| PURPOSE |
| SCOPE |
| APPLICABLE DOCUMENTS |
| RESPONSIBILITY |
| MANPOWER |
| TOOLS & EQUIPMENT |
| METHODS/PROCEDURES |
| QUALITY CONTROL |
| SAFETY PRECAUTION |
| ATTACHMENT |
1.0 PURPOSE
1.1 To ensure that Electrical Testing and Pre-commissioning of Control, Distribution and Misc. Panel are performed safely, efficiently and in accordance with good working practice, as per Project Job Specifications. This procedure is intended to provide general application guidance and establish controls during preparation and Testing.
2.0 SCOPE
2.1 This method statement will cover the testing & pre-commissioning of Control, Distribution and Misc. Panel (Lighting, Power, etc) and carry out all the applicable tests for REFINERY and Plants.
3.0 APPLICABLE DOCUMENTS
3.1 Saudi Aramco Specification and Standards
| 3.1.1 | SAEP-302 | Instruction for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirements |
| 3.1.2 | SAES-P-100 | Basic Power System Design Criteria |
| 3.1.3 | SAES-P-104 | Wiring Methods and Materials |
| 3.1.4 | SAES-P-111 | Grounding |
| 3.1.5 | SAES-P-119 | Onshore Substations |
| 3.1.6 | Schedule Q | Saudi Aramco Project Quality Requirements |
| 3.1.7 | Schedule G | Material, Tools, and Equipments |
| 3.1.8 | Schedule D | Safety, Health and Environmental Requirements |
3.2 Industry Codes
3.2.1 NFPA 70 National Electrical Code
3.3 Saudi Aramco Inspection Plan, Test Report and Inspection Checklist
3.3.1 SATIP-P-111-01 Grounding and Bonding
3.3.2 SATIP-P-116-07 Low Voltage Panelboards
3.3.3 SAIC-P-3002 General – Electrical Equipment, Storage, Handling & Preservation
| 3.3.4 | SAIC-P-3859 | LV Panelboard-Industrial Panelboard (<400A) Material Receiving |
| 3.3.5 | SAIC-P-3860 | LV Panelboard – Non-Industrial Panelboard Material Receiving |
| 3.3.6 | SAIC-P-3862 | LV Panelboard – Industrial Explosion-Proof Panelboard (<400A) Material Receiving |
| 3.3.7 | SAIC-P-3867 | LV Panelboard – Non-Hazardous AC/DC Panel board Installation and Pre-Commissioning |
| 3.3.8 | SAIC-P-3869 | LV Panel board – Explosion-Proof AC/DC Panelboard Installation and Pre-Commissioning |
| 3.3.9 | SATR-P-3203 | Low Voltage Power and Control Cable, Continuity and Megger Insulation Resistance Testing |
| 3.3.10 | SATR-P-3205 | Low Voltage Power and Control Cable, Termination Torque Testing |
| 3.3.11 | SATR-P-3825 | LV Panel board – Pre-Energized and Functional Testing |
3.4 Latest Revision of the following Documents shall be used
3.4.1 Latest Approved for Construction Drawing
3.4.2 Vendor Drawing / Data Sheet
4.0 RESPONSIBILITY
4.1 Construction Manager is responsible for implementation of all HSE requirements; he shall study, analyze and schedule all construction activities with his department to include manpower and equipment line up as well as other possible resources required for the successful implementation of the construction work activities. He shall study all aspects of work procedure as per Saudi Aramco Standards.
4.2 The pre-commissioning works will be a combined effort of Third Party testing team, Field Operation Group (FOG), QC, Engineering and witnessed by Vendor representative and SA representative.
4.3 Lead Pre-Commissioning engineer (Third Party) is responsible for giving orders / instructions to the site execution team to perform all activities at site as per contract specification based on work schedule and ensure to accomplished works as per standards and respect schedule at all times, maintaining quality of works.
4.4 All test forms shall be prepared by the Testing Engineer (Third Party) and submitted QC for SA approval upon completion of each test.
4.5 QC Inspector shall be responsible to verify and inspect the work and ensures that the work is performed and properly documented in accordance with Saudi Aramco Standards and Procedures.
4.6 QC Inspector shall be responsible for surveillance and inspection of the work and ensures that the work is performed and properly documented using applicable forms.
4. 7 Safety Engineer shall be responsible in monitoring safety aspects and ensuring that the work is done in accordance with Saudi Aramco Construction Safety Manual (CSM). He shall discuss to the workers the characteristics of related materials and status of work area giving reminders as an additional point to injury and incident free environmen
5.0 MANPOWER
5.1 The Electrical Supervisor shall control the overall activities at site and he will be directly reporting to the Site Superintendent. The basic manpower under him shall consist but not limited to the following:
5.1.1 Lead Pre-commissioning Engineer
5.1.2 Testing Engineer
5.1.3 Electrical Lead man
5.1.4 Senior Technicians
5.1.5 Technician
5.2 Vendor Representative (if needed)
5.3 QC Engineer/ Inspector
5.4 Safety Engineer
5.5 Company Representative
6.0 TOOLS AND EQUIPMENT
6.1 Tools and equipment should be in good condition for use in the construction area. All test equipment required to be calibrated not more than 3 months before the date of test. All equipment calibration “original” certificates should be presented at site. These includes but not limited to the following:
6.1.1 Common Hand Tools
6.1.2 Approved Voltage Tester
6.1.3 500/5000V MEGGER
6.1.4 Current Tester (Multi-Amp or equal)
6.1.5 Torque Wrench
6.1.6 Ductor (Micro ohm Meter)
6.1. 7 Personal Protective Equipments
6.1.8 Timing Tester
6.1 .9 DC power supply
6.1.10 Breaker Analyzer (If Required)
7.0 METHODS/ PROCEDURES
7.1 GENERAL PREPARATORY WORKS
7.1.1 Contractor for Installation shall appoint qualified employees as their “competent persons”. Such persons shall be capable of working safely and shall be knowledgeable on the precautionary techniques, personnel protective equipment, shielding and insulating materials and tools.
7.1.2 All permanent and consumable materials shall prepare prior to testing.
7.1.3 Manpower, equipment, tools and other logistics shall be prepared and ready for installation.
7.1.4 Prepare the workplace such as barricading the area and housekeeping.
7.1.5 Identify area classification and verify hazardous areas to be considered during pre-commissioning activities considering precautionary measures in using tools, equipment and materials to be affected, making sure that all this items are suitable and appropriate as per the area requirements.
7.1.6 Review the AC/DC control schematic of the disconnect switch assembly. All connection diagram vendor and IFC drawing shall be available in the work area.
7.1.7 Review all technical specifications, operating manuals and previous inspection data if appropriate.
7.1.8 Electrically Hazardous Task Plan / Permit shall be completed and signed before any work proceeds.
7.1.9 Pre-commissioning works are to be supervised by the equipment manufacturer specialists.
7.1.10 Complete all electrical clearing of equipment per the criteria defined in the Electrical Safe Work Standards and project specification/ procedure.
7.1.11 After de-energizing, appropriate lockout/tagout, and grounding if required, removed the panel main door/cover to facilitate visual inspection.
7.1.12 Perform the “test before touch”. Be aware and take necessary precautions against contact with energized system (wires, relays, terminal blocks, etc.). If power is found on a system that should not be energized as per review of control schematics, stop the job and investigate.
7.1.13 For panels that feed heavy loaded devices (HVAC, pumps, motors, etc.), perform an infrared inspection of all connections prior to de-energizing.
7.1.14 Red marking must be reflected in the drawing and make sure presented on site.
7.1.15 Installation and inspection of all panels must be completed prior to SAT and all documents are available on site
7.1.16 All panels’ inside shall be free from dust and applied with approved lubrication on all bolted area.
7.1.17 Panel installation drawings and circuit modification red marked drawings shall be attached in the Pre-commissioning documents.
7.2 VISUAL AND MECHANICAL INSPECTION
7.2.1 Compare equipment nameplate information data with actual operating conditions, drawings and specifications.
7.2.2 Inspect the physical condition of all electrical and mechanical components for deterioration and missing, broken, or loose parts, etc. This includes the inspection of insulation materials, signs of overheating or electrical sparks, enclosure and door fastener functionality.
7.2.3 Inspect grounding bars, wires or other grounding devices for proper condition.
7.2.4 Inspect indicators for mechanical damage.
7.2.5 Tighten all accessible electrical connections to the manufacturer’s torque specifications, if provided. If such information is not available, re-tighten in accordance SA-P-000. Use suitable marker or paint pencil and mark each connection/bolt after being torque.
7.2.6 Tighten control, VT, CT and metering wires on all devices and terminal blocks.
7.2.7 Clean the enclosure using approved methods and materials. Clean all accessible components.
7.3 ELECTRICAL TEST
7.3.1 Using a 500V megger, measure the insulation resistance of the total power panel bus system, phase to phase (or pole-to-pole for DC) and phase to ground.
7.3.2 For panels equipped with GFI breakers, test the earth leakage functionality of the outgoing circuits by means of test button of the earth leakage switch.
7.4 FUNCTIONAL TESTS
7.4.1 Verify that the branch breakers in the panel are properly sized for the loads that they feed.
7.4.2 As part of startup, test each branch circuit to confirm desired functionality.
8.0 QUALITY CONTROL
8.1 All testing and inspection shall be coordinated with JGC/DEC by ARCC Inspector.
8.2 QC Inspector will be assigned to attend to the quality control and quality assurance requirement of this work.
8.3 QC Inspector shall be responsible to conduct all required inspection/ documentation and ensures that all applicable requirements, codes, and standards are complied with.
8.4 QC Inspector has to utilize the applicable inspection and test forms reflected on approved SATl P.
8.5 QC Inspector, who conducts surveillance and inspection, shall coordinate Saudi Aramco Representative.
9.0 SAFETY PRECAUTION
9.1 Secure the approved work permit from the concerned JGC/DEC Representative before starting any work.
9.2 Provide warning sign and sufficient barricade on working area and only assigned personnel will be allowed in the area.
9.3 All electrical tools shall be checked and color-coded within the past month and checked by a competent person before use.
9.4 Hazardous area and its precautionary measure requirements shall be properly discussed to the working crew following all safety requirements.
9.5 Continuous monitoring and checking shall be conducted by concerned supervisor/foreman to detect and correct unsafe practices while performing the work activities.
9.6 Provide warning sign and sufficient barricade on working areas to avoid unauthorized entry. Only assigned personnel shall be allowed in the area. Log-in/out book to be maintained at building entrance.
9.7 LOTO procedure shall be used while testing any live circuit. Locks with keys shall be available with tags as required by the LOTO procedures.
9.8 Only those people directly involved in testing shall be within the barricaded area.
9.9 Supervisor shall monitor the work activities to help and protect all assigned workers against exposure to safety hazards. He shall ensure that Personal Protective Equipments (PPE’s) are being supplied and used all the time.
9.10 TSTI meeting shall be conducted by Electrical Supervisor daily so that work activities will be properly coordinated to all concerned and all safety measures will be carried out on the entire work duration. PPE will be checked by the electrical supervisor at TSTI meeting.
9.11 Housekeeping shall be maintained and working area shall be kept clean and tidy in accordance with Site Housekeeping Procedure.
9.12 Job Hazard and Risk Assessment of this procedure shall be disseminated and explained to workers for safety awareness.
10.0 ATTACHMENTS
| 10.1 Attachment 1 | JSA | Job Safety Analysis |
| 10.2 Attachment 2 | SA-P-000 | Pre-commissioning form — Testing Guidelines |
| 10.3 Attachment 3 | SA-P-030 | Molded Case Circuit Breakers |
| 10.4 Attachment 4 | SA-P-031 | Low Voltage Power Circuit Breakers |