Calculation Cover Sheet: Client Project Location
Calculation Cover Sheet: Client Project Location
Calculation Cover Sheet: Client Project Location
: 1792
ARABIAN CONSULTING ENGINEERING CENTRE CO.
Cal No.: CALC-E-004
Al-Khobar, Saudi Arabia
CALCULATION COVER SHEET Revision No.: 00
Page: 1 of 9
Client : HADEED/SABIC
Project : REPLACEMENT OF INERT GAS GENERATION SYSTEM
Location : Al-Jubail, Saudi Arabia
CALCULATION TITLE:
POWER SYSTEM STUDY – HADEED
(LOAD FLOW STUDY)
CALCULATION OBJECTIVE:
The objective of this study is to verify the adequacy of the existing electrical equipment in the HADEED DR Plant –Main
Substation after replacing the existing Inert Gas Compressor pumps with higher rating and re-assess the electrical system
in accordance with SABIC requirements.
INPUTS:
ASSUMPTIONS:
None.
None.
CONCLUSION:
Based on ETAP Power System study results for Load Flow, the existing equipment at HADEED DR Plant
–Main Substation is not adequate to accommodate the new loads under AF-1421035. Refer to section
5.4.
However, there are some alerts exist on the received model which requires further investigation. Refer to sections.
Revision 00
Preparer / RSC
Date ‘09/02/17
Checker/ RPT
Date ‘09/02/17
ACEC J.O. No.: 1792
ARABIAN CONSULTING ENGINEERING CENTRE CO.
Calculation No.: CALC-E-004
Al-Khobar, Saudi Arabia Revision No.: 00
CALCULATION
Page No.: 2 of 9
CONTINUATION SHEET
REVISION RECORD
REVISION NOTES:
ACEC J.O. No.: 1792
ARABIAN CONSULTING ENGINEERING CENTRE CO.
Calculation No.: CALC-E-004
Al-Khobar, Saudi Arabia Revision No.: 00
CALCULATION
Page No.: 3 of 9
CONTINUATION SHEET
TABLE OF CONTENTS
1.0 OBJECTIVE ............................................................................................................................. 4
2.0 SCOPE OF POWER SYSTEM STUDY ........................................................................................... 4
3.0 APPLICABLE STANDARDS ........................................................................................................ 4
3.1 SABIC STANDARDS................................................................................................................... 4
3.2 INDUSTRY CODES AND STANDARDS .......................................................................................... 4
4.0 INPUT DATA AND METHODOLOGY ............................................................................................. 4
4.1 SYSTEM ANALYSIS SOFTWARE ................................................................................................. 4
4.2 UTILITY GRID ........................................................................................................................... 4
4.3 ETAP ELECTRICAL DISTRIBUTION MODEL ................................................................................. 5
4.4 ETAP MODEL SCENARIOS SETTINGS........................................................................................ 5
5.0 LOAD FLOW STUDY ................................................................................................................. 7
5.1 LOAD FLOW STUDY OBJECTIVE ................................................................................................ 7
5.2 LOAD FLOW DESIGN ASSUMPTION ............................................................................................ 7
5.3 ETAP LOAD FLOW CASE STUDY CONFIGURATION..................................................................... 7
5.4 LOAD FLOW STUDY RESULTS, ANALYSIS, CONCLUSION AND RECOMMENDATION ........................ 8
6.0 APPENDICES ........................................................................................................................... 9
6.1 APPENDIX – 1 LOAD FLOW STUDY ETAP REPORT ..................................................................... 9
6.2 APPENDIX – 2 ELECTRICAL ONE LINE DIAGRAMS ....................................................................... 9
ACEC J.O. No.: 1792
ARABIAN CONSULTING ENGINEERING CENTRE CO.
Calculation No.: CALC-E-004
Al-Khobar, Saudi Arabia Revision No.: 00
CALCULATION
Page No.: 4 of 9
CONTINUATION SHEET
1.0 OBJECTIVE
The objective of this study is to verify the adequacy of the existing electrical equipment in the
HADEED DR Plant –Main Substation in accordance with SABIC requirements under AF-1421035,
Upgrade Inert Gas Generation system at HADEED Plant after replacing two (2) existing Compressor
pumps with new ones rated at 1350 kW.
These motors are connected on the 4.16kV Switchgear 3SG1-North Panel section as shown below:
Motor Tag
# Feeder no. Description Voltage Rating
no.
3.2.1 IEEE Std 141: IEEE Recommended Practice for Electrical Power
Distribution for Industrial Plants.
3.2.2 IEEE Std 399: IEEE Recommended Practice for Industrial and Commercial
Power System Analysis
“LF Normal”: Normal operating load, two transformers feed the whole
downstream loads with tie-breaker is open. Used for Load Flow Normal system
voltage study.
Table 4.4
Configuration Study Study Output
Scenario Study Case
Status Mode Type Report
LOAD
LF Normal Normal Operating Load Flow Normal-LF LF Normal
FLOW
LOAD
LF Minimum Minimum Operating Load Flow Minimum-LF LF Minimum
FLOW
4.4.4 Cables
All main high voltage cables shown in the existing model are assumed to be
correct representing the actual cable data. New cables when modeled are taken
from ETAP cable library data.
Table – 4.3.9
Table – 4.3.10
Load Description Continuous (C) Intermittent (I) Spare (S)
Motor 100 30 0
Lighting/UPS 100 - -
Lumped/Static Load 100 30 0
Motors and static loads with a demand factor of “0” are considered “SPARE” and
not running for power system studies.
Steady state voltage range, under all study conditions shall be as follows:
5.2.1 Allowable steady state Voltage drops shall be as listed below:
(a) Allowable Maximum Voltage Drop in the Switchgear, MCC and SWRK bus
is 3%.
(b) Allowable Maximum Voltage Drop in the branch circuit feeder is 3%.
(c) Allowable Maximum Voltage Drop is 5% (Total voltage drop for main,
feeders and branch circuit).
(d) Allowable Maximum Bus Over-voltage is 105% of nominal.
(e) Allowable Maximum Bus Under-voltage is 97% of nominal. Maximum 95%
at load terminal.
Table-5.4: Load Flow Normal, and Minimum System Voltage Level @ Hadeed DR Plant –Main substation
Case Scenario Results - Case Scenario Results -
Calculated Total Bus load in Calculated System Voltage
Bus
Percentage (%V)
Area Bus ID Voltage
Bus Bus
kV LF-
loading- loading- LF-Normal
Minimum
Normal Minimum
3SG1-NORTH
PANEL SECTION 4.16 66.9 115.8 98.4 97.16
(3B1-BUS)
Main
3SG1-SOUTH
Substation
PANEL SECTION 4.16 53.5 52.1 98.51 97.16
– DR Plant
(3B2-BUS)
EMERGENCY BUS
4.16 12.0 12.1 98.4 97.16
-3BS113
ACEC J.O. No.: 1792
ARABIAN CONSULTING ENGINEERING CENTRE CO.
Calculation No.: CALC-E-004
Al-Khobar, Saudi Arabia Revision No.: 00
CALCULATION
Page No.: 9 of 9
CONTINUATION SHEET
Based on the Table-5.4 above, the load flow calculations have determined the following:
• Bus voltages are within allowable limits as specified in the SABIC Engineering
Standard E02-E01, section 10.
• ETAP load flow reports show some equipment which has been critically and
marginally alerted with different conditions, such as overloading and under/over
voltage, initially by the received ETAP model and not due to the scope of work for
AF-1421035. These issues require further analysis for the overall ETAP model.
• The loading on the 4.16kV Switchgear 3SG1 buses is acceptable during normal
system voltage, i.e. normal condition. However, during minimum system voltage, i.e.
worst case, the main bus will be overloaded.
• Since the 4.16kV Switchgear 3SG1 might get overloaded during worst case scenario,
it is recommended to define a sequence of operation by the end user to address the
consequences and procedure during such condition.
6.0 APPENDICES
Appendix – 1
CASE # 1 - Normal Operation, 23T1 & 23T2 both in Service, 4.16kV Bus tie (3TB12) in Open position
3SG1-SOUTH PANEL 4.160 2500.0 1.029 0.438 0 -1.747 0 0 0 0 9.496 87.6 1337.8 53.5
BUS 481 0.480 3150.0 1.027 0.520 0.208 0.105 0 0 0 0 1.384 89.2 1850.1 58.7
BUS 482 0.480 3150.0 1.297 0.617 0.264 0.126 0 0 0 0 1.729 90.3 2305.0 73.2
BUS 483 0.480 3150.0 1.294 0.682 0.260 0.137 0 0 0 0 1.756 88.5 2357.2 74.8
BUS 484 0.480 3150.0 1.236 0.492 0.259 0.103 0 0 0 0 1.609 92.9 2114.5 67.1
BUS-485 0.220 800.0 0.050 0.031 0.012 0.007 0 0 0 0 0.072 85.0 194.6 24.3
CASE # 1 - Normal Operation, 23T1 & 23T2 both in Service, 4.16kV Bus tie (3TB12) in Open position
* Indicates operating load of a bus exceeds the bus critical limit ( 100.0% of the Continuous Ampere rating).
# Indicates operating load of a bus exceeds the bus marginal limit ( 95.0% of the Continuous Ampere rating).
ETAP
Project: HADEED - ETAP STUDIES Page: 3
12.5.0C
Location: JUBAIL, KSA Date: 08-23-2016
Contract: SN: ARABIANCEC
Engineer: EATON Revision: Base
Study Case: LF-NORMAL
Filename: HADEED - JUBAIL KSA Config.: Normal
CASE # 1 - Normal Operation, 23T1 & 23T2 both in Service, 4.16kV Bus tie (3TB12) in Open position
Transformer
CKT / Branch Cable & Reactor
Ampacity Loading Capability Loading (input) Loading (output)
CASE # 1 - Normal Operation, 23T1 & 23T2 both in Service, 4.16kV Bus tie (3TB12) in Open position
Vd
CKT / Branch From-To Bus Flow To-From Bus Flow Losses % Bus Voltage
% Drop
ID MW Mvar MW Mvar kW kvar From To in Vmag
Cable5 -10.921 -2.856 10.923 2.859 1.6 2.5 98.4 98.4 0.02
Cable16 1.306 0.529 -1.294 -0.527 11.9 2.2 98.4 97.6 0.83
Cable17 1.306 0.529 -1.294 -0.527 12.3 2.3 98.4 97.5 0.86
Cable18 0.557 0.232 -0.554 -0.232 2.7 0.5 98.4 98.0 0.44
Cable19 4.985 1.965 -4.948 -1.929 37.3 36.6 98.4 97.5 0.88
Cable20 0.214 0.092 -0.213 -0.092 0.6 0.1 98.4 98.1 0.25
Cable21 0.362 0.153 -0.360 -0.153 1.8 0.3 98.4 98.0 0.44
Cable22 0.306 0.130 -0.304 -0.130 1.1 0.2 98.4 98.1 0.33
Cable11 -8.318 -2.834 8.319 2.835 0.9 1.5 98.5 98.5 0.02
Cable24 0.373 0.157 -0.372 -0.157 1.4 0.3 98.5 98.2 0.33
Cable26 0.292 0.124 -0.290 -0.124 1.8 0.3 98.5 98.0 0.54
Cable27 0.718 0.298 -0.717 -0.298 0.4 0.4 98.5 98.4 0.06
Cable28 0.718 0.298 -0.717 -0.298 0.4 0.4 98.5 98.4 0.06
Cable30 0.345 0.146 -0.343 -0.145 2.2 0.9 98.5 97.9 0.62
3FB22-T10 0.327 0.148 -0.324 -0.138 2.5 9.8 98.5 96.8 1.71
34T2 1.598 1.004 -1.562 -0.743 36.8 261.4 98.5 90.2 8.27
35T1 0.062 0.039 -0.061 -0.038 0.2 1.1 98.5 97.5 1.03
Cable1 -10.941 -3.280 10.944 3.285 3.0 5.6 99.6 99.6 0.04
Cable3 10.941 3.280 -10.941 -3.280 0.1 0.2 99.6 99.6 0.00
23T1 10.941 3.280 -10.923 -2.859 17.8 420.8 99.6 98.4 1.14
Cable7 -8.329 -3.090 8.331 3.093 1.8 3.4 99.6 99.6 0.03
Cable9 8.329 3.090 -8.329 -3.090 0.1 0.1 99.6 99.6 0.00
23T2 8.329 3.090 -8.319 -2.835 10.7 254.4 99.6 98.5 1.07
Cable14 -0.360 -0.153 0.361 0.153 0.9 0.2 98.2 98.4 0.22
34T4 -1.494 -0.596 1.525 0.816 31.0 219.9 91.5 98.4 6.88
910AT04 10.947 3.433 -10.944 -3.285 3.5 147.4 100.0 99.6 0.41
910AT02 8.333 3.182 -8.331 -3.093 2.1 89.1 100.0 99.6 0.37
254.9 1945.6
ETAP
Project: HADEED - ETAP STUDIES Page: 5
12.5.0C
Location: JUBAIL, KSA Date: 08-23-2016
Contract: SN: ARABIANCEC
Engineer: EATON Revision: Base
Study Case: LF-NORMAL
Filename: HADEED - JUBAIL KSA Config.: Normal
CASE # 1 - Normal Operation, 23T1 & 23T2 both in Service, 4.16kV Bus tie (3TB12) in Open position
% Alert Settings
Critical Marginal
Loading
Bus 100.0 95.0
Bus Voltage
OverVoltage 105.0 102.0
Generator Excitation
OverExcited (Q Max.) 100.0 95.0
CASE # 1 - Normal Operation, 23T1 & 23T2 both in Service, 4.16kV Bus tie (3TB12) in Open position
MW Mvar MVA % PF
Number of Iterations: 3
ETAP
Project: HADEED - ETAP STUDIES Page: 1
12.5.0C
Location: JUBAIL, KSA Date: 08-23-2016
Contract: SN: ARABIANCEC
Engineer: EATON Revision: Base
Study Case: LF-MINIMUM
Filename: HADEED - JUBAIL KSA Config.: Minimum
CASE # 2 - Minimum Operation, 23T1 in service & 23T2 out of Service, 4.16kV Bus tie (3TB12) in closed position
3SG1-SOUTH PANEL 4.160 2500.0 1.029 0.438 0 -1.699 0 0 0 0 9.122 87.4 1303.0 52.1
BUS 481 0.480 3150.0 1.027 0.520 0.201 0.102 0 0 0 0 1.376 89.2 1870.5 59.4
BUS 482 0.480 3150.0 1.297 0.617 0.256 0.122 0 0 0 0 1.720 90.3 2330.2 74.0
BUS 483 0.480 3150.0 1.294 0.682 0.251 0.132 0 0 0 0 1.746 88.5 2383.4 75.7
BUS 484 0.480 3150.0 1.236 0.492 0.251 0.100 0 0 0 0 1.601 92.9 2134.7 67.8
BUS-485 0.220 800.0 0.050 0.031 0.011 0.007 0 0 0 0 0.072 85.0 196.3 24.5
CASE # 2 - Minimum Operation, 23T1 in service & 23T2 out of Service, 4.16kV Bus tie (3TB12) in closed position
* Indicates operating load of a bus exceeds the bus critical limit ( 100.0% of the Continuous Ampere rating).
# Indicates operating load of a bus exceeds the bus marginal limit ( 95.0% of the Continuous Ampere rating).
ETAP
Project: HADEED - ETAP STUDIES Page: 3
12.5.0C
Location: JUBAIL, KSA Date: 08-23-2016
Contract: SN: ARABIANCEC
Engineer: EATON Revision: Base
Study Case: LF-MINIMUM
Filename: HADEED - JUBAIL KSA Config.: Minimum
CASE # 2 - Minimum Operation, 23T1 in service & 23T2 out of Service, 4.16kV Bus tie (3TB12) in closed position
Transformer
CKT / Branch Cable & Reactor
Ampacity Loading Capability Loading (input) Loading (output)
CASE # 2 - Minimum Operation, 23T1 in service & 23T2 out of Service, 4.16kV Bus tie (3TB12) in closed position
Vd
CKT / Branch From-To Bus Flow To-From Bus Flow Losses % Bus Voltage
% Drop
ID MW Mvar MW Mvar kW kvar From To in Vmag
Cable5 -18.886 -5.641 18.891 5.648 4.8 7.8 97.2 97.2 0.03
Cable16 1.306 0.529 -1.294 -0.527 12.2 2.2 97.2 96.3 0.84
Cable17 1.307 0.530 -1.294 -0.527 12.7 2.3 97.2 96.3 0.87
Cable18 0.557 0.232 -0.554 -0.232 2.8 0.5 97.2 96.7 0.44
Cable19 4.986 1.966 -4.948 -1.929 38.3 37.5 97.2 96.3 0.89
Cable20 0.214 0.092 -0.213 -0.092 0.6 0.1 97.2 96.9 0.25
Cable21 0.362 0.153 -0.360 -0.153 1.8 0.3 97.2 96.7 0.44
Cable22 0.306 0.130 -0.304 -0.130 1.2 0.2 97.2 96.8 0.34
Cable24 0.373 0.157 -0.372 -0.157 1.4 0.3 97.2 96.8 0.34
Cable26 0.292 0.124 -0.290 -0.124 1.8 0.3 97.2 96.6 0.55
Cable27 0.718 0.298 -0.717 -0.298 0.4 0.4 97.2 97.1 0.07
Cable28 0.718 0.298 -0.717 -0.298 0.4 0.4 97.2 97.1 0.07
Cable30 0.345 0.146 -0.343 -0.145 2.2 1.0 97.2 96.5 0.63
34T2 1.591 1.006 -1.553 -0.739 37.6 267.1 97.2 88.8 8.38
35T1 0.061 0.039 -0.061 -0.038 0.2 1.1 97.2 96.1 1.04
Cable1 -18.946 -6.965 18.956 6.982 9.2 17.6 99.5 99.6 0.07
Cable3 18.946 6.965 -18.946 -6.964 0.3 0.5 99.5 99.5 0.00
23T1 18.946 6.964 -18.891 -5.648 55.5 1315.8 99.5 97.2 2.31
Cable14 -0.360 -0.153 0.361 0.153 0.9 0.2 96.9 97.2 0.22
34T4 -1.487 -0.593 1.519 0.817 31.6 224.2 90.2 97.2 6.96
910AT04 9.481 3.606 -9.478 -3.491 2.7 115.2 100.0 99.6 0.42
910AT02 9.481 3.606 -9.478 -3.491 2.7 115.2 100.0 99.6 0.42
291.1 2604.8
ETAP
Project: HADEED - ETAP STUDIES Page: 5
12.5.0C
Location: JUBAIL, KSA Date: 08-23-2016
Contract: SN: ARABIANCEC
Engineer: EATON Revision: Base
Study Case: LF-MINIMUM
Filename: HADEED - JUBAIL KSA Config.: Minimum
CASE # 2 - Minimum Operation, 23T1 in service & 23T2 out of Service, 4.16kV Bus tie (3TB12) in closed position
% Alert Settings
Critical Marginal
Loading
Bus 100.0 95.0
Bus Voltage
OverVoltage 105.0 102.0
Generator Excitation
OverExcited (Q Max.) 100.0 95.0
Critical Report
Marginal Report
CASE # 2 - Minimum Operation, 23T1 in service & 23T2 out of Service, 4.16kV Bus tie (3TB12) in closed position
Marginal Report
CASE # 2 - Minimum Operation, 23T1 in service & 23T2 out of Service, 4.16kV Bus tie (3TB12) in closed position
MW Mvar MVA % PF
Number of Iterations: 3
ACEC J.O. No.: 1792
ARABIAN CONSULTING ENGINEERING CENTRE CO.
Calculation No.: CALC-E-004
Al-Khobar, Saudi Arabia Revision No.: B
CALCULATION
Appendix: 2
CONTINUATION SHEET
Appendix – 2
o
R
R
o o
o
o
R
R
R
R
o
Cable1 Cable7
Cable3 Cable9
R 87
23T1 23T2
25 MVA 25 MVA
Cable5 Cable11
o o
R R
o o
Open
6%
97.1 6%
97.1
o
R
6% 2115 kVA 19710 kVA 8427 kVA 3SG1-SOUTH PANEL
EMER BUS 97.1 302.1 A 2815.5 A 3SG1-NORTH PANEL 1203.7 A
4.16 kV 88.9% PF 95.8% PF 4.16 kV 94.6% PF 4.16 kV
1724 kVA 0.0% PF 392 kVA 1409 kVA 1410 kVA 603 kVA 5360 kVA 1699 kVA 232 kVA 393 kVA 332 kVA 0.0% PF 471 kVA 0.0% PF 405 kVA 0.0% PF 1511 kVA 317 kVA 138 kVA 138 kVA 1699 kVA 777 kVA 1882 kVA 777 kVA 0.0% PF 372 kVA 1925 kVA 375 kVA 73 kVA
246.3 A 56 A 201.3 A 201.4 A 86.1 A 765.6 A 242.7 A 33.2 A 56.1 A 47.4 A 67.3 A 57.8 A 215.8 A 45.3 A 19.7 A 19.7 A 242.7 A 111 A 268.9 A 111 A 53.2 A 275 A 53.5 A 10.4 A
88.1% PF 92.1% PF 92.7% PF 92.7% PF 92.3% PF 93.0% PF 0.0% PF 91.9% PF 92.1% PF 92.0% PF 92.2% PF 92.1% PF 83.3% PF 92.0% PF 91.7% PF 91.7% PF 0.0% PF 92.4% PF 84.5% PF 92.4% PF 92.1% PF 82.3% PF 92.1% PF 84.4% PF
o o
o
R R
o
R
o o
R o
R R
o o o
R
R o
R R o
o
34 T3 35T1
34T4 R o o
o
R
R o
o
0.8 MVA R R o o
R 0.8 MVA o 0.2 MVA
o
R R
o
R R R
o
R
R o
34 T1 o o
3PFC17 R
Cable12 o o
R R R
R 1800 kvar R 3FB22-T10 0.64 MVA
o
Cable14 R
0.75 MVA
Cable29 Cable30
4.MCC6 4.MCC5
840 kVA
759 kVA
4MCC3 4MCC2
1019 kVA 1012 kVA
BUS 482 8%
88.7
0.48 kV
593 kVA 720 kVA 409 kVA
802.8 A 976.1 A 554.5 A
89.0% PF 92.7% PF87.4% PF
4MCC4 4MCC1
4MCC7
688 kVA 836 kVA 475 kVA
page 1 14:59:32 Aug 23, 2016 Project File: HADEED - JUBAIL KSA