CASE STUDIES

Our project portfolio varies throughout the various industry sectors and with our experience throughout these sectors we’re here to provide you with the most cost effective Engineering Power Solution.

We have been involved with a wide range of projects ranging from renewable energy technology to traditional fossil fuel extraction, chemical process and manufacturing projects. Many of these projects involved detailed design of either new large electrical equipment and others have been something as simple as area lighting for a new substation. Whatever the size of the engineering project you can almost guarantee that there’ll be some form of electrical engineering involvement.

At present we’re helping to connect the next generation of efficient wind turbine technology to the existing electrical power distribution network. We’re also providing solutions and answers to electrical engineering issues to extract oil & gas from the most onerous environmental conditions. So, whether its power system modelling for a larger water injection pump, plant electrical protection settings or a new hydro power plant electrical system design Engineering Power Solutions can help you.

Petrofac

Petrofac

A well known Danish oil operator was concerned about the reliability of their emergency diesel generator to provide power for their critical loads in the event they lose the main gas turbine power supply. Typically, emergency generators are periodically tested to ensure that they are operationally sound and can “pick up the load.” Because the diesel generator tests were performed on a weekly basis through an automated system, the emergency generator failed to start on a number of occasions, for an FPSO this could have been a potentially dangerous situation leading to a prolonged black out and loss of production if the generator was called for in a real emergency event. The faulty generator control panel components were replaced, however during a further investigation it was found that many of the existing components within the generator control panel were found to be obsolete. Engineering Power Solutions (on behalf of Petrofac) were requested to produce a detailed report on the condition of the generator control panel. The findings of the report showed that the client could either refurbish the existing panel or replace the complete panel both during a shutdown. In order to minimise the shutdown period it was decided to replace the complete panel. EPS produced the following necessary documentation for enquiry and enable equipment purchase:
  • Site survey
  • Schematic drawings
  • Cable routing drawings
  • Control panel specification
  • Purchase requisition
  • Factory Acceptance Test procedure
This solution modernised the emergency generator control system to enable the vessel essential power supply system to be in service for a further 20 years.
PetroSA

PetroSA

The PetroSA FA platform exports gas to the Mossel Bay GTL plant, gas production from the FA reservoir had over the years been supplemented by FA satellites to the North West of the platform, E-M from the West, and the South Coast Gas (SCG) development from the Southwest. The FO Development Project involved a Subsea tie-back to the existing FA Platform of five new production wells located approximately 40 km South East of the Platform. Once the project was completed produced gas, condensate and water was be piped to the F A Platform via a new subsea pipeline. Engineering Power Solutions Ltd. was requested by to provide electrical engineering and design services. Twelve new electrical pump skids required a number of new power supplies to supply the new 30kW water injection, 30kW Methanol injection and 90kW transfer pumps from existing MCC’s (Motor Control Centres). The project required new lighting above and below a 20 metre long ESDV (Emergency Shutdown Valve) platform. New electrical supplies from existing 440V switchboards to supply the UPS (Uninteruptable Power Supply) system and subsea EPU (Electrical Power Unit) were also required.
SSE

SSE

A wind farm in Scotland was granted planning permission including a connection in principal was offered, however SSE were concerned of the number of wind turbine transformers that could potentially be energised simultaneously. Energisation of unloaded transformers results in a magnetising inrush current with a high amplitude.

The inrush currents can have many unfavorable effects, including operation failure of transformer differential protection, deterioration of the insulation and mechanical support structure of windings and reduced power quality of the system. Without controlled switching the energisation may occur at any time on the voltage wave producing high current peak, when the transformer core is driven into saturation.

The wind turbines power transformers, a vital components of the 11kV electric power network, required the protective relays with very high dependability, security, and speed of operation. But the magnetising peak current, which is often generated when the transformer is energised, may have caused false tripping of the differential relay protection, therefore a reduction of peak current would be necessary. Some methods have been to reduce high peak currents. Pre-insertion of series resistors and synchronous closing of circuit breakers are examples of the available mitigation techniques.

However, Engineering Power Solutions concluded that the most convenient and cost effective solution in this case was to control transformer energisation through operational procedures by means of controlled step sequencing methods, switching on transformers individually through a PLC based system.

Enercon

Enercon

A number of wind turbines were granted planning permission near Edinburgh, Enercon required these wind turbines to be connected to the local 11kV distribution network. The nearest electrical 11kV connection point however was located 2.8 km and the land in between both the wind turbine and 11kV connection point was not owned by the client, this meant that it proved difficult to obtain wayleaves to install a new 11kV cable across the privately owned land. An alternative solution was to install a new 11kV cable at the side of an existing public road with a total route length of 4.8 km.

Using the electrical power software DigSILENT Engineering Power Solutions conducted a load flow and short circuit study to assess the impact of what the new wind turbines would have on the voltage and assess the magnitude of the additional short circuit current at the 11kV point of connection. SP Energy Networks accepted the load flow and short circuit study report and granted connection to the 11kV distribution network.

Engineering Power Solutions proceeded with the design and was requested to produce a detailed design for an 11kV switch station and an 11kV substation at both ends of the new 11kV cable. To enable the electrical contractors to quote for the work the EPS electrical design workpack included:

  • cable routing drawings
  • lighting and small power drawings
  • electrical protection settings schedules
  • Substation location / site drawings
  • LV and HV cable calculations
  • single line diagrams
  • schematic diagrams
  • earthing drawings
  • 11kV switchboard specifications
  • 415V switch gear specifications
  • 11kV / 415V transformer specifications
  • Substation & switch station layout design
  • Co-ordination with civil designers

The wind turbines were successfully installed and connected to the 11kV distribution system to produce a maximum of 2.4 MW electrical power (an average of 21,024,000 kWhrs per annum). This is the equivalent of supplying 840 homes.

Bluewater

Bluewater

Bluewater owns and operates a fleet of five Floating Production Storage and Offloading (FPSO) installations around the globe currently leased to oil & gas companies. EPS was requested to undertake a comprehensive electrical protection offshore survey of their Haewene Brim FPSO, the survey consisted of a 4 day period gathering details of electrical protection settings for the entire distribution network. EPS produced a total of 75 off schedules which were issued detailing the MV and LV electrical protection distribution system.

The up to date protection schedules were then used to create a comprehensive power system model with each protection device. This model was used to create a range of time current curves for a large number of individual circuits with a protection study report.

EPS provided recommendations based of on the findings from the protection report that would enhance the protection and increase the reliability of the electrical distribution system.

We’re currently undertaking an Arc Flash Assessment report complete with an Arc Flash risk assessment with recommendations of how to mitigate potential high energy arc flash using existing protection devices and how to protect their work force.

Dhabi Nortech

Dhabi Nortech

Over the years EPS has been providing ongoing engineering design services for Nortech Oil & Gas. Working for international clients based in the Middle East. Projects range from conceptual design studies for a new 11 kV ring main with approximately 15 km of cable and 5 off 11 kV Ring Main Units to be located within a petrochemical plant in the desert. Ongoing support includes equipment specifications, cable calculations, distribution board specifications, UPS adequacy report, trace heating calculations, earthing design, general design Checking and Approvals etc. EPS has a vast range of experience with Electrical & Instrumentation projects where larger EPC’s or Operators do not have the time or the personnel to undertake FEED or detailed design work.  
SP Energy Networks

SP Energy Networks

An earthing design was carried out and successfully completed for SP Energy Networks wind turbine substation. The substation tied back several 1 MW wind turbines with each wind turbine having its own below ground earthing system including lightning protection system. Each wind turbine required its own below ground earthing system.
Combined Heat & Power

Combined Heat & Power

EPS has recently (July 2016) been awarded the contract to design and build a new dedicated 11kV supply for a new Combined Heat & Power project. The project involves detailed design of a new 11kV switch room and substation, complete with earthing design and individual LV 415V supplies to each CHP plant. The installation will start soon after the detailed design has been completed and client approval. The project also includes a transformer energisation study to satisfy the local Distributed Network Operators voltage dip requirements. The project requires 400 metres of High Voltage (11kV) cable, cable trench, below ground earthing and excavation, 11kV transformer, 11kV switchgear, LV Switchboard and small power and lighting. The gas fired wood chip CHP plant will be fully commissioned at the end of the year supplying homes and buildings in the area.
Marathon Oil

Marathon Oil

At present power is generated on two of the three platforms for power generation, Marathon Oil is to decommission one of the platforms which operate with power generation and the remaining generating platform supporting the non generating platform. The power management system that manages the power flow between all three platforms is complex. Marathon Oil requested EPS to carry out a number of transient motor starting scenarios to determine whether the existing 33 kV power network would enable a 4.35 MW motor to start on their East Brae platform. The main concern is whether the limited power generation will maintain a voltage within a transient starting voltage dip limitation of no less than 20%. At the time Marathon Oil did not have a detailed work scope, EPS assisted in creating a work scope in the form of a project plan, the plan consisted of a structured logical plan to help Marathon achieve decommissioning of the Bravo within a certain time period. EPS set and achieved the realistic delivery dates for the following activities:
  • Dynamic motor and load model creation
  • Gas turbine generator dynamic model
  • Check and verify the existing power system model (originally constructed some time ago for an arc flash study)
  • Power system Transient stability model
  • Transient motor starting report
  • FEED study report
  • Offshore motor starting measurement recording
  • Determination of worst case events and scenarios
  • A new 33 kV topside 'T' connection solution incorporating new 33 kV switchgear to supply a decommissioning load
  • Interplatform protection schemes and designs
  • Transformer tap setting optimisation (once the Brae Bravo has been removed)
  • Statement of Requirements for 40 MVA transformer energisation studies
  • Transformer energisation studies
  • Worst case scenario transformer energisation scenarios and events
  • Platform neutral earthing schemes and solutions
Load flow, short circuit and protection analysis with an arc flash study revision to follow.

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