MV Control Panel of Adjustable Frequency Drive (SAT) Site Acceptance Testing

1.0 PURPOSE
2.0 SCOPE
3.0 DEFINITION
4.0 REFERENCE
5.0 RESPONSIBILITIES
6.0 TOOLS AND EQUIPMENT
7.0 WORK SEQUENCE PROCEDURES
8.0 QUALITY CONTROL
9.0 SAFETY PRECAUTIONS
10.0 ATTACHMENT

1.0 PURPOSE

To ensure that site acceptance testing are performed safely, efficiently and in accordance with good working practice, as per Saudi Aramco Job Specifications..

2.0 SCOPE

This Method Statement defines the requirements for site acceptance testing of MV AFD Panel in plants and refinery projects.

List of perform Site Acceptance Test (SAT):

1) JXX-0XX-AFD-251 AFD PANEL

4.0 REFERENCE:

4.1 Saudi Aramco Engineering Standard

SAES-B-068 : Electrical Area Classification
SAES-P-100 : Basic Power System Design Criteria
SAES-P-104: Wiring Methods and Materials
SAES-P-111: Grounding
SAES-P-116: Switchgear and Control Equipment

4.2 Saudi Aramco Inspection Test Plan

SATIP-P-121-02 Power Transformers (235 kV or >2.5 MVA)
SATIP-P-116-02 Medium Voltage Controlgear
SATIP-P-116-13 Variable Speed Drive (VSD) Equipment.

4.3 Saudi Aramco Test Report (SATR)

SATR-P-3812 MV Controlgear Pre-Energized and Functional Testing

4.4 Vendor’s Form

4.4.1 MV Drives Commissioning Report Template-ABB
4.4.2 Operation & Maintenance Manual of AFD (J10-K-500 A/B)

5.0 RESPONSIBILITIES

5.1 Site Manager

Site Manager is responsible for supporting and encouraging the related staffs
and workers, so as for them to participate actively as worksite. Site Manager is
responsible for implementation of HSE requirements.

5.2 Construction Manager

Construction Manager is responsible for compliance with this Method
Statement and shall ensure to review contract documents and provide all
resources necessary to effectively
implement throughout the construction
period. Construction Manager shall monitor the quality and progress of the
work and ensure that job target
is achieved. Construction Manager
is responsible for complying with HSE requirements.

5.3 Electrical Supervisor

The Electrical Supervisor shall be responsible for construction work
supervision, work permit, conducting TSTI and ensuring that work is completed
in conformity with drawings and specifications.

5.4 QA/QC Manager

QA/QC Manager has the overall responsibility for all QA/QC activities of the
project. He shall be
interacting with Site Manager related to all QA/QC
activities. He shall be responsible for Nonconformance Management and
Quality Audit.

5.5 QA/QC Inspectors

QA/QC
Inspectors shall be responsible for Site QA/QC activities,
in co­
ordination with HSE team for cable testing works at site.

5.6 SVC HSE Manager

HSE Manager shall monitor related works under carrying out, and advise
supervisors for corrective measures, if required. He shall ensure holding of pre
task HSE meeting /daily tool box talks covering details of specific tasks and
specific job risks involved to the work force involved. He shall also ensure
appropriate mode of communication in case of emergency.

6.0 TOOLS and EQUIPMENT

6.1 General Tools/ Test Equipment
• Pipe wrench
• Adjustable wrenches
• Ratchet wrenches
• Double offset wrenches
• Open ended spanners
• Screw drivers
• Cross-point screw drivers
• Pliers
• Crimping pliers for insulated AMP terminals
• Torque wrenches
• Motor pump.
• Hand tools
• Multi-meter/ Continuity tester
• Insulation Resistance Tool (Megger, etc.)

7.0 WORK SEQUENCE PROCEDURE

7.1 Pre-Testing Activities

7.1.1 Ensure that all materials, accessories and consumables shall be prepared and
checked prior to commencing with the work.
7.1.2 Manpower, tools and other logistics are ready and prepared for the work.
Ensure that all personnel are qualified to perform the work and are fully familiar
with the tools and equipment to be utilised.
7.1.3 Ensure that all test equipment to be utilised is newly calibrated.
7.1.4 Ensure that all relevant documents have been approved by DEC/JGC and
Aramco prior to commencing with the work, and that specification,
manufacturer’s instructions/factory test reports, including approved procedures
are disseminated to concerned personnel who will carry out the work.
7.1.5 Ensure that work permits are obtained prior to proceeding with the work in the
area, and are available to the working crew.
7.1.6 Ensure safety barriers are erected at designated work areas and warning signs
posted.

7.1.7 Always refer to
instruction manuals of equipment under test and the test
equipment to be utilised for detailed safety instructions and precautions.
7.1.8
Inspect, test transformers and record test results per approved DEC/JGC
/Aramco Installation/Test Checklist.
7.1.9 Test shall comply with the manufacturer’s
instructions and referenced
international standards.
7.1.10 Compare the test results to the acceptable results given in the manufacturer’s
factory test record.
7.1.11 Record ambient temperature for correction of test data.

7.2 Site Acceptance Testing Procedure:

7.2.1. COLD COMMISSIONING

1. Visual inspection of Converter (AFD) installation and other components (see Attach. 1 & 2).
2. Qualified persons shall use reliable communication equipment for power supply switching.
3. Assign qualified technician to switch ON/OFF the power supply from PIB0l0 & 55010.
4. First, make sure that all circuit breakers in WCU panel are switched OFF.
5. From PIB0lO UPS PDP, energize the 120VAC safe line voltage (see Attach.-2).
6. From SS010 LV MCC, energize the 480VAC auxiliary supply for AFD and WCU.
7. Switching ON the 480V auxiliary supply will also energize the 50kVA Exciter transformer and the Excitation Panel.
8. Check if all Protection settings of all devices to be the same as provided by ABB.
9. Switch ON all MCB in the AFD one by one; check corresponding components.
QlO0l – Switching ON this MCB will switch ON control circuit in the AFD.
Q1002 – Switching ON this MCB will switch ON control circuit in the Excitation Panel.
10. Energize 480VAC, 3-ph from LV-MCC in 55010 & check AFD control circuit.
For AFD-251, J10-010-MCC-011 panel AFF.
For AFD-252, J10-010-MCC-012 panel AIL.
For AFD-253, J10-010-MCC-017 panel ADD.
Q1101- This MCB provides power to DC Link charging circuit. Switch it OFF.
Q1102 – This MCB provides power to all components running on 3 phase 480V.

11. Check Cooling Fan, Grounding switch, Door interlock operation of AFD.
12. Check all components in Excitation panel if powered ON and healthy.
13. Check parameters of AFD I/O’s as per customer Interfaces with DCS, breaker.
14. Prepare to fill up potable water (drinking water) to the Water Cooling Unit (WCU).
For AFD 251 & 252 = approx. 200 liters; For AFD 253 = approx. 180 liters.
15. Switch ON the External water pump with capacity to fill 15 liters per minute.
16. Flush the air from the internal water lines and start the Internal Pumps Pl and P2. For complete
procedure, see Attach-3.

17. Check water circulation, leaks, temperature, pressure. Read Parameter 34.12, 34,13, 34.14.
18. Command to switch ON pumps were provided in AFD.
19. Keep both pumps in OFF condition. Parameter…..35.01 – None.
Q5001 & 2-Switch ON. Power supply to cooling Pump 1&2.
20. After de-aerating, Pumps can be started in Auto mode from AFD.
Change Parameter 35.02..
21. Pumps will continuously run to reduce conductivity of water below 0.SuS.
22. Check for all Faults in AFD and resolve to make it READY TO ON condition.
23. Keep the MCB Q5011 in OFF condition. This will NOT supply power to AFD space heater and motor
space heater.

7.2.2. HOT COMMISSIONING (Part-1)

1. Visual inspection of Converter (AFD) installation and other components (see Attach. 1& 2)
2. Qualified persons shall use reliable communication equipment for power supply switching.
3. Assign qualified technician to switch ON/OFF the power supply from PIB010 & 55010.
4. Energize & check AFD control circuit 120VAC safe line from UPS PDP in PIB010 (see Attach.-2).
5. Energize & check AFD auxiliary control using 480VAC from LV-MCC in 55010 (see Attach.-5).
6. Before Pre-charging start, VFD status should be READY ON condition.
7. AFD will automatically/internally check the following:
(a) Doors are locked and Grounding switch is Open condition.
(b) Conductivity of water, Inlet and Outlet pressure are within limits.
(c) No Emergency Off, Breaker in OFF condition and other control circuit
(d) Keep all doors (front & back) completely closed.
(e) Alarm is displayed for non-critical faults.
8. Switch ON the AFD to Pre-charge through 480VAC.
9. Then if the DC link voltage reach is set, voltage (5,300VDC in each phase), the close command to
Breaker is released.
10. Isolate the Motor cables, Transformer secondary cables & Exciter cables if the equipment pre­
commissioning is not completed.
11. Keep MV circuit breaker in SG-302 in Test Position.
Q1101 in AFD panel= Put to ON position.
12. During Pre-charging of capacitors in AFD using 480VAC from LV-MCC in 55010, monitor the voltage
rise through the AFD window tool (HMI) for first operation.
13. Any malfunction will be automatically detected by AFD and will discharge.
14. The AFD doors will only open, if DC Link is shorted by Grounding switch.
15. To operate Grounding Switch, DC link voltage should be less than 50V.
16. Check MCB control, OPEN & CLOSE in both Local & Remote mode.

7.2.3. HOT COMMISSIONING (Part-2)

1. Visual inspection of Converter (AFD) installation and other components (see Attach. 1 & 2).
2. Qualified persons shall use reliable communication equipment for power supply switching.
3. Assign qualified technician to switch ON/OFF the power supply from PIBOlO & SSOlO.
4. Energize & check AFD control circuit 120VAC safe line from UPS PDP in PIBOlO (see Attach.-2).
5. Energize & check AFD auxiliary control using 480VAC from LV-MCC in 55010 (see Attach.-5).
6. Pre-charging of capacitors in AFD using 480VAC from LV-MCC in 55010.
7. Check MCB control, OPEN & CLOSE in both Local & Remote mode.
8. Pre-charging of capacitors in AFD using MV Transformer (Prim. 13.8kV; Sec. 61.92kV). Note: LV breaker will be withdrawing automatically before MV switchgear is switched ON.
9. Check the parameter settings and tuning of Excitation panel with motor exciter. Note: During this process, the Lube oil Motor should be ON.
10. Before Motor start, check all motor auxiliary supplies are ON and motor is protected
11. Check if ESD signal from customer can be released in case of any failure such as:

(a) Motor Lube oil failure
(b) Purge, excessive vibration, high bearing temperature, etc.
12. Start-up AFD at NO-LOAD operation and check Motor speed is matching with the display.
13. Check if the NO-LOAD current is within limits.
14. Start-up AFD with LOAD operation (LOAD RUN). Check Motor speed control & tuning.
15. De-energize.

IMPORTANT: For HOT Commissioning items 10 14, make sure that an External Cooling Water source is readily available in the process line before starting Motor load run. MV Transformers supplying the AFD shall be thoroughly checked and tested prior to energizing. Coordination between Client, Contractor, Sub-con, HSSE and other responsible Sections is necessary.

7.2.4. END of S.A.T.

1. Check spare parts & documents. Perform Customer training & Quality check.

8.0 QUALITY CONTROL

Inspection shall be performed by the project approved Quality Control Inspector (QCI) and witness point shall be coordinated with the Contractor and Company.

9.0 SAFETY PRECAUTIONS:

9.1 Barricade the working area.
9.2 All safety precautionary signboards must be visibly posted.
9.3 Ensure that only authorized personnel are within the affected area.
9.4 The work shall be executed with the approved Risk Safety Analysis (RSA).
9.5 Maintained RSA at worksite by work Supervisor, requirements shall be discussed in daily TSTI. (See attachment).

9.6 Ensure valid HOT WORK PERMIT is signed prior to commencing splicing and personnel had undergone work at height training.

10 ATTACHMENT

Attachment-1: Job Hazard and Risk Assessment (JHRA).
Attachment -2: Commissioning Checklist (General and Detailed procedures).
Attachment -3: Water filling and circulation (Detailed procedures).
Attachment -4: Cold Commissioning of AFD panel (Detailed procedures).
Attachment -5: Hot Commissioning of AFD panel (Detailed procedures).