Electrical Best Practices and Lessons Learned from a Chemical Megaproject

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 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 cabling, revised zone-selective interlocking schemes, power management system segregation and interfaces, preservation practices, protection relay setting management, new medium-voltage motor control center products, grounding and lightning protection, synchronous machine settings, adjustable speed drive control, and arc flash protection. The incorporation of lessons learned and best practices is important to maximize standardization, minimize site changes/re-work, and enable effective commissioning.