introduction to electrical system and equipment commissioning

Note: The source of the technical material in this volume is the ProfessionalEngineering Development Program (PEDP) of Engineering Services.

Warning: The material contained in this document was developed for SaudiAramco and is intended for the exclusive use of Saudi Aramco’semployees. Any material contained in this document which is notalready 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, EngineeringServices, Saudi Aramco.

Chapter : Electrical For additional information on this subject, contactFile Reference: EEX30101 W. A. Roussel on 874-1320

Engineering EncyclopediaSaudi Aramco DeskTop Standards

Introduction To ElectricalSystem & Equipment Commissioning

Engineering Encyclopedia Electrical

Introduction to Electrical System & Equipment Commissioning

Saudi Aramco DeskTop Standards

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 1

COMMISSIONING DEFINITIONS

This section of the module provides definitions of some of the terms that are used in thedescription and explanation of the commissioning process. Selected commissioningdefinitions are as follows:

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

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

Inspection and Test Plan - A document that defines or identifies the inspections, testmethods, 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 SaudiAramco Inspection Department as its representative(s) to assist in all matters that arerelated to Project Quality and to ensure that the project is in compliance with allcompany standards and specifications.

Inspect (Work) - To carefully and critically examine a facility, especially for flaws indesign or workmanship.

Mechanical Completion - A state that is achieved when the total facility that is definedin the Project Proposal, construction documentation, drawings, specifications, andmaterial requisitions has been installed and tested (pre-commissioned) and is availablefor 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 "as-built" drawings and specifications for the final acceptance of the facilities.

Start-Up - The introduction of additional feed stock, liquids, or gases into the facilityto achieve normal operating conditions following commissioning.

Witness (Event) - To be present at or to have personal knowledge of an event (e.g., atest).




PURPOSE OF COMMISSIONING

The purpose of commissioning is to ensure that a new facility meets Saudi Aramco andindustry design criteria and installation standards. Because industrial system facilityconstruction is a detailed and complicated process, the commissioning process provides asystematic and uniform approach to commissioning facilities. Although each industrialfacility is unique, the use of a systematic and uniform approach to commissioning of a facilityensures that all major facets of the facility will be observed, inspected, tested, and operatedsatisfactorily prior to the facility being placed in service.

Although the commissioning process for a facility is lengthy and detailed, experience hasshown that the time and effort that is expended up front to ensure safety, quality control, andadherence to Saudi Aramco and industry standards maximizes safe, correct, and efficientoperation and helps to minimize equipment failures and unscheduled shutdowns.




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 equipmentis commissioned. Saudi Aramco has specific mandatory requirements and recommendedpractices that apply to equipment that is commissioned for use in Saudi Aramco installations.Industry standards are also used to provide guidelines for equipment commissioning. Thissection of the Module will provide of the following equipment commissioning standards andpractices:

• 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 practicesthat 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 MechanicalCompletion and Performance Acceptance of Facilities. This manual is intended to define therespective duties and responsibilities that are required of the Saudi Aramco ProjectManagement Team (SAPMT), the Construction Agency, the Project Inspection Division(PID), and the Project Proponent. The duties and responsibilities of key commissioningpersonnel are described to ensure a smooth and timely transition from the construction phasethrough 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 ofFacilities general instruction manual for the following:




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 mandatoryrequirements for the design, construction, maintenance, and repair of equipment. Deviationfrom the requirements of these standards is not permitted without the written approval fromthe designated Saudi Aramco authority. Any equipment user or specified requirements thatexceed the minimum requirements do not need a waiver approval, even though they aredifferent. When conflicts arise between a specified SAES and other SAESs, related SaudiAramco Materials System Specifications (SAMSSs), Codes, Forms, and Saudi AramcoMandatory Drawings (SAMDs) the conflicts should be resolved by the manager of thedepartment that is responsible for revisions to standards and specifications.

This section of the Module describes the following SAESs that apply to the commissioning ofelectrical 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 forinstallation 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.





• Battery chargers and distribution systems for communications dc power supplies.

SAES-P-104, Wiring Methods and Materials, describes the minimum mandatory requirements forthe design and installation of wiring and cable systems, excluding overhead distributionsystems. For overhead distribution system requirements, refer to SAES-P-107.

SAES-P-111, Grounding, describes the minimum mandatory requirements for grounding ofelectrical equipment and for design and installation of grounding and lightning protectionsystems.

SAES-P-113, Motors and Generators, describes the minimum mandatory requirements for theprocurement and installation of induction and synchronous motors and generators forindustrial facilities. Motors for nonindustrial facilities must meet the requirements of NEMAMG 1.

SAES-P-114, Power System and Equipment, describes the minimum mandatory requirements forthe design and installation of protective relaying for power systems and equipment.

SAES-P-116, Switchgear and Control Equipment, describes the minimum mandatory requirementsfor the design and installation of switchgear and control equipment that is rated 38kV andbelow, except for fire water pump motor controllers.

SAES-P-121, Transformers, Reactors, and Voltage Regulators, describes the minimum mandatoryrequirements for the design and installation of transformers, reactors, voltage regulatingtransformers, and instrument transformers.

Saudi Aramco Design Practices (SADP)

The Saudi Aramco Design Practices (SADP) provide procedures that are advisable but thatare not necessarily mandatory. SADPs also provide background information to assistengineers, designers, and contractors who are working on Saudi Aramco projects. Writtenapproval is not required to deviate from the SADPs, unless the information in the SADPs ispresented in capital letters. Because the information is cited from the SAESs, SAMSSs, orSAMDs (Saudi Aramco Mandatory Drawings), the information in the SADPs that iscapitalized is mandatory. The SADPs are referenced when explanatory, amplifying, orbackground information on the selection, theory, operation, specification, or troubleshootingof equipment is required.





This section of the Module describes the following SADPs that apply to the commissioning ofelectrical 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 SaudiAramco's experience. Batteries that are used for motive power service, and batteries andchargers that are used for engine cranking, will vary with the specific application and do notrequire a standard for their application. Communication batteries and chargers are covered inthe SAES-T-Series standards. The paragraph numbering of SADP-P-103 follows SAES-P-103.

SADP-P-104, Wiring Methods and Materials, provides a commentary on the rationale for thoseSAES-P-104 technical requirements that are not obvious and that are based on many years ofSaudi Aramco's experience. To provide a more comprehensive coverage of the subject in aseparate standard, SAES-P-107, overhead distribution system requirements are excluded fromthis 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-111technical requirements that are not obvious and that are based on many years of SaudiAramco'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 technicalrequirements that are not obvious and that are based on many years of Saudi Aramco'sexperience. The paragraph numbering of SADP-P-113 follows SAES-P-113.





SADP-P-114, System and Equipment Protection, provides a commentary on the rationale for thoseSAES-P-114 technical requirements that are not obvious and that are based on many years ofSaudi 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 forthose SAES-P-116 technical requirements that are not obvious and that are based on manyyears of Saudi Aramco's experience. The paragraph numbering of SADP-P-116 followsSAES-P-116.

SADP-P-121, Transformers, provides a commentary on the rationale for those SAES-P-121technical requirements that are not obvious and that are based on many years of SaudiAramco'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 ofSaudi Aramco's operational experience. Fractional horsepower motors are excluded from thisspecification because this class of motors is adequately specified in SAES-P-113 and AMScatalogue 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 forthose 17-SAMSS-516 technical requirements that are not obvious and that are based on manyyears of Saudi Aramco's experience. Uninterruptible power supplies that are rated 10 kVAand below are of standard design and can be adequately described in the AMS catalogdescriptions. 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 technicalrequirements (as opposed to commercial requirements) that vendor or manufacturer-suppliedmaterials must meet for use in Saudi Aramco electrical systems. Engineers should use theSAMSSs when new equipment is specified. Any equipment of facility construction,configuration, or installation deviations that reduce the requirements of the SAMSSs musthave written approval from the designated authority in Dhahran. Facility installationrequirements that exceed the minimum requirements that are set forth in the SAMSSs do notneed to have a waiver approved.





Most equipment or facility specifications that are contained in the SAMSSs are taken fromANSI Standards; however, the SAMSSs are being revised to include equipment that ismanufactured to IEC standards. The SAMSSs describe the exceptions, deletions, or additionsto ANSI and industry standards. The SAMSSs that are used to select or to specify a piece ofequipment 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 commissioningof electrical equipment:

• 14-SAMSS-531, Power Transformers• 16-SAMSS-501, Switchgear Assemblies including ControlSwitchboards• 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 SystemStandard• 17-SAMSS-517, Medium Voltage Induction Motor Variable Frequency

Drives

14-SAMSS-531, Power Transformers, is a specification that defines the minimum technicalrequirements of 60 Hz, oil-filled, power transformers with tap changers for de-energized orload-tap-changing operation.

16-SAMSS-501, Switchgear Assemblies Including Control Switchboards, is a specification thatdefines the minimum technical requirements for three-phase, 60 Hz, indoor switchgearassemblies that are rated above 1 kV through 34.5 kV. This SAMSS includes therequirements for control switchboards.

16-SAMSS-502, Metal-Enclosed Low Voltage Switchgear Assemblies, is a specification that definesthe minimum mandatory requirements for the design, the fabrication, the testing, and thehandling of indoor metal-enclosed low voltage switchgear assemblies. The requirements ofthis specification apply to metal-enclosed, low voltage switchgear assemblies that areemployed in three-phase electric systems that have a maximum rms ac voltage that is nothigher than 1000 volts and nominal frequency of 60 Hertz.




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

switchracks. The requirements of this SAMSS apply to full-voltage combination starters,feeder circuit breakers, contactors, dry-type transformers, panelboards, and auxiliaryequipment that is assembled into the MCCs and switchracks.

16-SAMSS-506, Indoor Controlgear - Medium Voltage, is a specification that defines the minimumtechnical requirements for medium voltage (5 kV class), metal-enclosed indoor motor controlcenters. The requirements of this specification apply to National Electrical ManufacturersAssociation (NEMA) Class E-2 current-limiting fused controllers and all control and auxiliaryequipment that is assembled into the motor control centers. Oil-immersed controllers are notacceptable for Saudi Aramco installations.

16-SAMSS-511, Metal-Enclosed Bus, is a specification that defines the minimum technicalrequirements for three-phase, 60 Hz, indoor/outdoor metal-enclosed bus that is rated up to andincluding 34.5 kV.

17-SAMSS-503, NEMA Frame Motors, is a specification that defines the minimum technicalrequirements 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 cranemotors, and valve-operator motors.

17-SAMSS-516, Uninterruptible Power Supply, is a specification that defines the minimumrequirements for solid state uninterruptible power supply (UPS) systems that are rated forabove 10 kVA.

17-SAMSS-517, Medium Voltage Induction Motor Variable Frequency Drives, is a specification thatdefines the minimum technical requirements for a variable speed drive (VSD) that is used tocontrol the speed of three phase, 4 kV and 6.6 kV, squirrel-cage induction motors.




Industry Standards (Cont'd)

SAESs and SAMSSs are derived from years of operational experience and from provenindustry standards and practices. Instead of incorporating the applicable industry standards,SAESs and SAMSSs state exceptions, additions, or deletions to the relevant industrystandards.

Saudi Aramco electrical power systems must be designed, constructed, and tested inaccordance with the following codes, standards, and guidelines:

• National Electrical Manufacturers Association (NEMA) Standards

• Institute of Electrical and Electronics Engineers (IEEE)/AmericanNational 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 theselection and specification of electrical equipment. NEMA designates the specifications towhich various pieces of electrical equipment are constructed. If these specifications are thesame specifications that are needed by a Saudi Aramco installation, the equipment is specifiedto comply with the given NEMA classification. Reference to the appropriate NEMA standardeliminates the need to restate all the individual equipment parameters. NEMA standardsshould be used when they are referenced by SAESs.

The IEEE standards provide information on how to produce, test, measure, and buyequipment. The IEEE information is the consensus opinion of a group of electronics andelectrical engineering subject matter experts. The requirements and procedures that are givenin these standards and guidelines are used to select, specify, and troubleshoot electricalequipment.

ANSI has adopted most of the IEEE standards that relate to electrical equipment. ANSI doesnot write standards; it adopts standards that are written by other organizations. The ANSIStandards provide a uniform method to manufacture, market, purchase, and use a given pieceof 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 astandard that has been developed by IEEE and adopted by ANSI. If the sponsor of a standarddoes not employ a designation, the standard will use the ANSI acronym alone.




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




ROLE OF KEY COMMISSIONING PERSONNEL

Throughout the construction of a new facility, several personnel perform key roles in theprocess that leads to the commissioning of the new facility. This section describes the roles ofthe key commissioning personnel.

Saudi Aramco Project Management Team (SAPMT)

The SAPMT has the responsibility to deliver a completed facility in accordance with theapproved scope of the facility as defined in the facility documentation (e.g., project proposal,expenditure request). The SAPMT is comprised of representative personnel from majorcognizant Saudi Aramco agencies.

Manager of the Consulting Services Department (CSD)

The CSD Manager is responsible for the investigation, the review, the processing of newfacility construction waiver request forms, and resolving conflicts in the standards.

Proponent

The Project Proponent or Proponent Organization is the person or group that requested theconstruction of the new facility. The Proponent appoints the members of the AcceptanceCommittee, serves as the Chairman of the Acceptance Committee, and has the responsibilityto coordinate the start-up and commissioning of the facility.

Acceptance Committee

The Acceptance Committee must consist of the following personnel or their designatedrepresentatives:

• 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.




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

of he facility.

The Acceptance Committee develops the new construction checklist for the project,coordinates the project exceptions with the Construction Agency, attends inspections, attendsthe Mechanical Acceptance meeting, and ensures that the facility is safe to operate. TheAcceptance Committee Chairman (or his delegate) will have full authority to act for and onbehalf of the Proponent. The Construction Agency Project Manager (or his delegate) willhave full authority to act for and on behalf of the Construction Agency. The ProponentMaintenance Superintendent (or his delegate) will have full authority to act for and on behalfof the Maintenance Supervisor. The Proponent Commissioning Representative (or hisdelegate) will have full authority to act for and on behalf of the Operations EngineeringCommissioning Representative.

Construction Agency

The Construction Agency has the responsibility to keep the Proponent advised of projectscheduling and commissioning and acceptance paperwork requirements. The ConstructionAgency maintains inspection and exception checklists. The Construction Agency coordinatesall facility design and construction personnel for the duration of the project.




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. The PDD has theresponsibility to provide power for new facility construction.




COMPLETE ELECTRICAL COMMISSIONING CYCLE

Saudi Aramco has developed a five-phase commissioning cycle that is used as a guide duringthe commissioning process. Each phase contains key tasks that should performed during thecommissioning 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 beselected to provide the optimal review, inspection, and testing of the installation. When thefive phases of a complete Electrical Commissioning Cycle are complete, the equipmentcommissioning process is complete, and the equipment is turned over to the cognizantequipment operating or governing group. This section will describe the following topics thatpertain 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 maintainquality control of equipment that is purchased from the manufacturer before it is received atSaudi Aramco. The manufacturing approval phase includes the approval of manufacturer'sdrawings, factory quality control inspections, and the witnessing and approval of testing by adesignated Saudi Aramco representative. It is critical that the designated Saudi Aramcorepresentative approve the equipment testing prior to the shipment of the equipment to SaudiAramco.

Equipment Receipt Phase

The equipment receipt phase of the commissioning cycle provides an opportunity for SaudiAramco 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.




Equipment Receipt Phase (Cont'd)

The received equipment is verified through use of a visual check of the nameplate data. Thenameplate data are checked to see whether they meet the installation specifications anddrawings. It is critical that verification personnel check to see that the equipment completelymeets the mechanical specifications and drawing requirements. During the equipmentverification, personnel should also check to see that all operation and maintenance manualsand special installation tools that are needed are provided with the equipment. Anymanufacturer-approved documentation that should be included with the equipment should bereceived 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 aspossible. Damage that is uncovered after the equipment is installed can result in costly repairsand schedule slippage. During the inspection, all equipment accessory parts should bepresent.

Because testing is performed at the manufacturer's facilities, and because testing is timeconsuming and costly, receipt testing is only done if it is necessary. If testing is the only wayto ensure that damage to the equipment did not occur during the shipment, the equipment istested when it is received.

Equipment Installation and Testing Phase

The equipment installation and testing phase of the commissioning cycle provides anopportunity 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 thevisual check, the Electrical Engineer verifies that the equipment has adequate electric poweravailable, all necessary accessory equipment, and is located and installed in accordance withproject drawings. Problems, inadequacies, or damage to the equipment that is uncovered afterthe equipment is installed can result in costly repairs or schedule slippage. System electricalrevisions and nameplate data are checked to ensure that they are functional and compatiblewith the system and the equipment in accordance with the project drawings.




The installation is also checked for compliance with Saudi Aramco and industry safetystandards. The equipment verification at the location is critical because it is the last time thatinspection 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 theplanned location.

The electrical equipment is inspected at the location to determine whether any damage hasoccurred and to ensure that all mechanical moving parts are operable. The equipment isinspected for cleanliness, operability, and to ensure that all electrical connections meet SaudiAramco and industry standards.

The electrical equipment is tested as it is installed to ensure that insulation levels, electricalcharacteristics, and ratings meet manufacturer and industry standards.

System Pre-Operational Checkout Phase

The system pre-operational checkout phase of the commissioning cycle provides anopportunity 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 completesystem. Wiring checks and component adjustments are also performed to verify compliancewith wiring diagrams and manufacturer specifications.

Subsystems are checked to ensure that electrical continuity exists for control, protective, andinterlock devices. The proper operation of all subsystems is tested through use of controlledoperation and check out of the controls, protection, and interlock devices.

Each subsystem is performance tested through the application of full operational voltage toeach subsystem through the proper protective devices. A complete operational test isperformed on equipment controls, interlocks, protective devices, and components with eachsubcircuit connected to its main system. During the performance test, the main systems arestill isolated and independent from plant systems. Before the equipment is connected to theplant system, subsystem performance testing is critical to ensure the proper and safe operationof the equipment protection and control subsystems.




System Operational Observance Phase

The equipment operational observance phase of the commissioning cycle provides anopportunity 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 infraredthermoscan. The infrared thermoscan can reveal heating problems that may exist when theequipment 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 indicatedamage or the potential for damage to the operating equipment. The system and componentelectrical parameters (e.g., voltage and current) are also monitored and recorded.

The operational observance phase of the system and component operating conditions iscomplete 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 pre-commissioning documents for completeness and the satisfactory resolution of all abnormalinspection or test results. To ensure a smooth and timely transition from the constructionphase through the start-up and operation of the facility, Saudi Aramco GI-2.710 providesguidance as to the duties and obligations that are required of the Saudi Aramco ProjectManagement Team (SAPMT)/Construction Agency, Project Inspection Division (PID), andthe Proponent. This information is documented in the Mechanical Completion andPerformance Acceptance Certificate.

Part 4 of GI-2.710, Completing and Turning Over the Work, explains the requirements for thetransition from a facility that has been certified as mechanically complete to the actualcommissioning and start-up phase.

The first part of completing and turning over the work is the acceptance of all or part of afacility, as certified to be mechanically complete. The acceptance of a facility asmechanically complete involves a number of steps that include inspection checks, testing,




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 thesequence of events that lead to the performance acceptance of a facility. These events includethe 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




DEFICIENCY RESOLUTION PROCESS

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

• 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. Arequest for a waiver must be submitted to a Saudi Aramco company representative on SaudiAramco Form 6409 (Waiver Request Form) in accordance with SAES-302. Saudi AramcoForm 6409 is described in the Waiver Request/Approval section of this Module. The waiverrequest 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 isforwarded to the appropriate CSD Coordinator. The CSD Coordinator reviews the waiverrequest form and, if appropriate, requests that the concerned departments (e.g., LossPrevention, Operations, or Maintenance) review the subject form. Comments andrecommendations for approval or rejection from investigating and reviewing departmentsmust be attached to the waiver request form. When the waiver request investigation andreview by the concerned departments are complete, the waiver request is forwarded to theInspection Department Manager for review and concurrence. After concurrence by theInspection Department Manager, the CSD Manager performs a final review and approval (orrejection) of the waiver.

Waiver Request/Approval

The Saudi Aramco Form 6409 (Waiver Request Form) contains the justification for thewaiver request. As a minimum, the justification must include how compliance with Saudi




Waiver Request/Approval (Cont'd)

Aramco standards will impact the safety and cost of the material, equipment, or fabricationactivity that is the subject of the waiver request. Any delay to the job completion should beincorporated into the cost of the job. Any cost benefits or penalties that are cited in the waiverrequest justification must be supported by economic analysis. The waiver request justificationshould address any alternatives that were reviewed. The waiver request justification must alsoinclude 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 theresult of an Inspection Work Sheet write up.

The waiver request form must be submitted at least four weeks prior to the date of theinspection of the material, equipment, or fabrication activity that is the subject of the waiverrequest. The waiver request form must include, as attachments, all reasonable and relevanttechnical and cost documentation that is necessary to justify the waiver. These documentsshould include, but are not limited to, economic analysis, engineering design calculations, andInspection Work Sheets.

When a waiver request is submitted, the waiver request must be approved by the ProjectManager/Superintendent (or by superior positions) of the initiating organization. If a waiveris submitted after the fact (i.e., a noncompliance action has already been initiated), the waiverrequest form must be approved by the Department Manager of the initiating organization. Awaiver to mandatory Saudi Aramco Engineering Requirements (MSAER, including SAESs,SAMSSs, and Saudi Aramco Standard Drawings) may also be requested through theassociated Project Proposal. The technical merits of the deviation(s) from the standards mustbe 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 CSDManager. Normally, a Waiver Request Form is approved with the concurrence of the CSDManager and the Inspection Department Manager. A Saudi Aramco mandatory EngineeringRequirement is considered to be waived through a Project Proposal only when all of thefollowing conditions are satisfied:

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

• The qualifications, justification, conditions, and he details of thewaiver(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.




Waiver Request/Approval (Cont'd)ny reviewing authority can recommend the rejection of a waiverrequest. Any reviewing authority that recommends rejectionmust return the waiver request form to the CSD Manager with aletter that explains the reason for rejection. The CSD Managerwill review the waiver request form. If appropriate, a letter isissued that explains the reason for the waiver rejection. Theletter and the original waiver request are also returned to theoriginator.




GLOSSARY

ANSI The American National Standards Institute. The ANSI standardsprovide a uniform method to manufacture, market, purchase, anduse a given piece of equipment.

commissioning The placement of a facility in service, after the scope of workthat is defined in the Project Proposal, constructiondocumentation, drawings, and specifications is complete andmechanical completion has been achieved.

facility The product of a Saudi Aramco project that consists of thefabrication and construction of structures, equipment, andmaterials.

GI General Instruction

IEEE The Institute of Electrical and Electronics Engineers. The IEEEstandards provide information on how to produce, test, measure,and buy equipment. The IEEE information is the consensusopinion of a group of electronics and electrical engineeringsubject matter experts.

inspection and test plan A document that defines or identifies the inspection, testmethods, procedures, and acceptance criteria that should be usedduring procurement, fabrication/construction, and pre-commissioning.

inspection representative A party or parties that have been appointed by the Saudi AramcoInspection Department as its representative(s) to assist in allmatters that are related to Project Quality and to ensure that theproject is in compliance with all company standards andspecifications.

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 inthe Project Proposal, construction documentation, drawings,specifications, and material requisitions has been installed andtested (Pre-Commissioned) and is available for thecommissioning and start-up.




NEC The National Electrical Code. A National Fire ProtectionAssociation (ANSI/NFPA) code that provides information onhow to safeguard personnel and property from hazards that arisefrom the use of electricity.

NEMA The National Electrical Manufacturers Association. NEMA is atrade association for manufacturers of products that are used inthe generation, transmission, distribution, and end-use ofelectricity.

NETA The National Electrical Testing Association. The NETAStandards provide inspection and test procedures for equipmentand systems.

pre-commissioning The performance of all necessary checks, tests, adjustments,repairs, and modifications; the presentation of test results; andthe production of "as-built" drawings and specifications for thefinal 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 intothe facility to achieve normal operating conditions followingcommissioning.

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

introduction to electrical system and equipment commissioning

Documents

commissioning standards

commissioning process

availablefor commissioning

saudi aramco project

project proposal

project quality

total facility

construction documentation