In the early year 2009 to late 2010, PowerQ had provided a comprehensive design and engineering services to an Italian EPC company which is responsible for the construction and operation of a sprawling state-of-art fabrication yard. This yard spread over several square kilometers in Karimun, Riau Islands Indonesia.
The scope involved electrical and piping engineering for more than 24 nos. electrical system, HV electrical substation spread across site and several kilometers of compressed air and gases. This includes water utility piping supplying essential utilities to building which is designed to produce oil and gas for offshore and subsea systems.
In the first quarter of year 2010, PowerQ had performed a study to upgrade power system for Discoverer drillship which was undergoing massive upgrade of electrical power system at vessel docked at Subic Bay, Philippines.
PowerQ's engineers had embarked on data collection of site and future power needs of the arctic operation.
Based on the input parameters validated by drilling and operation crew, a model was simulated for the electrical generation, power system and estimated power requirement for drilling operations. The protection setting for new generator circuit breakers and various loads including mud pumps, top drive and ship services transformer were recalculated and the relay was set by the Frontier Drilling team.
GB project (WP and CPP) was located in an open sea with high isokeranic level. When completed in year 2012, this project shall bring gas over to Singapore through a 300km subsea pipeline. The facilities at WP and CPP are electrical system, radio telecommunication system (VSAT), instrumentation system and pipelining. A lightning protection design was completed by client. PowerQ had to review design and provide practical recommendation for site implementation considering practical installation difficulties.
Two GTGs, one duty and one standby, are provided at CPP as main power generation. CPP and WP are steel structures of which all major structural components are intended to weld firmly to deck. The earth bars are intended to be bonded to platform legs.
Objective and Scope
This review was intended to address the need for lightning protection and electronic surge protection on CPP and WP. PowerQ was requested by EPC contractor to carry out a comprehensive evaluation of the design and the existing design of Lightning and Earthing Protection System. We were required to provide practical recommendation considering that the construction was ongoing.
The objectives of the lightning protection review study was to:
To address the objectives, PowerQ had undertaken the following tasks:
a) Review design and specifications
b) Review offshore code and standard
c) Review various lightning protection measures
d) Review current practice in offshore installation
The intent of review was to provide practical guidance and not to emphasize on lightning theory. PowerQ evaluated several offshore installation designs and had provided the best option to adopt . We had provided sufficient justifications for the recommendation thus meeting the codes while minimizing cost of installation.
The work was performed in year 2010 and shall be under continuous review. PowerQ is also providing Power System Analysis Studies for this project and shall be providing services to client till year 2011 as per contract.
During FPSO conversion project, the ship side system - 440LV Emergency Board, 65KA was retained and it was planned that a new generator to be connected to 440V emergency board. The new 1500kVA generator with same capacity as existing but lower reactance (11% compared to existing 15%) leads to higher fault level. Before any studies were carried out, generator was already ordered to meet deadlines.
PowerQ carried out analyses using SKM Power Tools software to determine the maximum fault currents under various scenarios including emergency operation. It was found that the short circuit level in 440 LV Emergency Board increased to 69kA thus rendering existing switchboard non-compliant.
Based on PowerQ's recommendation, the switchboard was replaced to meet the increased kA rating. As FPSO modifications occur, the load flow and short circuit calculation shall be (re) performed to identify any potential issues which may lead to Non Compliance to IEC and Class, and costly delays.
In order to ensure adequate distribution of electrical load to new and existing tenants, the building management had requested contractor to confirm that the electrical system installed by them was not contributing to excessive harmonics distortion. The client engaged PowerQ to undertake the monitoring of the three main switchboards supplying power to an MNC office, to review electrical load profiles, carry out harmonics analysis, provide electrical data and necessary recommendations.
PowerQ undertook a power quality audit and monitored the Main Switchboard. The measurements were taken using Power Quality Monitor-PQ3000p and the following results were found:
The average voltage THD was (1.72%-2.1%) and average current THD was (39.63% to 45.98% to 33.3%). The average Power Factor was higher than 0.85 indicating an acceptable power factor.
Monitoring showed the average voltage, frequency and current within the operating limits and standard guidelines. It was established and noted that 20% to 50% average current THD indicated presence of current harmonics in the tenant loads which is typical for office loads with IT equipments. PowerQ had advised on measures to arrest harmonics.
To complement T&C work, PowerQ was appointed to complete an additional task that was to create O&M Manual for the HVAC system of a new greenfield plant. To meet the high standard of the project, the remit was to produce a narrative and illustrative document. It was not merely a compilation of drawings, specifications and catalogs as normally practiced.
PowerQ's Commissioning Engineers were involved in intensive discussions on the overall operations with the Client's Engineers. It was a comprehensive involvement such as; collecting equipments' data, drawings, specifications and reviewing the physical systems. Generating the O&M Manuals comprised of three sections; SYSTEM DESCRIPTION, SYSTEM OPERATION and SYSTEM MAINTENANCE.
PowerQ had produced the manual with extensive application of user-friendly flowcharts and simplified layout drawings to ensure it could be understand by all technical levels.
Special emphasis was laid for a safe operation and energy efficient in the O&M procedure. The manual was produced in hardcopy and indexed pdf-softcopy. Information in the manual shall be further used to schedule predictive maintenance and Reliability Centered Maintenance (RCM).
PowerQ had provided a design, installation and testing for electrical systems training to 25 Electrical Managers and Engineers of a shipyard contractor to meet the European classification society certification.
The training covered the introduction to marine and offshore production vessel, grounding on marine system, characteristics of equipments in marine and offshore vessels (Drill-ships, FPSO, LNG carrier), safety, cable termination and testing & commissioning.