Challenges encountered when expanding a world-class petrochemical facility

This paper describes the challenges encountered when adding a new ethylene plant, a polyethylene plant, a cogeneration plant, and associated utilities to a major petrochemical facility located in Joffre, AB, Canada. It covers load estimation, power quality, reliability, common electrical specifications, and project coordination with several major engineering, procurement and construction firms. It also highlights the unique design and utility interconnection challenges of building Canada's largest cogeneration plant (rated at 420 MW) within an existing petrochemical plant. The challenges include transmission system capacity and connection, fault levels, stability, and voltage regulation. The paper makes recommendations based on the learning experienced during the implementation of this project, to assist the reader faced with a similar major plant expansion.