Documente Academic
Documente Profesional
Documente Cultură
and solutions
Power outages typically lead to damaging costs for refiners. Strategies are
needed to minimise them
Patrick J Christensen, William H Graf and Thomas W Yeung Hydrocarbon Publishing Company
Electrical: 19%
Other: 12%
Hydrocarbon
Publishing
Company collected data from
reports published by the US
Department of Energys Energy
Assurance Daily. The information analysed focused on power
failures and disruptions at US
refineries.
Maintenance: 23% Mechanical: 46%
From 2009 to 2012, there
were over 1700 refinery shut- Figure 1 Overall shutdowns
downs, which equates to an 2009-2012, %
www.digitalrefining.com/article/1000773
Surges: 1.9%
Breakdown: 17.6%
Weather: 16.4%
Other: 1.9%
Fire: 1.9%
Unspecified: 60.4%
July 2013 1
proper
maintenance
of
cause problems. Power lines can
Rotary equipment: 7.0%
processing units and electrical
be knocked down, lightning
Refinery
Unspecified
equipment can help avoid
strikes can disrupt units, and rain
processing
equipment:
units: 24.6%
12.3%
breakdowns.
can interfere with the steam
Unfortunately, over 60% of
supply. These are a few of the
the causes of electrical
examples that show how weather
disruptions are not specified.
can cause a refinery shutdown.
Most of the unspecified
In February 2010, Valeros
power failures were listed as
Ardmore, Oklahoma, refinery
a power failure occurred at
experienced thunderstorms that
the refinery and caused flarcaused temporary power outages
ing or similar statements.
at several units, reducing runs.
Electrical equipment: 56.1%
There are multiple reasons
Valero reported that it was restorwhy the reports were so Figure 3 Breakdowns causing power ing full production at the plant the
vague: the refiner did not disruptions 2009-2012
next day. On 1 December 2011, a
know the reason at the time
wind storm caused a power outage
of the report, there are confidentiality policies and forced several units offline at Chevrons El
that prevented the refinery from reporting the Segundo, California, refinery, halting production
causes, or the refinery for whatever reason did until 7 December. Among the affected units was
not want to be very specific in its report. The a CDU that caught on fire in the aftermath of the
fact that so many are unspecified makes it diffi- electrical failure. Flaring occurred as a result of
cult to minimise power disruptions. Therefore, the incident and during the subsequent restart
any prevention and protection strategies process. Fire damage to the CDU, six days of
deployed by a refinery should include detailed inactivity and flaring all adversely affected the
bookkeeping of failed equipment so that statis- refinerys bottom line.
tical analyses or predictive analytics can be
In March 2009, Motivas Port Arthur, Texas,
performed in identifying exact causes to reduce facility experienced lightning that led to a power
future incidents, as discussed in part 2 of this outage and also stated a fire. The lightning
article.
caused a crude unit, two hydrotreaters and a
In Figure 3, 56.1% of the failing units were delayed coker to shut down. Unlike Motivas
electrical equipment such as circuit breakers, experience, in July 2009, Pasadena Refinings
switchgears, transformers and substations. Some Pasadena, Texas, complex experienced a light24.6% of power disruptions were caused by ning strike that disabled all power to the Red
refinery processing units such as the FCC unit Bluff Tank farm, which resulted in loss of feed to
having electrical issues. About 7% of problems the refinerys crude unit. The feed was restored
were the result of rotary equipment such as with a backup generator, and the refinery was
motors and compressors having electrical prob- able to run using backup power and keep operalems. About 12% did not specify the unit or tions online despite the loss of power to the tank
equipment that was having problems.
farm. In April 2012, Valeros Norco, Los Angeles,
From 2009 through 2012, there were about facility experienced a power surge caused by
320 power disruptions at refineries in the US. In lightning, which caused the hydrocracking unit
this section, some of their experiences are to trip. Emissions of sulphur dioxide and hydroreviewed. All of these disruption events were gen sulphide were released during the flaring
gathered from the US Department of Energys caused by the shutdown.
Energy Assurance Daily publication. We chose
Although high wind and debris are the most
events that provided a clear picture of the causes commonly cited causes of hurricane damage, for
and impacts from power disruptions.
Gulf Coast refineries in the US, where hurricanes
hit most often and hardest, the greatest hurricane
Weather problems
damage is the result of flooding. Hurricane Isaac,
The most common weather event that causes which touched down in Louisiana 28-29 August
power failures is a thunderstorm. High winds, 2012, caused extensive flooding, forcing nine
lightning strikes, heavy rain and flooding can all Louisiana oil refineries with a collective capacity
2 July 2013
www.digitalrefining.com/article/1000773
www.digitalrefining.com/article/1000773
July 2013 3
14000
4 July 2013
www.digitalrefining.com/article/1000773
www.digitalrefining.com/article/1000773
of non-essential workers from the plant. Safetyrelated incidents can result in the loss of life
along with the potential for millions of dollars in
fines and civil lawsuits, not to mention any negative publicity from the event. Previously, BP paid
over $87 million in fines issued by OSHA along
with undisclosed amounts in civil suits related to
an explosion and subsequent fire at its Texas
City, Texas, refinery on 23 March 2005 that
resulted in 15 worker deaths and over 170
injuries.7
Conclusion
As previously noted, about 19% of refinery emergency shutdowns in the US between 2009 and
2012 were caused by power disruptions because
of severe weather, poor power quality and electrical equipment malfunctions. Costs to refiners
amount to millions of dollars every year due to
lost production, repairs to damaged equipment,
sending valuable material to flare, possible fines
for excessive emissions, and so on. Therefore,
equipment vendors, maintenance and reliability
servicing companies and refinery technology
developers have been seeking technical
approaches to prevent power failures, protect
equipment, speed up restarts and salvage
damaged components. A few of the techniques
available include approaches to examine transformer failure due to switching transients,
perform transformer end-of-life evaluations,
undertake early fault detection and diagnosis in
an FCC unit, reduce arc flash energy, predict and
diagnose medium-voltage switchgear and rotating machines, and other latest techniques.
Power grid reliability can be threatened by
anything from severe weather to cyberterrorism. CHP/cogeneration is said to be a good
way to preserve power reliability through natural
disasters. In the near future, microgrids will play
an important role in refinery power reliability and
security. Since there are many options available
and refiners are often limited by tight budgets,
the cost-effective strategy is first to combine electrical outage data and process reliability models
and identify the most vulnerable equipment and
units. The results assist in sound decision-making
on what options and investments to choose in
minimising power failures. Finally, disciplines
such as actuarial science and enterprise asset
management should be included in overall refinery operations management. The objective is to
July 2013 5
ensure that the plant can achieve utmost reliability and highest energy efficiency to maximise
profitability while fulfilling safety and environmental requirements.
This article is the first of a two-part series
from a white paper called Refinery Power
Failures: Causes, Costs, and Solutions from
Hydrocarbon Publishing Company. The paper is
an excerpt from a multi-client strategic report
called Refinery Power Outage Mitigations:
Latest Technologies and Strategies to Minimize
Financial Impacts, to be published in June
2013.
Special thanks to Baldwin A Yeung, PE of SAIC, who provided
technical assistance for this paper.
6 July 2013
5 www.phillips66.com/EN/about/our-businesses/refiningmarketing/refining/Pages/index.aspx
6 Feinstein to FTC: Investigate Spikes in California Gas
Prices,
www.feinstein.senate.gov/public/index.cfm/pressreleases?ID=d5f32f54-4bec-490e-a350-f68797cef1d7
7 BP Texas City Violations and Settlement Agreements. OSHA
website. www.osha.gov/dep/bp/bp.html
Patrick J Christensen is Project Manager, Hydrocarbon Publishing
Company, with seven years refining experience. He holds a BS
degree in chemical engineering from Drexel University.
William H Graf is Technology Analyst, Hydrocarbon Publishing
Company, and holds a BS degree in physics from HampdenSydney College.
Thomas W Yeung is Principal and Managing Consultant,
Hydrocarbon Publishing Company.He is a licensed professional
engineer in New York State and holds a BS degree in chemical
engineering from University of Wisconsin-Madison, a MS degree
in chemical engineering from University of Connecticut-Storrs,
and a MBA from New York University.
Email info@hydrocarbonpublishing.com
LINKS
More articles from: Hydrocarbon Publishing Company
More articles from the following categories:
Power Generation
Reliability & Asset Management
www.digitalrefining.com/article/1000773
art 1 of this series (PTQ, Q3 2013) discussed balloon caused a short circuit in a substation at
how electrical disruptions and power fail- ExxonMobils Torrance, California, refinery in
ures at refineries regularly cause enormous the US resulting in the evacuation of workers
damage in terms of lost production, excessive and elevated flaring.
repair costs, and can lead to environmental and
Refineries require a lot of power to operate.
safety concerns, raising the questions of how The overall mitigation strategy primarily consists
these outages can be prevented and how an of two parts: risk management and crisis
affected refinery can be brought back online as management (see Figure 1). In handling risk
quickly as possible. In this article, vital preven- management, a refinery must install the most
tion techniques, protective devices, quick restart reliable equipment available in the market that
equipment, and supply security methods will be can withstand disruptions caused by weather,
discussed.
power surges, blackouts, and any other outside
Electricity is the lifeblood of the refinery oper- elements. Since no equipment is perfect, reliabilation. Optimal design and excellent construction ity engineers and operators still need to prepare
mean nothing if the plant cannot receive a for worst-case scenarios as well as the most
consistent and reliable power supply. Plant shut- frequently occurring possibilities. This is where
downs, whether planned or unplanned, will they utilise prevention techniques to detect and
decrease production and reduce profits, as fix problems before they lead to a power failure,
shown by US refiner HollyFrontier, which and select protective equipment accordingly.
reported a loss of $98 million for Q1 2013 When a problem does arise, the second part of
because of planned and unplanned shutdowns.1
the strategy crisis management comes into
Not only is power reliability essential for prof- play. This involves the recovery technologies that
its, it is also important for
national fuel supply security
and environmental concerns.
Refinery outage
mitigations
On 8 July 2013, Enis Taranto
refinery in Italy suffered a leak
of untreated fluid following a
power outage. Italys industry
Crisis
Risk
management
management
ministry declared that the refinery must invest in a power feed
system to prevent further blackouts, or else the refinery would
Prevention
Protection
Recovery
Restart
lose its permits.2 The necessity
of flaring following electrical
failure is common, as on 30
May 2013 when a simple Mylar Figure 1 Refinery outage mitigations
www.digitalrefining.com/article/1000846
PTQ Q4 2013 1
allow for safe shutdown and continued operation, and the restart methods that will not lead
to the same problem that caused the previous
failure.
2 PTQ Q4 2013
Almost every malfunction is a result of the failure of the devices insulation system. The
insulation is what keeps the transformer in electrical balance and, when the insulation ceases to
function, the entire transformer is susceptible to
immediate failure. Faults, heat and mechanical
damage will lead to insulation failure, but the
electrical engineer can avoid these issues by
selecting a unit capable of withstanding expected
operating and fault conditions.
A study done by Hartford Steam Boiler during
a 20-year period showed that 13% of all transformer failures in the US were caused by
inadequate maintenance. It is important for
maintenance personnel to check the insulator
fluid. These tests will indicate the health of the
transformer. Regular testing such as an insulation resistance test, dielectric absorption test,
power factor test, dissolved gas in oil test, acidity
test, colour test, and insulating liquid test will
allow reliability engineers to track a transformers degradation and determine if replacement or
repair is necessary.3
The right transformer will provide the correct
level of power for refinery units. In May 2013, it
was announced that Siemens will be providing
220kV/110kV
power
transformers
and
35kV/10kV distribution transformers as part of
the electrical system for China National
Petroleum Corporations planned Guangdong
Petro-chemical Refinery.5
Switchgears
www.digitalrefining.com/article/1000846
signs of cracking, broken pieces and other physical damage or deterioration. Operators should
examine all bolts and connecting devices for signs
of deterioration, corrosion or overheating, and
ensure that bolts and connecting devices are tight,
according to manufacturers specifications.3
Switchgear is an extremely important electrical
unit for refineries. Outdated units should be
upgraded to protect the refinery from arc flashes
and other possible failures. In July 2013, ABB
installed its 11 kV Unigear ZSI switchgear with
REA arc-quenching technology at the Total
Lindsey Oil Refinery (LOR) in the UK.
Motor control centres
www.digitalrefining.com/article/1000846
PTQ Q4 2013 3
4 PTQ Q4 2013
www.digitalrefining.com/article/1000846
www.digitalrefining.com/article/1000846
Maintenance for UPS systems can be challenging and require certified personnel. Trained
workers should ensure that any areas of corrosion and deterioration are repaired as needed.
They should clean and examine all electrical
connections for signs of corrosion or deterioration, repair or replace as necessary, and ensure
that all connections are tightened according to
manufacturers specifications. They should also,
as applicable, clean and test all breakers, disconnects and relays as prescribed elsewhere in these
standards and as specified by the manufacturer,
and check all system alarms and indicator lights
for proper operation.3
UPS systems can not only provide backup
power for control units, but can also be set to
balance the electrical feed when the voltage is
fluctuating. In July 2011, Emerson provided a
UPS and generator package to Chevrons (now
Valero) Pembroke Oil Refinery (UK) for the
sulphur recovery unit as a way to operate in the
event of a grid failure and to operate emergency
shutdown procedures without environmental
impacts.17
PTQ Q4 2013 5
Energy
efficiency
Financial
performance
Plant safety
and liability
6 PTQ Q4 2013
Power failure
impacts
Negative
publicity
www.digitalrefining.com/article/1000846
Conclusion
No refinery can afford and tolerate power interruptions, as financial costs and potential
liabilities due to environmental and safety incidents can run into millions of dollars a day. The
www.digitalrefining.com/article/1000846
References
1 Zawadzki S, HollyFrontier vows less downtime at refineries,
Thomson Reuters, 7 May 2013.
2 Paraskova T, Italy orders Eni to install power feed at Taranto
refinery, Power Market Review, 6 Aug 2013, www.powermarket.
seenews.com/news
3 Recommended maintenance practices for electrical
distribution system equipment, The Hartford Steam Boiler, 2010,
www.hsb.com
4 56th Annual NPRA 2002 Technology Q&A, NPRA, 2002 p8, 20,
21.
5 Siemens and China National Petroleum Corporation
conclude framework agreement, 29 May 2013, Siemens Global,
www.siemens.com/press/en/pressrelease/?press=/en/
pressrelease/2013/energy/oil-gas/eog201305036.htm
6 Franklin J, De-energizing arc-flash in oil & gas facilities,
Oil & Gas Monitor, 6 Mar 2013, http://oilgasmonitor.com/deenergizing-arc-flash-oil-gas-facilities/4406/
7 Eatons press release on Jul 16 2013, Eaton to Enhance
Safety, Equipment Reliability for Valero Energy Corporations St.
Charles Petroleum Refinery.
8 Electrical installations in petroleum processing plants,
American Petroleum Institute, Jul 2004, p12.
9 Rockwell automations medium voltage drive solution helps
Chinas Daqing refinery plant reduce annual energy consumption
by 41%, Apr 2011, www.emea.rockwellautomation.com/
oilandgas/en/docs/mv.pdf
10 Case study: Hess Port Reading Refinery, Perth Amboy, NJ,
2010.
11 Case study: automated power management system an
economical approach to greater operational dependability.
12 Petroplus refines its technology with retrofit from Schneider
Electric, Schneider Electric, Mar 2011.
13 Cummins Power Blog press release on 6 Jun 2012, MICTA
PTQ Q4 2013 7
8 PTQ Q4 2013
LINKS
More articles from: Hydrocarbon Publishing Company
More articles from the following categories:
Power Generation Reliability & Asset Management
www.digitalrefining.com/article/1000846