Why, when and how to perform Industrial Power System dynamic studies

The unfortunate destiny of many expensive Industrial Power Systems (IPS) study reports is to become worthless desk products while multiple binders of computer printouts collect archive dust. While studies of electrical power system dynamical behaviour under heavy motor startup, fault conditions and re-acceleration have been carried out for many years, there is still confusion as to why, when and how such studies are of real value in project design. The purpose of this article is to discuss electrical, computer-based power system dynamic studies in relation to actual project needs. A case study is presented of a large offshore oil platform, providing an example of practical application. Dynamic simulations are compared with measurements made at site of direct-on-line starting of large induction motors. As the dynamic behaviour of the IPS may by far exceed the complexity of the industrial process which it supplies, it is vital that project management (often mechanical or chemical engineers) early are made aware of this complexity.

The IPS design process

Application of computer-based dynamic studies in IPS requires close attention to two important aspects. Firstly, the project phases ranging from the early feasibility studies to the operation stage of the facility must be understood. Fig. 1 shows a simplified electrical project lifecycle. The tendency in todays fast track projects is to jump straight from a conceptual study to procurement of long lead items such as the main power station and other large packages. It is then difficult to fit in the necessary dynamical analysis to ensure that the power system will work properly under all operating modes. By the time the complete data to carry out such studies are available, all the large packages are already on order and any delayed changes to the Single Line Diagram (SLD) or large equipment becomes very costly. Secondly, the electrical power system design process itself must be recognized. The design of an IPS is a repetitive process obviously dependent on the type of project and facility. Nevertheless, there are some common denominators. In order to arrive at a firm SLD and facilities for power system operation and control, Fig. 2 shows a typical design process. This article will not give detailed descriptions of the elements in this diagram, but merely point out the iterative nature of the process and discuss how to incorporate the dynamic analysis. The term dynamic here implies a broader context than just the time simulations on a system model utilizing a set of first order differential equations, load flow algorithms and applicable numerical methods. Voltage dynamics involves balancing the available fault level and equipment withstand capability against sufficient short circuit capacity to start up large loads without excessive voltage variations. The process of developing the conceptual SLD is iteration between short circuit and voltage dip calculations. These usually do not require numerical time simulations and can easily be carried out manually. The selection of voltage levels also involves equipment considerations such as availability, size, cost, standardization, etc. In the conceptual phase there is rarely sufficient data and time to conduct detailed dynamical simulations. However, simplified voltage dip calculations for motor starting and other Page 1 of 17

dynamic conditions are vital to avoid surprises in the subsequent project phases. Frequency variations on the other hand, cannot be predicted unless a full dynamic time simulation is carried out. Still, it is possible to assess the system step loads and include these in the power station and generator prime mover specifications and requests for bid. If the concept involves parallel operation of dissimilar power stations, such as diesel engines, gas or steam turbines, possibly with long power lines in between, there is a need for an early dynamical analysis assessing system stability. The big question is whether major dynamical analysis can be done while bidding is ongoing. This requires cooperation and supply of technical data from multiple equipment vendors. Moreover, the power system analyst requires long and specific experience from other projects with similar type of generators, prime movers and associated controls. The pre-engineering phase normally includes a full dynamic study with the objective of verifying earlier studies and identifying all long lead equipment parameters and control system requirements before issuing of purchase orders. For example, an early conceptual maximum voltage dip calculation for motor starting, would now be superseded by a full dynamic simulation assessing the entire starting time at given load torque. This verifies motor and generator thermal capacity requirements (including excitation system) prior to buying. In detail engineering, the dynamic analysis must be updated, this time with the objective of setting the relay and control systems parameters. In modern plants, Power Management and relay protection schemes are highly integrated. Microprocessor controlled multifunction relays become increasingly complex, and include many of those functions that used to be part of the Power Management Process Stations. A sound dynamical analysis capturing all of the relevant normal, special and failure operating modes is extremely important when setting the power management and protection relays. Relevant disturbances to be dynamically studied and their counterparts in relay and control systems engineering are shown in Table I.

Photo 1 - Oseberg C platform

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Table I System disturbances

Disturbance Loss of generation or distribution system sections with subsequent load shedding or load transfer Relay and control systems engineering counterpart Design and setting of electrical load shedding or load transfer systems which can be based on circuit breaker trip/status signals, under-frequency, rate of frequency change (df/dt), electrical power balance, generator prime mover temperature or combinations of such initiators Coordination of generator field failure protection, setting of bus coupler protection schemes and AVR supervision systems Coordination of generator over-current and frequency protection, setting of bus coupler protection schemes and power management load sharing supervision Coordination of over-frequency and over-voltage protection as well as engineering of process and emergency shut down schemes

AVR / excitation system faults leading to maximum or loss of excitation output for one generator Prime mover governor faults

Multiple levels of Process or Emergency Shut Down, which will impose large load rejection on the power station or feeding transformers with on-load tap changers Temporary voltage disturbances and subsequent re-acceleration of motors Transition from normal to back-up or emergency power supply with subsequent re-acceleration Short Circuits

Design and setting of motor re-acceleration systems Setting of consumer restart schemes

Coordination of short circuit, under-voltage and frequency protection

Feasibility Study Operation

Conceptual Study

Commissioning (Liven up)

Preengineering

Completion

Detail Engineering Follow-on Engineering

Construction (Installation)

Procurement

Manufacturing

Figure 1 Electrical project lifecycle

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Initial conditions

Plant Layout Production Capacity Operating Modes Electrical Codes

LOAD AND SUPPLY PLANNING

IPS must be:

Safe Simple Maintainable Flexible Reliable Economical Verifyable SHORT CIRCUIT AND DYNAMIC ANALYSIS

SELECTING VOLTAGE LEVELS

SELECTING SYSTEM NETWORK

SYSTEM EARTHING

SURGE PROTECTION POWER FACTOR CORRECTION

RELAY PROTECTION AND SELECTIVITY

HARMONICS OPERATION AND CONTROL

Specification and Procurement

Figure 2 Typical Industrial Power System Design Process

Case Study
The case study comprises a large offshore oil & gas platform. For this existing facility a large process extension was planned. The platform gas injection capacity had become a bottleneck in the oil production. Various process options to increase the gas injection capacity were considered. The electrically most extensive case was to install one new 9.0 MW compressor package and to upgrade the two existing ones from 6.8 MW to 9 MW. The compressors are all driven by induction motors with DOL (Direct-On-Line) start. Platform Electrical Power System The platform electrical power system is outlined in Fig. 3. Main generation consists of two 30 MVA generators at 13.8 kV. . Large induction motors for gas injection, recompression and oil export are fed from the main 13.8 kV switchboard while medium size motors for seawater lift, air compressors, etc. are fed from the dedicated 6.0 kV emergency switchboard. Three 1.75 MVA emergency generators (not shown) are connected to the 6.0 kV switchboard. Variable speed drives for drilling are fed from 660 V switchboards, while platform process auxiliary motors are fed from 440 V switchboards.

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The main power station consists of Cooper Rolls gas turbines, 24 MW, 4940 rpm with Woodward governor and Siemens generator, 30 MVA, 1800 rpm, 60 Hz, AVR is Siemens RG3 15. New 9 MW Direct-On-Line started induction motors The new compressor full load operation was with 65 BAR suction pressure and 8.2 MW power requirement at 1786 rpm while start duty was with 32 BAR suction pressure. The new (and existing) compressors are electrically driven by DOL started induction motors. Two alternative electric motor manufactures were considered during the study. In both cases motors with 9.0 MW (shaft) power rating, max. starting current of 4.2 p.u. and synchronous speed of 1790 rpm were applied. Challenges The new installation represented a number of challenges. Some of these were: 1. High utilization of the main power station The platform electrical load is quite variable due to changing requirements in drilling as well as process. Peak load with one new 9.0 MW compressor and upgrading the two existing ones from 6.8 to 9.0 MW was estimated to 46 MW. Gas turbines commonly used on offshore petrochemical plants generally have a variable output due to variation in ambient temperature, humidity, fuel quality as well as maintenance and overhaul intervals. This means that available output from the 24 MW rated engines can vary with several MWs both ways. However, deterioration of the engines usually implies that available power is lower than the rated values. The gas turbine control system applies an exhaust temperature dependent override of the speed governor. Depending on the setting of this control function and the associated allowed engine thermal stress, frequency drop will result if the engines are overloaded. 2. Running compressors are sensitive to power frequency variations Practical experience on the platform had shown that the running injection compressors driven by induction motors were sensitive to power frequency variations. Excursions rates exceeding 1 Hz/s represented a risk for the compressors to go into a surging mode with subsequent Process Shut Down (PSD). The system frequency excursions during start of one 9.0 MW compressor motor were therefore much more stringently defined by the gas process itself than the electrical statutory regulations applicable to the facility. The Norwegian electrical code permits minus 10 % transient frequency variations (6 Hz on a 60 Hz system) with no requirements for rate of change. 3. Generator field winding and excitation system thermal capacity constraints The high inertia of the combined 9.0 MW induction motor and compressor unit caused start-up times of about 14 sec. This required further investigations into the thermal capacity of the generator field winding. This is a common bottleneck for start-up of large motors with high inertia loads on local generators. The generators have IEC 60034 class F field winding insulation.

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GT/G A 30 MVA 13.8 kV

GT/G B 30 MVA

Oil exp. 3.0 MW Gas recomp. 6.0 MW Gas injection: 6.8 MW 6 kV 0.66 kV 0.44 kV

New 9 MW gas injection motor

Figure 3 - Platform electrical power system - Single Line Diagram

Measurements at site and associated calculations In order to establish the best possible basis for the computer analysis, on-site measurements were carried out on start-up and stopping of one 6.8 MW induction motor while an identical motor was already running. In addition, measurements were made on the two main generators with approximately 9 MW of initial load during the tests/measurements according to table II. Voltages and currents (instantaneous phase values) were measured according to table III. Based on these measured values, system frequency and active power for the generators and the two induction motors were calculated. Table II Test Description
Test no. 1 2 3 4 Description Stop of one motor from running condition Start-up of one motor Stop of one motor from running condition Start-up of one motor Operating condition - Two generators running (2x31 MVA) - Load (prior to stop of motor): 23 MW - Two generators running (2x31 MVA) - Load (prior to start-up of motor): 18 MW - Two generators running (2x31 MVA) - Load (prior to stop of motor): 23 MW - Two generators running (2x31 MVA) - Load (prior to start-up of motor): 18 MW

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Table III Tests Arrangement

Measured Phase quantity A B C x x x Bus voltage x x x Current, generator A 1 Current, generator B x x x Current, motor A Current, motor B x x x Bus voltage x x x Current, generator A 2 Current, generator B x x x Current, motor A Current, motor B x x x Bus voltage x x Current, generator A x Current, generator B 3 x x Current, motor A x Current, motor B x x x Bus voltage x x Current, generator A x Current, generator B 4 x x Current, motor A x Current, motor B For voltage and current measurements, existing voltage and current transformers in the 13.8 kV switchboard were used. A transient recorder Hioki 8826, equipped with a 12 bit A/D converter, 10 channels, was used. The sampling frequency for the measurements was 10 kHz. Test no

Calculations based on measurements The system frequency is calculated on the basis of the voltage measurements from phase A. The approach is based on finding the distance (in time, t) between two adjacent zero crossings of the voltage signal (half-period) and calculating the frequency, f, as:
f = 1 2 t

(1)

The three phase active power (instantaneous value) was calculated based on recorded instantaneous values of phase voltages (ua, ub, uc) and corresponding phase currents (ia, ib, ic), according to:
p el ,mom = u a i a + u b ib + u c ic

(2)

Equation (2) requires three pairs of corresponding phase voltages and currents. However, due to a limited number of input channels on the transient recorder, not all tests contained the necessary number of pairs of voltages and currents (see Table III). Where only two phase

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currents were measured, the third was derived from one of the two measured currents by shifting it 120 (+ or -). Where only one current was measured, the second and third were derived from the one measured by shifting them 120 and 240 respectively. It is reasonable to believe that the error introduced by this approach is relatively small, except for the initial part of the transient period. Measurements - comments and assessments The largest negative voltage deviation measured during motor start-up (test 4) was 9.5 %. The largest positive voltage deviation (over-swing) was measured during test 2 at +4.3%. This over-swing may be explained by the characteristics of the generator AVR and its brushless excitation. The largest frequency drop was measured during motor start-up in test 2 at -1.4% (see Fig. 8). The largest frequency increase was measured during motor stop in tests 1 and 3 at +0.8%. The maximum value of the breakdown power for the starting motor was calculated to be 12.6 MW (test 2). The calculated values for active power are very high and show large oscillations during the first 2 seconds of the motor start-up period (see Fig. 8). It is assumed that these results are not physical in nature, but rather are due to one or several of the following factors: Asymmetrical inrush current for the induction machine (DC component). Reduced accuracy of the current transformers at high currents. Non-symmetric three-phase system during the starting period. Aliasing effect (transient recorder/sampling frequency). Electromagnetic noise Non simultaneous closing of breaker poles(marginal effect) Bouncing of breaker poles (marginal effects)

Therefore, approximately the first 2 seconds of active electric power for motors and generators during the starting period are to be neglected when assessing power variations during motor start-up. The deviation band, observed on the time plots for the generator active power output is also attributed to these factors. System modeling on computer A system model was established on the EDSA software, a suite of programs developed by EDSA Micro Corporation in San Diego, covering all main electrical system calculation and simulation disciplines. The load flow and dynamical simulation modules were applied for the case study. The main generators were represented by a 5th order d-q axis model as shown in Figure 4. The two main generators, although with similar rating and rotor construction, had different Page 8 of 17

impedances and time constants. This was expected to cause power oscillations between the generators during motor start-up. To assess frequency variations during start-up of the new compressor motors, it was crucial to know the gas turbine and associated control system model. This is shown in Figure 5, covering the principal dynamics of the system. The speed control operates in isochronous mode by application of load sensor and paralleling lines. Moreover, fuel control, valve positioner and gas turbine dynamics are represented. The frequency excursions during motor start-up at high initial load were sensitive to the modelling of the gas turbine temperature control system. In Figure 5 the output from the temperature control system enters the low value select block in the speed controls governing the fuel actuator reference. If the temperature reaches pre-set limit levels, the speed governor fuel actuator reference is overridden by the temperature controls. As the study progressed, a number of simulations were carried out with different settings of the temperature control loop investigating the impact on system frequency excursions during motor start-up. The generator excitation system is of the alternator uncontrolled rectifier type. It comprises an S5 type programmable controller, redundant incoming feeders along with two separate automatic control systems. (One duty and one stand-by). The S5 has a built-in rotor thermal protection with inverse time current characteristic. If this protection is activated, it will alter the AVR feedback signal to limit the rotor current to nominal value. The shortest protection response time is 10 seconds at 1.4 times nominal rotor current. Motor starting simulations determined the excitation voltage and associated average field current during the start-up time of 14 seconds. The excitation system simulation results could thus be compared to the field winding thermal protection characteristics. The thermal utilization by starting the new 9.0 MW motor was found to be marginally within the protection limits. This was acceptable, considering that this protection was set conservatively and could be adjusted at site in cooperation with the manufacturer, if required. The excitation system model is shown in Figure 6. This model is relatively simple, as limited information was available to develop more sophisticated representation. Still, the principal effects of AVR, feedback and saturation are included. Induction motors are represented as shown in Figure 7. Induction motor parameters were estimated for the required model on the basis of speed-torque and speed-current characteristics.

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Figure 4 - Synchronous machine model

Figure 5 - Gas Turbine Prime Mover and associated Controls Page 10 of 17

Figure 6 - Excitation System model

Figure 7 - Induction motor model

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Comparison between simulated and measured results Figures 8, 9 and 10 show simulated and measured 13.8 kV bus frequency, generator active electrical power and 13.8 kV bus voltage, respectively.

[Hz]

Measured
60.8

Calculated

Measured: +0.25 Hz Simulated: +0.25 Hz

60.4

59.8

59.6

Measured: -0.8 Hz Simulated: -0.7 Hz

Figure 8 - Generator Frequency during start-up of 6.8 MW induction motor

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MW

Measured
Simulated
15

Measured: 15.3 MW Simulated: 15.6 MW

10

9.2 MW

11 MW

5.0

Figure 9 - Generator Electrical Power during start-up of 6.8 MW induction motor

:

kV L-L

Measured Measured Simulated

Measured: + 5.0 % Simulated: +5.4 %

14

Calculated
13

: -9.0 Measured: -9.5 % : -9.0 %

12

Simulated: -9.0 %

Bus Voltage (13.8 kV)

11

Sec.

Figure 10 - Main 13.8 kV bus L-L r.m.s. voltage during start-up of 6.8 MW induction motor Page 13 of 17

Looking first at the frequency envelope during start-up of the 6.8 MW induction motor in figure 8, the following can be observed: The shape of the measured frequency envelope is quite similar to the simulated envelope. The breakdown torque of the starting motor is seen to cause a relatively sharp dip in frequency 3.5 seconds after start. The measured frequency rate of change (df/dt) is slightly higher than simulated rate of change, both during the initial drop and the subsequent rise after the motor exceeds breakdown torque speed. This can be attributed to several factors, but is likely to be partially caused by somewhat higher inertia in the GT/G train model as compared to the actual equipment inertia. The same effect causes the simulated frequency drop to deviate 0.1 Hz from the measured value.

Next, from the generator electrical power results, figure 9, the following is observed: The simulation of initial and steady state power after start (although prior to fully loading the compressor itself) are identical to the measured values The measurements show a clear active power oscillation between the two main generators. Although the large active power amplitudes during the first two seconds of the start-up period are largely influenced by factors listed under Measurements comments and assessments, the oscillations can in principal be attributed to the fact that the electrical generators have different impedances. The difference is partly related to the arrangement of the damper windings and direct axis subtransient reactance (saturated) is 14.55 % and 10.8 % for generator A and B respectively. Transient reactance (saturated) has a smaller difference between the generators, 20.2 and 19.5 % for A and B respectively. Synchronous reactance (saturated) is 230 and 150 % for generator A and B respectively. This oscillation is also reproduced in the simulations, but the magnitude of the simulated oscillation is much smaller. The simulated electrical power at breakdown torque speed of the starting motor, however, matches the measurement

Finally, from the voltage results, figure 10, the following is observed: The simulated initial voltage dip matches the measured results indicating that applied motor and generator reactances in the model are close to actual values. These values are not significantly influenced by the AVR model itself, since both main generator transient field time-constants are 6.0 sec. Fast excitation voltage response will therefore only marginally compensate the initial voltage dip as the excitation current response is largely determined by the generator design. The following part of the voltage envelope indicates higher gain in the simulation model as compared to actual equipment data. The simulation gives a voltage overshoot just after the initial dip, which is not present in the measurements. The simulated voltage overshoot at the end of the start-up period matches the measurements. This phenomenon is related to the induction motor breakdown torque speed where the motor current changes from close to standstill starting level to load current within 200 300 ms.

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Start analysis for new 9.0 MW induction motor Starting analysis for the new 9.0 MW motor was carried out based on the developed model for the platform electrical power system and subsequent validation by comparison between measurements and simulations. Data from technical proposals from the pertinent compressor motor manufacturers were used in the motor start-up simulations. Data common to all motor alternatives were: Rated shaft power: Rated voltage: Rated frequency: Max p.u. starting current: Construction: Ex classification: Temp. group: Cooling method: 9.0 MW 13.8 kV 60 Hz 4.2 (including tolerances) 4 pole, (1800 rpm synchronous speed at 60 Hz) Eex p T3 Seawater

Results were evaluated against platform electrical system requirements as well as motor technical constraints. Simulation results from one of the study cases are shown in figures 11 to 14. Based on the dynamical simulations carried out, it was possible to pinpoint the bottlenecks within electrical and control systems, analyse them and finally permit go-ahead for purchase and installation of the 9.0 MW motor.

Chart 2 - Frequency 61 58 Hertz 56 54 52 50 0 2 4 6 8 10 12 14 Time in Seconds

60,24 Hz

59,59 Hz

59,62 Hz

16 18 20

Figure 11 Simulated generator frequency during start of 9.0 MW motor

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Chart 3 - Voltage 1,20 1,12 Per Unit 1,04 0,96 0,88 0,80 0 2 4 6 8 10 12 14 16 18 20 Time in Seconds

1,10 pu

0,85 pu

Figure 12 - Simulated main 13.8 kV bus voltage during start of 9.0 MW motor
Chart 4 - Electric Power 26 21 M Watts 16 10 5 0 0 2 4 6 8 10 12 14 16 Time in Seconds 18 20

24,72 MW

20,61 MW

Figure 13 Simulated generator electrical power during start of 9.0 MW motor

Chart 6 - Excitation Voltage 7,2 5,6 Per Unit 4,0 2,5 0,9 -0,7 0 2 4 6 8 10 12 14 16 18 20 Time in Seconds

3,76 pu

Figure 14 Simulated generator excitation voltage during start of 9.0 MW motor

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Conclusion
Electrical power system dynamical behaviour can be assessed using different methods, each requiring different levels of input data detail. The purpose of the IPS dynamical assessment is partly to find the correct size and parameters for the electrical equipment and partly to assist the design engineer in selecting control systems and relay protection settings. In the design process of an IPS it is imperative to recognise that each different project phase imposes distinct requirements to electrical dynamics assessment. The full numerical simulation of transient stability and dynamical behaviour with associated models of electrical power components and their control systems represent a highly valuable design tool. Such studies must, however, be carried out with great care as the risk of producing mistakes or useless paper products is high. High level of academic training, high-quality simulation software, correct assessment of operation modes, competent grasp of the interface between the power system and the industrial process are all necessary in order to arrive at trustworthy results. The case study presented in this article, shows simulation results close enough to measurements to have real practical application value. Although this article refers mostly to IPS in petrochemical plants, the principles discussed are generally useful for most types of industry.

References
[1] Unitech Power Systems, Overall System Design, Industrial Power System Design Course as if operation really mattered, December 1999.

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