Deer Park Refinery Substations

Deer Park Refinery Substations

Location: Deer Park, Texas

Client: Shell

Burns & McDonnell has engineers on-site to act as owner's engineer in a quality assurance leadership role, providing third-party design reviews as well as developing substation standards for all future utility and unit-level substations to be installed. Major emphasis is placed on solid-state relaying and communications systems with a goal of a site-wide, fully integrated electrical network monitoring and control system.

1220H project: Burns & McDonnell performed the engineering for the new 1220H substation. The substation is a steel-framed building with precast concrete panels, two 15-kV 4000A M-T-T-M maintenance bus configuration lineups of switchgear with remote operation. In addition to the switchgear building, there is a 1-MVA 15-kV to 480-V power transformer, 15-foot-high cable landing, six miles of 15-kV armored cable, one half-mile of elevated cable tray rack and two miles of cable tray. The switchgear is state of the art with solid-state SEL relays and communications back to the central monitoring system via a fiber optic network.

244D project: Burns & McDonnell performed the engineering for the new 244D substation. The substation is a prefabricated switchgear building on 5-foot raised piers, with a 2.4-kV 2000A M-T-T-M maintenance bus configuration of switchgear with remote operation. In addition to the switchgear building, there is a 1.5-MVA oil-filled 2.4-kV to 480-V power transformer and two 5-MVA oil-filled 15-kV to 2.4-kV power transformers. The switchgear is state of the art with solid-state SEL relays and communications back to the central monitoring system via a fiber optic network.

1224H project: Burns & McDonnell performed the engineering for the replacement and reconfiguration of the Distilling Unit 2 1224H substation. The building was modified with new equipment doors to facilitate removal of some old equipment and installation of new equipment. New personnel doors were added for safety. The equipment scope included one 15-kV 1200A M-T-T-M bus configuration of switchgear with remote operation capabilities. In addition to the switchgear, there is a 2-1.5-MVA oil-filled 15-kV to 480-V power transformer, and two 5-MVA oil-filled 15-kV to 2.4-kV power transformers, two miles of 15-kV armored cable and one half-mile of elevated cable tray. The switchgear is state of the art with solid-state SEL relays and communications back to the central monitoring system via fiber optic network.

Engineering-phase services

  • Project development utilizing CII "best practice" Front-End Planning (FEP)
  • Project scoping (FEP 1, 2, & 3)
  • Project execution planning
  • Project estimating Total Installed Cost (TIC)
  • Execute plan for projects (engineering, procurement and construction support)

Technical specialties

  • Project management
  • Project engineering
  • Detailed scheduling (engineering, procurement and construction)
  • Electrical power system studies and analysis
  • Detailed design for electrical, building, civil/structural and mechanical
  • Equipment sizing and specification, bid packages and tabulations
  • Procurement and expediting
  • Construction bid packages and tabulations
  • Construction packages

Construction-phase engineering services

  • Factory Acceptance Testing (FAT) support
  • Site Acceptance Testing (SAT) support
  • On-site commissioning support
  • System cutover planning and procedure development

Specialty services

  • Utilized 3-D laser scanning technology to support design execution
  • Utilized 3-D CAD environment for design
  • On-site engineers acted as owner's engineer and led QA/QC on several electrical infrastructure projects:
    • Hydrogen Booster Unit (HBU)
    • Distilling Unit 2 Desalter
    • Lower Dock Road (LDR)
    • South Environmental Treating (SET)
  • Engineering design and QA/QC support for HBU, LDR, SET and DU2 Desalter projects:
    • Grounding system design
    • Electrical power system studies
    • Electrical network monitoring and control system (communications) design
    • HVAC design
    • Automatic transfer scheme design

Shell engaged Burns & McDonnell in 2002 to perform a power system study that consisted of developing a SKM model of the entire Deer Park refining complex, including data collection, load flow, short circuit, protective device coordination and arc flash analysis. Since then Burns & McDonnell has continued to help with efforts to improve the refinery electrical systems' reliability through electrical infrastructure replacement and reconfiguration of existing substations.