Electrical Best Practices and Lessons Learned From a Chemical Megaproject: A Thorough Summary

A megaproject is summarized from feasibility design through commissioning and post-start-up support from an electrical perspective. The project includes a 230-kV utility connection stepped down to a 69-kV substation that is connected to 21 modular substations (MSs) for further distribution; internal generation integration; and load requirements of approximately 193 MW over 400 acres. Key lessons learned and best practices that are not covered in literature or industry standards are presented here. Topics include: 230-kV topology for grid connection; grounding and surge protection for high-voltage (HV) cabling; revised zone-selective interlocking schemes; power management system (PMS) segregation and interfaces; preservation practices; protection relay setting management; new medium-voltage (MV) motor control center (MCC) products; grounding and lightning protection; synchronous machine settings; adjustable speed drive (ASD) control; and arc flash protection. The incorporation of lessons learned and best practices is important to maximize standardization, minimize site changes/rework, and enable effective commissioning.