Electrical Testing and Commissioning of Control , Distribution Panel

 

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

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