RPM Engineering

Experience - Petro-Chemical and Pipeline Industry

• Completed complex investigation into arc-flash medium voltage switchgear failure for two large pumping stations. The equipment was less than 6 months in service. Also, conducted detailed review of seven 5000 HP motor protections, operating practices and field testing.

• Retrofited adjustable speed drive to an induction motor driving a reciprocating compressor for gas plant application.

• Conducted magnetic wedges failure analysis for 7500 HP motor driving reciprocating compressor.

• Design review, field measurements and Multilin relay protection setting for eight 7500 HP motors for compressor station.

• Prepared engineering specification for two 3000 HP adjustable speed drives for soft starting several 7500 HP motors.

• Conducted comprehensive review of implementation plan, justifications, methodology and overall cost for replacing obsolete electrical equipment in a large Petro-Chemical plant involving over 10 substations. The work includes installing multifunctional relays and modern switchgear - to be carried out during scheduled process unit shutdown.

• Conducted failure analysis, protection review and system engineering of a 25,000 HP Adjustable Speed Drive for starting and speed control of three synchronous motors for compressor applications. This IGBT based ASD rating was considered the first of its kind at 11KV directly connected to synchronous motor.

• Conducted investigation into operating history, repair work, motor protection and field measurements of three slow speed induction motors each rated 5400 HP for reciprocating compressor application.

• Selection and implementation of the 19000 HP, 7200 V, IGBT based ASD for compressor application and this to date is still considered the largest IGBT ASD drive ever build and placed in service in the world.

• Carried out design, specification and implementation of the largest medium voltage induction motor ASD for extruder application (7500 HP) in Petro-Chemical industry in North America. Also, worked on the first retrofit project of replacing eddy current clutch (ECC) with ASD rated 2500 HP for extruder.

• Completed comprehensive study of users and manufacturers experiences of medium voltage ASDs in North America, which was sponsored by a large electrical utility. This study was considered the first of its kind when conducted in 1995. Key recommendations were provided to the manufacturers to address the performance and reliability of ASDs as well as produced engineering specification to purchase medium voltage ASD for induction motor.

• Prepared specifications, selection, implementation and testing of the largest LCI drive in the world (1986) for retrofit compressor application. The system consisted of two 22000HP, 6000 rpm LCI with two brushless synchronous motors having 6-phase stator winding located in class1, division1 hazardous area. The key challenges included selecting design parameters to improve the performance and availability of drive train, design input filter to meet very stringent Hydro Quebec harmonic guidelines at 138 KV supply and torsional vibration when running at super synchronous speed.

• Conducted Plant wide computerized harmonic study for a 125 MW Petro-Chemical plant in Alberta having ASD type load to ensure compliance to harmonic guidelines of TransAlta/System Administrator and to IEEE 519-1992 standard. Also, conducted harmonic field measurements.

• Provided technical expertise for a very large Petro-Chemical project in Alberta. This involved 400 MW Co-generation plant, specification and selection of 5 Medium Voltage ASDs.

• Performance evaluation and testing of two 5000 HP MV ASDs for gas pumping station.

• Engineering specification and selection of 13000 HP motor for a mixer application.

• Selection and implementation of (2x2500 HP, 2x1500 HP) medium voltage ASDs for compressor and pump applications.

• Plant wide automatic re-acceleration system for 150 motors using PLC system.

• Rehabilitation of 10 MVA main substation.