1.0 PURPOSE
2.0 SCOPE
3.0 APPLICABLE DOCUMENTS
4.0 RESPONSIBILITY
5.0 MANPOWER
6.0 TOOLS & EQUIPMENT
7.0 METHODS/PROCEDURES
8.0 QUALITY CONTROL
9.0 SAFETY PRECAUTION
10. ATTACHMENT
1.0 PURPOSE
To ensure that Electrical Testing and Pre-commissioning of <1000V to 4.16kV Switchgear (SWGR) are performed safely, efficiently and in accordance with good working practice, as per Saudi Aramco 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 the <1000V to 4.16kV Switchgear (SWGR) 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-116 Switchgear and Control Equipment.
3.1.6 SAES-P-119 Onshore Substations.
3.1.7 Schedule Q Saudi Aramco Project Quality Requirements.
3.1.8 Schedule G Material, Tools, and Equipments.
3.1.9 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 Checklist
3.3.1 SATIP-P-111-01 Grounding and Bonding.
3.3.2 SATIP-P-116-01 Medium Voltage Switchgear.
3.3.3 SATIP-P-116-02 Medium Voltage Control gear.
3.3.4 SATIP-P-116-03 Low Voltage Switchgear and Switchboards.
3.3.5 SATIP-P-116-04 Low Voltage Control gear.
3.3.6 SA Tl P-P-116-05 Switch racks and Distribution Racks.
3.3.7 SATR-P-3801 Protection & Metering – Relay Calibration, Setting, and Functional Testing.
3.3.8 SATR-P-3802 Protection & Metering – Meter I Recorder Calibration, Setting, and Functional Testing.
3.3.9 SATR-P-3804 Protection & Metering – CT Pre-energization and Functional Testing.
3.3.10 SATR-P-3805 Protection & Metering – PT Pre-energization and Functional Testing.
3.3.11 SATR-P-3812 MV Controlgear – Metal-Enclosed Equipment Pre Energized and Functional Testing.
3.3.12 SA TR-P-3819 LV Controlgear – Metal-Enclosed Equipment Pre Energized and Functional Testing.
3.3.13 SATR-P-3820 LV Controlgear – Power Circuit Breaker – Calibration, Setting, and Functional Testing.
3.3.14 SATR-P-3821 LV Controlgear – Full Voltage Motor Controller Calibration, Setting, and Functional Testing.
3.3.15 SATR-P-3822 LV Controlgear – Reduced Voltage Motor Controller Calibration, Setting, and Functional Testing.
3.3.16 SATR-P-3823 LV Controlgear – Feeder Contactor Calibration, Setting, and Functional Testing.
3.3.17 SATR-P-3824 LV Controlgear – ATS / MTS Calibration, Setting, and Functional Testing..
3.3.18 SAIC-P-3829 MV Controlgear – Metal-Enclosed Equipment Installation and Pre-Commissioning.
3.3.19 SAIC-P-3830 MV Controlgear – Power Circuit Breaker Pre Commissioning..
3.3.20 SAIC-P-3849 LV Controlgear – Metal-Enclosed Equipment Installation and Pre-Commissioning.
3.3.21 SAIC-P-3850 LV Controlgear – Power Circuit Breaker Pre Commissioning.
3.3.22 SAIC-P-3851 LV Controlgear – Full Voltage Motor Controller Pre Commissioning.
3.3.23 SAIC-P-3852 LV Controlgear – Reduced Voltage Motor Controller Pre-Commissioning.
3.3.24 SAIC-P-3853 LV Controlgear – Feeder Contactor Pre Commissioning.
3.3.25 SAIC-P-3854 LV Controlgear – ATS / MTS Pre-Commissioning.
3.3.26 SAIC-P-3810 Protection & Metering – CT and PT Installation and Pre-Commissioning .
3.3.27 SAIC-P-3811 Protection & Metering – Relay Installation and Pre Commissioning.
3.4 Latest Revision of the following Documents shall be used.
3.4.1 Latest Approved for Construction Drawing.
3.4.2 Vendor Drawing I 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 environment.
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
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:
- Common Hand Tools.
- Approved Voltage Tester.
- 500/5000V MEGGER.
- Current Tester (Multi-Amp or equal).
- Torque Wrench.
- Ductor (Micro ohm Meter).
- Protective Relay Test Set.
- Personal Protective Equipments.
- Timing Tester.
- Hi-pot Tester.
- DC power supply.
- Relay testing set.
- CT Test Set.
- Breaker Analyzer (If Required).
7.0 METHOD STATEMENT FOR TESTING & PRE-COMMISSIONING OF SWITCHGEAR / PROCEDURES
7.1 GENERAL PREPARATORY WORKS
7.1.1 Contractor 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 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.
7.1.6 Review all technical specifications, operating manuals and previous inspection data if appropriate.
7.1.7 Electrically Hazardous Task Plan / Permit shall be completed and signed before any work proceeds.
7.1.8 Pre-commissioning works are to be supervised by the equipment manufacturer specialists.
7.2 SWITCHGEAR ASSEMBLIES
7.2.1 Visual and Mechanical Inspection
7.2.1.1 Check the equipment tag number and nameplate is correct against the tag number shown in One Line Diagram and equipment data sheet.
7.2.1.2 Verify that the number of sections is correct as per latest approved drawings.
7.2.1.3 Verify that busbars are properly connected together and torque marked.
7.2.1.4 General inspection of exterior of equipment.
7.2.1.5 Check panel lights for operation, burned out or missing bulbs and lamp covers.
7.2.1.6 Verify that doors are not damaged, bent or twisted.
7.2.1.7 Verify that instrumentations and other electrical components are not damaged or broken (e.g. relay cover glass, CT, VT’s etc.)
7.2.1.8 Inspect bus/breakers for physical damage, missing insulation, connection at joints, confirm plating is acceptable.
7.2.1.9 Check cleanliness of interior of cubicle and free from debris.
7.2.1.10 Inspect insulation, standoff insulators, and bus separators for damage or clearance problem.
7.2.1.11 Verify that control wiring cables, wire markings are readable, correct and properly tagged.
7.2.1.12 Verify that main bus tap bolted connections are properly torque in accordance with manufacture recommendations.
7.2.1.13 Check control knobs and switches for freedom of movement and contact condition.
7.2.1.14 Inspect door handles, locking bars, and mechanism.
7.2.1.15 Check breaker and door interlocks for proper operation.
7.2.1.16 Check bus support & proper spacing.
7.2.1.17 Check draw out, racking mechanism for breaker freedom movement and properly lubricated.
7.2.1.18 Check rails, guides, roller, and shutter mechanism.
7.2.1.19 Inspect breaker cell primary and secondary contacts alignment.
7.2.1.20 Close and trip breakers manually in the connected, test and disconnected positions.
7.2.1.21 Verify that all breaker of the same rating are inter-changed by racking each breaker in each cell of the proper rating.
7.2.2 Electrical Test
7.2.2.1 Perform insulation resistance test on each bus section, phase to phase and phase to phase ground for one (1) minute. Test voltage selection as per equipment rated voltage.
7.2.2.2 Perform High potential test on each bus section, each phase to ground for one (1) minute.
7.2.2.2.1 High potential (Hi-pot) test conducted by 3″ party SA approved laboratory technician only.
7.2.2.2.2 All Hi-Pot equipment shall be calibrated by approved calibration laboratory and documents will be submitted for conformation. Testing technician shall be carrying all documents card together.
7.2.2.2.4 Testing shall comply with SAES-P-116 and all meters system calibrated before Hi-Pot test and calibration sticker will be visible.
7.2.2.3 Perform control wiring performance test. Use elementary diagram of the switchgear to identify each remote control and protective device. Conduct tests to verify satisfactory performance of each control feature.
7.2.2.4 Perform secondary voltage energization test on all control power circuit and potential circuit. Check voltage levels at each point on terminal boards and at each terminal on devices.
7.2.2.5 Verify all control fuse and ratings are correct as per approved drawing.
7.2.2.6 Verify that the Voltmeter is accurately calibrated by voltage injection.
7.2.2.7 Verify that the Ammeter is accurately calibrated by current injection.
7.2.2.8 Verify that space heaters have been correctly installed and operate properly.
7.2.2.9 Carry out Current Transformer (CT) and Voltage Transformer (VT) test.
7.2.2.10 Carry out a complete functional check of the Control Scheme.
7.2.2.11 Verify and ensure that all instrumentation display/ screen indicators are working properly (e.g. relays, digital power meters).
7.2.2.12 Perform secondary current injection test on the entire current circuit in each section of switchgear.
7.2.2.12.1 Perform current test by primary injection, where possible, with magnitudes such that ampere flows in the secondary circuit.
7.2.2.12.2 Where primary injection is impractical, utilize secondary injection with a minimum current of 1.0 ampere.
7.2.2.12.3 Test current at each device and verify multipliers.
7.2.2.12.4 Determine accuracy of all meters and calibrate watt-hours meters per section.
7.2.2.12.5 Perform phasing check on double-ended switchgear to ensure proper bus phasing from each source.
7.2.2.12.6 Verify that all protective relays and analog meters have been tested and in proper operations by Secondary current injection.
7.2.2.12.7 Potential Transformer Circuits
-
- Perform secondary wiring integrity test. Disconnect transformer at secondary terminal and connect secondary wiring to proper secondary voltage. Check for proper potential at all device.
- Verify secondary voltage by energizing primary winding with system voltage. Measure secondary voltage with the secondary wiring disconnected.
7.2.2.13 CIRCUIT BREAKERS – MEDIUM VOLTAGE VACUUM
- Perform minimum pickup voltage test on trip and close coils.
- Trip circuit breaker by operation of each protective device.
- Perform vacuum bottle integrity test (over-potential) across each vacuum bolted with the breaker in the open position in strict accordance with manufacture instructions. Do not exceed maximum voltage stipulated for the test.
- Contact displacement shall be in accordance with manufacture data marked on the nameplate of each vacuum breaker or bottle.
- Interrupter shall withstand the over-voltage applied without breakdown.
- Compare circuit breaker travel and velocity values to manufacture acceptable limits.
8.0 QUALITY CONTROL
8.1 All testing and inspection shall be coordinated by 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 SATIP.
8.5 QC Inspector, who conducts surveillance and inspection, shall coordinate to JGC/DEC and Saudi Aramco Representative.
9.0 SAFETY PRECAUTION
9.1 Secure the approved work permit from the concerned 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.
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.
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 Safety 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.
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 Switchgear Inspection and Test Procedure.
10.3 Attachment 3 SA-P-000 Pre-commissioning form — Testing Guidelines.
10.4 Attachment 4 SA-P-010 Protective Relays.
10.5 Attachment 5 SA-P-011 Instrument Transformer.
10.6 Attachment 6 SA-P-012 Metering.
10. 7 Attachment 7 SA-P-020 Switchgear — General.
10.8 Attachment 8 SA-P-023 Automatic Transfer Switches.
10.9 Attachment 9 SA-P-030 Molded Case Circuit Breakers.
10.10Attachment 10 SA-P-031 Low Voltage Power Circuit Breakers.
10.11 Attachment 11 SA-P-032 HV Power Circuit Breakers.
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