Power System Analysis, Evaluation & Implementation of ETAP PMS

ETAP helped OMIFCO resolve the frequent breakdowns of their previously installed EMS/SCADA systems, automate processes, and reduce load shedding by implementing ETAP Real-Time.
Project Manager, OMIFCO

Oman India Fertilizer Company (OMIFCO) experienced several issues, including unplanned outages, disruptions in utility supply, and problems with its power management control system. Additionally, there were issues with the visualization and control of the company's connection to the grid. These issues impacted the company's operations, resulting in financial losses.

OMIFCO (Oman India Fertilizer Company) is a joint venture between the governments of Oman and India, established to create a modern petrochemical facility that produces ammonia and urea fertilizers. It is located at the Sur Industrial Estate in the Sultanate of Oman.

Location: Sur, Oman

Year: 2018

Challenges

The company was facing several challenges related to its electrical systems and power management. These challenges included:

  • Missing Electrical Data and Power System Model.
  • Lack of proper electrical data and system model.
  • Lack of system historical events.
  • Missing electrical data in the Distributed Control System (DCS).
  • Limited system knowledge by the operator.
  • Unplanned Outages and Process Interruptions.
  • Frequent unplanned outages due to improper protective device settings.
  • Nuisance load shedding triggers caused by power grid frequency fluctuations.
  • Inadequate frequency relay setting and operation.
  • Excessive process shutdown during load-shedding events.
  • Improper generator operating mode.
  • Excessive voltage drops due to un-sequenced motor starting.
  • Outdated and Faulty SCADA system.
  • Substation control and HMI failures.
  • Unable to effectively monitor energy usage.
  • Manual grid synchronization with GTGs.
  • No infrastructure for root cause analysis.

Solutions

The co-engineering effort between ETAP and OMIFCO provided the plant with an integrated power management solution with a unique model-based approach:

  • Creating and validating the entire plant’s electrical model.
  • Performing exhaustive power system analysis.
  • Finding out shortfalls of entire operations.
  • Replacing existing BCUs with the latest ones.
  • Segregating and interfacing all electrical data to ETAP.
  • Tuning and implementing the same model for PMS.
  • Configuring a user-friendly HMI for easy electrical system operation.
  • Installation of various interlocks to prevent operational and human errors.

Optimizing grid synchronization to prevent unnecessary system shutdowns. Implemented ETAP Real-Time™ applications:

  • Advanced monitoring.
  • Predictive simulation and what-if analysis.
  • State and load estimation.
  • Event playback and root cause analysis.
  • Intelligent load shedding and validation.
  • Grid synchronization.
  • Tabular events and alarm management.
  • Web-based HMI dashboards.

Benefits

The installation and application of ETAP software have proven to be a significant benefit to OMIFCO, enabling the operation and validation of their plant’s power system. This has led to an overall production increase by preventing unnecessary system shutdowns through predictive analysis.

  • Reduced process downtime from one hour to 15 minutes.
  • Increased the operations efficiency by 75%.
  • Over $41,000 in savings per month on synchronization procedures.
  • ROI after the second year of 105.6%.

Site Details

Load Characteristics:

  • Total No. of Substations = 8
  • 11 kV Switchgear = 3
  • 6.6 kV Switchgear = 18
  • 0.48 kV Switchgear = 20

Power Generation:

  • GT – 1 & 2 (2 X 40.72 MW).
  • OETC Grid – 30 MW Import, 6 MW Export.

Equipment Details:

ETAP Hardware system is composed of the following:

  • Redundant PMS and Stand-Alone Historian Server.
  • Engineering and Operator Workstation.
  • BCU & RTU.

Protocols supported:

DNP3.0, OPC, IEC 61850, I/O Tags - 10,000.


OMIFCO System Architecture

OMIFCO System Architecture

ETAP HMI Sync Checklist

ETAP HMI Sync Checklist

ETAP HMI Screenshot

ETAP HMI Screen


Literatures

Power System Analysis, Evaluation and Implementation of ETAP PMS

ETAP helped OMIFCO to resolve their frequent breakdown of previously installed EMS/SCADA, automate their processes and reduce load shedding by implementing ETAP Real-Time™.