This area of investigation was directed toward addressing the impact of Electrical practices on the Utility Units’ Asset Management Program. Table lists the issues addressed and the resultant findings.
ELECTRICAL ISSUES | PLANT INTEGRITY MANAGEMENT
|Are any electrical maintenance activities performed by contractors?||No. All maintenance activities are carried-out by SA Technicians with the support from TSD.|
|What are the bases of scheduling preventive maintenance?||The bases are Saudi Aramco common practices and manufacturers recommendations which are reflected in SAP-PM It is the team experience that manufacturer’s recommendations usually reflect accept standards such as National Electrical Manufacturer’s Association (NEMA), International Electrical Testing Association (NETA), and Institute of Electrical and Electronics|
|Are there any systems or procedures for recording failures, incidents and troubles?||Engineers (IEEE). 3
Are there any systems or procedures for recording failures, incidents and troubles?
None were observed. While this information could be entered into SAP, maintenance records for troubles/failures not appear to be available to the technicians. Only major incidents appear to have been recorded.
|Are test equipment tested certified or calibrated by Approved Third-Party agencies?||No. Only safety equipment is tested by Safaniya staff.|
|Are Preventive Maintenance sheets for
Automatic Transfer Switches (ATS) available?
|PM Sheet for ATSs are not available|
|Are the ATS actions simulated or exercised to verify operability?||It could not be verified if this is accomplished during shutdowns.|
|Are there any system in place for recording or documenting the “Lessons Learned” for failures and other unit issues?||For major failures and incidents a system called SAMER is in place. However, for minor incidents and failures there is no process.|
|Who verifies, analyzes, and interprets the results and outcome of electrical PMs?||No evidence was presented that this was accomplished|
|Is there any back-up power available for the
|An Uninterrupted Power Supply (UPS) system for the essential and critical loads to allow for controlled and safe shutdown.|
|As whole power system is there any back-up power if the main power source (SEC) is out?||No. Back-up power is not available. Once the main power source is unavailable, the GOSP is down, except those feed by the UPS as critical and essential loads.|
|What is the frequency of test conducted on the protection relay system?||Major PMs are performed done every six (6) years. PM sheets are also available. Tests are also conducted whenever, necessary as the need arise. This frequency is
in conformance with industry accepted intervals for this type of equipment.
|Are history and records of failures and incidents related to relays in place?||Item or device history is recorded in the SAP, but the specific cause is not; root-cause analysis is not done.|
|Are load-flow or fault calculations available?||Load flow Analysis and Fault Calculations are available and updated by Engineering by Dhahran.|
|When is/are relay settings are reviewed and updated?||Every 3-years, as a part of the minor PM. Changed settings are recorded. Currently SAPOD is planning to implement a system where these changes can be incorporated and implemented in SAP. This frequency is in conformance
with industry accepted intervals for this type of equipment.
|What is the system or procedure implemented by SAPOD (Saudi Aramco Power Operations Department) to make the System Protection Reliable?||SAPOD involves itself in the Pre-commissioning, Commissioning and Routine PM’s as part of the Field activities. And from Engineering/Specialist side a study is conducted from time to time.|
|Are the present equipment ratings (KAIC) are still capable or can still withstand the present available fault level?||Engineering in Dhahran, is updating for the systems fault level. A copy of the document was requested from Mr. Ali. However, Intertek did not receive the document.|
|Is inspection and monitoring carried-out and is there any records compiled and documented?||Inspection and monitoring is carried-out every 3-years in minor PM. This frequency is in conformance with industry accepted intervals for this type of equipment. A copy of the PM Procedure was requested. It was not provided|
|Are procedures are available and are documented?||Yes. Procedures are Available and in place.|
|Are up to date electrical drawings available to technicians to assist in addressing problems?||It was observed at the substations, that available drawings had not been updated. It was also observed that updated copies of the drawings were not available in the substation or in the document cabinets. Informed that they were updated in the system but not in the substations.|
The key findings from the Electrical area are summarized as follows:
• While records for troubles/failures are entered into SAP, these records do not appear to be available to the technicians. Only major incidents appear to have been recorded. Recommendation: Maintenance records for electrical failures and anomalies should be recorded to provide a history of failures/troubles with sufficient information from which assessments can be accomplished.
• Electrical test equipment is not certified or calibrated by approved third-party agencies.
Only safety equipment is tested by Safaniya staff. Recommendation: As a “best practice”, a program for independent calibration of test equipment should be developed and implemented.
• It was observed at the substations that available drawings had not been updated. It was also observed that updated copies of the drawings were not available in the substation
or in the document cabinets. The team was informed that they were updated in the system but not in the substations but this could not be verified. Updated copies of drawings should be available for each equipment item inside the substation to be available for ready reference. This should be a part of the MOC process.