Electrical equipment modernization project — A case study

The objectives of this project were to modernize electrical equipment within pumping stations to reduce arc flash levels, add protective devices for improved protection, and provide data for preventative maintenance and easier troubleshooting. These pumping stations are approximately every 30 miles between Houston, Texas and Linden, New Jersey. The installation of low impedance bus differential protection reduced the tripping time for bus faults and reduced arc flash incident energy levels. Motor protection relays were installed to protect the motor and collect actual data to assist in troubleshooting, measurement of pump efficiency, pre-motor failure notification and aid in operation controls. A remote measurement and control architecture enabled transformer protection using fiber optic communications which reduced current transformer saturation. Digital monitoring equipment with command capability was installed to access all protective relays operational data and trip resets could be performed from outside the arc flash boundary. This paper will discuss the lessons learned during design, installation and operation. The lessons learned aided the pipeline throughout the design, installation and operation phases of the project.