Finding and implementing the right electrical motor to reduce CO2 emissions at a refinery
Our client asked us to replace their steam turbine with an electrical motor. After thoroughly evaluating alternatives, we arrived at a suitable solution in the form of a 24 pulse variable frequency drive in combination with a transformer.
-
Preliminary engineering: evaluating alternatives
-
Implementation and engineering: cabling and power supplies, signal connections, operator panels
-
Designing documentation for the contractor and supervising construction
The challenge
Helping our customer in the transition to renewable energy
Refineries are working hard to reduce their CO2 emissions. A big refinery in the Port of Antwerp enlisted our site engineering team to replace a >4000kW steam turbine with a high voltage frequency controlled electrical motor.
“Engineering, implementation and preparing all documentation for the contractor: we’re in it for the long run.”
Our approach
From selection to flawless implementation
In the basic engineering phase, we helped the client to evaluate alternative options (Direct on line, capacitor bank, softstarter, variable frequency drive) for the replacement of the steam turbine. We evaluated load flow, selectivity, motor start current and voltage drop and the impact on the short circuit current for the different options in SKM Powertools. Finally, a 24 pulse variable frequency drive in combination with a transformer was selected.
For the implementation, we carried out the following engineering tasks: underground routing of cables, the extension of the substation with an additional 36kV and space for the VFD and transformer, HVAC evaluation, and signal interconnections with ESD and DCS systems. Based on the OEM’s input, Contec wrote a control narrative and created a Cause and Effect.
In the compressor hall, the old Exp panel with the operator start-up panel and machine protection system (bearing vibration and temperature monitoring) was replaced by a smaller Exe start-up panel, an HMI panel and a new machine protection system in the termination room.
All these modifications were condensed in clear electrical drawings, material and cable lists, work descriptions with photos and a bill of quantities. As such, the refinery was able to select the most suitable electrical contractor for the construction works. The contractor did an excellent job, divided into pre-turnaround and turnaround works, with the support of our construction supervisors.
The compressor was successfully started in the first half of 2024.
