Banyu Urip, which is the highest producing oil facility in Indonesia with 220 kbd, generates up to 40 MW electrical power to maintain production. Any power blackout results in significant production upset including high flaring. This is exacerbated by usually extended recovery time post power blackout due to complex electrical distribution system. The Banyu Urip facility has experienced production loss due to historical power blackout events, most recently in 2019. This paper provides a case study on optimizing load shedding and gas turbine fuel control system, which could serve as learning for other power generation facilities in various industries for designing a robust blackout prevention system.

An integrated blackout prevention system comprises of Electrical Control and Monitoring System (ECMS) as primary load shedding, Gas Turbine Generator (GTG) temperature peaking control, and backup load shedding by under-frequency protection relay is designed. All these load shedding layer of protection cover multiple blackout prevention scenarios or protection system element failure such as GTG trip, overloading, and ECMS failure.

Multiple parameter analysis and simulation were performed to determine characteristic of each protection layer. Turbine exhaust temperature response, load, fuel supply, as well as generator frequency are all taken into consideration for the integration of blackout protection layer.

Key factor for the seamless integration is timeline of each element to work and for backup element to activate. All must be done within GTG overload capability corridor.

ECMS load shedding system is put as the frontline to prevent overload in case GTG trip. As the backup layer, protective relay will enable under-frequency load shedding upon overload and GTG slowdown. GTG temperature peaking control and under-frequency set point are properly designed to ensure that the under-frequency relay is operating.

After implementing these optimizations, load shedding is proven to work very effectively and there has been some GTG trip events without blackout nor significant production impact.

Evaluation of system performance continues as Banyu Urip Central Processing Facility (CPF) operates. The results will be critical for reliability improvement as well as production continuity assurance. In other words, this also provides a best practice for blackout mitigation to optimize successful power generation facility operation.

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