Best practices: Planning and engineering through production for replacement of 16,500HP adjustable frequency drive system

Application and installation of high-power AFD's (Adjustable Frequency Drives) in the oil and gas industry requires a significant allocation of resources and a large "tool box" in the evaluation and deployment of tailing pumps as capital equipment. This paper was authored to describe a single successful installation of a 16,500 HP medium voltage AFD replacing an existing tailing pump AFD in an effort to increase process availability. This case study was written in a manner to provide a roadmap of key performance indicators, AFD design characteristics, life-cycle phases, and target measures used to support the goals and objectives of efforts in engineering, operations, and maintenance planning. This paper includes an explanation of major life-cycle stages of the project such as: initial planning; design for the purpose of modernization; business case development for funding approval; project execution through detailed engineering; manufacturing and functional testing; project execution; installation; commissioning; trial runs; factory acceptance testing; development of a maintenance strategy and planning for future replacement. The paper also addresses engineering of major AFD elements (power conversion, cooling system, control system and accessories).