Reliability Study of Electricity Distribution Network in Fertilizer Industry Sector

Study Case RELIABILITY STUDY OF ELECTRICITY DISTRIBUTION NETWORK IN FERTILIZER INDUSTRY SECTOR Michael Kurniawan University of Cincinnati, 2600 Clifton Ave, Cincinnati, OH 45221, United States michaelkurniawan2019@gmail.com Abstract The reliability of the power distribution system in the fertilizer industry is very important to be able to distribute electricity continuously. This is very necessary to support the continuity of production operations. The case study was conducted at factory III of Nutrien Ltd.. Data collection is taken from the electrical system data at the factory, then the data is processed so that it can be used to evaluate the reliability index. With the reliability index analysis and reliability study of the 20 KV electric power distribution system at factory III Nutrien Ltd. obtained SAIFI value of 0.1678 times / year, SAIDI value of 7.2632 hours / year, and CAIDI value of 43.278 hours / year. These results when compared to the IEEE 1366-1998 standard value, for the outage frequency value that occurs is still smaller, while the outage duration value that occurs is longer. However, when compared with SPLN 59: 1985, that the SAIDI and SAIFI reliability index values have a value smaller than the SPLN value, so that the existing power distribution system at Factory III Nutrien Ltd. can be said to be still reliable. Keywords: RELIABILITY, ELECTRICITY DISTRIBUTION, FERTILIZER INDUSTRY INTRODUCTION The electric power distribution system has a role to distribute electricity from large power sources to consumers. Therefore, its reliability is very necessary in meeting electricity needs. Nutrien Ltd. is one of the largest fertilizer industries in United States. The production unit consists of three units, namely the factory production unit I, factory production unit II and factory production unit III. Among the three units, the factory production unit III which produces PA (Phosphoric Acid) products as the main raw material for compound fertilizers is a very vital unit because its production is used as the main raw material for the largest NPK Phonska compound fertilizer in United States with a capacity of 2.8 million tons per year. The reliability of plant components that support the production process, namely all equipment used for the production process, greatly affects the quality and continuity of the products produced. Based on this, the calculation and evaluation of the reliability level of the 20 KV power distribution system in factory III of Nutrien Ltd. will be carried out. The results will be compared with the IEEE 1366-1998 standard and SPLN 59: 1985. Thus it will be known the level of reliability of the distribution system in factory III Nutrien Ltd. whether it meets the IEEE standards and SPLN 59: 1985 or not. If it does not meet the standard, an improvement plan program will be made. The reliability index is an indicator of reliability expressed in MICHAEL KURNIAWAN 1 Michael Kurniawan terms of probability. System reliability indices used for evaluation include: System Average Interruption Frequency Index (SAIFI), System Average Interruption Duration Index (SAIDI), and Customer Average Interruption Duration Index (CAIDI). DISTRIBUTION SYSTEM A. Distribution Network System The distribution network system generally has three important parts in the process of delivering electricity, namely generation, transmission, and distribution. Distribution system is part of the electric power system. This distribution system is useful for distributing electricity from large power sources (Bulk Power Source) to consumers. So, the function of electric power distribution is to share or distribute electric power to several places (customers). In addition, the distribution of electricity is a sub-system of electric power that is directly related to the customer, because the power supply to the load centers (customers) is served directly through the Distribution Network. B. Power Distribution System Reliability Reliable power systems and electrical energy with good quality or meet the standards, have a very important contribution in the industrial sector, all of which can operate because of the availability of electrical energy. These companies will suffer considerable losses if there is a sudden power outage, where their activities will stop or the products they produce become damaged or defective. SAIFI is the average number of failures that occur per consumer served by the system per unit time in one year. SAIFI can be expressed in the following equation: Where: λi : failure rate Ni : number of consumers on channel i N : total consumers in the system. SAIDI is the average value of the length of failure for each consumer in a one-year interval. SAIDI can be expressed in the following equation: MICHAEL KURNIAWAN 2 Study Case Where : Ui : duration of interruption of electricity supply Ni : number of consumers on channel i N : total consumers in the system. CAIDI is an index of the average consumer interruption duration per year, informing about the average time to normalize the interruption of each consumer in one year. C. Reliability Index Assesment The Reliability Index Assessment (RIA) method is a reliability method for predicting reliability in distribution systems. As an illustration, the input and output of this method are as follows: Figure 1 Input and Output of RIA Method D. Distribution System at Factory III Nutrien Ltd. Disturbances in the distribution system can be caused by, among other things, equipment malfunction. For example, it can be caused by age or poor equipment maintenance (preventive maintenance, predictive maintenance and time base maintenance), human error (doing work not according to SOP), natural factors (rain, weather and earthquakes). These disruptions can result in interruptions in the flow of electricity, so that under certain conditions it can result in the factory not being able to operate. So that the production target is not achieved. On equipment that is not reliable because the age of the equipment is obsolete. The flexibility of the electric power distribution network is still not perfect because the switching required is still inadequate. Especially in the fertilizer factory of Nutrien Ltd. which occurs in the factory there is a change in supply which was previously from the generator outside the factory III at this time can use its own generation from coal. Given that this new factory uses coal as raw MICHAEL KURNIAWAN 3 Michael Kurniawan material while from the original condition it was previously supplied using gas generation. This has the potential to disrupt system reliability if it is not designed according to its needs. The occurrence of disturbances can result in interruptions in the supply of electricity resulting in the factory not being able to operate. This is highly avoidable because it can affect the fertilizer production target that should be achieved. So that it can harm farmers as consumers who cannot get fertilizer. So that national food needs are not met. RESEARCH METHOD A. Studi Case The case study in this research was taken at Nutrien Ltd. factory III, specifically in the Phosphoric Acid Unit. B. Data collection is taken from the electrical system data in the Phosphoric Acid Unit of Nutrien Ltd. factory III. C. Electrical Transient Analizer Program Electrical Transient Analizer Program (ETAP) software is useful for performing various analyses. This software can do modeling, planning and description of electrical systems in the industry. Simulation in the calculation of this study used ETAP 12.6.OH. The required data information includes: MICHAEL KURNIAWAN 4 Study Case The parameters required as input data from items 1 to 4 above are RESULTS AND DISCUSSION The data of the electrical system in factory III Nutrien Ltd. after processing, obtained the following results: A. Single Line Diagram at factory III in the Phosphoric Acid Unit of Nutrien Ltd.. Figure 2 Single Line Diagram MICHAEL KURNIAWAN 5 Michael Kurniawan B. Load data of Phosphoric Acid Unit Subsystem Factory III Nutrien Ltd. Table 1 Factory III Sub System of Nutrien Ltd. C. Reliability Index The reliability index is a quantity to compare the appearance of the distribution system. From the calculation results, the average failure frequency index value per year (SAIFI), the average failure duration index value per year (SAIDI), the average consumer interruption duration index per year (CAIDI) is obtained as shown in the following table: Table 2 Reliability Index Value 1. SAIFI = 0.1678 times/year From the calculation results, the SAIFI index value is 0.1678 times/year. This result is smaller when compared to the IEEE 1366-1998 standard value of 1.10 times / year. So the frequency of interruptions in factory III of Nutrien Ltd. is still much better because it has a smaller value than the IEEE 1366-1998 standard. 2. SAIDI = 7, 232 hours / year From the calculation results, the SAIDI index value is 7.232 hours / year. This result turns out to be much greater when compared to the IEEE 1366-1998 standard value of 1.50 hours / year. So the frequency of interruptions in factory III Nutrien Ltd. needs to be reviewed again because it has a value greater than the MICHAEL KURNIAWAN 6 Study Case IEEE.1366-1998 standard, but when compared to SPLN 59: 1985 is still smaller so it is still quite reliable. 3. CAIDI = 43.278 hours / year From the calculation results obtained CAIDI index value of 43.278 hours / year. This result is much greater than the IEEE 1366-1998 standard value of 1.36 hours/year. So the duration of interruption in factory III of Nutrien Ltd. is still high, so further improvement is needed. D. Proposed Improvement Program as follows: The results of the calculation of the reliability index in the Phosphoric Acid Unit of Factory III of Nutrien Ltd. when compared with the IEEE 1366-1998 standard, the following suggestions are made: Considering that Factory III is a Phosphate-based factory, where the production process uses fine solid raw materials (Rock Phosphate and sulfur), the factory environment up to a radius of 2 km still feels the impact of dust exposure. This greatly affects factory operations both on factory equipment, humans, SOP (Standard Operation Procedure), IK (Work Instructions). Especially the nature of the fluid in the production process is prone to scalling, corrosive and abrasive, so it is necessary to propose a program or improvement plan to reduce the frequency and duration of power failure so that there is no breakdown of electrical equipment so that the factory cannot operate. Therefore, it is necessary to propose the following improvements: 1. To be applied to the Maintenance Management of the Production Directorate of Nutrien Ltd. with the following Maintenance Patterns: TPM (Total Productive Maintenance) Namely involving production personnel in carrying out maintenance functions for tools and the environment around the factory which are light in nature such as environmental cleanliness and production equipment to avoid the impact of dust, corrosion and abrasion to avoid equipment breakdown. Corrective Maintenance Forming an equipment Vibration Analysis Team Preventive Maintenance By performing the following functions: a. Time base maintenance b. Condition base maintenance c. Reliability Centered Maintenance (RCM) MICHAEL KURNIAWAN 7 Michael Kurniawan The above is intended to be able to reduce or avoid outage frequency and outage duration on equipment. 2. Evaluation of Single Line Diagram to perfect safety devices and Load shadding. 3. System Interuption & Automation 4. System Reconfiguration 5. SOP (Standard Operation Procedure), WI (Work Instruction) needs to be made to complete the shortcomings, both in the Har Dept & Production Dept of Nutrien Ltd. While the results of the reliability index calculation when compared to SPLN 59: 1985 the distribution system in the PA Unit of Factory III Nutrien Ltd. is still reliable. CONCLUSIONS From the calculation results of SAIFI, SAIDI and CAIDI when compared with the IEEE 1366-1998 standard, it can be concluded that the reliability of the power distribution system in factory III Nutrien Ltd. based on the cause of the outage seen from the outage frequency SAIFI = 0.1678 times / year is still reliable because the value is smaller than the standard, Outage duration SAIDI = 7.232 hours / year is less reliable because the value is greater than the standard and CAIDI = 43.278 hours / year is less reliable because the value is greater than the standard. However, when compared to SPLN 59: 1985 the reliability index value of factory III of Nutrien Ltd. is still reliable. MICHAEL KURNIAWAN 8 Study Case REFERENCES MICHAEL KURNIAWAN 9 Michael Kurniawan MICHAEL KURNIAWAN 10 Study Case MICHAEL KURNIAWAN 11