TENGIZ PROJECT - FIELD SUBSTATION REPLACEMENT / KAZAKHSTAN

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TENGIZ PROJECT - FIELD SUBSTATION REPLACEMENT / KAZAKHSTAN

Tengiz is one of the largest oil fields in the world, and is located in western Kazakhstan. It is operated by Chevron Kazakh affiliated Tengizchevroil (TCO). The weather conditions in Tengiz are extreme; it gets really hot in the summer and really cold in the winter. So this makes executing large-scale projects very challenging, requiring all the stakeholders to remain focused on reliability all the time.

The Field Substation Replacement Project aims to upgrade and rationalize the existing Field Power Supply System by replacing 6 existing field substations with 3 new substations.

END USERTENGIZCHEVROIL,A Consortium Of Chevron, Kazmunaigas, Exxon, Lukarco

SOLUTIONS DELIVEREDSkema was awarded the contract for the design, manufacturing, inspection and testing of HV switchboards and Remote Terminal Units (RTUs):

- 3 35kV, 1250A, gas insulated switchboards (25 columns)- 3 6kV, 1250A, 20kA, 1 sec., air insulated switchgear units (74 Columns) - 4 redundant RTUs (10 columns) and Electrical Control Systems based on PLC- Switchgear continuous thermal monitoring solution- Arc fault protection system.

INTEGRATED PROTECTION AND CONTROL SYSTEM The Integrated Protection and Control System (IPCS) for the project was designed to monitor and control HV and LV switchgear located inside the different packaged Substations (North, South and West).

Each packaged substation is equipped with a redundant Interface Control Unit (ICU) controlling 33kV and 6.6kV switchgear with pro-tocol IEC-61850, low voltage switchgear and other utilities (HVAC, UPS, F&G) via Modbus and hardwired interfaces. A SCADA system is installed in the Field Control Room to control and supervise the electrical network.

Every substation is also equipped with 4 video cameras and a vocal communication system. This allows to control the unattended sub-stations (both through cabled alarms and alarms generated by the video cameras registering unexpected movements), and to com-municate with the operators, giving them directions.

Data are recorded and are available in real time for an Asset Life-time Management System (maintenance and energy efficiency management of the plant and its components).

SWITCHGEAR CONTINUOUS THERMAL MONITORING SOLUTION Skema provided TCO with Exertherm™, a continuous thermal mon-itoring solution which allows to monitor, in real time, the thermal health and status of key busbar joints and critical cable connec-tions. This is achieved by installing small plastic, non-contact, non-powered, lifetime calibrated infrared and cable sensors within the main electrical panels supplied. This solution provides numerous tangible benefits over traditional periodic scans, including greatly increased levels of safety and in-tegrity protection and reliability assurance throughout the lifecycle of the electrical panels.

The integrity protection was further enhanced by utilising a Load-Map™ software module which enables TCO to dynamically adjust the thermal alarm levels applicable to the load on the circuit being monitored, which provided TCO with a level of integrity protection even at lower utilised load levels.

ARC FAULT PROTECTION SYSTEM The 6kV switchgear supplied for the project has been equipped with a REA arc fault protection system, which can operate as a stand-alone device or in combination with other modules, like the REF relays. The REA arc fault protection system function is based on detecting the intense light of an electric arc, alone or on a de-tection of light and simultaneous phase or neutral overcurrent. On detection of an arc fault, the REA protection system delivers trip commands in less than 2.5 ms to all circuit breakers that feed the fault zone. Furthermore, the system operation indicators help lo-calizing faults by selectively guiding the maintenance staff to the fault zone, that was identified by the arc fault protection system. The REA module supplied for the project features: two high-speed, galvanically isolated, insulated gate bipolar transistor (IGBT) outputs (HSO1 and HSO2) for CB tripping purposes; it offers one heavy-duty relay output (TRIP3) to be used, for example, as a circuit-breaker failure protection (CBFP) output for an upstream circuit-breaker, or as an alarm output; it features an adjustable three-phase overcur-rent or two-phase and neutral overcurrent condition monitoring function, which enhances the reliability of the arc fault detection by eliminating unwanted CB tripping caused by light not related to any arc fault, e.g. flash light used in photography.