Introduction to Electrical System and Equipment Commissioning

Engineering Encyclopedia Saudi Aramco DeskTop Standards

Introduction To Electrical System & Equipment Commissioning

Note: The source of the technical material in this volume is the Professional Engineering Development Program (PEDP) of Engineering Services. Warning: The material contained in this document was developed for Saudi Aramco and is intended for the exclusive use of Saudi Aramco’s employees. Any material contained in this document which is not already in the public domain may not be copied, reproduced, sold, given, or disclosed to third parties, or otherwise used in whole, or in part, without the written permission of the Vice President, Engineering Services, Saudi Aramco.

Chapter : Electrical File Reference: EEX30101

For additional information on this subject, contact W. A. Roussel on 874-1320

Engineering Encyclopedia

Electrical Introduction to Electrical System & Equipment Commissioning

CONTENTS

PAGES

Commissioning Definitions .......................................................................1 Purpose Of Commissioning......................................................................2 Equipment Commissioning Standards And Practices..............................3 Complete Electrical Commissioning Cycle.............................................15 Deficiency Resolution Process...............................................................20 Glossary .................................................................................................23

Saudi Aramco DeskTop Standards



COMMISSIONING DEFINITIONS This section of the module provides definitions of some of the terms that are used in the description and explanation of the commissioning process. Selected commissioning definitions are as follows: Commissioning - The placement of a facility in service after the scope of work that is defined in the Project Proposal, construction documentation, drawings, and specifications is complete and after mechanical completion has been achieved. Facility - The product of a Saudi Aramco project that consists of the fabrication and construction of structures, equipment, and materials. Inspection and Test Plan - A document that defines or identifies the inspections, test methods, procedures, and acceptance criteria that should be used during procurement, fabrication/construction, and pre-commissioning. Inspection Representative - A party or parties that have been appointed by the Saudi Aramco Inspection Department as its representative(s) to assist in all matters that are related to Project Quality and to ensure that the project is in compliance with all company standards and specifications. Inspect (Work) - To carefully and critically examine a facility, especially for flaws in design or workmanship. Mechanical Completion - A state that is achieved when the total facility that is defined in the Project Proposal, construction documentation, drawings, specifications, and material requisitions has been installed and tested (pre-commissioned) and is available for commissioning and start-up. Pre-Commissioning - The performance of all necessary checks, tests, adjustments, repairs, and modifications; the presentation of test results; and the production of "asbuilt" drawings and specifications for the final acceptance of the facilities. Start-Up - The introduction of additional feed stock, liquids, or gases into the facility to achieve normal operating conditions following commissioning. Witness (Event) - To be present at or to have personal knowledge of an event (e.g., a test).


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PURPOSE OF COMMISSIONING The purpose of commissioning is to ensure that a new facility meets Saudi Aramco and industry design criteria and installation standards. Because industrial system facility construction is a detailed and complicated process, the commissioning process provides a systematic and uniform approach to commissioning facilities. Although each industrial facility is unique, the use of a systematic and uniform approach to commissioning of a facility ensures that all major facets of the facility will be observed, inspected, tested, and operated satisfactorily prior to the facility being placed in service. Although the commissioning process for a facility is lengthy and detailed, experience has shown that the time and effort that is expended up front to ensure safety, quality control, and adherence to Saudi Aramco and industry standards maximizes safe, correct, and efficient operation and helps to minimize equipment failures and unscheduled shutdowns.


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EQUIPMENT COMMISSIONING STANDARDS AND PRACTICES To ensure safe, reliable, and cost effective equipment operation of Saudi Aramco installations, certain standards should be met and certain practices should be followed when the equipment is commissioned. Saudi Aramco has specific mandatory requirements and recommended practices that apply to equipment that is commissioned for use in Saudi Aramco installations. Industry standards are also used to provide guidelines for equipment commissioning. This section of the Module will provide of the following equipment commissioning standards and practices: • •

Saudi Aramco Standards and Practices Industry Standards

Saudi Aramco Standards and Practices This section of the Module will describe the following Saudi Aramco standards and practices that are used for equipment commissioning: •

General Instruction GI 2.710 and Associated Forms for Mechanical Completions

•

Saudi Aramco Engineering Standards (SAES)

•

Saudi Aramco Design Practices (SADP)

•

Saudi Aramco Materials System Specifications (SAMSS)

General Instruction GI 2.710 and Associated Forms for Mechanical Completions

Saudi Aramco GI 2.710 is a general instruction manual that covers the subject of Mechanical Completion and Performance Acceptance of Facilities. This manual is intended to define the respective duties and responsibilities that are required of the Saudi Aramco Project Management Team (SAPMT), the Construction Agency, the Project Inspection Division (PID), and the Project Proponent. The duties and responsibilities of key commissioning personnel are described to ensure a smooth and timely transition from the construction phase through the start-up and operation of a facility. GI 2.710 and its attachments are mandatory and are applicable to all Saudi Aramco Projects. Procedures are outlined in the Mechanical Completion and Performance Acceptance of Facilities general instruction manual for the following:


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Saudi Aramco Standards and Practices (Cont'd) • • •

To accept new facilities as mechanically complete. To commission and start-up new facilities. The final performance acceptance and financial closeout of new facilities.

Saudi Aramco Engineering Standards (SAES)

The Saudi Aramco Engineering Standards (SAES) contain the minimum mandatory requirements for the design, construction, maintenance, and repair of equipment. Deviation from the requirements of these standards is not permitted without the written approval from the designated Saudi Aramco authority. Any equipment user or specified requirements that exceed the minimum requirements do not need a waiver approval, even though they are different. When conflicts arise between a specified SAES and other SAESs, related Saudi Aramco Materials System Specifications (SAMSSs), Codes, Forms, and Saudi Aramco Mandatory Drawings (SAMDs) the conflicts should be resolved by the manager of the department that is responsible for revisions to standards and specifications. This section of the Module describes the following SAESs that apply to the commissioning of electrical equipment: • • • • • • •

SAES-P-103, Batteries and UPS Systems SAES-P-104, Wiring Methods and Materials SAES-P-111, Grounding SAES-P-113, Motors and Generators SAES-P-114, Power System and Equipment SAES-P-116, Switchgear and Control Equipment SAES-P-121, Transformers, Reactors, and Voltage Regulators

SAES-P-103, Batteries and UPS Systems, describes the mandatory requirements for

installation and application of stationary storage batteries, battery chargers, uninterruptible power supply (UPS) systems, and solar photovoltaic systems. SAES-P-103 does not apply to the following: • •

Storage batteries for motive power service.

Batteries and battery chargers for stationary


engine cranking

service.

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Saudi Aramco Standards and Practices (Cont'd) •

Battery chargers and distribution systems for communications dc power supplies.

SAES-P-104, Wiring Methods and Materials, describes the minimum mandatory requirements for

the design and installation of wiring and cable systems, excluding overhead distribution systems. For overhead distribution system requirements, refer to SAES-P-107. SAES-P-111, Grounding, describes the minimum mandatory requirements for grounding of

electrical equipment and for design and installation of grounding and lightning protection systems. SAES-P-113, Motors and Generators, describes the minimum mandatory requirements for the

procurement and installation of induction and synchronous motors and generators for industrial facilities. Motors for nonindustrial facilities must meet the requirements of NEMA MG 1. SAES-P-114, Power System and Equipment, describes the minimum mandatory requirements for

the design and installation of protective relaying for power systems and equipment. SAES-P-116, Switchgear and Control Equipment, describes the minimum mandatory requirements

for the design and installation of switchgear and control equipment that is rated 38kV and below, except for fire water pump motor controllers. SAES-P-121, Transformers, Reactors, and Voltage Regulators, describes the minimum mandatory

requirements for the design and installation of transformers, reactors, voltage regulating transformers, and instrument transformers. Saudi Aramco Design Practices (SADP)

The Saudi Aramco Design Practices (SADP) provide procedures that are advisable but that are not necessarily mandatory. SADPs also provide background information to assist engineers, designers, and contractors who are working on Saudi Aramco projects. Written approval is not required to deviate from the SADPs, unless the information in the SADPs is presented in capital letters. Because the information is cited from the SAESs, SAMSSs, or SAMDs (Saudi Aramco Mandatory Drawings), the information in the SADPs that is capitalized is mandatory. The SADPs are referenced when explanatory, amplifying, or background information on the selection, theory, operation, specification, or troubleshooting of equipment is required.


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Saudi Aramco Standards and Practices (Cont'd) This section of the Module describes the following SADPs that apply to the commissioning of electrical equipment: • • • • • • • • •

SADP-P-103, Battery and UPS Systems SADP-P-104, Wiring Methods and Materials SADP-P-111, Grounding SADP-P-113, Motors and Generators SADP-P-114, System and Equipment Protection SADP-P-116, Switchgear and Control Equipment SADP-P-121, Transformers SADP-P-703, NEMA Frame Motors SADP-P-716, Uninterruptible Power Supply System

SADP-P-103, Battery and UPS Systems, provides a commentary on the rationale for those SAES-

P-103 technical requirements that are not obvious and that are based on many years of Saudi Aramco's experience. Batteries that are used for motive power service, and batteries and chargers that are used for engine cranking, will vary with the specific application and do not require a standard for their application. Communication batteries and chargers are covered in the SAES-T-Series standards. The paragraph numbering of SADP-P-103 follows SAES-P103. SADP-P-104, Wiring Methods and Materials, provides a commentary on the rationale for those SAES-P-104 technical requirements that are not obvious and that are based on many years of Saudi Aramco's experience. To provide a more comprehensive coverage of the subject in a separate standard, SAES-P-107, overhead distribution system requirements are excluded from this standard. The paragraph numbering of SADP-P-104 follows SAES-P-104. SADP-P-111, Grounding, provides a commentary on the rationale for those SAES-P-111

technical requirements that are not obvious and that are based on many years of Saudi Aramco's experience. The paragraph numbering of SADP-P-111 follows SAES-P-111. SADP-P-113, Motors and Generators, provides a commentary on the rationale for those technical

requirements that are not obvious and that are based on many years of Saudi Aramco's experience. The paragraph numbering of SADP-P-113 follows SAES-P-113.


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Saudi Aramco Standards and Practices (Cont'd) SADP-P-114, System and Equipment Protection, provides a commentary on the rationale for those

SAES-P-114 technical requirements that are not obvious and that are based on many years of Saudi Aramco's experience. The paragraph numbering of SADP-P-114 follows SAES-P-114. SADP-P-116, Switchgear and Control Equipment, provides a commentary on the rationale for

those SAES-P-116 technical requirements that are not obvious and that are based on many years of Saudi Aramco's experience. The paragraph numbering of SADP-P-116 follows SAES-P-116. SADP-P-121, Transformers, provides a commentary on the rationale for those SAES-P-121

technical requirements that are not obvious and that are based on many years of Saudi Aramco's experience. The paragraph numbering of SADP-P-121 follows SAES-P-121. SADP-P-703, NEMA Frame Motors, provides a commentary on the rationale for those 17-

SAMSS-503 technical requirements that are not obvious and that are based on many years of Saudi Aramco's operational experience. Fractional horsepower motors are excluded from this specification because this class of motors is adequately specified in SAES-P-113 and AMS catalogue descriptions. The paragraph numbering of SADP-P-703 follows 17-SAMSS-503. SADP-P-716, Uninterruptible Power Supply System, provides a commentary on the rationale for

those 17-SAMSS-516 technical requirements that are not obvious and that are based on many years of Saudi Aramco's experience. Uninterruptible power supplies that are rated 10 kVA and below are of standard design and can be adequately described in the AMS catalog descriptions. The paragraph numbering of SADP-P-716 follows 17-SAMSS-516. Saudi Aramco Material System Specifications (SAMSS)

Saudi Aramco Materials System Specifications (SAMSS) contain the mandatory technical requirements (as opposed to commercial requirements) that vendor or manufacturer-supplied materials must meet for use in Saudi Aramco electrical systems. Engineers should use the SAMSSs when new equipment is specified. Any equipment of facility construction, configuration, or installation deviations that reduce the requirements of the SAMSSs must have written approval from the designated authority in Dhahran. Facility installation requirements that exceed the minimum requirements that are set forth in the SAMSSs do not need to have a waiver approved.


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Saudi Aramco Standards and Practices (Cont'd) Most equipment or facility specifications that are contained in the SAMSSs are taken from ANSI Standards; however, the SAMSSs are being revised to include equipment that is manufactured to IEC standards. The SAMSSs describe the exceptions, deletions, or additions to ANSI and industry standards. The SAMSSs that are used to select or to specify a piece of equipment for a new facility installation depend on the type of equipment that is needed. This section of the Module describes the following SAMSSs that apply to the commissioning of electrical equipment: • 14-SAMSS-531, Power Transformers • 16-SAMSS-501, Switchgear Assemblies including Control Switchboards • 16-SAMSS-502, Metal-Enclosed Low Voltage Switchgear Assemblies • 16-SAMSS-503, Low Voltage Motor Control Centers and Switchracks • 16-SAMSS-506, Indoor Controlgear - Medium Voltage • 16-SAMSS-511, Metal-Enclosed Bus Material System • 17-SAMSS-503, NEMA Frame Motors • 17-SAMSS-516, Uninterruptible Power Supply Material System Standard • 17-SAMSS-517, Medium Voltage Induction Motor Variable Frequency Drives 14-SAMSS-531, Power Transformers, is a specification that defines the minimum technical

requirements of 60 Hz, oil-filled, power transformers with tap changers for de-energized or load-tap-changing operation. 16-SAMSS-501, Switchgear Assemblies Including Control Switchboards, is a specification that

defines the minimum technical requirements for three-phase, 60 Hz, indoor switchgear assemblies that are rated above 1 kV through 34.5 kV. This SAMSS includes the requirements for control switchboards. 16-SAMSS-502, Metal-Enclosed Low Voltage Switchgear Assemblies, is a specification that defines

the minimum mandatory requirements for the design, the fabrication, the testing, and the handling of indoor metal-enclosed low voltage switchgear assemblies. The requirements of this specification apply to metal-enclosed, low voltage switchgear assemblies that are employed in three-phase electric systems that have a maximum rms ac voltage that is not higher than 1000 volts and nominal frequency of 60 Hertz.


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16-SAMSS-503, Low Voltage Motor Control Centers and Switchracks, is a specification that defines

the minimum technical requirements for low voltage (600 V and below, three-phase, 60 Hz) indoor motor control centers (MCC) and outdoor motor control Saudi Aramco Standards and Practices switchracks. The requirements of this SAMSS apply to full-voltage combination starters, feeder circuit breakers, contactors, dry-type transformers, panelboards, and auxiliary equipment that is assembled into the MCCs and switchracks. 16-SAMSS-506, Indoor Controlgear - Medium Voltage, is a specification that defines the minimum

technical requirements for medium voltage (5 kV class), metal-enclosed indoor motor control centers. The requirements of this specification apply to National Electrical Manufacturers Association (NEMA) Class E-2 current-limiting fused controllers and all control and auxiliary equipment that is assembled into the motor control centers. Oil-immersed controllers are not acceptable for Saudi Aramco installations. 16-SAMSS-511, Metal-Enclosed Bus, is a specification that defines the minimum technical

requirements for three-phase, 60 Hz, indoor/outdoor metal-enclosed bus that is rated up to and including 34.5 kV. 17-SAMSS-503, NEMA Frame Motors, is a specification that defines the minimum technical

requirements for induction motors that are rated 0.746 through 185 KW (1 through 250 HP), 460 V and below, 60 Hz. This SAMSS does not cover submersible motors, overhead crane motors, and valve-operator motors. 17-SAMSS-516, Uninterruptible Power Supply , is a specification that defines the minimum

requirements for solid state uninterruptible power supply (UPS) systems that are rated for above 10 kVA. 17-SAMSS-517, Medium Voltage Induction Motor Variable Frequency Drives, is a specification that

defines the minimum technical requirements for a variable speed drive (VSD) that is used to control the speed of three phase, 4 kV and 6.6 kV, squirrel-cage induction motors.


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Industry Standards (Cont'd) SAESs and SAMSSs are derived from years of operational experience and from proven industry standards and practices. Instead of incorporating the applicable industry standards, SAESs and SAMSSs state exceptions, additions, or deletions to the relevant industry standards. Saudi Aramco electrical power systems must be designed, constructed, and tested in accordance with the following codes, standards, and guidelines: •

National Electrical Manufacturers Association (NEMA) Standards

• Institute of Electrical and Electronics Engineers (IEEE)/American National Standards Institute (ANSI) Standards and Guidelines •

National Electrical Code (NEC)

NEMA is a trade association for manufacturers of products that are used in the generation, transmission, distribution, and end-use of electricity. The NEMA Standards are useful for the selection and specification of electrical equipment. NEMA designates the specifications to which various pieces of electrical equipment are constructed. If these specifications are the same specifications that are needed by a Saudi Aramco installation, the equipment is specified to comply with the given NEMA classification. Reference to the appropriate NEMA standard eliminates the need to restate all the individual equipment parameters. NEMA standards should be used when they are referenced by SAESs. The IEEE standards provide information on how to produce, test, measure, and buy equipment. The IEEE information is the consensus opinion of a group of electronics and electrical engineering subject matter experts. The requirements and procedures that are given in these standards and guidelines are used to select, specify, and troubleshoot electrical equipment. ANSI has adopted most of the IEEE standards that relate to electrical equipment. ANSI does not write standards; it adopts standards that are written by other organizations. The ANSI Standards provide a uniform method to manufacture, market, purchase, and use a given piece of equipment. If the organization that develops a standard employs a recognized designation, the acronym of the organization will be used with ANSI. For example, ANSI/IEEE is a standard that has been developed by IEEE and adopted by ANSI. If the sponsor of a standard does not employ a designation, the standard will use the ANSI acronym alone.


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The NEC is an ANSI National Fire Protection Association (ANSI/NFPA) code that provides information on how to safeguard personnel and property from hazards that arise from the use of electricity. The NEC is not intended as a design specification or instruction for untrained persons. The NEC contains provisions that are considered necessary for electrical safety.


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ROLE OF KEY COMMISSIONING PERSONNEL Throughout the construction of a new facility, several personnel perform key roles in the process that leads to the commissioning of the new facility. This section describes the roles of the key commissioning personnel. Saudi Aramco Project Management Team (SAPMT) The SAPMT has the responsibility to deliver a completed facility in accordance with the approved scope of the facility as defined in the facility documentation (e.g., project proposal, expenditure request). The SAPMT is comprised of representative personnel from major cognizant Saudi Aramco agencies. Manager of the Consulting Services Department (CSD) The CSD Manager is responsible for the investigation, the review, the processing of new facility construction waiver request forms, and resolving conflicts in the standards. Proponent The Project Proponent or Proponent Organization is the person or group that requested the construction of the new facility. The Proponent appoints the members of the Acceptance Committee, serves as the Chairman of the Acceptance Committee, and has the responsibility to coordinate the start-up and commissioning of the facility. Acceptance Committee The Acceptance Committee must consist of the following personnel or their designated representatives: •

The Acceptance Committee Chairman or his designated representative.

•

The Construction Agency Project Manager or his designated representative.

•

The Proponent Maintenance Superintendent or his designated representative.

•

The Proponent Commissioning Representative or his designated representative.

•

Senior Supervisor, Projects Inspection or his delegate.


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Acceptance Committee (Cont'd) •

The Area Loss Prevention Engineer or his designated representative.

•

The Fire Prevention Engineer or his designated representative.

•

The Area Fire Protection Department representative.

•

The Area Power Distribution Department representative.

•

The Area Communications Operations Department representative or his designated representative.

•

The Area Security Technical Services representative.

•

The Marine Department representative (for offshore facilities).

•

Any additional members that are agreed upon by the Proponent and the Construction Agency to facilitate the proper evaluation and acceptance he facility.

of

The Acceptance Committee develops the new construction checklist for the project, coordinates the project exceptions with the Construction Agency, attends inspections, attends the Mechanical Acceptance meeting, and ensures that the facility is safe to operate. The Acceptance Committee Chairman (or his delegate) will have full authority to act for and on behalf of the Proponent. The Construction Agency Project Manager (or his delegate) will have full authority to act for and on behalf of the Construction Agency. The Proponent Maintenance Superintendent (or his delegate) will have full authority to act for and on behalf of the Maintenance Supervisor. The Proponent Commissioning Representative (or his delegate) will have full authority to act for and on behalf of the Operations Engineering Commissioning Representative. Construction Agency The Construction Agency has the responsibility to keep the Proponent advised of project scheduling and commissioning and acceptance paperwork requirements. The Construction Agency maintains inspection and exception checklists. The Construction Agency coordinates all facility design and construction personnel for the duration of the project.


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Project Inspection Division (PID) The PID oversees and coordinates all Saudi Aramco project inspections. Power Distribution Department (PDD) The PDD is the electric power distribution coordinating body. responsibility to provide power for new facility construction.


The PDD has the

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COMPLETE ELECTRICAL COMMISSIONING CYCLE Saudi Aramco has developed a five-phase commissioning cycle that is used as a guide during the commissioning process. Each phase contains key tasks that should performed during the commissioning cycle. Because each facility or electrical equipment installation is different, not all of the phases are used in every circumstance. The phases that are used should be selected to provide the optimal review, inspection, and testing of the installation. When the five phases of a complete Electrical Commissioning Cycle are complete, the equipment commissioning process is complete, and the equipment is turned over to the cognizant equipment operating or governing group. This section will describe the following topics that pertain to the complete electrical equipment commissioning cycle: • • • • • •

Manufacturer Approval Phase Equipment Receipt Phase Equipment Installation and Testing Phase System Pre-Operational Checkout Phase System Operational Observance Phase Completion and Turning Over the Work

Manufacturer Approval Phase The manufacturing approval phase of the commissioning cycle provides a method to maintain quality control of equipment that is purchased from the manufacturer before it is received at Saudi Aramco. The manufacturing approval phase includes the approval of manufacturer's drawings, factory quality control inspections, and the witnessing and approval of testing by a designated Saudi Aramco representative. It is critical that the designated Saudi Aramco representative approve the equipment testing prior to the shipment of the equipment to Saudi Aramco. Equipment Receipt Phase The equipment receipt phase of the commissioning cycle provides an opportunity for Saudi Aramco personnel to perform the following: •

To verify that the equipment that was received is correct for the installation.

•

To inspect the received equipment.

•

To test the received equipment.


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Equipment Receipt Phase (Cont'd) The received equipment is verified through use of a visual check of the nameplate data. The nameplate data are checked to see whether they meet the installation specifications and drawings. It is critical that verification personnel check to see that the equipment completely meets the mechanical specifications and drawing requirements. During the equipment verification, personnel should also check to see that all operation and maintenance manuals and special installation tools that are needed are provided with the equipment. Any manufacturer-approved documentation that should be included with the equipment should be received prior to, or during, the receipt of the equipment. The received equipment is inspected to determine whether any parts are damaged, missing, dirty, or corroded. It is critical that problems upon initial receipt are detected as soon as possible. Damage that is uncovered after the equipment is installed can result in costly repairs and schedule slippage. During the inspection, all equipment accessory parts should be present. Because testing is performed at the manufacturer's facilities, and because testing is time consuming and costly, receipt testing is only done if it is necessary. If testing is the only way to ensure that damage to the equipment did not occur during the shipment, the equipment is tested when it is received. Equipment Installation and Testing Phase The equipment installation and testing phase of the commissioning cycle provides an opportunity for Saudi Aramco personnel to perform the following: • • •

To verify that the equipment has arrived at the nstallation facility. To inspect the equipment installation. To test the electrical equipment.

The electrical equipment is verified at the location through use of a visual check. During the visual check, the Electrical Engineer verifies that the equipment has adequate electric power available, all necessary accessory equipment, and is located and installed in accordance with project drawings. Problems, inadequacies, or damage to the equipment that is uncovered after the equipment is installed can result in costly repairs or schedule slippage. System electrical revisions and nameplate data are checked to ensure that they are functional and compatible with the system and the equipment in accordance with the project drawings.


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The installation is also checked for compliance with Saudi Aramco and industry safety standards. The equipment verification at the location is critical because it is the last time that inspection personnel will be able to check the equipment before it is permanently installed. Equipment Installation and Testing Phase (Cont'd) For example, a check is made to determine that the equipment will physically fit at the planned location. The electrical equipment is inspected at the location to determine whether any damage has occurred and to ensure that all mechanical moving parts are operable. The equipment is inspected for cleanliness, operability, and to ensure that all electrical connections meet Saudi Aramco and industry standards. The electrical equipment is tested as it is installed to ensure that insulation levels, electrical characteristics, and ratings meet manufacturer and industry standards. System Pre-Operational Checkout Phase The system pre-operational checkout phase of the commissioning cycle provides an opportunity for Saudi Aramco personnel to perform the following: • • •

System component check out. Subsystem operational check out. Performance test.

Each component is checked to ensure that it works individually and also as part of a complete system. Wiring checks and component adjustments are also performed to verify compliance with wiring diagrams and manufacturer specifications. Subsystems are checked to ensure that electrical continuity exists for control, protective, and interlock devices. The proper operation of all subsystems is tested through use of controlled operation and check out of the controls, protection, and interlock devices. Each subsystem is performance tested through the application of full operational voltage to each subsystem through the proper protective devices. A complete operational test is performed on equipment controls, interlocks, protective devices, and components with each subcircuit connected to its main system. During the performance test, the main systems are still isolated and independent from plant systems. Before the equipment is connected to the plant system, subsystem performance testing is critical to ensure the proper and safe operation of the equipment protection and control subsystems.


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System Operational Observance Phase The equipment operational observance phase of the commissioning cycle provides an opportunity for Saudi Aramco personnel to perform the following: • •

System and component temperature checks. System operational inspections.

System and component temperature checks are performed through the use of an infrared thermoscan. The infrared thermoscan can reveal heating problems that may exist when the equipment is under load. Temperatures are also monitored hourly on all operating equipment. Any abnormal readings or conditions are investigated immediately before damage can occur. System operational inspections are performed to detect any noticeable abnormal conditions. Noticeable abnormal conditions include any vibrations, noise, smells, or sounds that indicate damage or the potential for damage to the operating equipment. The system and component electrical parameters (e.g., voltage and current) are also monitored and recorded. The operational observance phase of the system and component operating conditions is complete after the operating conditions have normalized and when no problems exist. Completion and Turning Over the Work Completion of the commissioning process involves a thorough review of all precommissioning documents for completeness and the satisfactory resolution of all abnormal inspection or test results. To ensure a smooth and timely transition from the construction phase through the start-up and operation of the facility, Saudi Aramco GI-2.710 provides guidance as to the duties and obligations that are required of the Saudi Aramco Project Management Team (SAPMT)/Construction Agency, Project Inspection Division (PID), and the Proponent. This information is documented in the Mechanical Completion and Performance Acceptance Certificate. Part 4 of GI-2.710, Completing and Turning Over the Work, explains the requirements for the transition from a facility that has been certified as mechanically complete to the actual commissioning and start-up phase. The first part of completing and turning over the work is the acceptance of all or part of a facility, as certified to be mechanically complete. The acceptance of a facility as mechanically complete involves a number of steps that include inspection checks, testing,


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Completion and Turning Over the Work (Cont'd) systems verification, and many other similar verifications. Supplement 2.710-4 to GI 2.710, Mechanical Completion and Performance Acceptance Work Flow Diagram, shows the sequence of events that lead to the performance acceptance of a facility. These events include the following: • • • • • •

Mechanical Completion Inspection Mechanical Completion Acceptance Meeting Issuance of the Mechanical Completion Certificate Commissioning and Start-Up of the Facility Performance Acceptance Meeting Performance Acceptance Certificate for a Facility


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DEFICIENCY RESOLUTION PROCESS Although Saudi Aramco and industry standards provide a comprehensive coverage of most facility and equipment installation specifics, instances can occur in which Saudi Aramco or industry standards or specifications do not completely address all facets of a new facility installation. It is also possible that a new facility installation may not be able to meet some Saudi Aramco standard or specification due to a unique installation configuration or piece of equipment. When a deviation to a Saudi Aramco standard or specification is necessary, a waiver is requested. When a waiver is requested, a deficiency resolution process is carried out. This section will describe the following topics that pertain to the deficiency resolution process: •

CSD Investigation/Review

•

Waiver Request/Approval

CSD Investigation/Review A waiver of Saudi Aramco standards or specifications during the design, procurement, fabrication, or construction phases of a facility requires the approval of Saudi Aramco. A request for a waiver must be submitted to a Saudi Aramco company representative on Saudi Aramco Form 6409 (Waiver Request Form) in accordance with SAES-302. Saudi Aramco Form 6409 is described in the Waiver Request/Approval section of this Module. The waiver request form must be submitted to the Manager of the Consulting Services Department (CSD) for investigation, review, and processing. When the CSD Manager has received the waiver request form, the waiver request is forwarded to the appropriate CSD Coordinator. The CSD Coordinator reviews the waiver request form and, if appropriate, requests that the concerned departments (e.g., Loss Prevention, Operations, or Maintenance) review the subject form. Comments and recommendations for approval or rejection from investigating and reviewing departments must be attached to the waiver request form. When the waiver request investigation and review by the concerned departments are complete, the waiver request is forwarded to the Inspection Department Manager for review and concurrence. After concurrence by the Inspection Department Manager, the CSD Manager performs a final review and approval (or rejection) of the waiver. Waiver Request/Approval The Saudi Aramco Form 6409 (Waiver Request Form) contains the justification for the waiver request. As a minimum, the justification must include how compliance with Saudi


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Waiver Request/Approval (Cont'd) Aramco standards will impact the safety and cost of the material, equipment, or fabrication activity that is the subject of the waiver request. Any delay to the job completion should be incorporated into the cost of the job. Any cost benefits or penalties that are cited in the waiver request justification must be supported by economic analysis. The waiver request justification should address any alternatives that were reviewed. The waiver request justification must also include the status of the work that is to be performed for which the waiver is requested (e.g., work completed or work pending approval of the waiver), as well as whether the waiver is the result of an Inspection Work Sheet write up. The waiver request form must be submitted at least four weeks prior to the date of the inspection of the material, equipment, or fabrication activity that is the subject of the waiver request. The waiver request form must include, as attachments, all reasonable and relevant technical and cost documentation that is necessary to justify the waiver. These documents should include, but are not limited to, economic analysis, engineering design calculations, and Inspection Work Sheets. When a waiver request is submitted, the waiver request must be approved by the Project Manager/Superintendent (or by superior positions) of the initiating organization. If a waiver is submitted after the fact (i.e., a noncompliance action has already been initiated), the waiver request form must be approved by the Department Manager of the initiating organization. A waiver to mandatory Saudi Aramco Engineering Requirements (MSAER, including SAESs, SAMSSs, and Saudi Aramco Standard Drawings) may also be requested through the associated Project Proposal. The technical merits of the deviation(s) from the standards must be discussed at the Project Proposal or at the Technical Review meetings. The final approval authority of Saudi Aramco Form 6409 (Waiver Request Form) is the CSD Manager. Normally, a Waiver Request Form is approved with the concurrence of the CSD Manager and the Inspection Department Manager. A Saudi Aramco mandatory Engineering Requirement is considered to be waived through a Project Proposal only when all of the following conditions are satisfied: • is

It is clearly stated on the Project Proposal sign-off sheet that a waiver(s) requested.

• The qualifications, justification, conditions, and he details of the waiver(s) are discussed in the ody of the Project Proposal. •

The correct approval and review authorities of audi Aramco Form 6409 have reviewed the appropriate sections of the Project Proposal.


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Waiver Request/Approval (Cont'd) ny reviewing authority can recommend the rejection of a waiver request. Any reviewing authority that recommends rejection must return the waiver request form to the CSD Manager with a letter that explains the reason for rejection. The CSD Manager will review the waiver request form. If appropriate, a letter is issued that explains the reason for the waiver rejection. The letter and the original waiver request are also returned to the originator.


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GLOSSARY

ANSI

The American National Standards Institute. The ANSI standards provide a uniform method to manufacture, market, purchase, and use a given piece of equipment.

commissioning

The placement of a facility in service, after the scope of work that is defined in the Project Proposal, construction documentation, drawings, and specifications is complete and mechanical completion has been achieved.

facility

The product of a Saudi Aramco project that consists of the fabrication and construction of structures, equipment, and materials.

GI

General Instruction

IEEE

The Institute of Electrical and Electronics Engineers. The IEEE standards provide information on how to produce, test, measure, and buy equipment. The IEEE information is the consensus opinion of a group of electronics and electrical engineering subject matter experts.

inspection and test plan

A document that defines or identifies the inspection, test methods, procedures, and acceptance criteria that should be used during procurement, fabrication/construction, and precommissioning.

inspection representative A party or parties that have been appointed by the Saudi Aramco Inspection Department as its representative(s) to assist in all matters that are related to Project Quality and to ensure that the project is in compliance with all company standards and specifications. inspect (work)

To carefully and critically examine a facility.

MSAER

Mandatory Saudi Aramco Engineering Requirements.

mechanical completion

A state that is achieved when the total facility that is defined in the Project Proposal, construction documentation, drawings, specifications, and material requisitions has been installed and tested (Pre-Commissioned) and is available for the commissioning and start-up.


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NEC

The National Electrical Code. A National Fire Protection Association (ANSI/NFPA) code that provides information on how to safeguard personnel and property from hazards that arise from the use of electricity.

NEMA

The National Electrical Manufacturers Association. NEMA is a trade association for manufacturers of products that are used in the generation, transmission, distribution, and end-use of electricity.

NETA

The National Electrical Testing Association. The NETA Standards provide inspection and test procedures for equipment and systems.

pre-commissioning

The performance of all necessary checks, tests, adjustments, repairs, and modifications; the presentation of test results; and the production of "as-built" drawings and specifications for the final acceptance of the facilities.

SADP

Saudi Aramco Design Practices.

SAEP

Saudi Aramco Engineering Procedures.

SAER

Saudi Aramco Engineering Report.

SAES

Saudi Aramco Engineering Standards.

SAIP

Saudi Aramco Inspection Procedures.

SAMD

Saudi Aramco Mandatory Drawings.

SAMSS

Saudi Aramco Materials System Specifications.

SASD

Saudi Aramco Standard Drawings.

start-up

The introduction of additional feed stock, liquids, or gases into the facility to achieve normal operating conditions following commissioning.

witness (event)

To be present at, or have personal knowledge of, an event (e.g., a test).


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Introduction to Electrical System and Equipment Commissioning

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