........................................... 41Figure 13 Ring Bus With Two Pairs of Transformers (Two-Thirds Breaker) ................................ 41Figure 14 Breaker and Half.......................................................................................................... 42Figure 15 Double Bus single Breaker (One Breaker)................................................................... 43Figure 16 Double Bus Double Breaker (Two Breaker)................................................................. 43Figure 17 Double Circuit Tee-Off (No Breaker) ........................................................................... 44Figure 18 Double Circuit Tee-Off (Third of a Breaker) ................................................................. 44Figure 19 Double Circuit Tee-Off With Two Pairs of Transformers (Three Quarter Breaker) ...... 45Figure 20 Synchronizing Bus Bar ................................................................................................ 46Figure A-1 Operational Power Requirements Approximate Load Growth Profile Proposed

Brighton Synthetics Project ......................................................................................... 51Figure A-2 Peak Construction Power Requirements Approximate Load Growth Profile

Proposed Brighton Synthetics Project ......................................................................... 52Figure A-3 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 bysubsection. Also S purpose codes added and revisions marked with an arrow.REFERENCES – Titles of IPs updated. ANSI / IEEE Standard 141 replaced bylatest revision 1993-12-02 rev.POWER SOURCE REQUIREMENTS – Implications of partial loss of power on plantoverpressure protection added. Application of LGF clarified. Calculation added ofAdjusted Maximum Demand and Firm Capacity.PURCHASED POWER – Application of Variable Frequency Drive Systems forpower factor correction added.MAIN SUBSTATION DESIGN – Deleted example of basic spacing requirement andreference only made to DP-XV-G.DESIGN PROCEDURE - Additional information on design specifications for FrontEnd Loaded projects added. The General Instructions and Information (GII) addedto the list of vehicles by which information can be provided to contractors. Title ofthe document, and references to it, updated to: The Exceptions and Additions to theInternational Practices.DESIGN SPECIFICATION CHECKLIST OF INTERNATIONAL PRACTICESASTERISK ITEMS – This section has been revised inline with IP revisions.SAMPLE PLANNING DOCUMENTS – Q8 of Questionnaire for Public Utility toObtain Definitive Planning data "item 1" corrected to "item 7"COMPUTER PROGRAMS – Addresses and Contacts updated. Product codeadded for AST. Available Programs section updated to reflect presentnomenclature and available programs.


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

REFERENCES

DESIGN PRACTICESection XV Safety in Plant Design

INTERNATIONAL PRACTICESIP 4-3-1, Plant Buildings for Operation and StorageIP 4-3-2, Blast Resistant BuildingsIP 16-1-3, Protection of Electrical Equipment in Contaminated EnvironmentsIP 16-2-1, Power System DesignIP 16-4-1, Grounding and Overvoltage ProtectionIP 16-6-1, Substation LayoutIP 16-10-1, Power TransformersIP 16-11-1, Neutral Grounding ResistorsIP 16-12-1, Switchgear, Control Centers, and Bus DuctIP 16-12-2, Control of Secondary Selective Substations With Automatic Transfer

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

BACKGROUNDNearly all refineries and chemical plants are wholly dependent on electric power for operation. Hence, for any refinery orchemical 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 turbinesprovided are only capable of maintaining a safe condition and are not able to keep process units on stream. In addition to theloss 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 networkis generally one integrated system, great care must be exercised over the main power source installation in order to maintain theintegrity of the entire system. Therefore, the main power source is required to be as, or more, reliable than the supply toindividual 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.


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DEFINITIONS (Cont)

Back-Up Protection

A form of protection that operates independently of specified components in the primary protective system and that is intended tooperate if the primary protection fails or is out of service. In Exxon designs, it usually has the latter function and consists of atime / 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 suitableunits.

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 factorof a part of the system may be similarly defined as the ratio of the maximum demand of the part of the system to the totalconnected 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 theplanning (pre-DBM) stage of a project. The DBM design is the basis for the design specification. The DBM is issued togetherwith an Investment Basis Memorandum (IBM) which provides the necessary equipment and system data required by the costengineers.

Distance Protection

Protective relays in which the response to the input quantities is primarily a function of the electrical circuit distance between therelay 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 thewhole 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 abnormalcondition 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 throughexternal 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, whetheroil mist lubrication is to be applied, etc.


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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 disconnectedand 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 (excludingmajor basis changes). This increased load can result from many diverse reasons. Perhaps the most significant reason is theincreased amount of basic engineering which is applied as the project is developed. Other less significant reasons are lowerthan expected driver or driven equipment efficiencies, revised process requirements during design development, and revisednormal / spare driver designations. If the correct load growth factor is used, the capacity of the system should not change as thedesign 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 tomaintain 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 thecooling 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 naturalcirculation of air over the cooling surface such as integral cooling tubes or fins, the forced-air-cooled (FA) rating is obtained by theforced circulation of air over this same cooling surface, and the forced-oil-cooled (FOA) rating is obtained by the forced circulationof 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 samevoltage and frequency to share real power and reactive power loads as determined by turbine governor and voltage regulatorsettings.

Pilot Wire Protection

Protection in which a control circuit is used as the communicating means, between relays at the circuit terminals.


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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 rateis 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-phasecomponents 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 bycircuit breaker trip. A specified number of reclosures are made with the time delay after each trip specified. Since many open-wire line short circuits are line-to-ground and are not sustained short circuits, this practice provides quick re-establishment ofvoltage 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 loadwhich result from changes made by the Owner after start-up to accommodate revised plant running plans. This incrementalcapacity 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 anormally-open bus tie circuit breaker. The term “secondary-selective" is applicable to dual fed substations with or withouttransformers. The dual sources normally divide the load in non-parallel operation. Upon failure of one source, the substation isisolated 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 ofone source, the substation is isolated from the failed source by automatic operation of directional overcurrent relaying. Thisrelaying 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 dutythan 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 definesthe maximum fault clearing time that will permit the generators to remain in parallel with each other and/or the utility, followingfault 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 determinesthe current flow during the first few cycles after short circuit. Although the current decreases continuously, it is assumed to besteady for these few cycles. The subtransient reactance approaches armature leakage reactance, differing only by the leakageof damper windings.

Synchronous Reactance (Xd)

This reactance determines the current flow after the transient reactance period when a steady-state condition is reached. It iseffective after the transient reactance period. This is assumed usually to be several seconds after the short circuit occurs. Thecurrent excludes the effect of the automatic voltage regulator and the turbine or engine governor.


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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 ignoredand only the effect of the field winding is recognized. This reactance determines the short circuit current for the period betweenthe subtransient and steady-state conditions. The transient reactance is effective up to one-half second to two secondsdepending 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 inconjunction with differential type relays in which the zone limits are the locations of the current transformer sets supplying thedifferential relays. For other types, the zone limit is the most electrically distant point for which the relay will operate on shortcircuit 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 REQUIREMENTSBefore a utility company can be requested to provide power, or an in-plant generation design finalized, the following must bedetermined:

➧ CAPACITYThe capacity required from the power source is obtained from the process, offsites, and utilities load data lists which summarizethe electrical load on the overall system and on system components. The load data is used to establish the capacityrequirements for the various elements of the system. Load data summaries for the plant's normal and abnormal operatingconditions 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 listseach individual motor load for all processing units and offsite facilities and any other electrical load such as heaters, etc. Thesedata will be “normal" operating loads, unless there are specific operating conditions that substantially increase or decrease theplant load. In this case, as many sets of input load data are required as there are operating conditions. The various operationconditions 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 stageon 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 reflectthe changes in the quality of the load data being used. These are applied because, historically, loads tend to increase as theproject 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 shouldconfirm that this is the case. For example a motor associated with a cooling tower will already have LGF applied as part ofthe sizing of the cooling tower by the offsite designer. However an offsite's pump may not have had LGF applied.


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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 FACTORSLOAD BASIS

PRE-DBM DBM DESIGN SPECCONTRACTOR'S

OFFICE

Firm Load 10% 0 0 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 generationcapacity or purchased power substation capacity, and is intended to provide 10% reserve capacity margin at start-up. Note thatthis is the reserve required in normally operating units. It should not be confused with reserve capacity provided to cover forcedand scheduled outages of generating units.The application of load growth and reserve capacity factors for the overall utilities requirements of a coal gasification project isillustrated in Figure 1. The selection of the load growth factors for design basis memorandum (DBM) engineering for the sameplant is shown in Table 1. Note the majority of the facilities are non-firm loads and one facility's load is sufficiently uncertain torequire a 20% LGF.The use of Load Growth and Reserve Capacity Factors is an effort to improve the accuracy and provide a consistent basis formaximum 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. TheLoad 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, andincludes 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 withthe 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, theterms "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 ofany firm loads. The adjustment factor of 1.05, applied to non-firm load, provides a safety margin in the size of the sourceabove 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).


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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 maximumload. 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-mean-

square (rms) quantity which can be closely approximated as follows:a. Break the eight-hour period of maximum adjusted-demand into eight one-hour intervalsb. Estimate the average adjusted load magnitude (kVA, MVA, A, etc.) for each hourc. Square each magnituded. Obtain the mean by summing the 8 squared magnitudes and dividing by 8e. 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 15-Minute Maximum Demand plus 10% RCF.

3. In the absence of dedicated source transformers and generators, use Adjusted 15-Minute Maximum Demand plus 10% RCFto size main buses and incoming cables. Adjusted 15-Minute Maximum Demand is typically taken to be the same asAdjusted Maximum Demand (i.e., maximum simultaneous adjusted load). If there is a short duration peak load, use theaverage 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 thebase loading of the generators removed. The minimum required capacity the transformers is then the adjusted 8-hourmaximum demand of this modified load curve. Remember to check the adjusted 15-minute maximum demand of theremaining 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 largestsource is out of service. For 6 to 10 sources, the two largest sources would generally be considered out of service. However, ifthe load varies with time and there is a combination of transformers and generators, the firm source capacity verse effective loadmay have to be tested in more than one configuration.

NUMBER OF GENERATORSThe 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 processeswhere 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 isavailable, the decision to purchase power or install in-plant power generation is an economic decision based on comparison ofalternatives 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 ormajor potential power outages. This is the most important of the factors and covers the “forced" outage which occurs withoutwarning and causes either a total plant shutdown or a major plant upset; (2) Frequency and duration of power supply conditionswhich tend to reduce reliability and capability to meet load demands. Typical conditions are more than normal maintenanceoutages 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 supplyingthe plant.No single maximum forced outage rate sets the minimum acceptable reliability level. The minimum acceptable level isestablished by process plant type and complexity, cost of lost production and ability to make up lost production, likelihood that thetotal outage causes immediate or progressive equipment damage, and the complexity of emergency facilities required to providesatisfactory safety and equipment protection levels.In designing the electrical distribution system, the implications of a partial loss of power on the plant overpressure protectionfacilities 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 affectingreliability.


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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 yearrange are probably marginal for the large complex facility but acceptable for smaller less complex facilities. However, thesepower supplies should be carefully investigated to determine whether improvements could be made at an acceptableinvestment level.

3. Public utility power supplies which have total failure or serious disturbance rates exceeding 1 per year are generally notacceptable for large complex facilities. The improvements required to the supply to improve its reliability and their costshould 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 atthe 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 foreffect on the plant and whether the conditions can be accepted without change.

NUMBER OF CIRCUITS FROM UTILITYWhere the plant is totally dependent on the utility company, a minimum of two incoming circuits is required. These should, wherepossible, be independent of each other, i.e., come from different busses in the utility grid and be routed independently onseparate towers for overhead lines or in separate trenches for buried cables. However, we are often forced to accept two circuitsfrom a utility substation bus supplied from opposite sides of a normally closed tie breaker that are run overhead on commontowers (double circuit) to our facilities. We should endeavor to avoid such supply arrangements, but when no other is possible, atleast ensure that there are protective relays to open the utility tie breaker, and that a common pilot cable is not used to run controland/or protection circuits. It is usual to carry out maintenance of one circuit of a double circuit overhead line with the other inservice, 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 generatingcapacity and the normal maximum generating capacity. Generally, the design of the utility supply should be based on the largestin-plant generator being out-of-service while operating the plant at maximum demand. In some cases, a two generator outagemay 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 anagreed maximum demand from the utility.

VOLTAGE AND REGULATIONThe utility companies have standard voltages and will generally offer the supply from the lowest voltage they have locally withadequate capacity. This voltage in kV may vary from 1 to 10 times the capacity requested in MVA, with the higher loads having afactor 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 behigher 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 powergenerators normally control system voltage, a utility-tie transformer usually has an LTC to regulate voltage upon loss of inplantgeneration or to control power factor. Thus any design that would omit LTC's on main transformers must be carefully evaluatedto ensure that voltage and power factor variations are within acceptable limits.

SHORT CIRCUIT LEVELOnce the supply voltage level is defined, we have little control over the short circuit level of the utility supply. The short circuitlevel 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.


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

SYSTEM OPERATINGRANGE OF FAULT LEVEL (MVA) SWITCHGEAR RANGE (MVA)SYSTEM VOLTAGE

Min Max Min (MVA) Max (MVA)10–15 kV 150 1000 300 100020–69 kV 500 5000 500 5000

90–150 kV 500 10,000 5000 20,000160–240 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 forequipment rating. When selecting equipment short circuit ratings, the motor contribution from the load should be added to theutility 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 minimumshort circuit level required for stability and voltage profiles.

POWER FACTOR REQUIREMENTSThere may be little incentive to improve the inherent power factor of the plant unless the public utility insists, or there is a financialincentive 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 cageinduction 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 voltageharmonics).

When correction is required, we generally use banks of capacitors connected to the main busbars. This is the most economicalsolution 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 voltagedecay.

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 CIRCUITSThe utility may not permit paralleling of their two incoming circuits, either because they could at times be out of synchronism, or toavoid circulating currents. This will determine whether spot network substations can be used and the need for checksynchronizing relays on the secondary-selective substations. Often the utility will permit momentary parallel operation but notcontinuous 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.


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NEUTRAL GROUNDINGMost public utility transmission networks have the system neutral solidly grounded, as there are considerable savings ininsulation and lightning arrester costs. Also, high ground fault current levels are acceptable on transmission systems since thereare no motors or generators directly connected to such systems. The actual method of neutral grounding should be requestedfrom the utility and stated in the Design Specification.

FREQUENCY LIMITSOn large utility systems, the frequency can be expected not to vary more than about 0.5%, except when there is a major upset. Itis 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 fromthe utility to permit running part or all of the plant in island operation (see Section XXX-B). Frequency relays are also used aspart 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 beobtained. The settings should be given in the Design Specification and used to determine the setting of plant frequency relays.

RELAYINGThe 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 theutility 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 instantaneousprotection in order to ensure stability of the generators. (See Section XXX-E for more details on relaying.)

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

METERINGMetering for billing purposes is usually designed and installed by the utility. This metering usually requires separate currenttransformers and possibly a dedicated voltage transformer. Ratio, class, and fusing for these transformers should all be shownon 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 duringthe planning stage of the project. However, as the project progresses, more details are known about the load. The contractshould be reviewed again to ensure that the project basis is still sound and to determine the effects of any changed terms. Forexpansions at existing sites, it is usual for the Owner to carry out all negotiations with the utility.

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


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DEMARCATION OF RESPONSIBILITIESLocation of the utility incoming lines, a list of all equipment supplied by the utility, and/or equipment which must be provided bythe Owner should be established. The demarcation between utility and plant responsibility should be clearly defined in theDesign Specification.

GENERATED POWER IN PARALLEL WITH UTILITYThe complexity of a system deriving power from a utility, together with in-plant generation, is much greater than either source onits 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 lowvoltage if the alternate supply is healthy. If both in-feeds are lost, neither incoming breaker trips so that no breaker closing isnecessary when power is restored.) However, when there is in-plant generation operating in parallel, it is unacceptable toforce the generation to shutdown due to a failure of the utility. Therefore, a failure of the utility has to be detected andrelaying 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 wheneverpossible 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. 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 formeasurement. Factors affecting control are generators' excitation systems capability, range of utility tie transformer tapchangers, and the extent to which automatic control will be used.

4. Transformers with on-load tap changers may require a larger tap changer range in order to control var output from thegenerator(s).

5. Impedance between the generation and utility should be low for stability, but may intentionally need to be high to avoidexcessive voltage drops in the plant for faults on utility network.

6. 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 ofrunning in island.

7. Power flow through reactors should be minimized.


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POWER FOR EXPANSION OF EXISTING FACILITIESTie-in of expansions should be so arranged that the reliability of the existing plant is not impaired. The target should be to arriveat 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 designwith reactors and sophisticated switching sequences could prove to be very expensive in the final design and lower in reliability.

PURCHASED POWERWhere there are business incentives, plant expansions may be constructed to be completely independent of the plants existingfacilities. 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 ofseveral 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 ONLYA new generator will automatically increase the infeed fault level to the switchgear to which it is connected in proportion to thesize of the generators. Therefore, reactors may be required, either between generator busses, or to add new stub busses to asynchronizing bus arrangement. (See Section XXX-B for full details.)

PURCHASED POWER PLUS GENERATIONThis 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 iswhere the design for the plant prior to expansion included provision for the future facilities and included them in the networkstudies.For details, see Section XXX-B and the section above on GENERATED POWER IN PARALLEL WITH UTILITY.

MAIN SUBSTATION DESIGNGENERALThe purchased power supply components are the busses and switching equipment at the public utility supply substations, thesupply circuits from the utility substation to the plant, and the switching equipment and step-down transformers at the plant mainsubstation.Usually the supply circuits are part of the public utility system. The switching equipment and step-down transformers at the plantmain 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 typicalspace ratio is 1 to 30 favoring SF6 over outdoor air-insulated at 500 kV.


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MAIN SUBSTATION DESIGN (Cont)Other ancillary components of purchased power supply facilities are the protection, control and metering voltage and currenttransformers, and associated protective relays, control devices and meters. The protective relays, control devices and metersare located so they are convenient both for operation and maintenance. Control and metering circuits can be extended to permitoperation 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 voltagelevel. Type and application information on these transformers are covered in the section on transformers.

BUSBAR ARRANGEMENTA typical design would consist of two incoming circuits, two transformers and a secondary-selective (as detailed in IP 16-12-2) ora 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-and-a-half. (See Figures 3 through 20.)

TRANSFORMERSTransformer sizing should be based on the plant 8 hour Maximum Demand plus reserve capacity. Where transformers arespared by another power source, the forced cooled rating should be used with fans and/or oil pumps running whether integral ornot.If there are good reasons to believe that there will be a future expansion of the plant, consideration should be given to pre-investing, 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 verylarge difference in cost between larger units now as compared with replacement units in the future. Some of the points toconsider 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 oftenadvantageous to purchase to the utility company specification at one of their standard ratings, as they may do the maintenanceand 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 thebuild up of load, especially on the larger transformers where the reactance will be higher. During the final stages of DesignSpecification preparation or during engineering in the contractor's office, the need for the on-load tap changers should bereviewed. There are costly items, but it is very rare to purchase a main source transformer without an on-load tap changer. Anexception would be if the source is a closely regulated distribution voltage and the voltage profile shows acceptable voltagerange at utilization voltage levels.On-load tap changers in the Americas are generally equipped with 33 positions connected to 16 taps above nominal voltage and16 below; each step being 5/8 percent of the transformer voltage. In Europe and countries following European practice, 21 tapsis more normal. Usually ten below and ten above nominal voltage each step being in the range of one to two percent. This willvary 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 areusually on the HV winding up to 150 kV. In the Americas, they may be in either winding. Manufacturers prefer to have the tapchangers 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 theprimary winding controls the voltage on the other two windings, thus voltage control is not as good as with a two windingtransformer. A second on-load tap changer can be added to a secondary winding, but this can prove costly, thus nullifying theeconomy of the third winding.Exxon plants require close voltage regulation on the main substation transformer’s secondary, because normally there are no on-load tap changing transformers downstream of the main incoming transformers.


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MAIN SUBSTATION DESIGN (Cont)Transformer reactance should preferably be the manufacturers standard if it is suitable for the short circuit duty rating ofequipment downstream, stability, and motor re-acceleration needs. If a lower reactance than standard is required and costsextra, it may be better to spend the money on larger transformers. This will achieve the same result and give some additionalcapacity 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 secondaryvoltages 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 groundingarrangements. 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 thesubstation.

Preferred USA power transformer ratings are listed in Table 2. Preferred ratings and method for listing maximum capacity differin other countries.

SWITCHGEARThe incoming circuits from the utility may or may not be equipped with circuit breakers at the plant end. It may be difficult tojustify these breakers for smaller installations, but they should be included whenever possible. One exception is when the circuitto each transformer is supplied from its own dedicated circuit breaker in the utility substation and the utility agrees to a unitprotection 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, onlyone transformer per primary breaker is preferred, as the protection and switching maintenance are simplified, thus resulting inhigher reliability.The secondary switchgear usually consists of metal clad compartments with drawout circuit breakers installed indoors. Operationwith the tie breaker open (secondary selective) rather than closed (spot network) is more usual. This reduces the range ofmaximum to minimum short circuit level, which is beneficial for motor re-acceleration and may permit use of lower interruptingrated switchgear. Switchgear continuous current rating should be suitable for the transformer rating including any overloadcapacity. When operated with spot networks, transformers must be matched in size and impedance, and their on-load tapchangers must be equipped for cross compensation control.

REACTORSReactors are used to limit short circuit levels but should be avoided whenever possible. Where they are used, they preferablyshould interconnect networks to permit transfer of power under abnormal conditions rather than be in series with a main powercircuit 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 limitingexplosive 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 expensiveand lighter. On the other hand, the oil-immersed units are less susceptible to contaminants in the atmosphere, do not requirespecial construction features to avoid steel work in the vicinity, and do not require an additional enclosure around them. Bothtypes have been used in Exxon plants with the air core type being more common.

PROTECTIVE RELAYINGAll 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.


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MAIN SUBSTATION DESIGN (Cont)In some instances, the utility company will not provide instantaneous differential (unit) protection on their feeders to the mainsubstation (see PURCHASED POWER – RELAYING above). However, differential (unit) protection should still be provided onthe main transformers and secondary switchgear for fast clearance of faults in this equipment. The back-up protection shouldcoordinate with the utility relaying.A separate room may be required to locate the transformer primary breaker relays and sometimes the secondary switchgearrelays. This arrangement may be required by the utility company and can be useful where there are many relays that wouldrequire 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 CIRCUITSThese 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, directburied, or laid in a concrete trough finished flush with grade, or cable bus in air. Bus duct is only used when distances are shortenough to make it economical.

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

CONTROL AND INDICATIONOpen and closed indication of all the transformer primary and secondary breakers, plus any interconnecting circuit breakers, isrequired 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 synchronizingfacilities will be controlled from a control room unless automatic synchronizing is employed and Owner does not require control atthe control room.Transformer primary breakers are units in the overall utility transmission or distribution system. As such, the utility may requireprior 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 bythe 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 ofthe 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. Theseindicators and control devices are often incorporated into a mimic panel that represents the main components of the network ormore recently into a microprocessor-based system.

SURGE PROTECTIONIf the incoming circuits from the utility consist of uninsulated overhead wires, surge protection will be required at the substation toprotect the transformers and equipment downstream. This protection consists of surge diverters (lightning arresters) mountedoutdoors 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 forconnection to the line and mounting base at the bottom which also serves as the other terminal for connection to ground. Thearresters 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, over-voltage conditions.

2. Metal oxide (zinc oxide or gapless) type which has sufficient non-linearity that a series gap is not required to provide the highimpedance-low impedance characteristics.


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ENVIRONMENTA clean environment is required for the protection relays and the contacts on switches and interposing relays. Combinations ofhydrogen sulfide contamination, d-c circuits, humidity, silver migration along phenolic surfaces of relays, etc. have resulted infailure 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 thisequipment avoids some of the problems associated with induction disc and similar mechanical relays, they impose their ownrequirements 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 othercontaminants. 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 50to 100% of the duty should be provided.

MAIN SUBSTATION AUXILIARIESA 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, withsuitable protection, between the main transformers low-voltage terminals and the switchgear. Exxon installations usually use apair of transformers supplied from the main switchgear if there is no reliable low-voltage supply available from a nearbysubstation.

DESIGN PROCEDURE – ELECTRICAL DESIGN SPECIFICATION GUIDE

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

➧ PLANNING AND DESIGN BASIS ENGINEERINGDesign is a real time dynamic work process which leads to the detailed specification of equipment and facilities. The BasicDesign Specification (BDS) covers the critical engineering aspects and unique equipment engineering (e.g. mechanical, rotatingequipment, etc.) requirements in sufficient detail so that the Front-End-Loading (FEL) or Engineering, Procurement andConstruction (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 onsuch factors as the nature of the project, technology employed, contracting strategy etc.1. Full Basic Design Specification2. Abbreviated Basic Design Specification3. Duty SpecificationSelection of the type of BDS will be client and job specific. Protection of proprietary information and know-how for competitiveadvantage will need to be balanced versus job cost and schedule. The contractor would then use the BDS to produce a Front-End Engineering Package (FEEP). Additional information on FEL and FEEP is contained in Exxon Engineering Work ProcessesManual.This guide describes the electrical section of a Full Basic Design Specification.


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DESIGN PROCEDURE – ELECTRICAL DESIGN SPECIFICATION GUIDE (Cont)The Full Electrical Design Specification engineering is preceded by engineering work done during the planning and Design BasisMemorandum (DBM) stages of a project. Appendix A provides a Sample Site Survey questionnaire to assist in the planningprocess. 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 aone-line diagram, load list, equipment lists, system and equipment performance criteria, and results of studies carried out duringthe 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 isintended 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. Itis recommended that the Owner make a detailed review of the DBM in order to understand the basis of the facilities to beprovided.

➧ HOW INFORMATION IS PROVIDED TO THE CONTRACTORThere 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 InternationalPractices. Practically, however, this is not the case. There are still too many decisions left by the International Practices whichthe contractor cannot or should not make. These decisions are either made for him in the Design Specification or he is directedto perform studies which will result in a decision.Exceptions and additions to the International Practices indicate to the contractor areas where the International Practices aresuperseded. 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. Thesediscrepancies are also covered by the exceptions. Ideally, there should be no exceptions to the International Practices, but theaffiliates' preferences and requests may take precedence.The Design Specification brings together the International Practices, the exceptions and additions, affiliates' preference andrequests, and the most up-to-date Exxon Engineering thinking on plant electrical systems. Efforts should be made to include inthe Design Specification only those items which are not covered by the International Practices.

INFORMATION NEEDED TO WRITE A DESIGN SPECIFICATIONThe Design Specification should include all the features of the prepared design and should resolve as many of the alternativesdescribed by the International Practices as possible. The items marked with an asterisk in the International Practices require adecision. Table 3 provides a check list of International Practice Asterisk items for consideration in preparing an Electric PowerFacilities Design Specification. The specification writer is responsible for determining affiliate preferences on these items and forspecifying them in either the Design Specification or in IP exceptions. Decision on the remaining items will be made duringdetailed design.In addition to resolving the asterisked items, the following information should be available prior to writing an electrical systemDesign Specification:1. Power Source Characteristics (see POWER SOURCE REQUIREMENTS).2. Affiliate Preferences on Design Features.3. Load Description.4. DBM Design Features.5. Engineering Survey Data.


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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 theInternational Practices, then it would not be necessary to include a section of lighting in the specification. On the other hand, theabove items should not preclude any additional items which a Design Specification writer might deem necessary. The use ofsections 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. Thefunction of the Design Specification is to supplement the International Practices, not repeat the requirements of theInternational Practices.THE DESIGN SPECIFICATION SHOULD INCLUDE ONLY THOSE ITEMS THAT ARE NOT COVERED IN OTHERDOCUMENTS. BE COMPLETE BUT DO NOT BE REPETITIVE. IF SOMETHING HAS BEEN MENTIONED IN THEINTERNATIONAL 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, andrequire the minimum of maintenance. The International Practices contain most details of our requirements for processsubstations, their power supply, and all facilities downstream. Intermediate distribution systems (say 36 kV), incomingsubstations 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 DesignSpecification.During preparation of the Design Specification, it may not be known if the contract will be “Fixed Price" (Lump Sum) or “CostReimbursable." If this is the case, it should be assumed that the contract will be “Fixed Price" and the Design Specificationshould 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 beused, split of responsibilities and interfaces must be stated and checked carefully to avoid overlaps and to insure all electricalfacilities, 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'sEngineer” as used in the International Practices.The following apply to respective sections of SAMPLE DESIGN SPECIFICATION 94-1 included as Appendix B in this DesignPractice.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 partof 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. GeneralThis section points out how the contractor is expected to use the information supplied to him in the Job Specification. Itspecifies 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 SourceThis 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.


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

5. Distribution SystemThis section gives substation designations, locations, and types but does not repeat system information given on the one-linediagram. It describes any unusual features, such as three winding transformers, capacitor banks, and special busconfigurations.If the project is an addition to or an expansion of an existing facility, specify the contractor's responsibilities at any tie-inpoints.Based on the source bus information above and the load information (POWER SOURCE REQUIREMENTS), the design forthe 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.6. Load Description

The load description should include the simultaneous maximum demand at each load center, substation load centerassignments, 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.

7. Protection and ControlThe International Practices specify most of what is usually required for protection and control. Sometimes affiliatepreferences will require specifying motor controller types and relaying methods. Also, the relaying and metering on mainincoming substations, any special reacceleration control, or load shedding requirements are often specified. Differentialprotection must be specified where required.


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

9. LightingLighting is adequately covered by IP 16-5-1 except for affiliate preferences and whether or not to invoke the security lightingIP 16-5-2.

10. Instrument and Essential Services Power SupplyInstrument power supply systems are covered by the International Practices except for affiliate preferences, such asexpansion or duplication of an existing system. There are two key asterisk items in IP 16-8-1 that will set the basis for thedesign 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 otherunits. Following identification of all groups of critical and independent units, and the site selection of all control centers andremote instrument buildings, the instrument and essential services power supply configuration can be determined from IP16-8-1, Pars. 8.1, 9.1, and 9.2. This will require preparation of one or more one-line diagrams for inclusion into the DesignSpecification.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-linediagrams for the power sources and essential services switchgear configurations.

11. CommunicationsCommunications 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 systemscovered 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. DiagramsThis section should include a one-line diagram and any other diagrams which may not be covered by the InternationalPractices, such as an existing distribution system or an unusual instrument power supply systems.

COMPUTER PROGRAMS

GUIDANCE AND CONSULTINGFor up-to-date information on available programs and how to use them, affiliate personnel should get in touch with their AffiliateLibrary Contact. Exxon Research and Engineering personnel should consult either the Exxon Engineering Section responsiblefor 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 andER&E Engineers. The prime delivery mechanism for the ATS Catalog is the Windows “help” file format. To request a copy ofWindows “help” file version, contact:

➧ ER&E Manual DistributionOUTLOOK: AMERICAS(MANUAL)Exxon Research and Engineering Company


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COMPUTER PROGRAMS (Cont)

AVAILABLE PROGRAMSThe applicable programs available at the time of this writing are listed below:

PROGRAM TITLE AND DESCRIPTION3317 MAGNET Version 9

This is a program for calculating motor acceleration, generator performance, and network componentduties. The type of calculations which can be performed are:STEADY-STATE CALCULATIONSSteady-State Load Flow - “Load flow” based on a specified utility source voltage and/or voltages atgenerator busses.Steady-State Optimum Taps - Same as Steady-State Load Flow, with automatic selection of besttransformer taps to achieve desired voltages at load busses.Steady-State End of Transient - With in-plant generation, a calculation of the bus voltages andgenerator excitation values which will result from a given set of generator automatic voltage regulatorsettings V(Ref), but with a load situation which may be different from that for which the V(Ref) settingswere established.3-PHASE FAULT CALCULATIONSFault Bus XXX IEC - Classical short circuit study, giving voltages and currents at “time zero,” halfcycle, and steady-state (for switchgear duty and relay coordination).Dynamic Fault Bus XXX - A dynamic calculation of generator contribution and/or large motordeceleration during a short circuit of specified duration on a specified bus. Generator terminal voltageand 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, basedon specified priorities (and/or step assignments) and minimum allowable voltages.DYNAMIC NON-FAULT STUDIES (SUCH AS LARGE MOTOR STARTING ANDREACCELERATION)Dynamic General - General purpose calculation, starting from specified initial speeds of motors (andinitial conditions of generators, if any).Dynamic Loose - A modification of Dynamic General with reduced calculation time, especially forplants with no generation.Dynamic Tight - A modification of Dynamic General with difficult-to-solve networks.CABLE SIZING OR CHECKINGCable 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, checksthose 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.


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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 MicrosoftAccess 97. This provides a convenient tool for manipulating MAGNET data sets including exchangingdata with other applications.PCMagnet runs within a window and is a batch calculation process. It has the same calculation typesas 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 textfile 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 acomma-separated-value file which is plotted by a companion Microsoft Excel 97 based programcalled MagGraph.Operating Environments: WIN, WIN95/NTDocumentation / 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 powersystem 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 theirexisting DOS based programs within the Windows environment. SKM currently offer the followingmodules: DAPPER, CAPTOR, A_FAULT, IEC_FAULT, HI_WAVE and I*SIM.I*SIM ProgramThe I*SIM program is specifically designed to simulate the electro-mechanical dynamic behavior ofpower systems. I*SIM can simulate all types of balanced network disturbances including: isolationfrom the utility; fast transfer switching; motor starting, tripping, and reclosing; loss of generation; lossof excitation; blocked governors tie-line oscillations; load rejection; load shedding; and system split-up. I*SIM can be used to simulate small or large power systems. The I*SIM program provides recordkeeping capabilities which permit the updating of studies and reports as the power system is revisedor upgraded.

➧ CAPTOR: Computer Aided Plotting for Time Overcurrent Reporting Version 3.5This program aids in the plotting of the time current relationship of protective devices and equipmentin electrical power systems.Specification of variables by the user for each piece of equipment in the study. Program displays theresults 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 andequipment. The program has a library with the most common pieces of equipment but specificparameters of each are selected by the user.Results of the user specifications are displayed on the computer monitor. Reports may be requestedfor printing which include the time current curve (TCC) drawings, reports for each device setting, anda simple single line drawing depicting the electrical arrangement of the equipment displayed on theTCC.Operating Environments: WIN, WIN95/NTDocumentation / References: Power Tools User's Manual, SKM Systems Analysis, Inc.


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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 onarbitrary distribution systems. Add-on modules do ANSI fault calculations (A-fault) and IEC 909 faultcalculations (IEC-fault).Primary uses include load flow and short circuit analysis, synchronous and induction machinemodeling, transient motor starting analysis, and equipment sizing.Input / Output: Input is done by creating a one-line diagram using a component toolbar and byentering 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 isselected.Operating Environments: WIN, WIN95/NTDocumentation / References: Power Tools User's Manual, SKM Systems Analysis, Inc.

➧ EASYPOWER The Graphical Solution for Power System AnalysisPerforms 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 motoris 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 double-checking 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 textwindows.Operating Environments: WINDocumentation / References: Easypower User's Manual, Electrical Systems Analysis, Inc.


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TABLE 1OFFSITE DBM

RECOMMENDED DESIGN FACTORS

LGF (%)

STEAMLOAD GROWTH FACTORS(LGF) AREA

CONDENSATE PRODUCTELECTRIC

POWERCOOLINGWATER BFW COMPRESSED AIR

GasificationLock Gas Recompression(1)

Gas CoolingGas PurificationRefrigeration(1)

Gas Liquid SeparationPhenosolvantGas Liquid StrippingSulfur RecoveryCO2 IncinerationProduct Gas Compression(1)

FractionationOxygen Plant(1)

10——15—15151515——2010

10—10——————000—

151015151015151515151520—

—1015151015151515——2010

10—1015————15000—

15——15———————20—

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.


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TABLE 2POWER TRANSFORMER RATINGS

The following 3-phase transformer ratings are USA preferred per ANSI C57.12.00 Table 2 and C57.12.10 Table 2. Othercountries 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 20,00015,000 20,000 25,00020,000 26,667 33,33325,000 33,333 41,66730,000 40,000 50,00037,000 50,000 62,50050,000 66,667 83,33360,000 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 specified55°C/65°C temperature rise to permit limiting temperature rise to 55°C at 100% name plate rating. For thesetransformers, 65°C is 112% of 55°C rating.


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➧ TABLE 3DESIGN SPECIFICATION CHECK LIST OF INTERNATIONAL PRACTICE ASTERISK ITEMS

IPPAR. NO. (NOTE) ITEM

S 16-1-1 Area Classification and Related Electrical Design for Flammable Liquids, Gases or Vapors5.3 Specify if the "additional" 50 ft x 2 ft high classified zone can be waived.

16-1-2 Area Classification and Related Electrical Design for Combustible Dust4.2 (3) Specify values for the dust being classified

16-1-3 Protection of Electrical Equipment in Contaminated Environments2.2 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.

16-2-1 Power System Design2.3 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 Specify if buses need to be extendable with plant in service.5.5 (2) Specify process priorities for motor re-acceleration.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 Specify if differential relaying is to be used.

5.30 c (2) Specify design basis for sub-bus feeders.6.4 Specify if radial substation to be designed to be convertible to secondary selective.

6.6 c Specify Transformer impedance requirements to limit fault currents6.22 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.

S 7.17 Specify motor starter disconnect device type.8.1 Specify if additional or redundant switchgear control power source is required.8.6 (1) Specify minimum design ambient temperature.

S 8.14 Specify if start-stop control stations are required to be lockable in the stop position.S 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 Provide details of existing convenience plugs.

16-3-1 Wiring Methods and Material Selection4.2 d Specify if aluminum sheath is acceptable.


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TABLE 3 (Cont)


S 16-4-1 Grounding and Overvoltage Protection6.5 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.

16-5-1 Lighting9.11 Specify if additional provisions are required to protect against overvoltages.3.3 Specify any lighting requirements in areas not covered by IP's.3.8 (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.

S 3.27e Specify areas requiring emergency lighting above IP minimum, and identify power source, asnecessary.

16-5-2 Security Lighting of Plants1.2, 1.3 Specify if IP is to be used on project, and if so, the applicable areas.

S 6.1 Specify if backup (emergency generators) power is required.

16-6-1 Substation Layout2.2 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.)

S 5.1 (3), 16.116.2

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.

S 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 Specify if an alternative material for substation doors is required.10.1 a Specify weight limitation of draw out voltage transformers and low voltage motor controllers that require

permanent handling facilities.E 12.5 Specify the extent of the oil retention system.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 Specify if area around captive transformer will meet requirements for "Transformer Yards".18.1 Specify if a breaker test and inspection station is required.

S 18.2 Specify safety and maintenance equipment.

16-7-1 Motor Application2.1 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".


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TABLE 3 (Cont)


16-8-1 Instrument and Essential Services Power Supplies3.1 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 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.

S 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.S 12.14 Specify if other than static type inverters are to be used.

12.15, 12.25 Specify power factor range and crest factor for performance characteristics. Specify ambienttemperature extremes.

12.26 Specify tolerable limits of the loads served.Figure 2 (d) Note 7: specify if transfer switches are required.

16-9-1 Low Voltage A-C Motors Up To 200 HP (150 kW)2.1, 2.2, 2.3,

4.2Specify list of practice and standards to be used.

3.1 Specify motor data3.2 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.

16-9-2 A-C Motors: Medium Voltage and Low Voltage Over 200 HP (150kW)1.1 Specify if this IP is to be used for low voltage motors in sizes 200 HP(150kW) and below.

2.2,2.3,2.4 Specify practices and publications to be used.4.1, 4.2 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.


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TABLE 3 (Cont)


16-9-2 (Cont)6.1 Specify if vibration-monitoring systems are required.

6.1 a Provide probe size and other necessary mounting dimensions.6.2 Specify extent of SPM adapters or space for attachment of vibration transducers.7.1 Specify drive motors required to meet Pars 7.2 - 7.67.5 Specify if a rotor dynamic analysis is required.8.1 Specify enclosure type.8.12 Specify environment.

S 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 Generators3.2 Specify if IEC 85 is to be used3.4 Specify applicable standards of manufacture and test.5.3 Specify if neutral leads do not need to be brought out.5.5 Specify capability of excitation system.

5.8 d 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 Specify if an open-ventilated air-cooling system design is to be proposed as an alternative.

6.5 b 2 Specify if load break switches are to be provided.6.9 Specify if devices are to be mounted on Purchaser's control panel or metal enclosed freestanding

enclosure furnished by generator vendor.


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TABLE 3 (Cont)


16-10-1 Power Transformers2.2 Specify additional or equivalent standards to be used.2.3 Specify if IP 20-1-1 is to be used.

3.1 g 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 Specify if impulse, temperature and regulation tests required.6.4 Specify if certified copies required.

16-11-1 Neutral Grounding Resistors2.1 Specify or otherwise standard to be used.4.2 Specify period for carrying maximum system ground fault current.

16-12-1 Switchgear, Control Centers and Bus Duct1.3 a Specify type of switching device1.3 b Specify type of circuit breaker1.3 c Specify relaying for other than motor branch circuits.2.1 Specify codes and standards to use.

S 6.1 Specify if arc resistant switchgear is not required.S 6.2 Specify available current and relay time.

6.8, 7.1 Specify name or equipment numbers.S 6.13, 6.14,

7.3, 10.3Specify if main bus neutral required and its current rating.

6.22 Specify switchgear control power voltages.S 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 Specify time for memory timer.8.7 d Specify if ground fault relays are required.8.8 Specify ambient compensated overload relays.

S 8.9 Specify thermal overload alarm relay.


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TABLE 3 (Cont)


16-12-1 (Cont)8.14 Specify type of differential relay protection and responsibility to supply.8.15 Specify locked rotor damage time and type of relay.8.19 (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 Specify voltage, power source and method of control for space heaters.10.5 Specify fault current magnitude.11.2 Specify tests to be witnessed.

S 16-12-2 Control of Secondary Selective Substations With Automatic Transfer1.2. 3.3 Specify design modifications to the control system for manual transfer.3.3, 3.4 Specify if sources are not synchronized.

3.6 (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.S 16-13-1 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.

16-14-1 Standard LV Variable Frequency Drives14.6 b Specify if primary injection testing is required.

2.2 Specify standards to be used.3.2, 5.2, 5.6,5.11, 5.21,

Table 1

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 Systems2.3 Specify standards to be used.

4.1, 5.43 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.


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TABLE 3 (Cont)


16-14-2 (Cont)6.3 Specify if a torsional vibration analysis is not required.6.10 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 Specify if measurement of existing harmonic distortion required.

S 6.20 e 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) Not marked with an (✶) in the IP, but still comes under the intent of a DESIGN SPECIFICATION CHECK LIST.(2) Process design decision required.


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FIGURE 1APPLICATION OF LOAD GROWTH AND RESERVE CAPACITY FACTORS

CoolingWater

RequirementsX(1 + RCF)

Cooling WaterEquipment

(towers, pumps)

+(1 + RCF)

X(1 + RCF)

+(1 + RCF)

+(1 + RCF)

+(1 + RCF)X(1 + RCF)

X(1 + RCF)

X(1 + RCF)

X(1 + LGF)

X(1 + LGF)

X(1 + LGF)

X(1 + LGF)

X(1 + LGF)

X(1 + LGF)

Balance

WaterSupply

Equipment

WaterRequirements

ProcessWater

Requirements

ProcessCooling WaterRequirement

OxygenRequirements

O2 PlantAir & O2

Comp Power

ProcessElectrical

Requirement

ElectricPower

Requirements

Power SupplyFacilities

Purchased orGenerated

ProcessBFW

Requirements

BFW TreatEquipment

SteamBalance

BoilerSize

Boiler Fans,Deaerator, BFWand Fuel Pumps

FGDS

Process SteamRequirement

ProcessCoal

Requirement

CoalRequirements

AshRate

AshHandling

Equipment

CoalHandling

Equipment

Process Design

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.


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FIGURE 2SYMBOLS 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 breakerin a line from the utility to an Exxon transformercounts as a "Half Breaker" system i.e. one circuitbreaker for two circuits.

DP30AF2


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FIGURE 3DUPLICATE FEEDERS

(NO BREAKER)

DP30AF3

FIGURE 4LINE TEE-OFF

ONE SWITCH SUBSTATION(QUARTER BREAKER)

a b

DP30AF4

FIGURE 5DUPLICATE FEEDERS

(HALF BREAKER)

DP30AF5

FIGURE 6LINE TEE-OFF

TWO SWITCH SUBSTATION(HALF BREAKER)

a

DP30AF6

b


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FIGURE 7THREE SWITCH SUBSTATION(THREE QUARTER BREAKER)

a. b. c.

DP30AF7

FIGURE 8FOUR SWITCH SUBSTATION

(ONE BREAKER)

a. b.

DP30AF8

FIGURE 9FIVE SWITCH SUBSTATION

(ONE AND ONE QUARTER BREAKER)

a. b.

DP30AF9

FIGURE 10RING BUS

(ONE BREAKER)

DP30AF10


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FIGURE 11RING BUS

(ONE BREAKER)

b.

c.

DP30AF11

a. Preferred Layout for Expansion


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FIGURE 12RING BUS WITH TWO PAIRS OF TRANSFORMERS

(ONE BREAKER)

DP30AF12

FIGURE 13RING BUS WITH TWO PAIRS OF TRANSFORMERS

(TWO-THIRDS BREAKER)

DP30AF13


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FIGURE 14BREAKER AND HALF

c.

b.

a. Preferred Layout For Expansion

DP30AF14


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FIGURE 15DOUBLE BUS SINGLE BREAKER

(ONE BREAKER)

DP30AF15

FIGURE 16DOUBLE BUS DOUBLE BREAKER

(TWO BREAKER)

DP30AF16


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FIGURE 17DOUBLE CIRCUIT TEE-OFF

(NO BREAKER)

a. b.

DP30AF17

FIGURE 18DOUBLE CIRCUIT TEE-OFF

(THIRD OF A BREAKER)

DP30AF18


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FIGURE 19DOUBLE CIRCUIT TEE-OFF WITH TWO PAIRS OF TRANSFORMERS

(THREE QUARTER BREAKER)

Basking RidgeShale

Morristown SubstationChatham

Substation

DP30AF19


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FIGURE 20SYNCHRONIZING BUS BAR

DP30AF20

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

switchgear which is withdrawable. Withdrawable feature

Synchronizing Bus

Stub Bus Stub BusStub BusStub Bus

not shown for clarity.


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DateDecember, 1999


APPENDIX ASAMPLE PLANNING DOCUMENTS

SITE SURVEY QUESTIONNAIRE

Power Supply

Public Utility Power

1. Amounts available: kW.The following questions, 2 through 17, apply if the amount of public utility power available is sufficient to permit consideringpurchasing of power:

2. Characteristics: Phase Hertz Volts3. What is the minimum and future maximum short circuit level MVA at the source and/or the plant?4. Provide a one-line diagram of the source showing equipment sizes/capacities, impedances, and short circuit ratings.5. Submit rate schedule, including any fuel adjustment or low power factor clauses, and present cost of fuel.6. Dependability (outages per year, length of outages, % voltage variation, frequency, magnitude and duration of voltage dips,

etc., based on past records).7. What is the distance from plant limits to substation or substations from which utility would supply the power?8. How many feeders would utility install from substation or substations to the plant limits?9. What would be feeder characteristics as to construction method (underground or overhead) and insulation level?10. If two feeders are provided and carried overhead, would they be carried on separate poles?11. Would plant have exclusive use of feeder or feeders?12. If feeder voltage is too high for plant use, would the cost of this substation be borne by the utility or the plant?13. 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.

14. 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.

15. If voltage variation on secondary bus exceeds 5%, would utility provide voltage regulators or load tap changers?16. On what date could permanent power be available?17. 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?


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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 definitivedata for a project that has reached the planning stage.


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APPENDIX A (Cont)

BRIGHTON SYNTHETICS PLANT AND TROUP LIGNITE MINE.1. Schedule for implementation, including securing rights-of-way, construction of facilities, etc.2. Date when a firm load commitment is required in order to have power available for construction in 1995 and for plant / mine

operation in 1998.3. Anticipated reliability of separate rights-of-way for the two incoming double-circuited lines.4. Confirmation that the supply will be looped in from the 138 kV Stryker - S. E. Tyler lines.5. 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?6. Plan for supply of construction power requirements shown in Table A-1 beginning in 1995.7. 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).

8. Utility system X/R ratio for the short circuit conditions in Item 7, above.9. MVA limitation for future load additions to the Brighton 138 kV substation.10. Details of the facilities which would be installed and owned by the utility.11. What other customers are served from the S. E. Tyler-Stryker 138 kV lines?12. 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.13. 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.14. Voltage regulation expected at the Brighton 138 kV substation.15. Frequency regulation expected on the 138 kV system.16. Circuit breaker operation at S. E. Tyler-Stryker substations.

a. Reclosing practice.b. Single-pole switching operation.c. Relaying philosophy and settings.

17. 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.

18. 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?

19. Would it be possible to have two sets of meters: one for the plant and one for the mine?


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APPENDIX A (Cont)

TABLE A-1BRIGHTON 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 theinformation obtained during the site survey, responses from the utility company to questionnaires, and on additional planningengineering 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 thebase 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 MWneeded 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 itscenter. Utility access through the mine area is through the “western corridor" to the utility substation located near theSouthwest corner of the proposed plant site.

6. Substation Configuration and interface for Operational Power: A simplified one-line diagram of the utility substation is shownin Figure A-3. The utility company would be responsible for all materials and construction upstream of, but excluding, thefour main 138 kV transformers. Space for expansion to two additional bays should be provided. Major equipment providedby 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.


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APPENDIX A (Cont)

FIGURE A-1OPERATIONAL POWER REQUIREMENTS APPROXIMATE LOAD GROWTH PROFILE

PROPOSED BRIGHTON SYNTHETICS PROJECT

Elec

tric

Pow

er, M

egaw

atts

220

200

180

160

140

120

100

80

60

40

20

0

Alternate Load Profiles(Based on Mine Operationof Draglines PlusBucketwheels)

InstantaneousPeak Load

Maximum15-MinuteDemand

1998 1999 2000 2001 2006 20072002 2003 2004 2005 2008DP30AFA1


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APPENDIX A (Cont)

FIGURE A-2PEAK CONSTRUCTION POWER REQUIREMENTS APPROXIMATE LOAD GROWTH PROFILE


Elec

tric

Pow

er, M

egaw

atts

22

20

18

16

14

12

10

8

6

4

2

0

1994 1995 1996 1997 2002 20031998 1999 2000 2001DP30AFA2


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DateDecember, 1999


APPENDIX A (Cont)

FIGURE A-3UTILITY SUBSTATION SIMPLIFIED ONE-LINE DIAGRAM


Stryker138 KV Supply

S. E. Tyler138 KV Supply

Util

ity C

o.

Exx

on

ToMineArea

45/60/75/ MVA138-13.2-13.2 KV

Typicalof Four

Utility Co.

Exxon

To Brighton IndoorMain Substation(Typ.) Legend

Outdoor Oil CircuitBreaker

Disconnect Switch

Lightning Arrester

3-Winding Delta-WyePower TransformerWith AutomaticOn-Load Tap ChangerDP30AFA3


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APPENDIX BSAMPLE 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 NOTICEThis specification contains technical information that is the property of Exxon Research and Engineering Company. It is furnished to therecipient strictly for use in connection with the unit concerned and is to be held proprietary.By: Joe Grouphead Date: July 29,1994

John Engineer


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DateDecember, 1999


APPENDIX B (Cont)

D.S. 94-1

BURBANK FUELS PROJECTDESIGN 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


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APPENDIX B (Cont)

D.S. 94-1



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


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APPENDIX B (Cont)

Page 3D.S. 94-1



GENERALAny conflict between sections of this specification or between this specification and local codes shall be resolved with the Owner.

SCOPEThis specification covers the design requirements of the Electric Power Facilities for the Burbank Fuels Project (BFP). General Instructionsand 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 inSection 16 of the Burbank Refinery Regional Practices (BRRP).

DESIGN BASISThe electric power requirement of BFP, approximately 14 MVA, will be supplied by the local utility, PG&E, at 230 kV via the existing refinery230/12.47 kV main transformers and 12 kV distribution system. No modification to the PG&E facilities is required. The existing 12 kV mainswitch 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 lowvoltage Substations (36 and 37) will be housed in a common building to be constructed in the northeast side of the Clean Fuels processblock, 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 plantblock. Offsite loads will be supplied by way of expansions to existing substation.

CONTRACTOR RESPONSIBILITIESThe 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.


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APPENDIX B (Cont)

Page 4D.S. 94-1

• Computer studies of the complete Refinery electrical system. Only the portion affected by the Fuels Project needs to be analyzed indetail, 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 SUBSTATIONSThe following is a brief outline of work in and around existing refinery substations. The list is not meant to be comprehensive, but is providedhere to give the Contractor a feel for field construction requirements and the Refinery procedures that must be followed. Upon request, theOwner 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 safetypractices.The Refinery electrical work permit system is in effect when the Contractor is performing work in the refinery.

AREA CLASSIFICATIONContractor shall prepare an area classification study in accordance with BRRP 16-1-1 for the new facilities. Equipment installed withinexisting units can be added to existing Unit Area Classification Drawings.


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APPENDIX B (Cont)

Page 100D.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 double-circuit 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 entireplant load, including the BFP loads. The main switch house is provided with a 12 kV automatic transfer scheme to assure continuity ofsupply 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 anda 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 arecovered in Sections 600 and 800 of this specification.


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APPENDIX B (Cont)

Page 200D.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 FEEDERSContractor shall design the cable routing for the new 12 kV feeder to C-302D, as well as extensions or modifications to existing 12 kVcircuits. Power cables shall be installed using direct burial methods as detailed in BRRP 16-3-1.

MAIN SWITCH HOUSEOne new 12 kV circuit breaker, appropriate auxiliary panel, and field excitation equipment shall be installed in the existing main switch houseto supply the new hydrogen compressor C-302D. An empty breaker cubicle has been installed for this purpose by the Third 12 kV MainFeeder project. The cubicle contains the necessary fixed parts of the switchgear such that it will not be necessary to de-energize the mainbus 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 belocated near the compressor motor, in the hydrogen plant block. Excitation and control cabling shall be installed as required. Digital andanalog signals from the new breaker shall be connected tot he existing PLC monitoring system.

NEW 480 V SUBSTATIONS 36 & 37Two new grass roots 480 V low voltage substations will be built for the onsites portion of the project. Both substations will be located in acommon building located near existing Substation 24 (see attached Plot Plan). 15 kV rated, transformer feeder cables will be extended fromexisting Substation 29 to supply these new substations. Load assignments for services to be supplied from these substations are shown inSection 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 38A new 480 V LV substation will be built north of the existing hydrogen plants, between existing Substations 9 & 10. The 12 kV feeder cablesfrom 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, inthat order. A turnaround power center will be built in the Sub 38 building and shall be supplied from Substation 38, with a “backup” feederfrom existing Substation 9.


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DateDecember, 1999


APPENDIX B (Cont)

Page 300D.S. 94-1

SECTION NO. 3

LOAD DESCRIPTION

GENERALTable 3-1 summarizes the electrical loads expected on the new substations reflecting a 5% load growth factor for process loads. Substationdesignations, 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 designspecification number, service, duty, estimated operating kW, and reacceleration requirements are also shown.

TABLE 3-1SUMMARY OF DISTRIBUTION LOADS AND TRANSFORMER SIZES

Substation Nominal Design Total TransformerDesignation Voltage (V) (kW)(2) kVA(1) kVA (OA)

S/S 36 480 910 1138 1500S/S 37 480 965 1206 1500S/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.


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APPENDIX B (Cont)

Page 301D.S. 94-1

SECTION NO. 3 (Cont)

LOAD DESCRIPTION

TABLE 3-2SUBSTATION 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

Substation H (4.16 kV)D.S. Number Service Duty D.S. kW Reacc

94-23 C-1704A/B Refrigeration Tank N/I 270 A94-23 P-1864A/B Blending N/S 185 C94-13 P-4409A/B HCN T90 Distillate N/S 170 A94-13 P-4421A/B HSU Feed N/S 148 A94-14 P-4441A/B LCN Feed N/S 352 A94-21 P-4460A/B Hot Oil Circulation 2N/S 649 A94-21 B-4460 Hot Oil ID Fan N 140 A

Total (Incl. LGF) 2,010

Substation 36 (480)D.S. Number Service Duty D.S. kW Reacc

TAPC I 50 C94-21 B-4701A/B NH3 Air Inject. (ven. pkg) N/S 5 B94-12 E-4404A/B Heartcut SS Cooler 2N 21 A94-12 E-4414A HCN T90 Cond. N 22 A94-12 E-4414B HCN T90 Cond. (VFD) N 22 A94-12 E-4416A/B HCN T90 Bottoms Cooler 2N 22 A94-21 E-4460 Hot Oil Cooler I 7 C94-12 E-4403A-V Heartcut Condenser 22N 460 A94-12 P-4401A/B Heartcut Reflux/Distillate N/S 70 A94-12 P-4403A/B Heartcut Bottoms N/S 17 A94-12 P-4408A/B HCN T90 Reflux N/S 5 A94-12 P-4410A/B HCN T90 Bottoms N/S 30 A94-12 P-4411A/B H/C Feed N/S 55 A94-12 P-4412 C5/C6 Split Dist. to H2 Plant N 31 A94-21 P-4461 Hot Oil Inventory I 19 C94-22 P-4471A MRU Slop Oil Pump I 31 C

Total (Incl. LGF) 910


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DateDecember, 1999


APPENDIX B (Cont)

Page 302D.S. 94-1


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.


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APPENDIX B (Cont)

Page 400D.S. 94-1

SECTION NO. 4

PROTECTION AND CONTROL

GENERALContractor shall perform relay coordination studies for all electrical facilities installed with the project. Contractor shall review the relaycoordination 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 atpresent by the Owner.Contractor shall provide, install, and set all the relays required in the different substations. Contractor shall provide, install, and terminate therequired control wiring from the 12 kV main switch house to the new Substations 36, 37, and 38. Contractor will verify functioning of thecontrol circuits.Description of relay protection contained in this section is intended to compliment the requirements of BRRP 16-2-1. Details of existing relaytypes and settings records are available from the Owner.

PHILOSOPHYThe protective relaying scheme described in the subsequent sections features conventional circuit breaker, selective tripping, and automatictransfer 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 belocated near the compressor motor, in the hydrogen plant block. Excitation and control cabling shall be installed as required. Digital andanalog signals from the new breaker shall be connected to the existing PLC monitoring system.

MAIN SWITCH HOUSEThe main 12 kV switch house is secondary-selective and equipped with automatic-transfer circuitry activated by inter-tripping with the utility’s230 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 50have been set as described in the substation protective relaying section.

12 kV FEEDERSThe 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 byinstantaneous 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 andabove the sum of magnetizing inrush currents of all connected transformers. The 51 feeder relays are set to coordinate with thetransformer secondary 51 relays but not necessarily with transformer primary 51 relays. The minimum pickup of the 51 relays is 1.25times 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 operationcaused by current transformer unbalance during maximum inrush conditions.


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DateDecember, 1999


APPENDIX B (Cont)

Page 401D.S. 94-1



Backup protection for tapped feeders is provided by the main Substation 51 relays on the incoming 12 kV feeders. Any required changes tothe 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 areconsidered necessary for correct coordination of relaying in the system.

UTILIZATION SUBSTATIONSThe new secondary-selective Substations 36, 37, and 38 shall be equipped with automatic-transfer circuitry per BRRP 16-12-2. Inter-trippingwith the main switch house 12 kV feeder breakers shall be provided. The substations shall be protected against phase and ground faults byovercurrent 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 50relay must be set above the motor back feed so as not to block transfer for faults on the transformer secondary bus duct. The 51relay shall coordinate with the highest set outgoing feeder phase fault protection and shall be set to provide transformer through faultprotection. 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 shouldpreferably 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 51Nrelay shall be set to coordinate with the outgoing feeder ground fault protection. The 51N relay shall be set no lower than 10% of theavailable 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 PROTECTIONTransformers 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 thetransformer 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 mainsubstation feeder breaker via the 86T relay.

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

• Low voltage transformers (480 V) are solidly grounded, and shall have a time delay ground overcurrent 51G relay in the neutral. The51G relay shall coordinate with 51N relay on the transformer secondary breaker.

MOTOR PROTECTIONLow 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. Typeof reacceleration relays and motor control circuitry shall be reviewed with Owner prior to placing the equipment order. Contractor shall beresponsible for the overall reacceleration system and shall provide all data to the Owner. Section 600 of this specification covers the PLCcontrol for reaccelerated loads supplied from new Substations 36 & 37.


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APPENDIX B (Cont)

Page 402D.S. 94-1



SUBSTATION ALARMS AND METERINGContractor 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 requiredare detailed in BRRP 16-2-1.


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DateDecember, 1999


APPENDIX B (Cont)

Page 500D.S. 94-1

SECTION NO. 5

MODIFICATIONS TO EXISTING FACILITIES

GENERALThe new Substations 36 and 37 shall be supplied from existing 12 kV main switch house. The project also includes other new medium andlow voltage loads, and reused existing electrical drives, that shall be supplied from other existing substations. These existing substationsinclude: 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 duringthe development of the project.Contractor has complete responsibility for the design, field construction, and testing of all modifications to existing facilities as specifiedherein.Owner believes that sufficient physical space exists in the above substations for the proposed additional loads. However, Contractor shall beresponsible for investigating the spare compartments and space in the above-mentioned substations. In most cases, additional verticalsections will be required. In the case of older gear, transition sections will be required to interface to new equipment. Where transitionsections are required, a “top hat” type construction shall be used, if available from the manufacturer. Contractor shall be responsible forsizing starters and insuring that each service is provided with the proper protection meeting the guidelines and requirements of the jobspecification and as specified herein. Contractor shall coordinate with the Owner all substation investigation work, and shall obtain Owner’sagreement 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 bereclaimed if not presently designated for a specific use. Contractor shall check with the Owner prior to planning the use of any existingequipment.

SUBSTATIONS 3 & 30Existing loads P-707A/B/C shall be removed from Substation 3 and shall be supplied from Substation 30. These services shall utilize cablesand motor starters which have been previously installed as existing Substation 30 for this purpose.


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APPENDIX B (Cont)

Page 600D.S. 94-1

SECTION NO. 6

EQUIPMENT

GENERALTechnical acceptance of equipment is based on meeting the requirements of the Job Specification, the BRRPs, and the applicable designspecifications. Because of the detail contained in the above documents, the subsections on various major equipment items usuallycontained 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 ofjudging the technical acceptability of the equipment in question.Outdoor electrical equipment shall be designed for service industrial environment.

POWER CABLESAll 12 kV feeder cables shall be paper-insulated, lead-covered type, rated for 15 kV operation. BRRP 16-3-1 provides details on cableconstruction for 4160 V and 480 V cables.

NEW SUBSTATION CONSTRUCTIONNew substations built for the project will be evaluated-type buildings constructed in such a way to be able to accept direct buried power andcontrol cables entering through the floor. The building construction shall match the existing Burbank standard design that is basically aconcrete floor/foundation with an insulated, metal-enclosed building mounted on it. Package substations with steel floors mounted onconcrete 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 usingaluminum conduit, aluminum or fiberglass boxes, and filtered air for Substations 36 & 37 in the new process block. Contractor shall reviewhis proposed methods/designs with the Owner prior to finalizing the design.

PROGRAMMABLE CONTROLLERMotor reacceleration in Substations 36 & 37 shall be performed by a Programmable Logic Controller (PLC) system using software alreadydesigned 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 switchgearand 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 automatictransfer.

VARIABLE FREUENCY DRIVE UNITSProcess design specifications have designated certain air-cooled heat exchangers whose motor drives shall be controlled by variablefrequency 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 fixedspeed. It will not be necessary for the bypass to be made with the motor running; de-energized switching is sufficient.


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DateDecember, 1999


APPENDIX B (Cont)

Page 601D.S. 94-1


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 andmounting. If another philosophy is proposed, Contractor shall demonstrate that the units will be properly cooled, and that maintenance ofone unit can be safely performed, with other units in service.

EMERGENCY GENERATORIn 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 SystemsEmergency generator shall be brushless, a-c synchronous type, self-cooled, and enclosed in a fully guarded housing suitable for theenvironment 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 thefollowing:• 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 engravednameplates, 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 PANELA 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 Vcircuit breaker used to supply the generator load resistor shall be in addition to the above requirements and may be included in the sameline-up.The building shall also be sized to accommodate the future installation of two ASCO automatic transfer switches, in addition to the controlsand panel(s) required for the new generator.

GENERATOR LOAD BANKA load bank shall be permanently installed in the generator building, to be used for periodic exercising of the diesel generator. This loadbank shall be capable of loading the generator to its full nameplate rating for at least one hour. In consideration of the heat produced, theload resistor may need to be mounted in a separately ventilated room or shelter. The Contractor shall review his preliminary design with theOwner. The design shall be submitted for Owner’s approval, prior to finalizing construction details.


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APPENDIX B (Cont)

Page 700D.S. 94-1

SECTION NO. 7

LIGHTING AND COMMUNICATIONS

LIGHTING, WELDING, AND CONVENIENCE OUTLETSLighting for the new Fuels unit shall be supplied at 480 volts from the new Substation 36/37 turnaround power center, TAPC. Lightingcontactor(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 Fuelsunit process block. Power supply for this transformer shall be from the TAPC located in Substation 36/37.

FIBER OPTIC AND TELEPHONE COMMUNICATIONSA fiber optic and telephone communications shall be installed in each new substation. A telephone and circuit for a computer terminal shallbe 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 fromexisting Substation 9. A fiber optic/coax cable termination cabinet shall be installed in new Substations 36/37 and 38.


XXX-APage


DateDecember, 1999


APPENDIX B (Cont)

Page 800D.S. 94-1

SECTION NO. 8

INSTRUMENT POWER SUPPLY

INSTRUMENT POWERTwo 120/208 V, 3-phase UPS panel boards shall be installed in the new Fuels Unit to supply the instrument power requirements of the onsitearea. 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 inthe 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. Othercritical instrument loads not requiring backup shall have their supplies balanced equally from UPS No. 1 and UPS No. 2, consistent with theexisting 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 51PL-EJ, located in the Annex Room of the Control House. The Contractor shall investigate the voltage tolerance of this equipment andreconcile his design with the expected voltage drop during the starting of C-302D connected to Main Switch House 12 kV Bus 1 and, ifnecessary, shall install the hardware required to provide regulated power to the instrumentation.

ANALYZER SYSTEMSA Continuous Emissions Monitoring (CEM) System and Stack Gas Analyzer (for F-446) require instrument power as well as lighting andutility outlets. Refer to D.S. 94-19.

EMERGENCY DIESEL-GENERATORTo supply incremental power requirements of the Fuels Unit and improve reliability of power supply to the Control Center, the existing175 kW steam-driven emergency generator shall be replaced with a 500 kW diesel-generator. Refer to Page 1003 of this specification forthe 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 locatednortheast of existing Substation 12, adjacent to the existing Substation 12 building. The new 480 V distribution panel will be located in thegenerator building but in a separate room from the generator. The generator shall start automatically upon loss of normal power supply toSubstation 12, picking up the loads served from existing distribution panels MCC 12-4-1 and MCC 12-4-2. The present feeder from MCC12-4-1 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 adetailed purchase specification for the Owner’s review. The new generator distribution panel and load resister are also specified in thissection.All existing functions presently available on the mimic panel in the UPS Room for the existing generator shall be maintained for the newemergency diesel-generator.


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APPENDIX B (Cont)

Page 900D.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 existingplant. Load flow, short circuit, and motor starting analysis for C-302D shall be done using SKM Dapper program. The analysis required forthe 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 theelectrical facilities to meet system design and operating requirements determined by the computer studies. The Contractor shall verify thatthe correct input data has been used and that the results are acceptable.


XXX-APage


DateDecember, 1999


APPENDIX B (Cont)

Page 1000D.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 arepreliminary and must be confirmed by the Contractor except where, and equipment size is specifically stated in this specification to be therequired size for the reason given.Burbank drawings referenced in this specification, and other drawings required for the Contractor’s detailed design, are available from theOwner.


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XXX-APage


DateDecember, 1999


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Page76 of 76

POWER SOURCES


EXXONENGINEERING


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