QA/QC NOTES | By SIKANDAR MEHAR

Interview Question for QA/QC Inspector Electrical, Instrumentation & Cathodic Protection

General questions for electrical and instrumentation

Q What is QC/Quality Control?

Ans Quality control is a technique of inspection, testing and examination that are used to fulfill the quality
requirements.

Quality control is an inspection or testing of products/activities to uncover defects and reporting to

management who make decision to allow or deny the product release.

Q What is QA/Quality Assurance?

Ans Quality assurance is a technique to improve and stabilize the production/work activities by avoiding or
minimizing the issues which led to defects.

Q What are the job responsibilities of QA/QC inspector at site?

Ans A QA/QC inspector is responsible for quality control and quality assurance of all the construction works, and
all the activities at site should be according to the standards, project specifications, approved procedures
and ITP’s. When some construction activity starts, QC will do internal inspection and will do review of
documents before raising the RFI. If there is some violation or non‐conformance in work, QC shall raise NCR.
When there is some issue/complication/irregularity regarding to construction activities, QC will consult with
his management and PID and PMT to resolve it.

Q What is schedule Q? How many attachments it has?

Ans Schedule Q is an Aramco document that describes the project quality requirements, inspection schedules
and procedures, documentation requirements, contractor and subcontractor quality personnel qualification
requirements and quality requirements for contractors supplied materials.

It has 6 attachments:

(1) Attachment‐I >> Contractor and Subcontractor Quality Personnel Qualification Requirements
(2) Attachment‐II >> Saudi Aramco Standards and Procedures Containing Quality Requirements
(3) Attachment‐III >> Quality Requirements for Contractor Supplied Materials
(4) Attachment‐IV >> Quality Requirements for the Construction Phase
(5) Attachment‐V >> Summary of Quality System Deliverables
(6) Attachment‐VI >> Project Specific Quality Requirements

Q What is the quality plan?

Ans Quality Plan is a document includes quality standards, procedures and description of sequences of work
activities.

Q What is SAES, SAEP, SAIP, SAMSS, SAER, GI, SATIP, ITP, SAIC, QMIS, RFI?

Ans SAES: Saudi Aramco engineering Standards

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SAEP: Saudi Aramco engineering procedures

SAIP: Saudi Aramco inspection procedure

SAMSS: Saudi Aramco materials systems specifications

SAER: Saudi Aramco engineering report

GI: Saudi Aramco general instructions

SATIP: Saudi Aramco typical inspection plan

SATIP is a document which provides us information related to activity, activity number, SAIC number and
responsibility of contractor and client QC personnel inspection level.

ITP: Inspection and test plan

SAIC: Saudi Aramco inspection checklist

QMIS: Quality management information system

Mandatory Saudi Aramco Engineering Requirements (MSAERs) are Saudi Aramco Materials System
Specifications (SAMSSs), Engineering Standards (SAESs) and Standard Drawings (SASDs).

RFI: Request for inspection

Q Name some international standards which you follow for electrical and instrument work?

Ans IEEE: Institute of electrical and electronic engineers

NEC: National electrical code

IEC: International electrotechnical commission

NEMA: National electrical manufacturers association

NFPA: National fire protection association

NACE: National association of corrosion engineers

ANSI: American national standards institute

ASTM: American society for testing and materials

UL: Underwriters laboratories

AEIC: Association of Edison illuminating companies

ICEA: Insulated cables engineering association

IS: International standards

ISO: International standards organization

BS: British standards institution

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Q How a QC inspector will raise a RFI?

Ans When some activity starts, QC will do pre inspection as per approved drawings and will do review of
documents and then will raise the RFI.

Q How much time before the inspection you will raise RFI?

Ans 24 hours before the inspection time.

Q What is the inspection, documentation, document review, standards, hold point, witness point?

Ans Inspection: An activity such as measuring, examining, testing of a product/equipment/activity and

comparing the results with specified standards and procedures in order to know whether conformity is
achieved or not.

Documentation: Any paper record or pictorial information.

Document review: To collect all the documents related to an activity and to evaluate the requirements for
quality of that specific activity are fulfilled or not and to identify if there is any problem or non‐conformity
exists.

Inspection assignment package: A set of documents that include details of purchased material, needed to
perform full inspection.

Standards: A document approved by a generally recognized body.

Specification: A detailed description of design and materials used to make something.

Quality management system: All activities that determine the quality policy, objectives and responsibilities,
and implement them through quality planning, quality control, quality assurance.

Quality System: Organizational structure, procedures, processes and resources needed to implement the
quality arrangements and requirements.

Quality audit: A systematic and independent examination to determine whether quality activities comply
with the planned arrangements.

Hold point: Inspection or test stage beyond which work/activity should not proceed without the QA/QC
organization representative in attendance.

Witness point: A point that provides QA/QC representative with the opportunity to attend the
inspection/test at his option.

Surveillance: Generally visiting the site work without RFI.

Quality Control Procedure (QCP): A QCP is a documented procedure detailing the processes necessary to
complete a specific work activity.

PIM: Pre‐Inspection Meeting

RIO: Responsible Inspection Office

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SAIR: Saudi Aramco Inspection Representative

VID: Saudi Aramco Vendor Inspection Division

Compliance: A judgment that the product or activity meets the requirements of the relevant specification or
standard.

Non‐conformity: Non‐fulfillment of a specific requirement of the relevant specification or standard.

Corrective action: Action taken to eliminate the defect or existing non‐conformity, or other undesirable
situation.

Preventive action: Action taken to eliminate the causes of the existing non‐conformity, defect or other
undesirable situation in order to prevent recurrence.

Procedure: A specified way to perform an activity.

Pre‐commissioning: Testing of system components for continuity, operability.

Commissioning: Process by which an equipment, facility, or plant is tested to verify if it functions according
to its design objectives or specifications.

Q What is NCR, Define and explain it with example?

Ans None‐conformance report, we raise NCR when there occur some non‐conformity/violation at the site during
the construction work or when there is some non‐conformity/violation occurred during material receiving.

There are 4 parts of a NCR... (1) Violation occurred (2) Root cause analysis (3) Corrective action to be taken
(4) Preventive action (Recommendations to avoid re‐occurrence of violation).

Q What will you do when you see some violation/non‐compliance has occurred at site?

Ans I will raise internal NCR and will ask to construction team to take action to rectify it.

Q After how much time of occurrence of violation you will raise NCR?

Ans Within 24 hours

Q Within how much time the violation/non‐conformity should be resolved?

Ans As per ACD‐(Agreed Completion Date).

Q There are how many types of NCR?

Ans: There are 2‐types of NCR, and what is the difference between them?

1‐ Internal NCR
2‐ LBE Standard Violation/Client NCR
3‐ Company NCR

Internal NCR is a NCR which is raised by the Contractor QC‐Inspector and LBE/Client NCR is a NCR which is
raised by PID (Client QC‐Inspector)

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Q How many types of RFI are?

Ans There are two type of RFI; (1) Internal RFI (2) QMIS RFI

Q What is walk through?

Ans Preparation of balanced work report (punch list items) upon completion of 80% of construction work

Q What is punch list items?

Ans Any balanced work report during completion of work is called punch list items.

Q What is two week look ahead schedule?

Ans It is the schedule of work that have to complete in the next two weeks. The project planner/ project
scheduler will prepare two week ahead schedule.

Q What is the T.Q.?

Ans If there is some conflict/issue occurred to execute work as per approved IFC Drawing, T.Q. is raised according
to site requirement and the designer/CSD/Client will approve it.

Q What is red‐mark/as‐built drawing?

Ans Changed drawing according to the site requirement, for example re‐routing/re‐location of
cable/conduit/equipment.

Q How to resolve conflicts between any standard and other Mandatory Saudi Aramco Engineering
Requirements (MSAERs), what is the procedure?

Ans Any conflicts between a standard and other Mandatory Saudi Aramco Engineering Requirements (MSAER)
i.e. applicable Saudi Aramco Engineering Standards (SAES), Materials System Specifications (SAMSS),
Standard Drawings (SASD), or international standard, codes, and forms shall be resolved in writing by the
company or buyer representative through the Manager, Consulting Services Department of Saudi Aramco.

Q What is the way/procedure to deviate from any standard or to get waiver?

Ans To deviate from any standard, requests shall be submitted electronically through the SAP Waiver
Process in accordance with SAEP‐302.

Q For obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement which standard we
follow?

Ans For obtaining a waiver of a Mandatory Saudi Aramco Engineering Requirement we follow SAEP‐302.

Q What is a waiver?

Ans To get favor to deviate from any Mandatory Saudi Aramco Engineering Requirements is called waiver.

Q What is FAT test?

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Ans The factory acceptance test procedure is a test that is performed to determine that an equipment or product
meets the requirements or specifications of a client before it shipped out to its destination site.

The FAT is normally performed at the manufacturer’s workshop. The manufacturer checks that the safety
instrumented system works as intended according to the requirements stated in the safety requirements
specification (SRS).

Q What are the test activities included in FAT?

Ans During the FAT the manufacturer checks:

I) The equipment is according to the specification.

II) The equipment is installed according to the manufacturer’s specifications.
III) The inputs and outputs are connected according to the drawings.
IV) The calibration of the equipment are correct.
V) The trip points operate according to the requirements in SRS.
VI) The logic solver and associated software operate according to the requirements.
VII) The outputs and their actions behave according to the SRS.
VIII) The reset function operate according to the SRS.
IX) The alarms operate according to the SRS.
X) The operator functions operate according to the SRS.
XI) The bypass function operate according to the SRS.
XII) The manual shutdown function operate according to the SRS.
XIII) The diagnostic alarm functions according to the SRS.

Q What is SAT test?

Ans SAT is site acceptance test of an equipment to ensure that it is tested in accordance to client approved test
plan & specifications and to show the equipment is installed properly and interfaces with other systems and
peripherals in its working environment.

Q What is low resistance test?

Ans

Q What is winding resistance test?

Ans

Q What is temperature test of motor and transformer?

Ans

Q What is the turn ratio test of transformer?

Ans

Q How we do contact resistance of busbar and cable joints?

Ans We do this test with ducter test.

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Q What is ducter test?

Ans Contact resistance test (commonly known as the ducter test) measures the resistance of electrical
connections such as joints, terminations and connectors etc. This test measure the resistance at the micro or
milli ohm level and is used primarily to verify that electrical connections are made properly. This is
particularly important for contacts that carry large amount of current e.g. switchgear busbar.

Important Standards References

SAES‐B‐068 Electrical Area Classification
SAES‐O‐113 Security Lighting System
SAEP‐302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement
NEMA ICS 6 Enclosures for Industrial Controls and Systems
NEMA VE 1 ‐ 2002 (Design & specifications of Metal Cable Tray Systems)
NEMA VE 2 ‐ 2006 (Cable Tray Installation Guidelines)
NEMA 250 Enclosures for Electrical Equipment (1000 Volts Maximum)
NEMA FG 1 Fiberglass Cable Tray Systems
NEMA ICS 6 Enclosures for Industrial Control and Systems
NEMA RN 1 Polyvinyl‐Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate
Metal Conduit
NEMA TC 2 Electrical Polyvinyl Chloride (PVC) Conduit
NEMA TC 3 PVC Fittings for Use with Rigid PVC Conduit and Tubing
NEMA TC 6 & 8 PVC Plastic Utilities Duct for Underground Installations
NEMA TC 9 Fittings for PVC Plastic Utilities Duct for Underground Installation
NFPA 70 ‐ National Electrical Code (NEC)
NFPA 72 ‐ National Fire Alarm Code
ANSI C80.1 Rigid Steel Conduit ‐ Zinc Coated
ANSI C80.3 Electrical Metallic Tubing ‐ Zinc Coated
IEC 60529 Degrees of Protection Provided by Enclosures
NEC Article 110 Requirements for Electrical Installations
NEC Article 250 Grounding
NEC 725
NEC 760

Q What is hazardous and non‐hazardous area?

Ans Hazardous locations are areas where flammable liquids, gases, vapors or combustible dusts exist in sufficient
quantities to produce an explosion or fire, otherwise non‐hazardous area.

Q What is classified area?

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Ans Hazardous locations are called classified areas, where flammable liquids, gases, vapors or combustible dusts
exist in sufficient quantities to produce an explosion or fire.

Q What is IP code? (Ingress protection rating or International protection rating)

Ans Ingress protection describe the degree of protection provided against intrusion, dust, accidental contact, and
water by electrical enclosures.

Q How we classify the severe corrosive environment?

Ans Severe corrosive environments include:

a) Offshore locations

b) Onshore locations within 1‐Km from the shoreline of the Arabian Gulf; and within 3‐Km from the
shoreline of the Red Sea.

Q What is a substation?

Ans A substation is a part of an electrical generation, transmission, and distribution system, which transform
voltage level from high to low, or the reverse. It contain transformers, and control equipment, i.e. breakers,
relays, contactors, disconnecting switches etc.

Q What is electrical area classification?

Ans Production facilities contain, or may contain, flammable gases and vapors, combustible dust or fibers in
normal operations. These can form an explosive environment that is ignitable by hot surfaces, electrical arcs,
and sparks. To prevent this from happening, facilities must be classified properly, so that all electrical
equipment and systems are properly selected and installed. (SAES‐B‐068)

Classes:
There are three categories of hazardous materials that have been designated as Class I, Class II, or Class III.
The Classes define the type of explosive or ignitable substances which are present in the atmosphere such
as:
Class I locations are those in which flammable vapors and gases may be present.
Class II locations are those in which combustible dust may be found.
Class III locations are those which are hazardous because of the presence of easily ignitable fibers or flying.

Each of the three Classes is further subdivided into two Divisions,

Division 1 or Division 2

Divisions:
The Division defines the likelihood of the hazardous material being present in a flammable concentration.

Division 1: In which ignitable concentrations of hazards exists under normal operation conditions and/or
where hazard is caused by frequent maintenance or repair work or frequent equipment failure.
Division 2: In which ignitable concentrations of hazards are handled, processed or used, but which are
normally in closed containers or closed systems from which they can only escape through accidental rupture
or breakdown of such containers or systems

Groups:

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The explosive characteristics of the air mixtures of gases, vapors, or dusts vary with the specific material
involved. Materials have been placed in groups based on their ignition temperatures and explosion
pressures. Combustible and flammable gases and vapors are divided into four Groups, A, B, C, D.

Zone Method of Area Classification

Class I, zone 0

Locations

In which ignitable concentrations of flammable gases or vapors are present continuously for long periods of
time.

Class I, zone 1

Locations

In which explosive or ignitable concentrations of flammable gases or vapors are likely to exist under normal
operating conditions.

Class I, zone 2

Locations

In which ignitable concentrations of flammable gases or vapors are not likely to occur in normal operation
and if they do occur will exist only for a short period

Unclassified

All areas in the facility that are not Zone 0, Zone 1, or Zone 2 are considered unclassified. Arcing electrical
equipment in unclassified areas need not be explosion‐proof. General‐purpose enclosures are acceptable in
these areas.

Q What is cable?

Ans A group of individually insulated conductors.

Q What is cable gland?

Ans A gland is a connector designed to attach, secure and seal the end of a cable to an equipment.

Q What are types of cable glands?

Ans Types of glands

a) Metal glands (For Armored cables & Hazardous Area Applications)

b) PVC Glands ( For Non Armored and Flexible Cables)

Q What is an electrical connector?

Ans Electrical connectors join wires/cables to an electrical terminal.

Q What are types of electrical connectors?

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Ans There are many types of electrical connectors

a) crimp‐on connectors
b) twist‐on (spring pressure type) connectors
c) plug and socket connectors
d) screw connectors
e) blade connectors
f) ring & spade connectors (fork or split ring terminals)

Q What are terminal blocks?

Ans A device that joins wires or cables to equipment or electrical/instrument enclosure, types are:

a) screw type terminal blocks

b) spring‐clamp terminal blocks
c) panel mount terminal blocks

Q What is conduit? Types of conduit?

Ans An electrical conduit is a tubing system used for routing & protection of electrical wiring. Types are:

a) Metal conduit (rigid metal conduit, galvanized rigid metal conduit, intermediate metal conduit, electrical
metallic conduit)
b) Non‐metal conduit (PVC conduit)
c) Flexible conduit (flexible metallic conduit, liquid‐tight flexible metal conduit, flexible metallic tubing)

Q What are cable raceways?

Ans Cable raceways are enclosed channels of metallic or plastic materials designed to hold, hide and protect
cables.

Q What is cable dressing?

Ans Neat and clean arrangement of cables is called cable dressing.

Q What is cable lacing?

Ans Cable lacing is a method of arranging the cables and wires.

Q What are cable ties?

Ans A cable tie is a type of fastener, for holding together wires or cables.

Q What are the types of cable ties?

Ans hose‐tie, zip‐tie, tie‐wrap, zap‐trap.

Q What is fastener?

Ans A fastener is a hardware device that mechanically joins or affixes two or more objects.

Q What is cable termination?

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Ans Cable termination is the process of connecting cables up to the final equipment/enclosure.

Q What are the conduit fittings?

Ans Conduit fitting are accessories used to connect, redirect, extend or terminate a conduit.

Q Name some conduit fittings?

Ans (a) bushing (b) hubs (c) locknuts (d) couplings (e) reducers (f) nipples (g) conduit union (h) elbows (i) conduit
bodied

Q What are the conduit supports and their types?

Ans A conduit or pipe support is an element that transfer the load from the pipe to the supporting structures.
There are many types of conduit supports.

(1) Clamps (2) Hangers (3) Clips (4) Brackets (5) Straps

Q What are the cable tray fittings?

Ans Cable tray fittings are.

1) Clamps 2) Hangers 3) splice plates 4) reducer plates 5) blind ends 6) tray cover

Q What are the cable tray fasteners?

Ans There are many types of cable tray fasteners.

1) Nuts 2) bolts 3) washers

Q What is sealing compound?

Ans It is a substance used to prevent the passage of gasses, vapors of flames from one portion of the electrical
installation to another through conduit.

Q What is conduit sealing?

Ans Conduit sealing is used at the conduit ends to effectively seal the conduit.

Q What is cable tray? How many types?

Ans A cable tray is a system used to support and routing of insulated cables used for power distribution, control
systems or communication.

Types are: 1) Ladder type cable tray 2) Perforated bottom & Solid bottom type cable tray

Q What is duct bank?

Ans A duct bank is a group of conduits or ducts, encased in concrete.

Q What is splicing? Splice?

Ans The joining of wires in electrical wiring is called splicing.

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Q What is wire ferrule?

Ans A plastic sleeve used on terminated ends of cables, which is imprinted with tag.

Q What is creepage distance?

Ans The shortest distance between two conductors.

Q What is electrical enclosure/terminal enclosure?

Ans An electrical enclosure/terminal enclosure is a cabinet for electrical or electronic equipment to mount/install
switches, knobs and displays and to prevent electrical shock to equipment users and protect the contents
from the environment.

Q What is the junction box?

Ans A box containing the connections and terminal blocks of wiring cables.

Q What is distribution board?

Ans A distribution board (distribution panel or power panel) is an enclosure which distributes an electrical power
to subsidiary circuits, and provides protective fuse or circuit breaker for each circuit.

Q What is switch board?

Ans A switchboard is an electrical enclosure that controls electricity from one or more sources of supply to
several smaller devices.

Q What the difference is between switch board and switch rack?

Ans Switch board is installed inside and switch rack is installed outside, and switch board contains only switches
which controls electricity of small equipments while switchrack it is a package of transformer, busbar, and
power panels.

Q What is bonding box?

Ans A box (electrical enclosure) in which the bonding cables are terminated for CP is called bonding box.

Q What is megger (IR Tester) and what is meggering (IR Testing/Cable testing)?

Ans A Megger meter (Insulation resistance tester) is designed to check insulated cable jacket condition.

The measurement of the insulation resistance of cables is called meggering/IR testing.

Meggering/Megger Testing is to check that electrical insulation of cables is intact and in good condition.

Q What are inspection points for a cable tray installation?

Ans Checking of material as per approved spec, size and type, tray installation as per drawings, clearance from
top of the tray, proper distance from tray to tray, supports are at proper distance, expansion joints and
splice plates are properly installed. Cable tray is free of any debris.

Q What are inspection points for field instruments with impulse tubing?

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Ans Checking of material as per approved material, type and size, installation as per Instruments Points & Line
drawing, P&ID & hook up, checking of size and material of tubing, check the route to be free of any
obstruction, check tube bending and tube support, fittings.

Q What is inspection points for cable laying?

Ans Material should be as per approved type and size, cable routing as per Instrument cable layout & cable
schedule, meggering, dressing and cable tags.

Q What is the inspection points for instrument junction boxes and marshalling cabinets (electrical/instrument
enclosures)?

Ans Checking of material is as per approved material, type and size, drain & breathers, installation as per IFC
layout & installation details drawing, hardware type, name plate, tag number and shall be easily accessible
for maintenance work.

Q What are the inspection points for conduit installation?

Q What are the inspection points for power penal/ distribution panel installation?

Q What are the inspection points for duct bank installation?

Q What are the inspection points for battery enclosure installation/ solar modules/ solar system installation?

Q What are the inspection points of lighting fixture/pole?

Ans Material inspection as per approved material, type, installation as per lighting layout and installation details
drawing, termination inside fixture, heat resistive sleeve over the cables inside fixture, if armored cable then
brass glands if non‐armored then pvc glands, shrouds, tag number on cables, color coding of cables, IR,
continuity, termination inside fuse box/breaker compartment, degree of lighting fixture.

Q What is ITP?

Ans Inspection & testing plan provide us details and sequence of activities i.e. document review, material
receiving, installation & pre‐commissioning.

Q What are the material receiving inspection points for material in classified area/ hazardous area?

Ans

Q What is red line drawing? Brief its color coding?

Ans In case of any change occur to the IFC drawing during construction or installation the relevant drawing will
be redlined. Following color coding shall be used for this purpose:

a) Red: If any addition required in the drawing.

b) Green: If any deletion is required from the drawing

(c) Blue: If any comment is added in the drawing.

Q What are the difference between surveillance, witness and hold point?

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Ans Surveillance: Work can be executed without client's inspection and it can be inspect some part of them if it
required.

Witness: Work can be executed without client inspection and then it can be inspected upon the completion
of work.

Hold Point: Work can't be executed without client inspection.

Q What is difference between Hazardous and Non Hazardous area?

Ans Hazardous: A hazardous location is an area where a potential for fire or explosion exit due to the presence
of flammable gases, liquid or vapors, combustible dusts or fibbers' and flying in sufficient quantities to
produce an explosion or ignitable mixture .

Non‐Hazardous: An area where no risk of presence of any kind of fire or explosion.

Q What are different kinds of certification?

Ans i) Weather Proof

ii) Dustproof

iii) Water Tight

iv) Explosion Proof

v) Flam Proof

vi) Intrinsic Safety Proof

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Material Receiving Questions

Q Which document provide us information about the material inspection?

Ans Inspection levels are mentioned in SAEP‐1151 (Inspection Requirements for Contractor Procured Materials
and Equipment)

Q Which document used for minimum inspection and testing requirements for procured inspectable material
and equipment?

Ans SAER‐1972 (Saudi Aramco Materials Inspection and Testing) / SA‐175 Forms

SAER‐1972 is used for the minimum inspection and testing requirements for procured inspectable material.

Approved procurement documents are called Saudi Aramco Inspection Requirements (SA‐175 Forms)

Q How we do material receiving, describe the general procedure?

Ans We collect all the documents related to the material to be inspected and after document review we do the
inspection and we check that the arrived material is according to the NMR, PO, MTO, IRC and Delivery Note
and verify that Aramco standards and specifications are complied, then we raise the RFI for final inspection
and acceptance.

Q What documents are required for material receiving?

Ans Material receiving RFI includes the following contents depending upon the type of material.

(1) PO‐‐‐(Pay order)

(2) Delivery note
(3) MR/NMR‐‐‐(Material Requisition>> include the approved material’s details and specifications) (NMR—If
there is some conflict in MR then NMR >> Non material requirement)
(4) IRC‐‐‐(Inspection release certificate/Vender inspection certificate)
(5) MTC/MTR‐‐‐(Material testing certificates/ material testing reports)
(6) Aramco‐manufacturer vender ID // Aramco‐supplier vender ID
(7) MTO‐‐‐(Material take off list/ Project complete items list)
(8) Technical Drawings for electrical equipments and instruments/ Calibration certificates/ ISS‐Data sheets
for instruments.
(9) If equipment/instruments are for hazardous area should have certificates of flameproof/explosion proof
(i.e. EEx D, IECEx).
(10) If Cable material then cable schedule.
(11) Layout/IFC Drawings

Q What documents are required for material supplied by Aramco?

Ans When material is supplied by Aramco, following document are required.

(1) Out Bond TO

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(2) MTO
(3) Layout/IFC Drawings

Q What type of label or certification requirements are for equipment in classified (hazardous) area?

Ans IEC or EX labeled equipment meeting the requirement of IEC 60079.

IECEx certification is needed for equipment and shall meet shall meet NEC requirements (Article 505).

Q What type of label & certifications are required for enclosures in classified (hazardous area)?

Ans Enclosures shall be flameproof (explosion proof), EEx D II certification, meeting the NEC requirements
(Article 505) & IP‐54.

Q What are the requirement for equipment used in severe corrosive environments (and offshore locations)?

Ans NEMA Type 4 X, IP‐66

Q What are the material inspection levels according to SAER‐1972/SAEP‐1151?

Ans There are 5‐levels

(1) Level‐0 >> required documentation only, no vendor inspection required.

(2) Level‐1 >> only final inspection is required prior to shipping.
(3) Level‐2 >> include pre‐inspection meetings, one or more surveillance inspections, all witness and hold
points, final inspection before release for shipping.
(4) Level‐3 >> include pre‐inspection meetings, surveillance inspections on regular basis (daily, weekly or
bi‐weekly), all witness and hold points, final inspection and release for shipping.
(5) Level‐4 >> resident inspector continuously monitoring the work

Levels:

Inspection levels might be elevated or lowered by SAIR on case by case basis, based on criticality of procured
materials, performance of selected manufacture, qualification of Contractor’s inspector, etc.

In case of materials/ equipment not listed in below table, the SAIR will determine the appropriate inspection
level.

SAIR and/or PQM is responsible to verify the assignment of appropriate level of inspection. He is also
responsible to determine the level of inspection for none listed materials/ equipment.

Contractor is responsible to propose the proper level of inspection in accordance with this procedure
and/or other contractual documents.

RIOs are responsible to provide monitoring inspection services when requested by the SAIR.

VID Management will insure the timely review and issuance of the revised version of this procedure.

SAIR is responsible to escalating to SAIR’s management any repetitive major observations from the
same vendor for any further actions.

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Material Inspection Level

Transformers (Distribution, Pad‐mounted/Self‐cooled) 1

Transformers (Power/Dry‐type) 1

Transformers (Distribution, Overhead, Self‐cooled) 1

Transformers (Power, Oil Filled) 2

Wire 0

Fasteners 2

Medium Voltage Power cable 1

High Voltage Power cable 2

Switchboard, Controlgear, Switchgear, Circuit breakers, 2

Switchrack, AFD/VFD

Motors (Less than 500HP/4KV) 1

Motors (Greater than 500HP 2

Generators 3

Diesel Engine Generators Set 2

Rectifiers 1

Galvanic Anodes/Impressed Current Anodes 2

Cable for Cathodic Protection 0

Battery Charger/Rectifier/Photovoltaic/UPS/ 1

Stationary Batteries 0

DCS/SACADA/RTU 2

Pump 0

Valves/Actuators 2

Valve Safety Relief 0

Valve Surge Relief 1

Instrument Control Panels/ Marshalling 2

Cabinets/LDS/PLC/ESD/

Annunciators 1

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Fire Alarm Systems 0

Instrument Cable 0

HVAC Units 2

Skid Mounted/Packaged Equipment 3

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Grounding
(SAES‐P‐111)

Q What is the difference between bonding, earthing and grounding?

Ans Bonding: Bonding is simply a technique of joining two electrical conductors together to bring them to the
same electrical potential. Bonding has to be done by connecting of all the metal parts (that are not supposed
to be carrying current under normal conditions) to bring them to the same electrical potential. Bonding
ensure that these two things which are bonded will be at the same electrical potential.

Earthing: Earthing means connecting the dead part (which does not carry current under normal conditions)
to the earth for example electrical equipment’s frames, enclosures, supports etc., to minimize the risk of
receiving an electric shock if touching metal parts when a fault occurs.

Grounding/Neutral: Grounding means connecting the live part to the earth, for example neutral of the
power transformer, for the protection of the power system equipment and to provide an effective return
path from the machine to the power source.

Q What is the purpose of grounding?

Ans The purposes of grounding are personal safety, equipment & distribution circuit protection, electrostatic
discharge, building safety protection etc.

Q What are the names of international standards which are used for grounding and ground system
installation?

Ans Grounding and ground system installation shall be designed in accordance with IEEE‐142 and meet the
requirements of NEC‐250.

For 1 kV nominal voltage and below, grounding and ground systems shall be in accordance with the IEEE
142 and meet the requirements of ANSI/NFPA 70 (NEC‐250), and ANSI C2.

For substations having equipment operating at a nominal system voltage exceeding 1 kV, a ground grid
meeting the requirements of IEEE 80 for step and touch potential shall be installed.

Health Care Facility grounding shall meet additional requirements of NFPA 99.

*Measurements of earth resistivity and ground impedance shall be made in accordance with IEEE‐81

Materials and Installation

Q Describe the characteristics/properties of ground Conductors?

Ans Ground conductors shall have the following characteristics:

(a) Should be of copper.

(b) If insulated should have green jacket or a green jacket with yellow stripes.
(c) If larger than 35 mm² (#2 AWG) be stranded.

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Exceptions:

Steel copper clad conductors can be used for grounding tower structures of 69 kV and above overhead
transmission lines in outside facilities.

Grid conductors and grounding electrode conductors used for substation grids shall not be insulated.

Grounding conductors used for isolated ground equipment, installed per IEEE 1100, must be labeled or color
coded to distinguish them from standard equipment grounding conductors.

Q Describe the requirements/characteristics of ground rods?

Ans Ground rods shall have the following characteristics:

(a) Shall be UL listed & meet the requirements of UL 467.

(b) i) copper or ii) copper jacketed‐steel or iii) galvanized‐steel
(c) Have a minimum length of 2.4 meters. (Jointed rods are permitted but each joint must be 2.4 meters
long)
(d) Copper or copper jacketed steel rods shall be minimum of 16 mm in diameter,
Galvanized steel rods shall be minimum of 19 mm in diameter.

Exception:

Soils in Saudi Aramco areas which are lower than 70 ohm‐meters resistivity normally have high salt content
and are corrosive to copper. Galvanized steel is very durable in low resistivity soils. Buried bare copper has a
detrimental effect on pipeline cathodic protection.

Q What type of ground rod is used in areas of 70 ohm‐meters resistivity areas or areas protected by cathodic
protection (low resistivity areas)?

Ans In areas where cathodic protection is present (lower than 70 ohms‐meters resistivity), galvanized steel
ground rods (minimum 19 mm dia) are used.

Q What is the standard color for insulated grounding conductor?

Ans The color of grounding conductor shall be green (For Instrument Grounding) or green with yellow strip (For
Electrical Grounding).

Q What is the size of ground conductor used for grid and equipment?

Ans SAES‐P‐111 says that the cable size for main grid interconnection and with ground rods shall be minimum 70
mm2 and for the equipment grounding minimum 25mm2 shall be used.

Q What is the length of grounding rod?

Ans SAES‐P‐111 says, ground rods shall have a minimum length of 2.4meter.

Q What is the diameter of a copper and galvanized steel rod?

Ans For copper or copper jacketed steel rod minimum diameter is 16mm.

And for galvanized steel rod diameter is minimum 19mm.

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Q How we do grounding at pipeline valve stations? What are the grounding requirements at valve stations?

Ans According to SAES‐P‐111, grounding at pipeline valve stations shall be done with zinc or magnesium anodes
interconnected by insulated copper cable, each magnesium or zinc anode spaced a minimum of 2 meters
apart.

Q Which grounding rod is used when area is subject to cathodic protection?

Ans According to SAES‐P‐111, the ground rods shall be galvanized steel if area is subjected to cathodic
protection.

Q How much there will be distance between the ground rods installed in triangular shape for MIG ground
(master instrument ground)

Ans There shall be a distance of 1.83m (6ft) between them.

Q What is the goal of installing more than one ground rods?

Ans To achieve resistance of 25 ohms

Q What is the grounding electrode?

Ans The copper or steel rod which is used for grounding purpose.

Q What is the resistance for ground grid/ grounding network for electrical system?

Ans It shall be 5 ohms i.e., voltage drop 5V

Q What is the resistance for ground grid/ grounding network for instrument system?

Ans It shall be 0 ohms i.e., voltage drop 0V

Q What Type of method we use to measure the ground resistance?

Ans Fall off potential method

Q How we do the below ground and above ground connections to grounding grid or ground rods or between
grounding conductors or ground rods?

Ans (a) By thermite welding or brazing

(b) By irreversible compression type connectors

(c) To steel structure by compression type connectors bolted to bare steel.

(d) Approved mechanical connectors, where it is necessary to disconnect ground conductors for test at
ground test stations.

Bare grounding conductors shall not be installed in metallic conduit.

Grounding conductors extending through concrete or asphalt shall be run in PVC conduit (preferred) or
PVC coated rigid steel conduit.

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*Underground ground conductors shall be insulated when within 3 meters of a buried metal pipeline or
metal piping.

*Underground ground conductors electrically connected to buried metal pipelines, buried metal
vessels, or metal tanks sitting on grade shall be insulated.

*Master Instrument Ground grid is made by connecting the ground rods in ground in a triangle shape each
1.83m apart.

Substation Grounding

Q How we do the substation equipment grounding?

Ans Substation equipment shall be grounded as follows:

(a) For substations having equipment operating at a nominal system voltage exceeding 1,000 Volts, a
ground grid meeting the requirements of IEEE 80 for step and touch potential shall be installed.
(b) All electrical equipment in the substation, substation yard, and within 5 meters of the substation fence
shall be connected to the grid or to a ground bus connected to the grid.
(c) Substation ground grids shall be constructed of minimum 70 mm² (2/0 AWG) stranded bare copper
cable.

Q What is the size of substation ground grids cable?

Ans Substation ground grids shall be constructed of minimum 70 mm² (2/0 AWG) stranded bare copper cable.

Stranded bare copper conductor, and if used in soils less than 70 ohm‐meters resistivity shall be tinned.

For calculations of allowable step and touch potentials, the resistivity of the surface material shall be
assumed to be 3,000 ohm‐meters for a minimum 75 mm thick pad of clean crushed rock, 10,000 ohm‐
meters for a minimum 50 mm layer of asphalt, and 200 ohm‐meters for a minimum 75 mm layer of
concrete. For all other surface materials, the lower of 100 ohm‐meters or the actual measured top layer
(minimum 0.3 m layer thickness) soil resistivity shall be used.

Grounding Electrodes

Q Can the reinforcing bar of building be used as a grounding electrode?

Ans Reinforcing bar of buildings shall not be used as a grounding electrode.

Structural steel of a building may be used as a grounding electrode in accordance with the NEC provided it is
continuous and effectively grounded by connecting at least every other structural steel column on the
perimeter of the building to a concrete‐encased electrode or a ground ring installed per the NEC and this
standard.

Q If concrete‐encased electrode is used, what type of conductor is should be?

Ans If a concrete‐encased electrode is used, the conductor must be bare copper.

Q What type of ground rod is used for system grounding?

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Ans The ground electrode for system grounding shall consist of

(1) A rod or pipe electrode OR

(2) Combination of rod or pipe electrodes and a grid or loop of bare copper conductors

Q How much the buried depth required for grounding conductor used to interconnect rod or pipe electrode?

Ans SAES‐P‐111 says, the conductor shall be buried a minimum depth of 460 mm.

Q Where supplementary grounding electrode shall be provided?

Ans Supplementary grounding electrodes (per NEC 250) shall be provided in outdoor industrial areas, plant
areas, and in substations

Q What is the minimum burial depth for ground conductor or loop?

Ans The grids or loops shall be buried a minimum of 460 mm.

Q Supplementary electrodes are made of what?

Ans Supplementary electrodes shall consist of ground rods connected by bare or insulated conductors or
combinations.

Q How many connections require for above ground supplementary electrode?

Ans Two connection are required to supplementary electrode.

If an above ground bus or loop is used for extending the supplementary grounding electrodes, this bus
or loop shall have two connections.

Conductors used for interconnection of ground rods shall be minimum of 70 mm² (2/0 AWG).

System Grounding

Q What is system grounding?

Ans System grounding is a technique used to protect a power system and to give the return path from load to
the source.

Q What is grounding system for three phase electrical system as per SAES‐P‐111?

Ans As per SAES‐P‐111, three phase electrical system shall be grounded at neutral point of the wye connection of
the transformer or generator by connecting directly to grounding grid or grounding electrode.

Q How we do grounding of dry type transformer?

Ans Dry‐type transformers in substations, in switchgear rooms, or in equipment rooms may be connected to a
ground bus that is directly connected to the grid or other grounding electrode.

Q What is solidly neutral grounded system?

Ans In solidly grounded system, the neutral point in connected to earth directly by ground electrode.

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Solidly grounded systems below 1 kV

Q What is the ground resistance in solidly grounded system?

Ans The ground resistance of ground rods and/or ground grid used for solidly grounded system /system
grounding shall not exceed 5 ohm. Neutral conductor shall be selected based on 3 seconds fault duration.

Impedance grounded systems above 1 kV

The ground resistance of made electrodes (ground rods and/or ground grid) used for system grounding shall
not exceed 5 ohm. For industrial facilities, grounding impedance shall be 400 A, 10 Second Resistor.

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For commercial facilities and residential areas, grounding impedance shall be 1,000 A, 10 Second Resistor.
Neutral conductor shall be selected based on 10 seconds fault duration.

Solidly grounded systems above 1 kV

The ground resistance of made electrodes (ground rods and/or ground grid) used for system grounding shall
not exceed 1 ohm. Neutral conductor shall be selected based on 3 seconds fault duration.

Generator neutral grounding: Neutral conductor shall be selected based on 10 seconds fault duration.

All grounding electrodes used for system grounding in plants, bulk distribution facilities, or other industrial
areas shall be interconnected to form a single ground system.

The grounding electrode used for system grounding (including separately derived systems) for each area in
the facility or plant shall have a minimum of two connections to the ground grid or ground loop used in the
area. This requirement can be met by connections to the grounding electrode of the substation(s) which
supply the area.

The secondary of dedicated (captive) transformers supplying electric submersible pumps in water or oil well
service are permitted to be ungrounded provided that the motor controller has ground fault detection and
the transformer is located at the same well site as the pump served.

Q What is low resistance grounding? Where we use low resistance grounding?

Ans A grounding in which a transformer or generator is grounded by connecting a resistor between the system
neutral and ground rod/grid to provide the desired higher value of ground current. The impedance is
selected to limit line to ground fault current normally between 100A to 1000A

Q What is high resistance grounding? Where we use high resistance grounding?

Ans A grounding in which a transformer or generator is grounded by connecting a resistor between the system
neutral and ground rod/grid to provide the desired lower value of ground current. The impedance is selected
to limit line to ground fault current normally less than 10A.

With an HRG system, service is maintained even during a ground fault condition. If a fault does occur, alarm
indications and lights help the user quickly locate and correct the problem or allow for an orderly shutdown
of the process.

Equipment Grounding

Q What is the equipment grounding?

Ans Equipment grounding is the grounding used for protection of our using equipment and for protection of
human life from electric shocks.

Equipment grounding conductor shall be provided with each power circuit. Except as otherwise noted
below, conduit, cable tray, or cable armor, shall not be relied on as the equipment grounding conductor.

An insulated copper conductor shall be installed in the same conduit, cable tray, cable, or cord or shall
otherwise accompany the power conductors.

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Conduit or cable armor may be used in accordance with the NEC for grounding electronic instrumentation
operating at 24 V DC nominal or below.

Aluminum cable trays containing only circuits operated at, or below, 50 V to ground may be used as
equipment grounding conductors provided that NEC requirements for such use are met.

For 69 kV cables and above, equipment grounding conductor is not required for cross‐bonded sheath
systems as the cable sheaths shall be cross bonded as per IEEE 575.

In hazardous locations, equipment grounding conductors run in conduit or cable tray shall be insulated or
enclosed within the jacket of a multi‐conductor cable.

Q How many grounding connection are provided from grounding bus to electrical panel board?

Ans Electrical panel board (in switchgear, switchboards, and motor control centers) shall have two connections
to the local ground grid or to the main ground electrode.

Q How many grounding connections are provided from ground grid to ground bus?

Ans Two connections

Q How many grounding connection are provided from grounding bus to instrument/electrical panel board?

Ans 2 connections

Q How many grounding connection are provided from grounding bus to instruments?

Ans Two connections.

Q How many grounding connection are provided from grounding bus to electrical equipments?

Ans Under 1000 V panels shall be provided with one connection and above 1000V shall be provided with two
connections.

Frames of equipment (motors, generators and transformers and other equipments) operating at 1000 V or
greater shall have two connections to the grounding electrode.

Q Which two grounding systems are required for instrumentation systems?

Ans These two grounding systems are required for instrumentation systems:
a) Safety Ground for personnel safety.
b) Instrumentation DC & Shield Ground.

Q What is the minimum size of equipment ground conductor?

Ans The minimum size of equipment ground conductor is 25mm2/ 4 AWG.

Q Metallic cable tray after how many meter need to be bond?

Ans According to SAES‐P‐111, metallic cable trays shall be bonded at both end points a minimum of 25 meters.

*Aluminum cable trays containing only circuits operated at, or below, 50 V to ground may be used as
equipment grounding conductors
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*A cable concentric neutral, if properly sized and not used as a current carrying grounded circuit conductor
(3 phase 3 wire system; no neutral loads are served), may be used as the equipment grounding conductor.

*Electrical submersible pump motors in oil and water well service do not require a dedicated
equipment grounding conductor, provided the motor controller has ground fault detection. The well
head must be bonded by an approved means to the ground bus at the motor controller or supply
transformer.

*Armored submarine cables do not require equipment grounding conductors.

*Shields and armor of power cable shall be grounded at both ends. Continuity at splices shall be maintained
by bonding across the splice.

Q How we do grounding of shields and armor of power cables?

Ans Shields and armor of power cable shall be grounded at both ends. Continuity at splices shall be maintained
by bonding across the splice.

Q How we do grounding of the metallic conduit?

Ans Metallic conduit shall be grounded at both end points by bonding to a grounding conductor, a grounded
metal enclosure, or to a grounded metal cable tray. This may be accomplished:

a) With approved grounding clamps connected externally to the conduit or

b) Bonding to a grounded enclosure using threaded bushings or using a conduit hub which is approved for
grounding purposes or
c) Bonding to a grounding conductor using an approved grounding bushing.
*Grounding with locknuts is not acceptable.

*Isolated sections of rigid metal conduit that are buried at all points at least 0.5 meters below grade are not
required to be grounded.

*Conduit sleeves used to enclose power cables transitioning from above grade to below grade are required
to be grounded only at the above grade end.

Where non‐PVC coated rigid conduit is used to protect cable entering or exiting a grounded metal cable tray,
by bonding with a conduit clamp to the cable tray. A grounding bushing must be used with PVC coated
conduit.

Q How is the neutral conductor identify?

Ans Neutral conductor is identified by colors white or grey.

Q How is an insulated ground conductor identify?

Ans An Insulated ground conductor is identified by colors green or green with yellow stripes.

Q How we do grounding of metallic cable trays?

Ans Metallic cable trays shall be bonded to the local ground grid or ground electrode at both end points ensuring
that bonding continuity is met throughout all the racks in the system.
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Q What is the minimum size of bonding jumpers copper wire and connected to a Safety ground bus?

Ans 4 mm²

Q How many connections are required for ground bus to main ground electrode?

Ans Ground busses (in switchgear, switchboards, and motor control centers) shall have two connections to the
main ground electrode.

Q How electrical manholes should be grounded?

Ans Electrical manholes shall be grounded using two ground rods located close to diagonally opposite corners of
the manhole. These rods shall be connected to each other, to a ground loop or bus accessible from inside
the manhole, and, where applicable, to a minimum 120 mm² (4/0 AWG) grounding conductor that is
connected to the local (within 15 m) grounding grid.

Q How raised computer floors should be grounded?

Ans Raised computer floors shall be grounded by bonding a minimum of two pedestals at opposite corners to the
nearest ground bus or grounding electrode.

Q How Structural steel supports for process equipment and piping and structural steel columns for buildings
should be grounded?

Ans Structural steel supports for process equipment and piping and structural steel columns for buildings shall be
grounded at least every 25 m (i.e., No part of the base of the structure shall be more than 25 m from a
grounded support or column.) with a minimum of two connections at opposite corners of each structure or
building.

Q How many grounding connection require for equipment operating above 1000 V?

Ans Equipment operating above 1000V (MCC, switchboard, switchgear) shall have two connection of grounding
electrode.

Q How motors, generators and transformers operating at 480V should be grounded?

Ans Motors, transformers, and generators operating at a nominal voltage of 480 V shall have a minimum of one
connection to a supplementary grounding electrode.

Motor Operated Valves (MOV), lower voltage motors and transformers are grounded through the associated
EGC (equipment grounding conductor).

The following equipment when not bolted to grounded structural steel shall be connected to a
supplementary grounding electrode:
1) Metallic enclosures for panelboards, circuit breakers, switches, fuses, motor controllers, switchgear,
switchracks, motor control centers, and motors and transformers not covered above.
2) Metal vessels, stacks, exchangers, and similar equipment.

3) Loading and unloading facilities.

Offshore Platform Grounding

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Q What is the size of copper cable or copper bar for off‐shore platform grounding?

Ans A copper cable or copper bar minimum size 120 mm² (4/0 AWG) which is connected to two platform legs.

Connections to the platform legs, structural steel and any splices in this main ground electrode shall be
made by exothermic welding or brazing. System grounding connections shall be made directly to this ground
electrode.

Tanks of medium and high voltage transformers and ground busses for switchgear and motor control centers
shall have two paths for current to flow to this ground electrode. The main ground electrode is not required
on platforms that do not have transformers or generators which require system grounding connections.

Where two or more platforms which require main ground electrodes are connected by walkways, two
insulated conductors, minimum size 120 mm² (4/0 AWG) shall be installed between the respective main
ground electrodes.

Fence Grounding

Q How we do the substation fence (not be PVC coated) grounding?

Ans Electrical substation fences shall be grounded as following methods:

(1) Substation fences shall not be PVC coated and shall be grounded in a minimum of two locations to the
local ground grid or loop.
(2) The fence shall be connected to the grounding conductor(s) at intervals not exceeding 15 m.
(3) Corner posts and gateposts shall be connected to the grounding conductor.

Q How we do the non‐substation fence grounding?

Ans Non‐substation fences shall be grounded as follows:

(a) Fences which are within 10 m of a ground grid or ground loop that is connected to equipment operated
at 1 KV or greater shall not be PVC coated and shall be grounded at intervals not exceeding 15 m to the
ground grid or loop.
(d) All fences within 3 meters of a ground grid or ground electrode shall be bonded at the nearest fence
post to the ground grid or ground electrode.
(e) Fences that pass under a transmission line operating at 34.5 kV and above shall not be PVC coated and
be grounded at intervals not exceeding 15 m, on that portion of the fence within 100 m of the power
line.
(f) Fences that cross over a ground grid, or conductors that connect two ground grids, shall not be PVC
coated and shall have a bond between the grid or conductors and the nearest post. If the crossing area is
extensive, the bond is required every 50 m.

If the ground conductors used to connect the ground grids are insulated and sleeved with PVC conduit at
points within 10 m of the fence, then the bond is not required.

Fences constructed with concrete posts and PVC coated fencing material are not required to be grounded.

Tank Grounding

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Q How we do grounding of shells of onshore storage tanks?

Ans The shells of onshore storage tanks in hydrocarbon service shall be grounded at a minimum of two points on
diagonally opposite sides of the tank. Each point shall be bonded to the area ground grid or to a minimum 16
mm x 2.4 m ground rod.

The tank shell to remote earth resistance shall not exceed 10 ohms.

Floating roof tanks shall have stainless steel shunts between the tank roof and the metal sealing ring. These
shunts shall be spaced a maximum of 3 m apart, shall be above the seal, and shall be bolted to the sealing
ring and the roof.

Lightening Protection

Q Which standards are applied for design and installation of lightening protection system?

Ans Lightning protection system design and installation shall be based on

NEC 780 and UL 96A, IEEE 998 or IEC 61662, IEC 61024‐1, and IEC 61024‐1‐1.

Q Which Facilities shall be provided with a lightning protection system?

Ans The following Facilities shall be provided with a lightning protection system:

a) Buildings and occupied structures over 30 m in height

b) High Voltage outdoor substations and switchyards, if area is 3250 m² or greater.
c) If required by NEC 780.
d) Schools
e) Hospitals

Q For lightening protection system components which standard is used?

Ans Lightning protection components shall be UL Listed or Labeled in accordance with UL 96.

*Protection systems design for petroleum facilities shall comply with API RP 2003.

Q Which standard is applied for static electricity grounding?

Ans Tank trucks, tank cars, tanks, other large containers, associated filling apparatus, and other equipment which
during normal operation can cause accumulation of sufficient static charge to cause an ignition of
hydrocarbon vapors in the area shall be bonded and grounded in accordance with API RP 2003.

Standard Drawings for Grounding

1) Library Drawing DD‐950022 shows recommended details for making grounding connections.
2) Manually operated switches for overhead power lines shall have operating platforms and be
grounded as shown on Standard Drawing AA‐036572.
3) Grounding Arrangement for Disconnect Switch Structure AA‐036572.

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Basic Power System Design Criteria

(SAES‐P‐100)

Q What is the scope of SAES‐P‐100?

Ans This SAES prescribes mandatory design basis and performance criteria of electrical power systems.

Q What is bus tie breaker?

Ans A breaker used to connect the two busses of secondary‐selective system.

Q What is captive transformer?

Ans A transformer whose output is dedicated to a single piece of utilization equipment.

Q What are the critical loads?

Ans Critical Loads are loads

a) Where a single possible failure could cause an immediate hazard and severe loss.
b) Security systems.
c) Which cannot be shut‐down for a minimum of 5 consecutive days annually for scheduled
maintenance on upstream power supply equipment.

Examples of critical loads are: major computer centers, major office buildings, process units in gas
plants and refineries.

Q What is electrical demand load?

Ans Demand Load: Electrical load averaged over a specified time period.

Q What is electrical load?

Ans Electrical load is the averaged usage of electricity over a specified time period.

Q What is distribution equipment?

Ans The equipment used to distribute power to utilization equipment or other distribution equipment. For
example switchgear, Panel boards, Switch racks, switchboards, etc.

Q What are the industrial facilities?

Ans Industrial Facilities includes the following:

a) Facilities directly associated with production, processing, or distribution of hydrocarbons.

b) Hospitals.
c) Office buildings (exceeding 3 occupied floors)

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d) Control buildings.

Q What are the non‐industrial facilities?

Ans Non‐industrial Facilities includes commercial type building applications. This includes, but is not limited to,
the following:
a) Shops
b) Small office buildings
c) Schools
d) Community buildings
e) Warehouses

Q What is the operated load?

Ans Operating Load:

a) For new facilities: 1‐hour demand based on plant or facility design conditions.
b) For existing facilities: When data from metering equipment is available, maximum 60‐minute demand
measured over a minimum of one year.

Q What is secondary‐selective switchgear?

Ans A switchgear assembly consisting of two buses connected with a single bus tie breaker. Each bus has
one breaker to receive incoming power

Q What is secondary‐selective substation?

Ans A substation fed by two independent power sources (different transmission or distribution lines) which
consists of one or more sets of two transformers and associated secondary‐selective switchgear. Also
referred to as a “double‐ended” substation.

Q What is utilization device/equipment?

Ans The equipment whose primary function is to convert electrical energy to another form or store
electrical energy.

Examples of utilization equipment would be motors, heaters, lamps, batteries, etc.

Equipment directly feeding/controlling the utilization equipment is considered part of the utilization
equipment (e.g., AFDs, reduced voltage starters, battery chargers, etc.)

PCB Free: Containing less than 1 ppm polychlorinated biphenyl.

PCC: The Point of Common Coupling, i.e., the high side of the step down transformers connecting the
Aramco facility to the Grid.

Plant: Facility requiring perimeter security fencing.

UPS: Uninterruptible Power Supply

EED Coordinator: Coordinator, Electrical Engineering Division, Consulting Services Department.

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TSD General Supervisor: General Supervisor, Technical Support Division, Power System Engineering
Department.

Utilization Device/Equipment: Utilization equipment would be motors, heaters, lamps, batteries, etc.

General

Q What are the basic design codes for electrical power systems?

Ans Electrical power systems shall be designed and constructed in accordance with the SBC, NEC, ANSI C2
and Saudi Aramco Engineering Standards.

Q How the low voltage AC distribution systems shall be protected?

Ans Low voltage AC distribution systems shall be protected by circuit breakers. Fuses shall not be used.

*Molded case circuit breakers with integral current limiting fuses are permitted and fuses are permitted for
protection of circuits fed from UPS systems.

*All interrupting devices shall be fully rated for the short circuit duty.

Q What type of switchgear shall be used to feed critical loads?

How the critical loads shall be fed from?

Ans Only secondary‐selective switchgear shall be used to feed critical loads.

Q What type of power source shall be used to feed Critical facilities or equipment?

How the Critical facilities or equipment shall be fed from?

Ans Critical facilities or equipment fed from a single‐ended substation bus which has a standby generator
capable of automatically supplying the required power to the bus within 10 seconds after a power failure are
permitted with approval.

Q What types of loads shall be supplied by stand‐by power or emergency power?

Ans Loads to be supplied by standby power or emergency power include the following:

a) Security system
b) Emergency control room
c) HVAC and air handling control equipment
d) Emergency lighting, if DC power or UPS is not sufficient for the intended purpose.
e) Essential loads, that cannot be supplied from UPS or DC system

Q How to do the sizing (load designing) of the electrical system?

Ans Sizing of the electrical system shall be based upon using 110% (1.1 times) of the sum of the operating
load plus all known future loads.

Q Which standard requirements shall meet electrical equipment for fire pump?

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Ans Electrical equipment for fire pump installations shall meet the requirements of NFPA 20.

Q What are the requirements for insulating material/insulation liquids?

Ans Insulating materials, insulating liquids in new equipment shall be PCB‐free.

Q Which standard shall be followed for the interfaces of power systems with communication systems?

Ans Interfaces of power systems with communications systems shall be in accordance with SAES‐T‐ and
SAES‐Z‐Series.

Q Which standards shall be followed for the design of 69kv and above transmission lines?

Ans 69 kV and above transmission lines shall be design in accordance with SEC series standards.

Design Basis

Q What is the frequency of alternating current electrical power systems?

Ans The frequency of alternating current electrical power systems shall be 60 Hz.

Q What is the voltage for the primary distribution within industrial facilities?

Ans The primary distribution within industrial facilities shall be 13.8 kV, three‐phase, three‐wire.

Q What is the voltage level for the secondary distribution within industrial facilities?

Ans The Secondary distribution shall be either 4.16 KV, three phase three wire and/or 480 V, three phase
three wire.

Q For nominal system voltage 400Y/230V, 400V, 480V which type of grounding system shall be used?

Ans The nominal system voltage and grounding shall be according to the following table:

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Q Where the 400Y/230V system is acceptable or shall be used?

Ans 400/230 V is only acceptable at sub‐distribution levels (general power supply inside buildings, distribution
transformer to panelboards feeding lighting, receptacles, etc.)

Q Does the neutral busses use for low voltage switchgear and controlgear?

Ans Not allowed.

Saudi Aramco material specifications prohibit neutral busses for low voltage switchgear and controlgear.

Steady state voltage range:

Q What the steady state voltage range shall be for nominal voltage for low voltage systems?

Ans Steady state voltage range shall be as follows:

i) At branch circuit/distribution equipment connection points (switchgear, controlgear, panelboards,
switchracks, etc.): 95% to 105% of nominal voltage.
ii) At light fixtures: 91.7% to 104.2% of nominal voltage.
iii) At utilization equipment other than lights: 90% to 104.2% of nominal voltage.

Q What the steady state voltage range shall be for nominal voltage for high voltage systems?

Ans Steady state voltage range shall be as follows:

i) Originating and ending in the same plant:
a) At branch circuit/distribution equipment connection points (e.g., switchgear, controlgear, etc.): 97.5% to
105% of nominal voltage.
b) At the utilization device: 90% to 105% of nominal voltage.
ii) Originating and ending in different plants or facilities: At main distribution equipment (e.g., switchgear):
95% to 105% of nominal voltage.

Voltage Drop associated with Motor Starting:

Q When a low voltage motor is started, how much voltage drop shall be of the nominal voltage?

Ans When a low voltage motor is started, the voltage at every utilization device, anywhere in the electrical
system, shall not drop below 85% of the nominal voltage.

When a motor is started, the voltage at the terminals of the motor being started shall not drop below 85% of
the rated motor voltage.

Q Where the utilization equipment is modeled as lumped load at the distribution bus, how much voltage
drop shall be of the nominal voltage?

Ans The voltage at the distribution equipment level shall not drop below 90% of the nominal voltage.

Q How much shall be the drop of voltage for nominal voltage value of high voltage motors?

Ans For high voltage motors, a drop to 80% of rated motor voltage is permitted at the terminals of the motor
being started.

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Q How much shall be the lagging value of power factor of facilities with total load exceeding 1.0 MVA?

Ans Facilities with total load exceeding 1.0 MVA shall maintain a power factor not less than 95% lagging at
the PCC.

For powering offshore projects with cable length greater than 50 km, High Voltage Direct Current (HVDC)
shall be evaluated as a viable option. The evaluation shall be submitted to EED coordinator for concurrence.

Q How much shall be the maximum total and average voltage drop for main, feeder, and branch circuits for
Backup (UPS) Systems?

Ans Maximum total voltage drop for main, feeder, and branch circuits shall not exceed 5%.

The average voltage drop in branch circuits shall not exceed 2% with a maximum of 4% at the most distant
load.

Q Can we use equipment suitable for Class 1, Zone 0 locations in Class 1, Zone 1 locations?

Ans Equipment suitable for Class 1, Zone 0 locations may be used in Class 1, Zone 1 locations. Both areas are
hazardous.

System Studies

Q Which software is used for electrical system studies?

Ans The Electrical Transient Analyzer Program (ETAP) shall be used to conduct the system studies.

*Alternative software may be used without a need for waiver or approval if the network database (load flow
data, dynamic data, and network diagrams) can be read directly by ETAP without a need for any middleware
tools.

*The ultimate and minimum short circuit levels at the utility interface point shall be obtained prior to the
commencement of system studies.

*When modeling the system for the different studies, it is acceptable to assume that the off‐load
transformer taps can be set one step off the neutral position. In this case, all studies shall use the same
transformer tap position.

*It is acceptable to use transformer on‐load tap changer, which will automatically regulate the voltage level
to the nominal voltage, as long as the tap position does not exceed mid‐range on either side of the neutral
position.

Q How much transformer impedance tolerance shall be used unless the actual impedance of a transformer is
known from the transformer tests?

Ans Unless the actual impedance of a transformer is known from the transformer tests, 7.5% transformer
impedance tolerance shall be used.

So, the specified design impedance shall be increased by 7.5% for load flow and motor starting calculations,
and decreased by 7.5% for short circuit calculations.

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Load‐Flow Analysis:

Q How the maximum system voltage levels shall be determined in load flow analysis?

Ans Maximum system voltage levels shall be determined assuming all motor loads are disconnected, and in the
case of secondary‐selective substations, that both transformers are operational and the bus tie breaker is in
its normal state.

*Normal system voltage levels shall be based upon operating load.

Q How the minimum system voltage levels shall be determined in load flow analysis?

Ans Minimum system voltage levels shall be based on the normal operating load plus the operating load of the
largest spare (standby) motor.

Minimum voltages downstream of secondary‐selective substations shall be calculated assuming that one
transformer is out of service and the bus tie breaker is closed.

Short‐Circuit Analysis/Studies

Q How to calculate the maximum available short circuit current at utility bus, in short circuit analysis?

Ans The ultimate 3‐phase short circuit fault‐current at the utility bus shall be used, with a pre‐fault voltage of
102% of the bus base voltage.

Q What shall be the short‐circuit ratings of buses and interrupting devices, in short circuit analysis?

Ans Short‐circuit ratings of buses and interrupting devices shall not be less than 105% of the calculated fault
current at the point of application.

*The calculated fault current shall include future planned conditions, which are identified in the engineering
documents (e.g., future motor loads, generation, etc.).

*The fault current shall be computed using the procedures set forth in ANSI C37.13 for equipment rated 600
V and below and ANSI C37.010 for equipment rated above 600 V. Similarly, IEC method shall be used for IEC
equipment.

Q How to calculate the short‐circuit studies for secondary‐selective substations, in short circuit analysis?

Ans Short circuit studies for secondary‐selective substations shall be evaluated assuming:

a) One incomer breaker is open and the bus tie breaker is closed (i.e., one transformer is supplying the entire
load).

b) With the normal operating load plus the operating load of the largest spare (standby) motor if the spare
motor is not interlocked to prevent starting while the primary motor is running.

c) For existing normally closed systems, all incomers and bus tie breakers are closed (i.e., normal system
configuration).

Arc Flash Analysis/Studies

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*The design of all new electrical distribution equipment rated up to 38 kV shall include an arc flash hazard
analysis, in accordance with IEEE 1584 to determine the Arc Flash Protection Boundary and the incident
energy a worker may be subjected to.

For DC equipment the Arc Flash Hazard Analysis shall be based on NFPA 70E.

Personal protective equipment (PPE) to be worn shall be based on NFPA 70E.

Q What shall be included in arc flash analysis?

Ans The Arc Flash analysis shall include minimum and ultimate utility fault contribution as well as no load and full
load motor contribution.

Q How much the maximum allowable incident energy, in arc flash analysis?

Ans The maximum allowable incident energy shall not exceed 8 Cal. /cm².

*The analysis shall be performed in conjunction with both short‐circuit and protective relay coordination
analysis during the detailed design phase. However, a preliminary analysis shall be conducted at an early
stage to identify the scope and possible mitigations strategies.

Motor Starting and Voltage Drop Analysis

*The maximum source impedance (i.e., minimum available short circuit current at the utility bus) shall be
used to calculate the associated voltage drops and acceleration requirements during motor‐starting.

Q Which motors are included for motor starting and voltage drop analysis/studies?

Ans Motor starting studies shall be performed on the following high voltage motors:

i) Largest motor on each switchgear

ii) largest motor on each controlgear

Q For what size of motors, the transient (time‐domain) motor acceleration study shall be conducted and what
is the purpose?

Ans For high voltage motors rated 10,000 HP or above, a time‐domain (transient) motor acceleration study shall
be conducted, to ensure that the motor will not stall and is able to start the driven load within the motor’s
thermal capacity.

*A margin of 10% or greater, between the motor torque and the driven load torque, shall be maintained
throughout the acceleration period.

*A transient motor acceleration study shall be conducted even if the largest motor is less than 10,000 HP.

Transient Stability Study

Q For facilities with generation greater than 10 MW, What shall be included in transient stability study?

Ans For facilities with generation greater than 10 MW, transient stability study shall include, but not limited to,
the disturbance scenarios below.

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‐ A sudden disconnection of any plant including a generating unit

‐ A close by 3‐phase fault on main buses, especially those interfacing with the Grid.

‐ A single‐line‐to‐ground fault in cases where a 3‐phase fault leads to instability with normal fault clearing.

‐ The loss of a transmission line while exporting power to the Grid.

‐ Load rejection resulting from loss of major load or loss of a major load center.

‐ Load shedding scenarios, such as loss of utility line while importing, or loss of generation.

‐ Specific system simulations.

Q For what type of load a frequency scan analysis/harmonic analysis shall be conducted?

Ans If significant non‐linear load (AFD, Power Convertors, etc.) is added to the power system, a frequency scan
analysis shall be conducted in order to identify any potential harmonic resonance issues. Corrective actions
shall be made to avoid any harmonic resonance in the system.

*For existing facilities, baseline measurements shall be conducted at each bus and feeder where a harmonic
load to be added. Initial study shall be conducted to validate the model using the baseline measurements.

*Harmonic distortion results shall be within the harmonic limits stated in the latest revision of IEEE 519.

*The harmonic limits identified in IEEE 519 shall be met at the at the switchgear bus feeding multiple MCCs
or controlgear.

Power Factor Correction Study

Q What to do if the load power factor at the PCC is below 0.95 for the maximum load‐flow scenario?

Ans If the load power factor at the PCC is below 0.95 for the maximum load‐flow (minimum voltage) scenario, a
power factor correction study shall be carried out to determine the size of the reactive compensation device
needed to meet the power factor requirements.

*A frequency scan analysis shall be conducted for each capacitor’s step to identify potential resonance
points in the system. If necessary, a detuned Filter Bank application shall be considered to reject harmonics
during steady state operation.

*The capacitor bank shall be automatically switched to maintain target power factor at 0.95. Capacitor steps
shall be chosen to match the load profile.

Q How much rise of voltage shall be acceptable during no‐load condition?

Ans Voltage shall not rise more than 5% during no‐load condition.

Q How to connect the capacitor bank?

Ans Capacitor bank shall be fed through a definite purpose capacitor switching circuit breaker.

*In addition, capacitor back‐to‐back switching shall be evaluated, and integral mitigation components shall
be specified to mitigate high frequency over currents.
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*For existing facilities, baseline measurements shall be conducted at each bus where a capacitor bank to be
added. The measurements shall be done for a period sufficient to capture the complete load profile
including harmonic contents.

Q What are the alternative power factor correction methods?

Ans Alternative power factor correction methods shall be evaluated such as synchronous machine excitation and
synchronous condensers utilization.

Q Where the Switching Transient Analysis, Transient Recovery Voltage (TRV) evaluation and Insulation
Coordination studies shall be conducted?

Ans Switching Transient Analysis, Transient Recovery Voltage (TRV) evaluation and Insulation Coordination
studies shall be conducted for the following:
i) Shunt capacitors and reactors switching
ii) Submarine cable switching
iii) 34.5 kV and above systems
iv) Motors fed from autotransformers or captive transformers
v) Dry type transformers closely coupled to vacuum or SF6 breakers for less than 30 m
vi) Interrupting high inductive currents, e.g., in the case of large generators.

Electrical Area Classification Design

Q Which standard shall be followed for the hazardous area classification?

Ans Hazardous area classification shall be in accordance with the requirements of SAES‐B‐068.

Q Which labeling, listing or certification is required for electrical equipment in hazardous area?

Ans In hazardous (classified) areas, electrical equipment shall be labeled, listed or certified by any of the agencies
in the Approved IECEx Certification Bodies (ExCBs) under the IECEx Certified Equipment Scheme.

Q Which labeling, listing or certification is required for electrical equipment in hazardous area?

Ans IEC or Ex labeled equipment meeting requirement of IEC 60079.

Class and Zone markings are not required on Ex marked equipment

Q Which NEC article shall be followed for hazardous area protection methods?

Ans The method of protection must be marked and must correspond with NEC Article 505 requirements for
suitable protection methods for the hazardous area where the equipment is applied.

Markings based on other schemes or directives such as ATEX are not acceptable.

*Equipment suitable for Class 1, Zone 0 locations may be used in Class 1, Division 1 locations.

Q Is “e” method of protection is acceptable for class 1 Zone 1 location for hazardous area protection?

Ans Increased safety (protection type “e”) motors and terminal boxes are not permitted in Zone 1 locations.

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The “e” protection method is acceptable if it is used in combination with the “d” protection method, if d” is
the primary protection method.

Q What type of protection is used for flameproof enclosures?

Ans EEx d II

Q What type of protection is required for enclosures in Class I, Division 1 locations?

Ans Flameproof enclosures EEx d II are permitted in Class I, Division 1 locations.

Provided:

Q What is the IP rating required for enclosures in Class I, Division 1 locations?

Ans The enclosure is rated a minimum of IP54, if used outdoors.

*The equipment selection, approval and labeling requirements in the NEC for Division 2 installations also
apply to Zone 2 installations.

Environmental Conditions

Q Which areas shall be considered as “severe corrosive environments” for the purposes of selection of
electrical equipment?

Ans The following locations shall be considered as “severe corrosive environments” for the purposes of selection
of electrical equipment:

a) Outdoor offshore locations

b) Outdoor onshore locations within 01 kilometer from the shoreline of the Arabian Gulf
c) Outdoor onshore locations within 03 kilometers from the shoreline of the Red Sea
d) All of the Ras Tanura Refinery and Terminal Plants
e) Location where chlorine or other corrosive chemicals are being handled (sulfur plants, waste water
treatment, water treatment, R.O. facilities).

Q What is the average monthly normal and maximum ambient temperature ratings for locations air, soil, and
water for electrical equipment and its installation?

What is the average monthly normal and maximum ambient temperature ratings for locations ventilated
buildings, air‐conditioned buildings and non‐ventilated enclosures exposed to sun for electrical equipment
and its installation?

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Ans Table 2 ‐ Temperature Criteria

Ambient Temperature
Location Average Monthly Maximum
Normal Maximum (°C) Daily Peak (°C)

Outdoors (Air) 45 50
Earth (Soil) 40 40
Ocean (Water) 30 30
Indoors in Well‐Ventilated
40 50
Buildings
Indoors in Air‐Conditioned
30 30
Buildings
Non‐ventilated Enclosures
56 56
Exposed to the Sun

*Commentary Note: Stationary storage batteries are normally rated for operation in 25°C ambient.

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UPS and DC Systems

(SAES‐P‐103)

Q What is the scope of SAES‐P‐103?

Ans This standard prescribes mandatory requirements for installation and application of
● DC power systems (stationary storage batteries and rectifiers/chargers)
● Uninterruptible power supply (UPS) systems
● Solar photovoltaic systems

This standard does not apply to the following:

● Storage ba eries for mo ve power service

● Rec fiers for communica ons applica ons
● Ba eries and ba ery chargers for sta onary engine cranking service
● Ba eries for self‐contained emergency lighting fixtures
● Photovoltaic systems for cathodic protec on.

Systems Descriptions

Q Describe the DC Power System?

Ans DC power system produce/generate DC power from photovoltaic Solar Cells which is directly supplied to the
DC load or store it in the batteries.

Q What are components of DC Power System?

Ans DC Power System shall consist of, but not limited to batteries, battery circuit breaker, rectifier/charger,
DC/DC stabilizer (if requested), output distribution panelboards (if requested) and management system.

Q What are components of Uninterruptible Power Supply System (UPS)?

Ans Uninterruptible Power Supply (UPS) System shall consist of, but not limited to batteries, battery circuit
breaker, rectifier/charger, inverter, static transfer switch, manual bypass line, bypass shielded isolation
transformer, output distribution panelboards and management system.

Q What are components of Photovoltaic Power System?

Ans Solar Photovoltaic (PV) Power System shall consist of, but not limited to batteries, photovoltaic panels,
charge regulator and output distribution panelboards. If AC output is required, inverter (DC/AC converter)
shall be included.

Battery Selection, Sizing and Load Determination

*Batteries shall comply with 17‐SAMSS‐511.

Q Where the lead‐calcium or lead low antimony pasted flat plate batteries shall be used?

Ans Lead‐calcium or lead low antimony pasted flat plate batteries are generally the most suitable for standby
float service applications in an indoor temperature controlled environment.

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*Such applications include electrical substations and UPS systems where shallow moderate cycling is
expected.

Q How many cycle operations (charge/discharge cycles), lead‐calcium batteries are capable of per year?

Ans Lead‐calcium batteries are capable of charge/discharge cycles up to 5 cycle operations per year.

*Lead calcium battery features low current during float charging, and requires equalize charging only as
needed. In comparison, lead low antimony batteries are capable of many charge/discharge cycles, but
require equalize charging yearly.

Q Where the usage of lead selenium batteries or tubular plate lead‐antimony batteries is suitable?

Ans Lead selenium batteries or tubular plate lead‐antimony batteries are suitable for cyclic loads (frequent
charge/discharge cycles) and for high current short discharge applications.

*Such batteries can also be successfully used in locations where frequent battery discharges are anticipated.
Lead selenium batteries feature low water loss.

Q Where the usage of nickel‐cadmium batteries is suitable?

Ans Nickel‐cadmium batteries are suitable for the applications including outdoor non‐temperature controlled
applications such as remote unattended substations and photovoltaics systems.

*Nickel‐cadmium batteries are fairly immune to corrosion, are resistant to mechanical and electrical abuse,
operate well over a wide temperature range, and can tolerate frequent shallow or deep discharges.

Q Where the usage of valve regulated lead acid (VRLA) batteries is suitable?

Ans Valve regulated lead acid (VRLA) batteries shall be used where flooded batteries cannot be used and when
installed in temperature‐controlled (25°C) environment.

*Valve‐regulated lead‐acid batteries are generally a short‐life product with a proven service life of 10 years.

*Use of these batteries shall be considered only for special applications with prior approval.

Q What is the minimum design life acceptable in Saudi Aramco?

Ans Only long‐life batteries (design life >= 10 years) shall be permitted in Saudi Aramco.

*Use of VRLA batteries for UPSs <= 10kVA is exempt from the above approval requirement.

Q What are the factors to be considered for selection of batteries?

Ans The following factors shall be considered in selecting a battery for a particular application:

a) The design life of the battery shall be at least 20 years for flooded lead acid/nickel cadmium batteries,
and at least 10 years for VRLA batteries.
b) The design life of the battery shall be based on 25°C.

*For performance characteristics of various types of batteries, refer to IEEE 1184.

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Q Which standard shall be followed for the battery sizing criteria for applications involving a combination of
continuous loads, non‐continuous loads and/or momentary loads?

Ans For applications involving a combination of continuous loads, non‐continuous loads and/or momentary loads
(such as switchgears)

Lead acid batteries shall be sized in accordance with the battery sizing worksheets of IEEE 485.

Nickel cadmium batteries shall be sized in accordance with the battery sizing worksheets of IEEE 1115, or the
equivalent IEC standards as applicable.

Q What standard shall follow for the battery sizing criteria for photovoltaic (PV) applications involving a
combination of continuous loads, non‐continuous loads and/or momentary loads?

Ans For photovoltaic (PV) applications involving a combination of continuous loads, non‐continuous loads and/or
momentary loads, lead acid and nickel cadmium batteries shall be sized in accordance with IEEE or IEC
applicable standards.

Q What is the formula for the calculation of battery ampere‐hour capacity for applications of constant current
consumption loads?

Ans For applications of constant current consumption loads, the battery ampere‐hour capacity shall be
calculated as follows:

Where:

Battery Ah Capacity @ CBT = Ah capacity of battery at required backup time

Battery Ah Capacity = Ah capacity of battery at C8/C10 and C5, for lead acid battery and nickel cadmium
battery, respectively (consult battery manufacturer for the conversion factor to convert Ah @ CBT to Ah @
C8/C10 and C5, for lead acid battery and nickel cadmium battery, respectively)

L = Continuous load current (dc amperes)

BT = Battery back‐up time (hours)

AF = Aging factor (use 1.25 for all batteries)

DF = Design factor (use DF = 1.1 for all types of batteries)

KVA Load = Load designed apparent power (= Actual Load Power Consumption + Future Growth)

PF = Load power factor

No. of Cells = Number of series connected battery cells

Eff. Inverter = Efficiency of UPS inverter

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Voltage End Cell = Battery cell voltage at end of discharge

TC = Temperature compensation factor (cell size correction factor)

Q How the battery capacity shall be selected?

Ans If the calculated battery capacity exceeds a manufacturer's standard rating by more than 5%, then the next
larger standard battery capacity shall be selected.

Q How many sets of batteries shall be allowed in Parallel to make of battery banks to achieve the required
Ampere Hour capacity?

Ans Paralleling up to 4 sets of battery banks of identical Ah capacity and potential shall be allowed, to achieve
the required Ampere Hour capacity.

*The minimum battery backup time shall be based on the actual load calculation.

Q What are the redundant DC system?

Ans Redundant DC system, which consists of 2 rectifiers/chargers connected in parallel, shall have separate
battery banks such that each battery bank shall be sized for 50% of the required total battery backup time.

Table‐1 Battery Backup Times

Load Location Type of Load Primary Power Source Battery Backup Time
In‐Plant or In‐Office AC (UPS) Utility Only 60 minutes
In‐Plant or In‐Office AC (UPS) Utility + Generator 30 minutes
In‐Plant or In‐Office DC Utility Only 2 hours
In‐Plant or In‐Office DC Utility + Generator 30 minutes
Remote AC & DC Solar Photovoltaic 5 days (120 hours)
Attended Substation DC Utility + Generator 2 hours
Attended Substation DC Utility 4 hours
Unattended DC Utility 8 hours
Substation
Unattended DC Utility 12 hours
Offshore Substation

*Battery backup time (battery duration) for emergency or life‐critical loads shall be as specified in NFPA‐70
and NFPA‐101

*Battery backup time for all security emergency systems shall be per the requirements of SAES‐O Standards.

*No‐load losses of redundant systems shall be included in the battery sizing calculations.

*Switchgear DC system shall be dedicated for loads that are critical and require continuous operation during
utility power loss.

*In‐plant DC loads shall not be connected to the battery bank which is dedicated to the UPS system.

*Substation battery systems shall be dedicated to connected DC loads and shall not be part of a plant UPS or
other DC system.
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Q What is the method of minimum number of series connected battery cells shall be in accordance with?

Ans The minimum number of series‐connected battery cells shall be in accordance with battery manufacturer's
recommended number of cells based on the specified battery backup time shall be followed, if available.

For UPS applications, the number of series connected cells (DC voltage value) shall be selected by the UPS
manufacturer.

Note1‐: Assuming the maximum DC system voltage = nominal system voltage +17.5%, and equalizing voltage
of 2.35 volts/cell for lead‐acid batteries and 1.55 volts/cell for nickel‐cadmium batteries.

Note‐2: The number of cells required for photovoltaic systems are based on a minimum allowed DC system
voltage of 91.5% of the nominal voltage and an end‐of‐discharge voltage of 1.85 and 1.14 volts for lead‐acid
and nickel‐cadmium batteries, respectively.

Table 2 – Required Number of Cells

Number of cells DC Systems Number of Cells Photovoltaic

Systems
Nominal Lead Acid Nickel Cadmium Lead Acid Nickel Cadmium
Battery
Voltage
(VDC)
12 6 9 6 10
24 12 18 12 19
48 24 36 24 38
120/125 60/62 91 60 95
240/250 120/125 182 120 191
360 180 273 NA NA
408 204 309 NA NA
480 240 364 NA NA

Q What shall be the calculation formula for the maximum number of series connected battery cells?

Ans The maximum number of series connected cells shall be calculated as follows to ensure an optimal and safe
DC system voltage and battery recharge voltage:

Max. Number of Cells = Maximum Allowed DC System Voltage / Equalizing Volts per Cell

Q How the end‐of‐discharge voltage for each cell shall be calculated?

Ans The end‐of‐discharge voltage for each cell shall be calculated as follows to ensure that the system voltage
does not fall below the minimum acceptable level:

Voltage Discharge‐ of‐ End = Minimum Allowed DC System Voltage / Number of Cells

*The minimum allowed DC system voltage shall be 87.5% of the nominal system voltage for DC and UPS
systems, and 92.5% for Photovoltaic systems.

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Table 3 – Battery Cell End of Discharge Voltage

Battery Type General Applications PV Applications

Lead‐Acid 1.65 VPC to 1.75 VPC 1.85 VDC
Nickel‐Cadmium 1.0 VPC to 1.14 VPC 1.14 VPC to 1.2 VPC

*VPC = Volt per Cell

Battery Installations

Q What are the international standard codes for installation of batteries?

Ans All batteries shall be installed in battery rooms or battery enclosures in accordance with
NFPA 70 (NEC), IEEE 484, IEC 50272‐2

*Batteries shall not be installed in enclosures inside a battery room.

Exceptions:

1) When a pre‐approval is obtained for the use of valve regulated lead acid (VRLA)batteries, then the battery
can be exempt from the battery room requirements provided that the minimum battery room ventilation
shall be one complete air change every 3 hours, and the temperature inside this battery room is maintained,
but never exceed, 25°C.

2) Portable type UPS systems having built‐in sealed valve regulated lead acid batteries shall be exempt from
the battery room requirements.

Q What are the air handling/ventilation and temperature requirements for batteries room?

Ans The minimum battery room ventilation shall be one complete air change every 3 hours, and the temperature
inside this battery room is maintained, but never exceed, 25°C.

Q Can we install batteries in hazardous/classified area i.e. Class I, Division 1 locations and Class I, Division 2
locations?

Ans Batteries shall not be installed in Class I, Division 1 locations.

Batteries installed in Class I, Division 2, locations shall be in a building or enclosure made safe by pressurized
air.

*Loss of pressurization shall be monitored in accordance with NFPA 496.

Q How much working space shall be required for battery rack or enclosure?

Ans Working space of at least 1 meter shall be provided in front of each battery rack or enclosure.

*Batteries shall be supplied with covers for all inter‐cell connecters and terminals or insulated copper
busbars to enhance safety.

Battery Rooms

Q Battery room walls and floor shall be made of what type of material?

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Ans Battery room walls and floor shall be made of concrete construction and finishing.

*Battery room finishing shall not contain drywall (such as plasterboard, wallboard, gypsum board, sheetrock,
or gyprock).

*Manned workstations shall not be located in battery rooms.

Q What type of lighting fixtures shall be installed in battery rooms?

Ans Battery rooms shall be provided with enclosed and gasketed (vapor tight) corrosion resistant lighting
fixtures.

Q What shall be the minimum level of illumination, battery room lighting in battery rooms shall provide?

Ans Battery room lighting shall be installed to provide a minimum level of illumination of 30‐ft candles (300 lux).

Q What shall be the minimum level of illumination, emergency lighting in battery rooms shall provide?

Ans Emergency lighting with illumination level of 10‐ft candles (100 lux) shall be installed to operate in the event
of loss of mains power supply.

Q What type of battery room doors shall be?

Ans Battery room doors shall open outward, away from the room, to the outside of the building, and be fitted
with door closers and anti‐panic (quick‐release, quick‐opening) hardware. No hasp, padlock, or other device
shall be installed which will hinder operation of the emergency door opening devices.

*Doors between battery rooms and other rooms shall not be permitted.

*Potable water facilities shall be provided for rinsing spilled electrolyte in the battery room. Raw water shall
not be used (as it is rich of minerals and dissolved solids that may react with the electrolyte).

*The amount of water supply shall be determined based on a risk assessment of the extreme scenario where
the largest battery or electrolyte container gets spilled.

*Provisions for neutralizing the battery electrolyte (acid or alkali) and caustic spillage shall be included in the
battery room design.

*Floor drains shall comply with SAES‐S‐060.

*Sealed valve‐regulated batteries do not require floor drains.

*Emergency eyewash facilities shall be provided as required by SAES‐B‐069.

*Sealed valve‐regulated batteries do not require eyewash facilities.

Q What type of battery room floor shall be?

Ans Battery room floor shall be covered with an electrolyte (acid or alkali) resistant, durable, antistatic and slip‐
resistant surface overall, to a height 100 mm on each wall.

Q Where the batteries are mounted against a wall, the wall shall be coated with what type of coating?

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Ans Where batteries are mounted against a wall, the wall behind and at each end of the battery bank shall be
coated to a distance of 500 mm around the battery with an electrolyte resistant paint or tiles.

Q What type of fire extinguisher shall be installed in the battery room?

Ans A dry type chemical fire extinguisher shall be installed on the outside of the battery room.

*Cabinets or racks shall be provided in the battery room for storing maintenance tools and safety
equipment. These cabinets and racks shall be acid or alkaline resistant as applicable.

Q Shall the lead acid batteries be mounted in the same room together with nickel cadmium batteries?

Ans Lead acid batteries shall not be mounted in the same room together with nickel cadmium batteries, and vice
versa.

Q What shall be the limit of hydrogen concentration level inside the battery room?

Ans The ventilation system is designed such that the hydrogen concentration shall not exceed 1% of the total air
volume of the battery room.

*The maximum hydrogen evolution rate for all kinds of flooded batteries is 0.000457 m³/hour (0.016
ft³/hour), per charging ampere, per cell, at 25°C, at standard pressure.

*The worst condition (the maximum hydrogen evolution) occurs when current is forced into a fully charged
battery (overcharge).

Q Shall there be any interlock between the High‐Rate Charge and Ventilation Operation?

What type of interlock shall be between the High‐Rate Charge and Ventilation Operation?

Ans An interlock between the air‐handling unit and the high‐rate charging switch shall be provided, such that
failure of the air‐handling unit shall cause the high‐rate charging of batteries to stop.

Q What type of Ventilation System shall be for battery room?

Ans The ventilation system shall be 100% redundant. Only direct driven exhaust fans shall be used. An interlock
with the ventilation system shall be provided to stop the high‐rate battery charging if the exhaust fan stops.

Q What type of interlock shall be between the high‐rate batteries charging system with an air‐flow or air‐
pressure measuring device?

Ans An interlock the high‐rate battery charging system with either an air‐flow or air‐pressure measuring device,
such that ventilation insufficient to the 1% hydrogen limit will cause the high‐rate charge to stop.

*Audible and visual alarm shall be installed outside the battery room entrance to annunciate a failure in
ventilation for prompt repair.

Q How much time duration shall be for one complete air change the battery room?

Ans The minimum ventilation shall be one complete air change every 3 hours.

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*A battery area that meets the above ventilation requirements and the high‐rate charge interlock shall be
considered non‐hazardous. Therefore special electrical equipment enclosures to prevent fire or explosions
shall not be required.

Q How the equipment with arcing contacts shall be installed in the battery room?

Ans Equipment with arcing contacts shall be located in such a manner as to avoid those areas where hydrogen
pockets could form.

Q What shall be the clearance of electrical equipment form nearest cell in the battery room?

Ans Electrical equipment shall not be located directly above the batteries and, as a rule, shall have a minimum
horizontal separation of 1.5 meters from the nearest cell.

Q What shall be the minimum temperature for the battery room?

Ans Temperature in a room that contains batteries shall not exceed 25°C.

Q How the increase in the temperature for the battery room shall affect the batteries?

Ans If battery operating temperature increases by 10°C above the 25°C reference, battery design life is reduced
by 50% for lead acid batteries, and 20% for nickel cadmium batteries.

*Return air‐conditioning ducts from battery rooms shall be prohibited.

Q What shall be the installation height of lighting fixtures in battery room?

Ans Lighting fixtures shall be installed at least 300 mm below the finished ceiling.

Q How the inlets and outlets of air‐conditioning shall be in battery room?

Ans Inlets of air‐conditioning shall be no higher than the top of the battery cell and the outlets (exhaust) at the
highest level in the room.

Air inlets and outlets shall be located in such a manner to provide effective cross ventilation over the
batteries.

*Batteries installed in a sealed passively cooled shelter shall be located in a separate compartment with a
dedicated entrance. All battery cell vents shall be tubed so that hydrogen gas is vented outside the battery
compartment.

Battery Racks

*Battery racks shall be constructed in accordance with 17‐SAMSS‐511.

Q How the grounding and bonding shall be done at battery racks?

Ans Battery racks shall be bonded at both end points to a local supplementary grounding electrode per NEC 250
or EN 50178.

*Install lug and cable on the steel rack and tighten to ensure ohmmeter reading between each component
and a common point on rack frame indicated continuity for proper grounding.

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Q How the stationary batteries shall be installed on open battery racks within a battery room?

Ans Stationary batteries shall be installed on open battery racks within a battery room to facilitate proper
cooling, routine inspection, and maintenance.

*Either covers for all inter‐cell connecters and battery terminals or insulated copper busbars shall be
supplied as part of the battery.

Q How much clearance shall be for battery cell to the rack?

Ans Clearance from the top of the battery cell highest point to the bottom of the rack above it shall be 350 mm,
and airspace between battery cells shall be approximately 10 mm.

Battery Enclosures

For outdoor installations and some special indoor applications, batteries may be installed in an enclosure.

Q What are the requirements for battery enclosures?

Ans Battery enclosures shall be in accordance with the following requirements:

a) The enclosure design shall include a removable lid, secured by quick‐ release latches, type 316L stainless
steel or equivalent. Hinged enclosures shall be designed to open at least 120 degrees to facilitate proper
maintenance access.
b) The enclosure base shall be provided with cell supports designed to raise the cells a minimum of 5 cm
above the enclosure floor.
c) For indoor use, the battery enclosures and cell supports shall be made of fiberglass reinforced material
or steel, with provisions for anchoring to the floor and grounding.
d) Valve regulated (sealed) lead acid (VRLA) batteries shall be mounted in ventilated indoors enclosures
unless installed inside a dedicated battery room, where battery racks are sufficient. VRLA batteries shall
not be used for outdoors applications.
e) Battery enclosures for outdoor use shall be made of fiberglass‐reinforced material, and shall be
completely weatherproof, dust‐tight, and rain‐tight. The gasket shall be one‐piece, heavy‐duty black
neoprene or Buna nitrile rubber, mechanically attached to the enclosure lip and in continuous contact
with the enclosure lid.
f) Minimum protection Class for outdoors enclosures shall be NEMA 250 Type 4 (or IEC 60529 IP 65). For
offshore outdoors applications, corrosion resistance enclosure NEMA 250 Type 4X (or IEC 60529 IP 65
with corrosion protection) shall be required.
g) The fiberglass material shall meet the flammability rating of UL 94 type V‐0.
h) Steel enclosures and grounding lugs shall be coated with an acid‐resistant or alkali‐resistant, chip and
scratch resistant, baked powder epoxy or propylene.
i) All hardware shall be 316L stainless steel or equivalent.
j) The enclosure shall have an adequate number of drain openings at the bottom and a minimum of two
ventilation openings at the top. The ventilation openings shall be fitted with breather‐type plugs to
release hydrogen gas without allowing sand/dust to enter the enclosure.
k) Clearance above each battery cell shall be 350 mm, to allow proper air circulation and to permit filling,
testing, and replacement of cells. Adequate clearance shall also be maintained in between cells. Air

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space between battery cells, as well as between the cells and external enclosure walls shall be
approximately 10 mm.
l) Enclosures with front access only shall have no more than 2 rows of stepped cells. Enclosures with
access from the front and back sides may have a maximum of 4 rows of stepped cells. In the stepped cell
arrangement, for vented battery application, cells shall be positioned in such a way that the electrolyte
levels markings (both minimum and maximum) can be easily seen.

Electrical Requirements

Q What shall be the total voltage drop for battery cables?

Ans Battery cables shall be sized for a total voltage drop of less than 3%.

*Positive and negative battery cables shall be run in the same conduit to prevent inductive heating.

*The positive and negative buses of batteries shall be isolated from earth ground.

Q What type of protection shall be for the battery protection?

Ans Each battery‐based system shall be equipped with properly sized two‐pole fused disconnect switch or circuit
breaker with an under voltage release feature to prevent battery discharge beyond the battery's end‐of‐
discharge voltage. The under voltage device shall disconnect the battery from the load when the battery
voltage drops to the end‐of‐discharge voltage.

Q What is the formula for short circuit current for the battery?

Ans Battery Short‐circuit Current = Battery Voltage/Battery Internal resistance.

*The protective fault level at the battery terminals can be considered to be twenty times the nominal
battery capacity.

Battery Alarms

Q Where the alarm shall be installed to indicate the battery circuit breaker open condition?

Ans An alarm to indicate the battery circuit breaker open condition (or fused disconnect switch open or blown
fuse condition) shall be provided on the charger cabinet or the UPS cabinet. This alarm shall also be
annunciated to the main control room DCS or to an area where operators are present.

Q How shall be routed the battery circuit breaker open condition?

Ans The battery circuit breaker open condition (or fused disconnect switch open or blown fuse condition) shall
be routed via Standalone or the Supervisory Control and Data Acquisition (SCADA) system or Network
Management System (NMS), to the power control center.

*Another alarm to indicate the battery room high temperature shall be annunciated to the main control
room.

Wiring Color Code

Q What is wiring color coding for batteries wiring for grounded and ungrounded systems?

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Ans Un‐grounded Systems for Industrial Facilities

Positive: Red
Negative: Black
Battery rack and other equipment grounding conductors: Green

Grounded Systems for Special Applications

a) Negative Grounded Systems

Positive: Red (ungrounded)
Negative: White (grounded)

a) Positive Grounded Systems

Positive: Black (grounded)
Negative: Red (ungrounded)

*Battery rack and other equipment grounding conductors: Green, or green with yellow stripes

Safety Equipment

Q What are the safety equipments shall be provided near stationary batteries?

Ans The following safety equipment shall be provided near stationary batteries:

a) Safety face shields and goggles

b) Safety aprons
c) Acid resistant rubber gloves
d) Safety shoes
e) Eye washing facilities
f) Neutralizing agent

Q Which chemicals shall be needed to neutralize the batteries?

Ans ‐To neutralize lead acid battery:

Mix 0.1 kg (100 grams) bicarbonate of soda to one liter of water.

‐To neutralize nickel cadmium battery spillage:

Mix 50 grams boric acid solution to one liter of water.

‐Or use other suitable neutralizing agent recommended by the manufacturer for acid electrolyte spillage or
the manufacturer of alkaline electrolyte spillage, whichever applicable.

Q What the safety signs shall be posted on battery room?

Ans The following safety signs shall be permanently posted on battery room entrance at a visible location in
Arabic and English languages:

a) Sign: “DANGER CAUSTIC/ACID”

b) Sign: “DANGER CAUSTIC/ALKALINE”
c) Sign: “DANGER NO SMOKING”
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d) Sign: “EYE PROTECTION REQUIRED IN THIS AREA”

Rectifiers/Chargers

*Rectifiers/chargers for utility type applications shall comply with 17‐SAMSS‐514.

Q What type of rectifiers/chargers shall be used in double ended substations?

Ans Parallel redundant rectifiers/chargers with dynamic load sharing capability shall be provided for all double‐
ended substations. Each rectifier/charger shall be fed from a different source.

Q What type of rectifiers/chargers shall be used in single ended substations?

Ans A single rectifier/charger shall be provided for single‐ended substations unless an alternative power supply is
available, in which case dual rectifiers/chargers shall be required.

Q How many chargers shall be used for critical systems?

Ans For critical systems, two parallel battery chargers should be provided, so that maintenance can be
performed without loss of load supply.

Q How the critical DC loads shall be supplied/fed through?

Ans Critical DC loads that are sensitive to high DC supply voltage, that can reach up to +18% of nominal, shall be
supplied through DC/DC stabilizer.

*During loss of mains supply and fault clearances, the DC/DC stabilizer shall be automatically isolated
(bypassed) and loads supply shall be directly from the batteries of the DC system.

Q Where shall be used the DC/DC stabilizer?

Ans The DC/DC stabilizer shall secure supply voltage to sensitive critical loads within ±1% of nominal under all
operating conditions. Voltage supply to sensitive loads through DC/DC stabilizer shall be performed during
normal operating conditions only.

Q What type of enclosure shall be used for outdoors mounting rectifier/charger?

Ans Rectifier/charger enclosure for outdoors mounting shall be completely weather‐proof, dust‐tight and rain‐
tight. Enclosure minimum protection class shall be NEMA 250 Type 4 (or IEC 60529 IP 65).

Q What type of enclosure of rectifier/charger shall be used for marine applications?

Ans For marine applications, rectifier/charger enclosure shall have corrosion protection as follows:

a) Outdoors Mounting: NEMA 250 Type 4X (or IEC 60529 IP 65 with corrosion protection).

b) Indoors Mounting: NEMA 250 Type 12 (or IEC 60529 IP 54) with corrosion protection.

Q How the rectifier/charger enclosure doors shall be designed?

Ans Rectifier/charger enclosure doors shall be hinged and designed to open at least 120 degrees to facilitate
maintenance access.

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Rectifier/Charger Output Current Determination

Rectifier/Chargers for DC Systems:

*For indoors mounting, the output current rating of all DC system rectifiers/chargers, except
rectifier/charger of a UPS, shall be computed at 40°C ambient temperature.

*For outdoors mounting, a temperature compensation factor of 1.2 shall be multiplied by the result to
ensure the rectifier/charger supplies its rated output continuously.

A = (SF x DC Load Current Consumption) + (BIF x Battery Charging Current)

A = SF x L + BIF x {Battery Ah Capacity/RT}

Where:
A = Ampere output rating of rectifier/charger
SF = Service factor (this is a design margin, Use 1.1)
L = Sum of continuous DC loads (in amperes)
BIF = Battery inefficiency factor: 1.15 for all batteries
Battery Ah capacity = Ampere‐hour capacity of the battery at C8/C10 and C5, for lead acid batteries and
nickel cadmium batteries, respectively
RT = Battery recharge time (for photovoltaic applications: Use 30 days; and for all other applications: Use 10
hours)

Rectifier/Charger for UPS Systems:

The rated current of a UPS rectifier shall be computed by the following formula:

Where:
A = Ampere rating of the rectifier/charger output
SF = Service factor (this is a design margin: Use 1.1)
kVA Load = Load designed apparent power (= Actual Load Power Consumption + Future Growth)
PF = Power factor of UPS load (use PF = 0.9 lagging)
Eff. Inverter = Efficiency of UPS inverter
No. of Cells = Number of series connected battery cells
Voltage Float Cell = Float voltage per battery cell
RT = Required recharge time of the system battery (Use 10 hours for UPS applications)
BIF = Battery inefficiency factor (use 1.15 for all batteries)
Battery Ah Capacity = Ah capacity of battery at C8/C10 and C5, for lead acid battery and nickel cadmium
battery, respectively

Q How the Rectifier/Charger shall be monitored remotely and what things required to be equipped with?

Ans The Rectifier/Charger shall be monitored remotely and be equipped with, but not limited to the following:

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1) Rectifier/Charger management software and hardware

2) Web‐based monitoring facility

a) Card for network connection
b) Software for network management
c) Web/SNMP manager

3) RS 232/RS 485 ports.

4) Battery management technology.

5) Environment sensor for SNMP/Web application (to monitor temperature and humidity).

Uninterruptible Power Supply (UPS) Systems

*UPS rating larger than 10kVA shall comply with 17‐SAMSS‐516.

*Single, non‐redundant UPS system is for critical loads.

*Parallel redundant UPS system is for extremely critical loads.

*Dual standalone UPS configuration for loads that accept dual input feeders.

*Industrial UPS rating less or equal to 10 kVA shall comply with UL 1778 or IEC 62040.

UPS Specifications (Less or Equal to 10 kVA)

AC Input

Input Voltage = 230 VAC 1‐Phase, or 400 VAC 3‐Phase, 50/60 Hz or as per project specified requirements

Voltage Tolerance = ±15%

Frequency Tolerance = ± 5%

Inverter Output

Output Voltage = 230 VAC 1‐Phase, or 400 VAC 3‐Phase, or as per specified requirements Steady State
Condition: ±1%

Operating Frequency = 50/60 Hz

Frequency Regulations = When Synchronizing ±1% , When Free Running ±0.1% , Maximum Total Harmonic
Distortion at 100% nonlinear loads 5% THDV

Load Power Factor = 0.8 Lagging to 0.8 Leading

Overload Capacity (Inverter) = 150% for 1 minute, 125% for 10 minutes

Maximum Voltage Transient =5% for 0 to 100% step load with recovery to ±2% of nominal within 1 mains
cycle.

Equipped with Built‐in

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a. Bypass static transfer switch – rated for continuous operation at full load

b. Manual transfer switch – for maintenance purpose

c. Battery circuit breaker that has low DC voltage disconnect

d. UPS management software

e. Battery management technology

f. Web‐based monitoring facility

‐ Card for network connection

‐ Software for network management

‐ Web / SNMP manager

g. Environment sensor for SNMP / Web application

‐ Monitoring of temperature and humidity

h. RS232 port

i. 6 outlets, fused (UPS up to 6 kVA UPS only)

j. Input cable and plug

k. UPS control LCD display to

‐ Display UPS measurements and alarms

‐ Control UPS functionality

l. UPS manuals in English language (both hardcopy and softcopy)

‐ User Manual

‐ Maintenance, Troubleshooting and Repair Manual

‐ Complete circuit diagram(s)

Battery Backup Time

Minimum 30 minutes at full load, or as per requirement/specifications.

Battery Type

Valve Regulated Lead Acid; Long lifetime type (design life >= 10 years)

Recharge Time

Within 10 x battery backup time to 95%of battery Ah capacity

Warranty
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At least two (3) years from UPS successful commissioning

*UPS enclosure doors shall be hinged and designed to open at least 120 degrees to facilitate maintenance
access.

UPS rating larger than 50 kVA:

Q What shall be the input requirements for UPS rating larger than 50kVA?

Ans 1) UPS rating larger than 50 kVA: Normal and alternate source voltages shall be 3 phase, 3 wire + ground.

2) The normal input to the UPS rectifiers/chargers and the feed to the bypass shielded isolation transformer
(alternate source) shall be from different sources. The separate sources could be separate buses of a double‐
ended system. If separate sources are not available, then the UPS shall be supplied from separate breakers
of the same source.

3) UPS rectifier/charger shall contain a programmable walk‐in ramp circuit, for which input current shall
gradually increase from 0 to UPS rated power in approx. 10 seconds after the rectifier/charger input circuit
breaker is closed.

Q What are the output requirements for USP rated larger than 50kVA?

Ans 1) UPS Systems Rating <= 50 kVA: 1 phase, 2 wire; or 3 phase, 4 wire, plus ground.

2) UPS Systems Rating > 50 kVA: 3 phase, 4 wire, plus ground.

Determination of kVA Rating

Q What shall be the kVA rating for a UPS system?

Ans The power (kVA) rating of the UPS system shall be equal to or greater than the steady‐state kVA of all the
downstream loads plus a future load growth factor.

Q Why the UPS system will not be capable of delivering inrush currents of large loads when starting during the
utility power loss?

Ans Because the UPS is current‐limiting source.

Q What value of load power factor shall be considered in sizing the batteries for the UPS system?

Ans The load power factor (PF) of 0.9 lagging shall be considered in sizing the batteries for the UPS system.

*The UPS inverter shall be sized to deliver full rated power at PF = 0.8 and PF = 0.9 lagging without derating,
for Plant UPS and IT UPS, respectively.

Q What type of switch shall the UPS system have for continuous operation?

Ans Every UPS system shall have the static bypass switch and maintenance (manual) bypass switch, fully rated

Q How much shall be the overload bearing capability of a UPS system?

Ans 150% for 1 minute, 125% for 10 minutes.

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Q What shall be the growth factor value for a UPS system rated 50kVA and below and over 50 kVA?

Ans The UPS shall be sized to include the load growth factors
50 kVA and below = 1.20 (growth factor)
Over 50 kVA = 1.10 (growth factor)

Q How the UPS shall be monitored remotely and what things required to be equipped with?

Ans The UPS shall be monitored remotely and be equipped with, but not limited to the following:

1) UPS management software and hardware.

2) Web‐based monitoring facility

a) Card for network connection

b) Software for network management

c) Web/SNMP manager.

3) RS 232 / RS 485 ports.

4) Battery management technology.

5) Environment sensor for SNMP/Web application (to monitor temperature and humidity).

Installation

Q How much workspace shall be provided in front and rear and sides of the UPS cabinets?

Ans A workspace of 1 m shall be provided in front of the UPS cabinets. If rear access or side access is required for
UPS maintenance, a clearance of 1 m shall be allowed.

Q How much temperature shall be maintained in UPS located room?

Ans UPS system shall be located in a temperature‐controlled room in which the temperature is maintained
≤25°C.

*Redundant AC systems are preferred for continuous and reliable operation.

Q shall the cables for the primary AC input, output for UPS and the alternate AC source be run in same
raceways?

Ans No, The cables for the AC input, output of UPS system and the alternate AC source shall be run in separate
raceways.

AC input power to industrial UPS systems

Q How much the initial magnetization current shall be for UPS charger/rectifier input for a duration of one
main cycle?

Ans The initial magnetization current shall be limited to 600% of the rectifier/charger rated input current for a
duration of one main cycle.

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Q What type of circuit breakers shall be for both the primary and alternate AC sources for UPS system?

Ans The circuit breakers for both the primary and alternate AC sources shall be equipped with overcurrent
protection, sized and coordinated with upstream and downstream protections.

Commentary Notes:

i) Include UPS overall efficiency and battery charging current on sizing rating of the primary feeder circuit
breaker.

ii) Consider UPS inverter overload capability on sizing rating of the alternate feeder circuit breaker.

Q When a generator and automatic transfer switch arrangement is used to extend the protection time of a UPS
system, how shall it be connected to deliver power?

Ans It shall be connected to deliver power to the UPS rectifier, but not directly to the critical load.

Q What to install for the event of a malfunction of the inverter or to clear a load fault?

Ans The UPS static switch shall be arranged to transfer the entire UPS load to the alternate AC source (bypass
line) in the event of a malfunction of the inverter or to clear a load fault. After fault clearance, the load shall
be transferred automatically from the mains supply to the UPS output supply.

Q What shall be the kVA rating of a backup generator used for supplying emergency backup power to the UPS
system?

Ans The kVA rating of a backup generator used for supplying emergency backup power to the UPS system shall
be at least 2.25 times the rated kVA of the UPS.

Exception:

*The emergency generator may be sized at 1.4 times the rated kVA of the UPS: Provided that the feedback
injection of current harmonics by the UPS rectifier is limited to 5% THDI during all UPS operating conditions.

*The UPS system shall automatically block (inhibit) battery charging during supply of power through the
emergency generator.

Q How the UPS loads shall be distributed?

Ans UPS loads shall be distributed through panelboards.

*Protection for the outgoing circuits shall be accomplished through circuit breakers rated for continuous
operation with capability to quickly open and clear short‐circuit and/or overload conditions.

Q Is it allowed the fuses to be installed within the panelboard enclosure for UPS system?

Ans Panelboards specification does not allow the fuses to be within the panelboard enclosure.

Q What type of fuses shall be installed for panelboards for UPS system?

Ans Fast acting fuses type KTK or equivalent, if required to protect specific loads, would have to be installed in a
separate enclosure.

*Ratings of distribution panel's main feeder and branch circuits shall be coordinated with UPS and bypass
ratings.

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When the UPS is not equipped with a static bypass switch

Q What shall be the size of the largest branch circuit breaker in the distribution panel for UPS system? When
the UPS is not equipped with a static bypass switch.

Ans The maximum current rating of the largest branch circuit breaker in the distribution panel shall be no greater
than one‐half (1/2) the rated current output of the inverter.

Q What shall be the size of the largest load‐side fuse for UPS system? When the UPS is not equipped with a
static bypass switch.

Ans The largest load‐side fuse shall be no greater than one‐fourth (1/4) the rated current output of the inverter.

*This is to ensure proper selectivity between the tripping of the load circuit protective devices and the
inverter's internal protective devices.

Q When the UPS is equipped with a static bypass switch, in that case how the protective devices for the
outgoing loads shall be selected?

Ans When the UPS is equipped with a static bypass switch for transferring to the bypass (alternate) line, the
protective devices for the outgoing loads shall be selected to achieve selective coordination with the primary
breaker on the line side of the bypass transformer.

*Branch circuit breakers shall be coordinated with the load crest factor (in‐rush current) as applicable.

Q What is the bolted fault test for the UPS distribution system?

Ans A bolted fault test (three phases connected to ground) shall be conducted on the UPS distribution system to
establish that proper fuse coordination has been achieved.

Q How to conduct the bolted fault test for the UPS distribution system?

Ans Conduct the test by placing a bolted fault, by means of a contactor, on a typical branch circuit of the UPS
distribution system.

*The branch circuit fuse shall clear the fault without affecting any upstream fuses and circuit breakers.

Photovoltaic (Solar) Systems

Installation

*Solar photovoltaic systems shall be installed in accordance with NFPA 70/NEC, Article 690 or IEC equivalent
standard.

*The metallic frames and support structures of photovoltaic panels shall be grounded.

*Enclosures housing electronic equipment and batteries shall be shaded from direct sunlight regardless of
the sun inclination angle.

Q What type of enclosure is used for housing electronic equipment and batteries for solar system?

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Ans Minimum enclosure protection class for all outdoors mounting applications shall be NEMA 250 Type 4X (or
IEC 60529 IP 65 with corrosion protection).

*Each solar photovoltaic module shall be equipped with a Shottky blocking diode to prevent reverse flow of
power into the photovoltaic module.

Q How much should be the tilt/inclination angle of the solar photovoltaic array?

Ans Solar photovoltaic array shall be installed at a tilt/inclination angle equal to the latitude of the location plus
10‐15 degrees.

*Solar photovoltaic array shall be directed toward the geographical south (±5 degrees).

*Battery shall be selected for minimum topping‐up interval of 1 year, at 25°C operating temperature and
float charging.

Q What are the parameters of battery selection for photovoltaic application?

Ans Battery shall be selected for photovoltaic application with a cycling life of at least 8000 cycles to a shallow
cycle of 20% depth of discharge (DOD), and 1000 cycles to 80% DOD.

*Batteries shall be photovoltaic‐graded to tolerate harsh weather conditions; hence the under shade
ambient temperature may reach 55°C.

Charge Regulator/Controller

Q What type of regulators shall be used for photovoltaic solar system?

Ans The charge regulator shall be designed to provide two‐step charging for the batteries (float charging and
equalize charging) and to provide the power requirements of the load when the photovoltaic solar array is
producing power.

*The charge regulators shall be of the solid‐state design.

Q Does ON‐off type regulators are acceptable for photovoltaic solar system?

Ans No, On‐off type regulators, which simply disconnect the solar array from the entire system when the battery
reaches a certain terminal voltage, are not acceptable.

Q What is the ambient temperature range for charge regulator?

Ans The charge regulator shall be designed to operate continuously at full rate in ambient temperatures
between 0 and 55°C.

Q What is the purpose of shottky blocking diode?

Ans The charge regulator shall be equipped with a Shottky blocking diode to prevent reverse flow of power into a
faulty regulator.

*The charge regulator shall be equipped with temperature compensation feature to adjust the charging
voltage with temperature.

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Q What type of protection shall be provided for end‐of‐discharge voltage?

Ans The charge regulator shall be equipped with a low‐voltage battery disconnect which shall act to disconnect
the load from the battery when the battery reaches the end‐of‐discharge voltage (1.85 Volts per cell for
lead‐acid batteries and 1.14 Volts per cell for nickel‐cadmium batteries) to prevent severe battery discharge.
Battery manufacturer's recommended cell end of discharge voltage shall be followed.

Q What are the signs and alarms for the charge regulator?

Ans The charge regulator shall include the following signs and alarms:

a. Battery voltage
b. Battery current (charging or discharging)
c. Solar array current (for each array)
d. Load current
e. Local indication of high and low battery voltage, plus normally open and normally closed voltage free
contacts for activating remote alarms
f. A set of normally open and normally closed voltage free contacts shall be provided for annunciating the
alarms to a central control room via Remote Terminal Units (RTUs) or similar facilities, where such
facilities are available.

*Surge protection shall be provided for the DC load bus.

*All controls and indicators shall be housed in a NEMA 250 Type 4X (or IEC 60529 IP 65 with corrosion
protection) enclosure.

Q What shall be the backup time for batteries for solar photovoltaic power system?

Ans Maximum backup time shall be 5 days or as per application requirement.

Q How the charge regulator shall be rated, for solar photovoltaic power system?

Ans Charge regulator shall be rated for the maximum array current plus 10% design margin.

Q How the solar array shall be sized for the recharge of a battery?

Ans The solar array shall be sized to fully recharge the battery to 95% state of charge in 30 days.

Q For how many sun hours the solar array shall be sized?

Ans The array shall be sized based on 5 effective sun hours for all installations in Saudi Arabia.

Q How the solar array shall be sized for dust accumulation?

Ans The array size shall be derated 10% for dust accumulation.

Q How the solar array shall be sized for aging over the array expected life?

Ans The array size shall be derated 10% for aging over the array expected useful life.

Q How the solar array shall be sized for additional capacity for future growth?

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Ans The array sizing shall include additional 10% capacity for future growth.

Battery Tests and Records

All commissioning data shall be dated, recorded, and maintained in a permanent file to facilitate required
future maintenance and interpretation of the operating data.

* The following data shall be maintained in a permanent record file:

a) Initial battery capacity test performed in accordance with IEEE 450 (for lead acid), IEEE 1106 (for nickel
cadmium), or IEEE 1188 (for VRLA) or the IEC equivalent standard, as applicable.

b) The initial resistance values of the inter‐cell connections.

c) The initial individual cell voltages and specific gravity measurements.

*Routine battery maintenance and testing shall be in accordance to SAEP‐350.

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Wiring Methods and Materials

(SAES‐P‐104)

Q SAES‐P‐104 is used for what purpose?

Ans This Standard prescribes mandatory requirements for the design and installation of insulated power and
control wiring and cable systems.

Q Define control wiring and instrumentation wiring?

Ans Control wiring:

Control wiring is wiring used to power up the electrical control devices, such as pushbuttons, relays, meters,
transducers, etc.

Instrumentation/Signal wiring:

Wiring connected on one or both sides to instruments is called instrumentation wiring.

*Signal cables/instrument cables carry signals of 24 VDC and 4‐20 mA.

Q What are the low, medium and high voltages levels commonly operated in the industry?

Ans Low Voltage Levels: 120‐230V 1‐Phase, 400‐480V 3‐Phase

Medium Voltage Levels: 4.16 KV, 13.8 KV, 34.5 KV

High Voltage Levels: 69 KV

Q What are the low voltage, medium voltage and high voltage values?

Ans Low voltage  Less than 1000 V

Medium voltage  2.4 kV to 34.5 kV

High Voltage  34.5KV to 69 KV

Extra high Voltage  Greater than 69KV

Q What is the hazard location in area classification?

Ans Hazardous locations are: CLASS I, ZONE 0 & CLASS I, ZONE 1

Q Which standard code is used for the design and installation of wiring and cable systems?

Ans Design and installation of wiring and cable systems shall be in accordance with Saudi Building Code,
ANSI/NFPA 70, and NEC 725.

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*Locations where chemicals are being handled, enclosures, conduits, fittings, and wirings must be resistant
to the chemicals present.

*A structure enclosed by walls on three sides only, and has a roof, is considered an outdoor location. A non‐
air‐conditioned building is considered an indoor location. A shop that has its doors kept open to facilitate
entry of vehicles is considered an indoor location.

Basic Wire and Cable Specifications

Q What type of conductor material is used for wires and cables?

Ans Wires and cables shall have copper conductors.

Q What is the minimum size of aluminium conductors?

Ans Aluminum conductors are permitted to be used in community areas for sizes 25 mm² or larger.

Q What the aluminium conductors are permitted to be used?

Ans Aluminum conductors are permitted to be used in community areas.

*Equipment grounding conductor shall be provided with each power circuit

Q What are the low voltage Jacketed wire and cable specifications, according to SAES‐P‐104? Which standards
shall comply low voltage jacketed cables?

Ans Low voltage jacketed cables shall comply with NEC or IEC 60502‐1 and shall conform to UL standards.

1) NEC low voltage cables shall be rated 600 V, shall have a minimum temperature rating of 90°C dry/75°C
wet, and shall conform to UL standards according to the particular type (e.g., UL 1277, including its vertical
tray flame test, for type TC tray cables, etc.)

2) IEC 60502‐1 type cables shall be rated 600/1000 V, shall have a minimum rating of 85°C, and shall meet
the flame test of IEC 60332‐3.

Q What are the low voltage unjacketed wire and cable specifications, according to SAES‐P‐104? Which
standards shall comply low voltage unjacketed cables?

Ans Low voltage unjacketed insulated wires shall comply with NEC, IEC 60227 or SASO 55 and shall conform to
UL standards.

1) NEC low voltage wires shall be rated 600 V, shall have a minimum temperature rating of 90°C dry/75°C
wet, and shall conform to UL standards according to the particular type (e.g., UL 83 for THHN/THWN and UL
44 for XHHW).

2) SASO 55 or IEC 60227 type low voltage wires shall be rated 450/750 V, shall have a minimum rating of
85°C, and shall meet the flame test of IEC 60332‐1.

3) Low voltage unjacketed insulated wires shall not be used in cable trays (except when used as grounding
conductors or listed and marked for use in cable trays), duct banks involving manholes, or direct burial
applications.

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*Low voltage unjacketed insulated wires shall not be used in cable trays, duct banks involving manholes, or
direct burial applications.

Q What are the medium voltage power cables specifications, according to SAES‐P‐104?

Ans Medium voltage power cables, rated 5 kV to 35 kV, shall comply with 15‐SAMSS‐502, and shall be either IEC
or ICEA & AEIC type cables.

Medium voltage power cables, rated 5 kV through 35 kV, to be used on systems with nominal voltages
between 2 kV and 34.5 kV.

Q What are the high voltage power cables (rated 69 KV high voltage) specifications, according to SAES‐P‐104?
The power cables rated 69KV and above should comply with which standard?

Ans According to SAES‐P‐104, Power cables rated 69 kV and above, with solid dielectric insulation, shall comply
with either AEIC CS6 (69 kV EPR insulated cable) or AEIC CS9 (69 kV and above XLPE insulated cable).

*Insulation thickness shall be 16.5 mm (650 mils) for 69 kV rated cables and 20.3 mm (800 mils) for 115 kV
rated cables.

Q How much thickness of the insulation required for power cables for high voltage?

Ans 16 mm to 20 mm.

Q The submarine power cables shall be according to which standard?

Ans Submarine power cables, 5 kV through 35 kV, shall comply with 15‐SAMSS‐503.

Submarine power cables, 69 kV through 230 kV shall comply with 15‐SAMSS‐504.

Q What type of cables should use in areas Class I, Division 2 and Zone 2 (hazardous) locations?

Ans Medium‐voltage cables meeting the requirements of 15‐SAMSS‐502 are suitable for use in Class I, Division 2
and Zone 2 locations.

Cables manufactured in accordance with IEC 60502‐1 and rated 600/1000 V, having similar constructions to
those listed in NEC Article 501, are suitable for use in Class 1, Division 2 and Zone 2 locations.

*For land cable concentric neutral wire, metallic armor, and metallic sheaths shall be protected with a PVC
or equivalent jacket.

*Power and control conductors shall be stranded.

*Solid copper conductors 6 mm² (10 AWG) and smaller may be used in non‐industrial locations.

*Mineral insulated cables and specialty cables (downhole pump motor cables, high temperature cables, etc.)
with solid conductors are also permitted.

*Stranded power, control and grounding conductors shall have stranding in accordance with ASTM B8 Class
B or C, or ASTM B496, or IEC 60228 Class 2.

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*Flexible cords, portable cables, battery leads and motor leads may have finer stranding in accordance with
appropriate UL Standards or the manufacturers' recommendations.

*Splicing of conductors shall be kept to a minimum.

Q What is the maximum number of field splices permitted in any one circuit for new installations of cables
rated above 1000 V?

Ans The maximum number of field splices permitted in any one circuit for new installations of cables rated above
1000 V (excluding submarine cables) is the number made necessary by the use of standard size reels with full
length cables.

In case of accidental damage of the cable during installation, one additional splice is permitted with the
concurrence of the cable Proponent.

Splices and terminations on cables rated above 1000 V shall be made by personnel certified in accordance
with Saudi Aramco General Instruction GI‐0002.705.

Conductors used for grounding metallic shields or maintaining shield continuity through splices or
termination shall have a current rating no less than the metallic shield.

Conductors of multi‐conductor control cables shall be numbered or color‐coded by colors other than green,
green with yellow stripes, white or gray.

Size of Conductors

Minimum Conductor Size for Rated Voltage (Table‐1, SAES‐P‐104)

Voltage Size
600 V and below (control) 2.5 mm² (14 AWG)
600 V and below (power) 4 mm² (12 AWG)
5 kV 10 mm² (8 AWG)
15 kV 35 mm² (2 AWG)
35 kV 50 mm² (1/0 AWG)
69 kV 120 mm² (4/0 AWG)

Q What is the minimum size of control conductor?

Ans The minimum size of control conductor for 600V and below shall be 2.5 mm2 (14 AWG)

Q What is the minimum size of power conductor?

Ans The minimum size of power conductor for 600V and below shall be 4 mm2 (12 AWG)

Q What is the minimum size of control cable in a multicore type of conductors in Saudi Aramco Standard?

Ans 18 AWG

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Q What is the minimum size of control cable in a single core type of conductor in Saudi Aramco Standard?

Ans 16 AWG

Q What are the minimum size of control cable conductor rated 600 Volts and Below in Aramco Standard?

Ans 2.5 mm² or 14 AWG

Q What is the minimum size of power conductor rated 600 V and Below in Aramco Standard?

Ans 4 mm²

Q What is the minimum size of power conductor rated 5 KV in Aramco Standard?

Ans 10 mm²

Q What is the minimum size of power conductor rated 15 KV in Aramco Standard?

Ans 35 mm²

Q What is the minimum size of power conductor rated 35 KV in Aramco Standard?

Ans 50 mm²

Q What is the minimum size of power conductor rated 69 KV in Aramco Standard?

Ans 120 mm²

Q What is the maximum size of power conductor rated below 69 KV?

Ans 500 mm² or 1000 Kcmils

Q What kind of cables used for security lighting (perimeter and area lighting)?

Ans Cables used for security lighting (perimeter and area lighting) shall be armored or metal clad.

Q According to which standards the armored cable shall be manufactured, as per SAES‐P‐104?

What standard code shall be followed for armored cable?

Ans Armored cable shall be manufactured to IEC 60502‐1 or IEC 60502‐2, and shall have galvanized steel wire
armor or galvanized steel tape armor under the jacket.

Exceptions:

A) In Class I, Division 1 and Zone 1 hazardous locations, only cables specifically permitted by NEC Article 501
are allowed without rigid steel conduit;

B) Cable terminators shall be approved for the specific type of cable used;

Commentary Note:

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Armored cable Type AC per NEC, referred to also as type BX, not to be confused with the above, is light duty
cable, and is not permitted in hazardous locations. Metal clad cable type MC per NEC is permitted in Class I,
Division 2 and Zone 2, and if listed in Class I, Division 1 and Zone 1 locations.

Q What type of cables shall be permitted to be installed and exposed where it is not subject to damage by
vehicular traffic or similar hazards?

Ans Type MC Cable and armored cable shall be permitted to be installed and exposed where it is not subject to
damage by vehicular traffic or similar hazards.

Q What shall be the support intervals for MC or armored cables, installed exposed where it is not subject to
damage by vehicular traffic or similar hazards?

Ans Sections of exposed type MC or armored cable shall be supported at intervals not exceeding 1.8 meters.

*Other types of cables shall not be installed or exposed above ground, and shall be installed in cable trays,
conduit, or where flexibility is required in flexible conduit. Except exposed cable section due to cable gland
installation.

Q Does equipment grounding conductors shall be permitted to be installed exposed?

Ans Equipment grounding conductors shall be permitted to be installed exposed where they are protected from
physical damage.

Q What type of cables are used for underground installations?

Ans Type MC Cable and armored cable for Medium voltage power cables, rated 5 kV through 35 kV, shall be used
for underground installations.

Q What type of cables are used for cable tray and conduit systems installations?

Ans Un‐armored type cables shall be used for cable tray (TC type) and conduit systems installations.

Q If the cable run has transition from direct burial to cable tray, then what type of cable shall be used?

Ans If the cable run has transition from direct burial to cable tray, then the cable shall be armored for the entire
length or to the nearest point where it become practical to change to unarmored cable.

Q Which standard shall be followed for the grounding of shields, sheaths, armor and other materials in cable?

Ans The grounding of shields, sheaths, armor and other materials in cable systems shall be in accordance with
SAES‐P‐111.

*Circulating currents and induced voltage effects within shields and/or sheaths of single core cables rated
above 1000 V shall be considered and minimized to a safe level.

*Design of cable, lay out, arrangements, and penetration to equipment shall minimize induced voltage and
circulating currents to safe limits.

Q Which standard shall be followed for fireproofing of the cables?

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Ans Fireproofing of cables shall be in accordance with SAES‐B‐006 (onshore facilities) or SAES‐B‐009 (offshore
facilities).

Connections and Terminations

Q What type of connectors shall be used for splicing and terminating stranded conductors?

Ans Compression (crimped) type connectors shall be used for splicing and terminating stranded conductors.

Q Could the solder lugs be used for splicing and terminating stranded conductors?

Ans The use of solder lugs is prohibited.

Q What type of compression terminal connectors (lugs) design shall be used for 4/0 AWG (120mm2) and larger
conductors?

Ans Compression terminal connectors for 4/0 AWG (120 mm2) and larger conductors shall be two hole design.

*All compression connectors for 8 AWG and larger conductors shall have a manufacturer's reference
compression die number and conductor size printed or stamped on the connector.

*The use of die‐less compression tools is acceptable, provided that the tool is suitable for the connector, and
(for 8 AWG and larger conductor connectors), the tool ram embosses the tool manufacturer's logo on the
crimp.

*Single hole compression terminal connectors for 4/0 and larger conductors are permitted for terminations
on manufactured equipment that has integral provisions for single hole lugs only.

*Compression in compression connectors is accomplished by means of a compression or crimping tool.

*Connectors in which compression is accomplished by means of bolts, set screws, etc., are mechanical, not
compression connectors.

Q What type of material shall be for compression connectors?

Ans All compression connectors shall be tinned copper.

*Separable load‐break or dead‐break connectors having non‐copper current carrying components, are
permitted, provided they are marked and approved as suitable for copper conductors.

*New suppliers of compression connectors for conductors 4/0 AWG and larger must submit type tests
performed by a third party testing agency.

Q What type of connectors are used for lighting, receptacle circuits in non‐hazardous area and non‐industrial
applications?

Ans Spring pressure type twist‐on connectors, and pressure set screw connectors with insulating caps are
permitted for lighting and receptacle circuits in non‐hazardous locations, and in non‐industrial applications.

Q Is the use of connectors or terminals other than compression type permitted?

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Ans Use of connectors or terminals other than compression type, except solder connectors, supplied as integral
parts or components of manufactured equipment such as molded case circuit breakers, contactors, outlets,
etc., is permitted.

Q Is the use of mechanical connectors or terminals permitted?

Ans Use of mechanical connectors or terminals supplied as integral parts of splice and termination kits (including
connectors or terminals with breakout bolt heads) for 69 kV cables are permitted.

Q What type of connectors are used for control wiring?

Ans Insulated ring tongue, locking fork tongue, flanged fork tongue and pin type compression terminals shall be
used for control wiring.

Q What type of connectors are used for current transformer circuits?

Ans Only ring tongue compression (crimped) terminals shall be used for current transformer circuits.

Cable terminators relying on inwardly protruding flat springs or tines for grounding the metallic sheath or
armor are prohibited.

Q What type of threads shall be for threaded cable fittings including terminators?

Ans All threaded cable fittings including terminators (glands) for metric size cables shall have tapered (NPT)
threads in accordance with ANSI/ASME B1.20.1

Q What type of design shall be for cable glands?

Ans Cable glands shall be designed to permit disconnection without the need to rotate the cable or the
equipment on which the gland is terminating (e.g., sealing glands shall have a built‐in union).

Q What is the cable identification method for electrical cables?

Ans Identification of cables shall include the cable number and destination.

Q What is the wire identification method for individual control wires?

Ans Individual control wires shall be identified by two labels at each end. The first label (closest to the end of the
wire) shall identify the number of the terminal to which the wire is connected. The other label shall identify
the terminal of the opposite end of the wire.

Q How the individual phases of power circuits shall be identified?

Ans Individual phases of power circuits shall be identified by color coding to be synchronized as per SASO color‐
coding conductors, or by other means (e.g., marked A, B and C).

Neutral (grounded) conductors shall be identified by colors white or grey, and insulated grounding
conductors by colors green or green with yellow stripes.

Q What are marking methods for wires at terminations points?

Ans Wires at termination points shall be identified by the use of:

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(a) Permanently imprinted or embossed wire markers (of the heat‐shrinkable or slip‐on type).
(b) Cables may be identified by special plastic or non‐corrosive metal labels held with cable ties, or similar
methods.
(c) Colored insulating tapes may be used for phase identification (R‐Y‐B) of power circuit conductors.

*Wrap‐around, rigid Snap‐on, or adhesive type markers are not permitted for wire or cable identification.

Q How to identify the individual phases of power cable circuit?

Ans Individual phases of power circuit shall be identified by the color coding cable (Red, Yellow and Blue).

Q How the voltage stress relief shall be provided at terminations of cables?

Ans Voltage stress relief shall be provided at terminations of cables with insulation shields.

Q What is creepage distance?

Ans The clearance between phase to phase and phase to the ground at the terminated ends is called creepage
distance.

Q How much creepage distance shall be for 13.8 KV outdoor terminations?

Ans For 13.8 kV outdoor terminations, each phase shall have a creepage distance of 552 mm to ground.

Q What is the creepage distance for medium and high voltage terminations installed outdoor?

Ans Medium and high voltage terminations (operating at 2.4 kV and above) installed outdoors shall have a
minimum creepage distance to ground of 40 mm per kV line‐to‐line nominal system voltage.

Q What is the creepage distance for medium and high voltage terminations installed indoor?

Ans Medium and high voltage terminations installed indoors shall have a minimum creepage distance to ground
of 25 mm per kV line‐to‐line nominal system voltage.

Q What is the minimum creepage distance for MV/HV terminations?

Ans For outdoors installed is 40 mm per KVL‐L and indoors installed is 25 mm per KVL‐L.

*Medium and high voltage terminations installed inside enclosures located outdoor shall be considered
indoor terminations if the enclosures are rated NEMA Type 3 or 4, or IEC 60529 Type IP54. And shall be
considered outdoor terminations if the enclosure a lesser degree of protection (e.g., NEMA Type 3R).

Q Might the AWG connectors be used for metric size conductors, and vice versa?

Ans AWG connectors may be used for metric size conductors, and vice versa, provided the connector range
spans the actual cross‐sectional area of the conductor.

Q Might the standard connectors suitable for non‐compact conductors of the same size be used for compact
stranded conductors?

Ans For compact stranded conductors, standard connectors suitable for non‐compact conductors of the same
size may be used. No down‐sizing of standard connectors for compact stranded conductors is allowed.

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*Before compression on a compact stranded conductor, a standard connector usually appears too loose, but
since the cross‐sectional area of copper is the same, the end result after compression is the same.

Q Cable glands should be in accordance with which code standard?

Ans Cable glands (for hazardous and non‐hazardous locations) shall be in accordance with BS 6121 or BS 50262.

Enclosures

Q For outdoor enclosure ho the conduit connection shall be installed?

Ans Outdoor enclosure conduit connection shall be installed with bottom or side entries.

Q Which type of equipment / terminal enclosure shall be used in outdoor plant areas and within the perimeter
of process units?

Ans In outdoor plant areas and within the perimeter of process units, enclosures shall be:

(a) NEMA Type 4

(b) NEMA Type 3
(c) IEC 60529, Type IP54 or better.

Q Which type of material of equipment / terminal enclosure shall be used in outdoor plant areas and within
the perimeter of process units?

Ans Stainless steel, Copper free Aluminium, Plastic including Fiberglass.

Q Which type of terminal/equipment enclosure shall be used in outdoor plant areas in severe corrosive
environment?

Ans In outdoor plant and other industrial areas located in severe corrosive environments, equipment and
terminal enclosures shall be:

(a) NEMA Type 4X

(b) NEMA Type 4 or 3
(c) IEC 60529, Type IP 54 or better

Q What type of enclosure material shall be used in severe corrosive environments?

Ans a) Except galvanized and/or painted or coated carbon steel, sheet metal enclosures are not permitted

b) Aluminium (Copper free 04‐1%)

c) Plastic (including Fiberglass)

d) Stainless steel

Q What type of enclosure shall be used for dry‐type transformers in outdoor locations?

Ans In outdoor locations, enclosures for small dry‐type transformers shall be totally enclosed NEMA Type 3R.

*In severe corrosion environments, enclosure material shall be suitable for the application.

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Q What type of enclosure requirements are for hazardous (classified) locations?

Ans EEX d II type, IP‐54.

In hazardous (classified) locations, enclosures that are required to be approved for Class I locations by NEC
Article 501 or 505.

Q What type of hardware shall be used for enclosures rated NEMA Type 3, 4 or 4X, or IEC 60529 Type IP54, or
better?

Ans Hardware shall be Type 300 Series stainless steel.

Q What type of hardware shall be used for aluminium enclosures?

Ans Aluminum enclosures may have aluminum or aluminum alloy hinges and operating handles.

Q What type of breathers and drain fitting shall be used in enclosures and junction boxes having an internal
volume exceeding 2,000 cm³?

For how much volume of enclosures and junction boxes, breathers and drain fitting shall be required?

Ans Enclosures and junction boxes having an internal volume exceeding 2,000 cm³ shall be provided with Type
300 Series stainless steel breather and drain fittings or a combination of breather and drain fitting.

Q What shall be the size of drain hole in enclosures and junction boxes having an internal volume exceeding
2,000 cm³?

Ans Enclosures and junction boxes shall have 5mm hole in the bottom.

Enclosures shall be provided with tamper‐resistance factory assembled breather/drainer (or provision for
future breather/drainer) system where required.

Conduit, Conduit Fittings and Supports

Underground conduit

Q What are the specifications of direct buried PVC conduit? What type of PVC conduits shall be used for direct
buried applications?

Ans Type DB‐120 per NEMA TC 6 & 8 or Type EPC‐40‐PVC per NEMA TC 2.

Q What type of conduits shall be used for class I division I areas?

Ans Direct buried conduit in class I division I shall be threaded, rigid steel, hot dip galvanized and PVC coated.

Q What are the specifications of concrete encased underground PVC conduits? What type of PVC conduits shall
be used for concrete encased PVC conduit applications?

Ans DB‐120 per NEMA TC 6 & 8 or Type EPC‐40‐PVC per NEMA TC 2 or Type EB‐35

Q What type of direct buried conduit for hazardous area/classified area?

Ans PVC coated RGS conduit

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*Internal diameters of NEMA TC 6 & 8 conduit are larger than NEMA TC 2 conduit internal diameters;
consequently, the maximum number of conductors permitted in NEMA TC 6 & 8 conduits may be slightly
larger.

Q What type of conduits shall be used aboveground/exposed installations in industrial facilities?

Ans RGS conduit as per ANSI C80.1

Conduit installed exposed, above ground in outdoor, industrial facilities shall be rigid steel per ANSI C80.1,
and in addition it shall be galvanized.

Q What type of conduits shall be used aboveground/exposed installations where flexibility is required in
industrial facilities?

What type of conduits shall be used aboveground/exposed installations where flexibility is required in Class
I, Division 2 and Zone 2?

Ans Liquid‐tight flexible metal conduit shall be used.

Q What type of conduits shall be used aboveground/exposed installations where flexibility is required in Class
I, Division 1 and Zone 1?

Ans explosion‐proof neoprene coated or PVC coated couplings shall be used.

Q What type of aboveground conduit in hazardous area/classified area/corrosive area environments?

Ans PVC Coated RGS

Conduit above ground in severe corrosive environments and hazardous area/classified area shall be rigid
steel per ANSI C80.1, and it shall be galvanized, in addition, it shall be factory PVC coated (1 mm/40 mils)
per NEMA RN 1.

Q How much thick coating shall be for PVC Coated RGS conduits?

Ans 1 mm/40 mils per NEMA RN 1.

Q Does EMT is acceptable?

For which locations usage of EMT is acceptable?

Does EMT is acceptable for indoor locations?

Ans EMT is acceptable only for non‐hazardous indoor location.

Q EMT shall be according to which standard code?

Ans EMT shall comply with the requirements of ANSI C80.3

*Intermediate metal conduit (IMC) is prohibited.

Q What shall be the minimum size of conduit for electrical systems?

Ans The minimum conduit size shall be 3/4 inch or equivalent in metric size.
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Q What shall be the minimum size of conduit for prefabricated skids, and in non‐industrial areas?

Ans The minimum size conduit shall be 1/2 inch

Conduit Fittings

Q What type of threading shall be for conduit and conduit fittings?

Ans Conduit and threaded conduit fittings shall have tapered (NPT) threads in accordance with ANSI/ASME
B1.20.1

Q What type of coating shall be done for field cut conduit threads?

Ans Threads shall be coated with a zinc rich protective coating.

Q What type of conduit fittings are used for outdoor rigid steel conduit and liquid‐tight flexible metal conduit?

Ans Conduit fittings for outdoor rigid steel conduit and liquid‐tight flexible metal conduit shall be

a) Cast or forged steel either hot‐dip galvanized, or zinc electroplated

b) Cast iron or malleable iron either hot‐dip galvanized, or zinc electroplated

Q Shall the aluminium fittings be allowed for RGS, LTFM conduits for outdoors?

Ans No aluminum fittings and fitting covers shall be used outdoors.

Q Shall the gray cast iron split type (EYSR) retrofit sealing fittings be allowed for RGS, LTFM conduits for
outdoors?

Ans If required for repair purposes, gray cast iron split type (EYSR) retrofit sealing fittings may be used.

Q Shall the rigid steel conduit hubs and liquid‐tight flexible metal conduit hubs, manufactured from zinc be
acceptable?

Ans Rigid steel conduit hubs and liquid‐tight flexible metal conduit hubs, manufactured from zinc, that are UL or
CSA listed are also acceptable.

Conduit fittings for Underground and Severe corrosive environments

Q What type of conduit fittings are used for underground and severe corrosive environments rigid steel
conduit and liquid‐tight flexible metal conduit?

Ans Conduit fittings for rigid steel conduit and liquid‐tight flexible metal conduit used for underground and in
severe corrosive environments shall be

a) Cast or forged steel either hot‐dip galvanized, or zinc electroplated shall be factory‐coating with PVC or
field coating prior to installation.
b) Cast iron or malleable iron either hot‐dip galvanized, or zinc electroplated shall be factory‐coating with
PVC or field coating prior to installation.

Factory‐coating with PVC shall be per NEMA RN 1.

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Minimum thickness of PVC: 40 mils/1mm

*Internal surfaces of PVC sleeves and other mating PVC surfaces shall be coated with PVC patching
compound (1000421977).

*Uncoated plugs and other bare metal shall be coated with PVC patching compound.

Q Shall field‐coating be allowed for conduit fittings used for underground and severe corrosive
environments?

Ans Field‐coating prior to installation is allowed and shall be in accordance with SAES‐H‐001 APCS‐22
(offshore), or APCS‐26 (onshore).

Q Shall protection by heat‐shrinkable tubes or wrap‐arounds be allowed for conduit fittings used for
underground and severe corrosive environments?

Ans Protection by heat‐shrinkable tubes or wrap‐arounds is allowed, where the geometric configuration
permits it.

Q Shall red leaded brass or silicon bronze conduit fittings be used in severe corrosive environments, for rigid
steel conduit and liquid‐tight flexible metal conduit?

Ans Red leaded brass or silicon bronze conduit fittings may be used in severe corrosive environments.

*Conduit fittings for direct buried PVC coated rigid steel conduit shall be factory PVC coated.

*Threads of plugs, junction boxes and other fittings shall be lightly lubricated with a rust preventive
grease before assembly.

*The use of conduit unions with underground conduit should be avoided whenever possible. If this is
not possible, conduit unions must be protected with heat‐shrinkable sleeves or wrap‐arounds.

PVC conduit fittings

Q Fittings for NEMA TC 6 & 8 Type PVC conduit shall be in accordance with which standard?

Ans Shall be in accordance with NEMA TC 9.

Q Fittings for NEMA TC 2 Type PVC conduit shall be in accordance with which standard?

Ans Shall be in accordance with NEMA TC 3.

Supports (channel erector system components)

Q What type of channel erector system components are used to support conduits, cables, cable trays,
enclosures, lighting fixtures and other electrical equipment?

Ans Channel erector system components used for support shall be made of steel or iron, either hot‐dip
galvanized, or zinc electroplated.

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Q What type of channel erector system components are used to support conduits, cables, cable trays,
enclosures, lighting fixtures and other electrical equipment used in severe corrosive environment?

Ans All supports shall be made of

(A) Steel or iron, either hot‐dip galvanized (preferably), or zinc electro plated and in addition, shall be
factory‐coating with PVC or field coating prior to installation.
(B) Stainless steel
(C) Fiberglass

Q What type of associated hardware shall be for conduits, cables, cable trays, enclosures, lighting fixtures and
other electrical equipment used in severe corrosive environment?

Ans Associated hardware (bolts and nuts) shall have Type 300 Series stainless steel.

*Process piping shall not be used to support conduits, except with the Proponent's approval. If process
piping is used to support conduits, adequate corrosion protection at the interface between the piping and
support fittings shall be provided.

*Conduit fill shall not exceed the maximum fill specified in NEC Chapter 9.

Q What is the maximum distance between supports for RGS conduit system?

Ans Horizontal: 3 mtrs. (10 ft)

Vertical: 6 mtrs. (20 ft)

Cable Trays

Q What kind of material is used for the cable trays?

Ans Cable trays materials shall be

a) Aluminum (copper free, 0.4%)
b) Fiberglass
c) Galvanized carbon steel (Indoor air conditioned area)
d) Stainless steel (Fireproofing requirements)

Q What type of cable trays shall be used in electrical systems?

Ans Cable trays shall be of the ladder type.

Q What type of covers shall be for cable trays installed outdoors?

Ans Cable tray installed outdoors shall have ventilated covers. Only flanged type covers shall be used.

Q What type of banding and fasteners shall be used for securing and fixing the covers?

Ans Cable tray covers shall be secured with stainless steel banding and fasteners, one band per ½ m of cover
length, with a minimum of 6 bands per cover.

Q How the covers shall be installed for cable trays run vertically in outdoors?

Ans Cable trays run vertically in outdoor areas shall have covers on both sides.
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*Cable tray system shall be used to support cables or raceways only.

Q What type of banding and fasteners shall be used for securing and fixing the covers in severe corrosive area
and other areas?

Ans The banding and fasteners shall be of grade SS‐316 in sever corrosive areas and 304 in other areas

*Cable trays containing only instrument and communications cables may have unventilated covers.

Q What type of covers are required for cable trays installed inside switchgear buildings?

Ans Cable tray covers are not required if cable trays are installed inside switchgear buildings.

Q What type of cable trays shall be used when required by SAES‐B‐006, for fireproofing requirements?

Ans Stainless steel cable trays shall be used when required by SAES‐B‐006, to satisfy fireproofing requirements.

*Cable tray covers provide additional protection for cables from deterioration caused by sunlight, and
provide protection from mechanical damage.

*If cable tray covers are not installed, cable trays should be located to minimize the potential for mechanical
damage and to minimize the effects of sunlight on the cables.

Q What shall be the impact on the ampacity of cables if installed in uncovered cable trays exposed to sunlight?

Ans The ampacity of cables installed in uncovered cable trays exposed to sunlight is reduced.

Q Aluminum and galvanized carbon steel cable trays are designed, manufactured, rated and tested in
accordance with?

Ans Aluminum and galvanized carbon steel cable tray shall be designed, manufactured, rated, tested and
installed in accordance with NEMA VE 1 and NEMA VE 2.

Q Which method shall be used for determining the rated load capacity of cable trays?

Ans Method A (Loading to Destruction) shall be used for determining the rated load capacity.

Q What is the minimum individual rung load capacity of cable trays?

Ans Minimum individual rung load capacity shall be 90 kg.

Q What is the minimum thickness of covers of cable trays?

Ans Minimum thickness of covers shall be 1 mm.

Q Which standard shall be followed for installation of cable trays?

Ans NEMA VE 2, NEC (Article 392)

Q What is purpose of providing the cover of cable tray?

Ans Cover provide for protection from sun light and mechanical damage.

Q According to which standard fiberglass cable trays are designed, manufactured, rated and tested?
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Ans Fiberglass cable tray shall be designed, manufactured, rated, and tested in accordance with NEMA FG 1.

*Fiberglass cable trays shall be sunlight (ultraviolet radiation) resistant.

Q How the working load for cable trays shall be calculated?

Ans The working load for cable trays shall consist of the weight of the cables (or tubing, etc.) including future
additions (if required), plus a concentrated static load of 90 kg at the center of the span.

If the cables plus future additions do not fill the selected cable tray to its NEC capacity, the weight of
additional cables of the largest size contained in the tray, filling the cable tray to its NEC capacity shall be
added for calculating the working load.

The concentrated static load may be converted to an equivalent uniform load using the formula in NEMA VE
1 or NEMA FG 1.

The working load shall not exceed the rated load capacity of the cable tray defined in NEMA VE 1 or NEMA
FG 1 (destruction load divided by a safety factor of 1.5)

Q How the splice plates shall be installed?

Ans Splice plates (joints) shall not be located over supports, and shall be located between supports and quarter
points.

*No more than one splice shall be located between two adjacent supports.

Q On what temperature, maximum spacing between expansion joints shall be based for cable trays?

Ans The maximum spacing between expansion joints shall be based on a temperature differential of 55°C (100°F)

Q On what temperature, expansion gap settings shall be based for cable tray systems?

Ans Expansion gap settings shall be based on a minimum temperature of 0°C and a maximum temperature of
55°C.

*Cable trays shall be installed as a complete system. Cable tray systems shall not have mechanically
discontinuous segments of cable tray runs.

Q How the cables shall be extended from cable trays to equipment?

Ans Cables may be extended from cable trays to equipment

(a) If they are armored or metal clad and are properly supported in accordance with NEC requirements

(b) They are installed in rigid or flexible conduits.

Q If the cable run has transition from direct burial to cable tray, then what type of cable shall be used?

Ans If the cable run has transition from direct burial to cable tray, then the cable shall be armored for the entire
length or to the nearest point where it become practical to change to unarmored cable.

Q What type of cables are used for cable tray systems installations?

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Ans Un‐armored type cables shall be used for cable tray (TC type) systems installations.

*Process piping shall not be used to support cable trays.

Q How much shall be of cable tray system, when loaded to the working load?

Ans Deflection of the cable tray system, when loaded to the working load, excluding the concentrated static load,
shall not exceed L/100 where L=span length, for example maximum permissible deflection for a 6 m span is
60 mm.

Q How much spacing require on expansion joint/splice plate for aluminum cable tray?

Ans Spacing between expansions joint that allowed a 25 mm (1 inch) movement in every 20 meters

Q How to install the cable ties to secure cable in the cable tray?

Ans At the gape of every 12 – 18 inch.

Q What is the minimum individual rung load capacity of Aluminum and Galvanized Carbon Steel Cable tray?

Ans Its 90 kg.

Q What is the minimum thickness of a cable tray?

Ans 1 mm

Q What is the minimum elevation of a cable tray above the main substation floor from the bottom of the
lowest interior?

Ans 2.67 Meter

Q What is the minimum distance between a cable tray and ceiling/roof?

Ans A minimum of 460mm shall be maintained between the top of any cable tray and the ceiling or roof.

Q What is the minimum clear space distance above the cable tray/between two cable trays?

Ans 300 mm

Q How much the vertical clearance is required between cable trays?

Ans A minimum of 200 mm of vertical clearance shall be provided between cable trays.

Q What should be the minimum distance/gape/intervals of supports for a cable tray?

Ans 600 mm

Q At what minimum distance from supports, expansion splice plate shall be installed in cable tray?

Ans 600 mm

Q At what minimum distance from supports, splice plates shall be installed in cable tray?

Ans 900 mm, Supports should be located within 900 mm (3 ft) of each side of the splice plates.

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Q How to install supports on expansion splice plates?

Ans Supports should be located within 600 mm (2 ft) of each side of the expansion splice plates

Q How to install splice plates?

Ans Splice plates (joints) shall not be located over supports and shall be between supports and quarter points.
Splice plates should be placed on the outside of the cable tray with the bolt heads on the inside of the cable
tray. No more than one splice shall be located between two adjacent supports.

Splice joints should be between the support and the quarter point, a support spacing of 3.7 m (12 ft) causes
the splice joints to fall at the same position every time.

Q How to install supports on vertical cable tray?

Ans The cable tray should be supported on both the left and right side rails to the wall or support structure with
hole‐down clamps. Cable trays of less than 12 feet (ft) in length should be supported in a minimum of one
location; and trays over 12 ft in length should be supported at a minimum of two locations.

Q What are the Hole‐Down and Guide Clamp Locations on cable tray?

Ans One hole‐down clamp is installed at midpoint between two expansion splice plates (one in every 20 meters)
and remaining guide clamps.

The cable tray shall be anchored at (the support nearest to its) midpoint between the expansion splice plates
and secured by expansion guides at all other support locations.

Q What is the temperature for the cable tray installation?

Ans The spacing between expansion joints is based on a temperature differential of 55°C (100°F), expansion gap
settings shall be based on a minimum temperature of 0°C and a maximum temperature of 55°C.

Q What type of material is used for cable tray fasteners?

Ans All fasteners for cable trays (i.e., nuts, bolts, washers, etc.) used to connect and assemble the cable tray
system shall be 304 SS. In severe corrosive environments, 316 SS fasteners shall be used.

Q How the cables comes out from the cable tray to the equipments/enclosures?

Ans The drop‐outs and drop‐out bushings are provided for a smooth surface to protect the cable as it exits the
cable tray.

Q What is the single length of a cable tray?

Ans Its 3 meters (3.66m‐12 ft) / 6 meters (7.32m‐24ft)

Q What is the width of a cable tray?

Ans Its 6”, 9”, 12”, 18”, 24”, 30”, 36”

Q At what length of cable tray, an expansion joint is required?

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Ans For an aluminium cable tray every 20 m (65 feet) an expansion joint is required and for stainless steel cable
tray at every 40m (128 feet).

Underground Cable Systems

Q What are the minimum depth of burial requirements for underground installations?

Table 2 – Minimum Cover Requirements (Depth of Burial)

Millimeters from Grade Level to the Top Surface of Cable, Conduit or Duct Bank
System Voltage Direct Buried Direct Buried Duct Bank and Direct
Cables PVC Buried Rigid Steel

600 V and below 610 460 460

Over 600 V to 35 kV 920 610 460

Over 35 kV 1070 760 460

Q What shall be the minimum burial depth for grounding grid conductors under roads, parking lots and other
areas subject to vehicular traffic?

Ans Minimum burial shall be not less than 610 mm.

Q How the cables that cross under paved roads, concrete slabs, railroads, or other areas that would require
extensive or impractical excavations to replace shall be installed?

Ans Cables shall be run in duct banks or in conduits.

Q Where the duct banks are used?

Ans At cross under paved road, railroads, parking lots, areas with frequent traffic and when depth is
restricted/minimized due to some reasons.

Q Are duct banks or sleeves require for asphalt‐paved parking lots and plant areas paved with asphalt for soil
stabilization?

Ans No duct banks or sleeves are required in these cases.

Q What is the underground conduit installation depth requirements in rocky areas, in areas where cables being
below the water table, or to avoid underground obstructions such as other cables, conduits or piping?

Ans In rocky areas where digging must be minimized, in areas where depths would result in cables being below
the water table, or to avoid underground obstructions such as other cables, conduits or piping, cables may
be installed in one of the following configurations:

(a) total cover not less than 300 mm

PVC coated rigid steel conduit with a total cover not less than 300 mm, which shall include a 50 mm
thick reinforced concrete slab over the conduit.
(b) total cover not less than 150 mm

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PVC coated rigid steel conduit with a total cover not less than 150 mm, which shall include a 100 mm
thick reinforced concrete slab over the conduit.
(c) total cover not less than 150 mm
A reinforced concrete encased duct bank with 150 mm of total cover, measured from the top of the
upper conduit, which shall include a minimum of 100 mm of concrete over the upper conduit.

Q What color shall be of the top layer of concrete slab or the duct bank and what shall be the minimum
thickness of that layer?

Ans The top layer of the concrete slab or the duct bank shall be mixed with red dye. Minimum thickness of red
concrete layer should be 5 mm.

Q What is the minimum thickness of red concrete tiles and red plastic tiles?

Ans Minimum thickness of red concrete tiles shall be 50mm and 12 mm for red plastic tiles. Tiles dimensions are
200x400 mm.

Q What shall be placed 300 mm (sand cover) above direct buried cable or direct buried conduit?

Ans Red concrete tiles, Red plastic tiles, or PVC coated steel fence fabric. In addition, a yellow warning tape shall
be installed over the tiles or fence fabric.

Q What is the depth, width of trench? And what is the minimum sand bedding height? And what is the
minimum height of sweet sand before the yellow warning tape?

Ans For direct buried cable trench the minimum depth is 610 mm from the top surface of the cable and
minimum 150 mm sand bedding below the cable and minimum 300 mm sand over the cable and then put
red tiles and yellow warning tape and then backfill it.

Duct Banks

Q Duct banks shall consist of what? What the duct banks shall consist of?

Ans Duct banks shall consist of PVC conduit encased in concrete.

Q In duct banks with steel conduit, what type of concrete shall be used?

Ans In duct banks with steel conduit, unreinforced non‐structural concrete shall be used. (With minimum 28 day
design compressive strength of 14 Mpa / 2000 psi)

Q What type of duct banks shall be constructed under areas with no traffic, or occasional traffic including roads
with occasional traffic?

Ans In duct banks with PVC conduit, under areas with no traffic, or occasional traffic including roads with
occasional traffic, unreinforced non‐structural concrete shall be used.

Q What type of duct banks shall be constructed under areas with frequent traffic, such as roads and parking
lots inside plants or communities?

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Ans In duct banks with PVC conduit, under areas with frequent traffic, such as roads and parking lots inside
plants or communities, reinforced concrete shall be used (with minimum 28 day design compressive
strength of 28 Mpa / 4000 psi).

Q How the cables that cross under paved roads, concrete slabs, railroads, or other areas that would require
extensive or impractical excavations to replace shall be installed?

Ans Cables shall be run in duct banks or in conduits.

Q Are duct banks or sleeves required for asphalt‐paved parking lots and plant areas paved with asphalt for soil
stabilization?

Ans No duct banks or sleeves are required in these cases.

Q What shall be the minimum burial depth of duct bank?

Ans The minimum burial depth from the grade level to the top surface of duct bank is 460 mm.

Q What shall be a minimum layer of concrete from the outside surface of the duct bank?

Ans There shall be a minimum of 75 mm of concrete from the outside surface of the duct bank to any conduit or
reinforcing steel.

Q At what intervals spacers shall be required for duct banks?

Ans Fabricated spacers shall be used at intervals not exceeding 2.4 meters.

Q What separation spacers shall provide for conduits in duct banks?

Ans The spacers shall provide a minimum conduit separation of 50 mm for 2 inch conduits and larger, and 25 mm
for 1½ inch conduits and smaller.

Q What separation spacers shall provide for conduits in duct banks?

Ans Conduit runs within the duct bank shall be made continuous, by the use of threaded steel couplings for rigid
steel conduit, and PVC solvent cement with PVC couplings or belled ends for PVC conduit.

*Bell end fittings or protective bushings shall be provided on each duct where it terminates.

Q What color shall be of the top layer of concrete slab or the duct bank and what shall be the minimum
thickness of that layer?

Ans The top layer of the concrete slab or the duct bank shall be mixed with red dye. Minimum thickness of red
concrete layer should be 5 mm.

*The top layer (5 mm minimum thickness) of the concrete shall be mixed with red dye.

Q How much spare ducts shall have duct banks?

Ans Duct banks shall have 20% spare ducts (minimum of one).

This number may be decreased by the facility Proponent.

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Q How the PVC conduits shall be extended above grade in industrial facilities?

Ans Using threaded PVC to rigid steel conduit adapters.

Where above grade extensions of buried PVC conduits are required, a transition shall be made underground,
using threaded PVC to rigid steel conduit adapters.

Q How much height of PVC stub‐ups extending above ground is allowed in industrial facilities?

Ans PVC stub‐ups extending up to a maximum of 150 mm above ground and not attached to equipment are
permitted.

Q Is PVC conduit is allowed to install above ground for grounding conductor in industrial facilities?

Ans Yes, equipment grounding conductors running separately from power conductors may be installed above
ground in PVC conduit.

*Both ends of the rigid steel conduit shall be bonded to the ground conductor.

Q How the metallic conduit entering shall be from below grade to switchgear, control cabinets and similar
enclosures sitting on the ground?

Ans Metallic conduit entering (from below grade) switchgear, control cabinets and similar enclosures sitting on
the ground shall be cut and threaded 50 mm above finished grade level, and a threaded insulated grounding
bushing shall be installed.

Q How the PVC conduit entering shall be from below grade to switchgear, control cabinets and similar
enclosures sitting on the ground?

Ans PVC conduit entering switchgear, control cabinets and similar enclosures shall be cut flush with finished
grade level, and shall have its inner edge filed to a smooth radius.

Q How the location of underground cable, conduit or duct bank shall be marked?

Ans Standard Drawings AB‐036273 or AB‐036326

*No underground cable markers are necessary inside switchyards and under elevated substations.

Q Manholes containing cables rated 5 kV and above shall be in accordance with which standard drawing?

Ans AA‐036025

*Manholes and hand holes shall not be located in hazardous (classified) locations, or where prohibited by
SAES‐B‐008.

*Where permitted inside hydrocarbon‐handling plants, all ducts inside all manholes and hand holes shall be
sealed with duct sealing.

Q How much minimum crossing or parallel clearance shall be the between direct buried cables or conduits and
underground piping, including hydrocarbon pipelines?

Ans 300 mm

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*For conduits, the crossing clearance may be reduced to 80 mm, if underground obstructions make it
difficult to meet the 300 mm requirement.

*For direct buried cables, the crossing clearance may be reduced to 80 mm, if the cable is installed in a PVC
sleeve at the crossing.

*Direct buried cables, conduits, or duct banks shall not be installed directly above or below parallel
underground piping.

*Direct buried cables and conduits shall be installed in a single layer, except where rearrangement is
necessary at transitions to multi‐layer concrete encased duct banks or for entering buildings.

*Installation of cables in outdoor concrete‐walled trenches with metal or concrete slab covers is not
permitted.

*The ends of ducts and conduit terminating below grade or in open air shall be sealed with duct sealing
putty or an equivalent compound.

Submarine Power Cable

Cable Burial

Q What factors shall be under consideration when route assessment of submarine cable is performed?

Ans Route assessment of submarine cable shall be performed taking in consideration issues like water depths
and area topology, tidal currents or surf action, marine habitats, and other requirements associated with the
environmental impact assessment (EIA).

Q For water depth less than 7.5 m, how much submarine cable shall be buried?

Ans For water depth less than 7.5 m measured at the Lowest Astronomical Tide (LAT), submarine cable shall be
buried a minimum of 1 m.

Q In areas within 100 m of a platform structure, how submarine cable shall be buried and protected?

Ans In areas within 100 m of a platform structure, submarine cable shall be

a) Buried a minimum of 1 m
b) Protected with grout‐filled bags and by a split tubing protection system

Q What shall be the axial spacing between separate circuits of the land section?

Ans The axial spacing between separate circuits of the land section shall be minimum of 4.5 m.

Q What shall be the axial spacing between cables in the submarine section?

Ans The axial spacing between cables in the submarine section, shall be equal to the mean water depth,
excluding that portion of the cable within 200 m of the platform.

Platform Transition

Q How the platform transition of submarine cable shall be and how it shall be protected?

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Ans Submarine cable shall be physically protected from the bottom of the jacket leg to the point of cable armor
termination, by a trough, tube or direct mounting to the jacket leg.

Cables shall not hang unprotected.

*Cable shall be attached to a jacket leg by means of hot‐dip galvanized chains.

*Galvanized carbon steel armor clamp designed to withstand the maximum tension exerted on the cable
due to dragging.

*Design of the armor clamp shall include safety factor of 3.

*The galvanized CS armor below the J‐Tube entrance to the flange shall be protected by applying PVC
coating on each strand or protected with corrosion protection material at the area inside the J‐TUBE.

*The cable armor shall be terminated in an armor clamp located in a vertical riser section below the cable
disconnecting device. The clamp shall provide positive anchoring and grounding of the armor wires, in
addition to terminating and grounding the inner flat armor tapes.

Cable Sizing

Q What are the factors used for the sizing of the power cables?

Ans The sizing of power cables shall be based on the following:

a) Load Factor – 100%
b) Ambient Temperatures
c) Earth Thermal Resistivity (RHO)

Ambient Temperatures

Outdoor Exposed To Sun (for exposed cables, cables in conduit, and cables in uncovered cable trays): 56°C

Outdoor Shaded (for exposed cables, cables in conduit, cables in covered trays in the sun, and cables in cable
trays in the shade): 50°C

Indoor Non‐Air‐conditioned: 50°C

Indoor air‐conditioned: 35°C

Soil Temperature: 40°C

Sea Water Temperature: 30°C

The summer design dry bulb temperature at 1% per SAES‐A‐112 for the specific location may be used as the
outdoor shaded location ambient temperature (or increased by 10°C, if exposed‐to‐sun ambient
temperature).

Shielded Cables:

Shields Bonded and Multi‐point Grounded (at both ends and possibly additional points).

Submarine Cables

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Maximum Conductor Operating Temperature: 90°C

Maximum Conductor Emergency Temperature: 110°C

Maximum Conductor Short Circuit Temperature: 200°C

Maximum Shield Short Circuit Temperature: 150°C

Ampacity Sources and Calculations

Ampacity calculations and cable sizing shall be based on the NEC, or from the tables in IEEE 835, IEC 60364,
and IEC 60502‐2.

To obtain ampacities at 120°C‐cm/watt, when not listed in the tables, ampacities at 90°C‐cm/watt should be
divided by the following factors:

Direct buried single core 1.12

Direct buried multicore 1.11

Duct bank cable, single core 1.08

Duct bank cable, multicore 1.05

*The Cable Derating Program of the Electrical Transient Analyzer Program (ETAP) or other power simulation
software are permitted to be used to calculate ampacities, as an alternative to the NEC, IEC or IEEE 835
tables.

*A derating factor of 0.85 shall be applied to cables that are fireproofed by coating or wrapping with a
compound or other material, unless the fireproofing compound or material manufacturer recommends a
different derating factor value.

*The sizing of cables rated 69 kV and above shall be per IEC 60287

*The specialty cables are, down‐hole pump motor cables, high temperature motor leads.

*For cable sizing adjustment for fault conditions, the fault location shall be assumed to be at the load end of
the cable. For low voltage cables, fault duration time shall be a minimum of 110% of the clearing time of the
protective device providing primary protection to the cable (maximum total clearing time in the case of
fuses). For medium voltage cables, fault duration time shall be a minimum of 110% of the clearing time of
the protective device providing backup protection to the cable.

MV‐105 cable (e.g., EPR insulated cable rated 105°C) shall be sized as a 90°C rated cable (using 90°C
ampacities and derating factors).

*For the basis of sizing a feeder which supplies distribution equipment, the maximum operating load shall be
equal to the lower of:

1) The continuous current rating of the distribution equipment main bus or

2) The site rating of the upstream transformer.

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Q What is the distribution equipment?

Ans Distribution equipment would generally be equipment that will distribute power to multiple devices.
Examples are switchgear, panel‐boards, control‐gear, switchboards, switchrack, etc.

Cable Testing after Installation

Q Why we do megger test/IR test? For what purpose we do megger test/IR test?

Ans To check the insulation resistance of the cables.

Q Why we do hypo‐test? For what purpose we do hypo‐test?

Ans To check the insulation condition (di‐electric strength of insulation) of the cables.

Q What is Hi‐Pot Test?

Ans The Hi‐Pot test involves the measurement of leakage current when a high potential (above nominal) is
applied to the cable to determine the condition of the cable, specifically the insulation.

Q What is the procedure for DC Hi‐Pot Testing of medium voltage cables?

Ans STEP‐BY‐STEP PROCEDURE FOR HI‐POT TESTING

• Ground all conductors, except the one to be tested.

• Ground any adjacent equipment.

• Ensure adequate clearance of the conductor/terminals to be tested from ground to prevent flash over.

• Do the IR/ Megger test of the cable to be tested. Any cable that exhibits low ‘Megger’ readings is
questionable and should be cleared before the high voltage DC test is performed.

• Connect output of test set to conductor/terminal to be tested and connect ground terminal of test set to
ground.

• Apply the test voltage slowly in a minimum of five equal increments until maximum test voltage is reached,
with no increment exceeding the voltage rating of the cable, and with each voltage step being held for an
equal interval of time long enough to allow the leakage current to reach stability, approximately 1 to 2
minutes.

• Raise the voltage to specified maximum test voltage and hold for 15 minutes on shielded cable and 5
minutes on non‐shielded cable. Record readings of leakage current at 15, 30, 45 seconds and at one minute
intervals thereafter.

• Reading of leakage current and voltage shall be recorded at the end of each minute prior to increasing to
the next specified voltage level. (A linear increase in leakage current is expected, and it should stabilize or
decrease from the initial value at each step)

• Plot test voltage versus leakage current on graph paper as the test progresses. Any excessive or non‐linear
increase in leakage current can indicate imminent cable failure. Discontinue the test and, consult the
manufacturer for recommendations.
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• Calculate the resistance of the cable at each step. Note: At any step where the calculated leakage
resistance decreases approximately 50% or more of that of the next lower voltage, discontinue the test to
prevent cable failure and to retain the cable in a serviceable condition until a replacement cable is available

• After recording all measurements, rapidly turn the test equipment to zero volts and monitor cable voltage.
Record the decaying voltage every 15 seconds for 90 seconds, and then every 60 seconds until the charge is
down to 1000 volts, then ground the cable.

• Calculate the polarization index for the cable. The polarization index is the ratio of leakage current after 1
minute to the leakage current after 5 minutes of the maximum test voltage. Polarization index for
satisfactory cable is between 1.25 and 2. NOTE: Polarization indices less than 1 are considered failures, and
indices between 1 and 1.25 are considered marginal.

• Where one or more cable have not passed DC high‐potential testing, isolate and locate the failed section of
the cable. Repair or replace the failed section in accordance with manufacturer recommendations.

• Test each conductor/cable in the circuit in the same manner.

Q Which equipment is used for hi‐pot test?

Ans High‐potential tester

Q How can we check the condition of the cable insulation in field?

Ans 1) The insulation resistance test megger test.

2) The DC high potential test for MV cables.

3) The very low frequency high potential test (VLF hi‐pot test) and Isothermal Return Current (IRC) [for old
cables installed more than 05 years ago)

Q For low voltage cable, how much megger/IR test voltage requires?

Ans Megger voltage shall be 1000 VDC for one minute.

Q What are the ratings of low voltage cables?

Ans Low voltage ratings are 600, 450/750, or 600/1000 V

Q When IR/Megger test shall be done?

Ans Cables shall be megger tested after installation and prior to placing in service (during commissioning).

Q For medium voltage cables how much IR/megger test voltage requires?

Ans For medium voltage cables (5KV to 35 KV), megger voltages shall be 5000 VDC.

Q What kind of cable testing shall be performed at medium voltage (5 kV to 35 kV) cables?

Ans 5 kV megger tested before and after backfilling and then DC‐ high‐ potential testing after installation and
prior to placing in service (during commissioning).

Q For how long time we applied the DC high potential test for 5kv and high rating direct buried cables?
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Ans 15 minutes on shielded cable and 5 minutes on non‐shielded cable

*High voltage cables (69 kV and above) shall be tested after installation (during commissioning). Soak
test is an acceptable alternative for cables rated at 69 kV and above.

Table 3 – DC and AC High‐Potential Field Test Voltages

Cable Voltage Rating (Insulation After Installation – before In Service –

Thickness) Cable is Placed in Regular First 5 Years
Service

5 kV (115 mils) or 6/10 kV (3.4 mm) 36 kV DC 11 kV

15 kV (220 mils) or 12/20 kV (5.5 mm) 64 kV DC 20 kV

35 kV (345 mils or 9 mm) 100 kV DC 31 kV

69 kV (650 mils or 16.5 mm) 72 kV AC ‐‐‐‐‐

115 kV 128 kV AC ‐‐‐‐‐

*It is recommended, wherever possible, to perform high potential tests on buried cables prior to backfilling,
to avoid excavation costs if the cables do not pass the tests.

Q How to check integrity of the direct buried cables?

Ans The integrity of the overall jacket of direct buried cables rated 5 kV and higher shall be tested by
conducting a 5 kV megger and high potential test between the cable insulation metallic shield (and
sheath or armor, if any) and ground.

Q How much DC hi‐pot value shall be and for how much time?

Ans The DC high potential value shall be 4 kV/1 mm for one minute and not to exceed 10 kV.

*IEC 60229 shall be used for HV cable jacket integrity testing.

*Medium voltage (5‐35 kV) direct buried cables shall be backfilled, and the backfill shall be soaked in
water.

*For 69 kV and above cables, the outer jacket of the cable shall be coated with manufacturer‐applied
graphite.

Q Which pre‐commissioning forms shall be used for IR/Megger Test and Hi‐Pot Test?

Ans Saudi Aramco Pre‐Commissioning Forms P‐004 and P‐005.

*Test voltages shall not exceed 80 percent of cable manufacturer's factory test value or the maximum test
voltage

Q What kind of test may be applied to determine the condition of old cables?
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Ans Very low frequency test (VLF) and Isothermal Return Current (IRC)

Q For what purpose we applied VLF test and IRC test?

Ans Very Low Frequency test (VLF) and Isothermal Return Current (IRC) shall be applied to determine the
condition (dielectric strength of insulation) of old cables.

Q For what purpose we use high potential test and megger test?

Ans To check to integrity and dielectric strength of insulation of the cable jacket.

Q How we check the integrity of the overall jacket of direct buried low voltage armored or metal clad cables?

Ans The integrity of the overall jacket of direct buried low voltage armored or metal clad cables shall be tested by
conducting IR/megger test.

Q What is the minimum Insulation resistance acceptance value of power and control insulated conductor?

Ans 50 MΩ

Q What is the minimum acceptable insulation resistance of cable test result from conductor to sheath that the
cable shall not be used?

Ans 20 MΩ

Cable Separation

Q How much minimum separation requirements shall be between power and/or control conductors for DC or
AC circuit voltages less than 1000 V?

Ans There are no minimum separation requirements between power and/or control conductors for DC or AC
circuit voltages less than 1000 V, provided the insulation is rated at least 600 V or 450/750 V.

*While it is technically acceptable to install power cables operating at less than 1000 V with no separation or
with little separation, this may require a significant increase in conductor size, because separation between
power cables affects their ampacity.

Q What shall be the minimum separation (above or below ground) required between a power cable operating
at 1000 V or above, up to 34.5 kV, and a parallel or crossing power or control cable operating at less than
1000 V?

Ans 300 mm separation is required

Minimum separation (above or below ground) between a power cable operating at 1000 V or above, up to
34.5 kV, and a parallel or crossing power or control cable operating at less than 1000 V, shall be 300 mm.

Exception:

Except when the medium voltage cable is armored or metal clad or is installed in rigid steel conduit, or is
installed in aluminum cable tray and is separated from the lower voltage cable by solid fixed metallic
barriers, or when the low voltage cable is installed in rigid steel conduit.

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*Minimum separation requirements between a power or control cable and any communication conductors
shall be in accordance with SAES‐T‐911 or SAES‐T‐928.

Q How much separation shall be required for redundant feeders, direct buried or in direct buried conduit,
supplying industrial loads or other loads that are critical?

Ans Shall be separated by a minimum distance of 1.8 meters.

Q How much separation (above or below ground) shall be required between any cable operating at above 34.5
kV, and cables operating at or below 34.5 kV?

How much separation (above or below ground) shall be required between the medium voltage cables?

Ans Shall be 1 m

Conduit and Cable Sealing

*Conduit sealing fittings shall not be used for power cables.

Q How the conduits shall be terminated when they cross hazardous location boundaries?

Ans Conduits that cross hazardous location boundaries shall terminate in the open air at both ends of the
conduit.

Q How the cables entering enclosures shall be sealed when they are required to be sealed?

Ans they shall be sealed by means of barrier type cable glands (EEx d), utilizing sealing compound, or be an
MI cable.

*Flameproof (EEx d) non‐barrier type cable glands, without sealing compound, are not acceptable.

Q How cable entry shall be into control buildings and similar buildings in hydrocarbon processing plants
below grade?

Ans Penetration of the wall of the building basement or underfloor space shall be via short horizontal
sections of PVC conduits (sleeves) that will be encased or grouted into the wall.

*The inside of the sleeves shall be sealed to provide fire retardancy on the building interior side.

Q How much away cables outside the building shall be direct buried?

Ans The cables outside the building shall be direct buried for a distance of at least 2 meters

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Overhead Distribution Systems

(SAES‐P‐107)
Q What are the environmental conditions on which overhead line design is based?
Ans Overhead line design shall be based on the following environmental conditions:
a) Minimum temperature: 0°C
b) Maximum temperature: 50°C
c) Wind speed (50 yr.): 160 km/h

Q What is the length of distribution line span?

Ans Distribution line spans should normally not exceed 90 m in length.

The changes in elevation between any two poles would not result in variations of more than 2 meters in the
vertical clearance of the lowest conductor.

Q What type of connectors are used for splicing and tapping of overhead line?

Ans Compression type connectors shall be used for splicing and tapping. Connectors for aluminum conductors
(ACSR‐aluminium clad steel reinforced) shall be filled with an oxide inhibiting and sealing compound such as
Burndy PENETROX.

Q What type of lugs are used for overhead line connections?

Ans Compression type lugs shall be used for overhead line connections.

*Compression lugs or splices used for connections of insulated or covered cables to overhead lines shall have
a closed barrel or solid center stop to prevent ingress of water into the insulated cable.

Non‐current carrying metallic enclosures, brackets, and braces shall be bonded together via grounding lugs
and shall be connected to a grounding electrode conductor. Pole ground conductors shall be minimum 4
AWG, stranded, bare copper.

Q What should be the vertical clearance above grade for desert installation of conductors?

Ans Vertical clearances above grade for desert installations of conductors, including service drops, messengers,
and guys shall be minimum 8.5 m at final unloaded sag, no wind, and 50°C ambient temperature.

*For designs using emergency service conditions, minimum vertical clearance shall be calculated using 120°C
total conductor temperature.

Q What type of Arial‐to‐ground transitions should be?

Ans Aerial‐to‐underground transitions shall be in rigid galvanized steel conduit or PVC coated galvanized rigid
steel conduit.

Supporting Structures

Q What type of material supporting structures for overhead lines shall be?
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Ans Supporting structures for overhead lines shall be hot dipped galvanized steel or seamless aluminum alloy
poles and fiberglass poles or wood poles.

Q What type of wood poles for supporting structures shall be?

Ans Wood poles used for supporting structures shall be Class 4 or better as defined in ANSI O5.1.

Q Where wood poles shall be used?

Ans Wood poles shall be permitted for use in stand‐alone Water Injection Plants, Water Treatment Plants, and
for supply lines located outside of industrial and plant areas (for example, Cathodic Protection supply lines in
desert areas).

*Supporting structure, guy, messenger, and anchor locations shall be selected based on accessibility, limited
use of guys, minimal obstructions to pedestrian and vehicular traffic, and shall be as inconspicuous as
possible.

*Messenger wire used on the transmission line to support FOC wire

*Guy wire is used to support the pole with ground

Q How shall be protected supporting structures located less than 9m from a roadway, in transmission line?

Ans Supporting structures located less than 9 m from a roadway shall be protected by barriers meeting the
requirements of the Highway Design Manual.

Q What is the clearance between supporting structures and curbs?

Ans Supporting structure clearance from curbs shall be maintained at a minimum of 0.6 m from face of curb.

Q What is the height of dating nail above grade for wood supporting structures?

Ans Wood supporting structures shall have a dating nail indicating the year of installation located at
approximately 2 m above grade.

Armless Construction

*Armless type construction shall be used for the conductor support system.

Q What is the value limit for horizontal loading for line post insulators?

Ans Horizontal loading for line post insulators shall not exceed 2.2 KN for initial sag at the minimum
temperature, and wind loading of 430 pa.

*Line conductors up to 336.4 kcmil ACSR shall be dead‐ended for line angles larger than 30°.

*Line conductors 336.4 kcmil and larger shall be dead‐ended for line angles larger than 5°.

*Lines more than 2 km long shall be double dead‐ended a minimum of every 1.5 km.

Guys, Messengers and Anchors

Q What should be the angle between the down=guy and the supporting structure?

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Ans The angle between a down‐guy and the supporting structure shall not exceed 60°.

Q What is the load limit of supporting structure for sidewalk guys?

Ans The use of sidewalk guys shall be limited to supporting structure loads of less than 6.6 kN.

Q What type of structure for sidewalk guy horizontal member shall consist of?

Ans Sidewalk guy horizontal member shall consist of a 2 inch galvanized pipe at a minimum height of 2.4 m
above grade.

Q What type of sidewalk guys shall be?

Ans Sidewalk guys shall have reflective finished guy guards with the open side of the guard facing away from the
sidewalk.

*Guys from supporting structures having ungrounded or resistance grounded circuits shall be insulated with
strain insulators.

Q What is the height of insulators from above grade shall be in overhead line?

Ans Insulators shall be located a minimum of 2.4 m above grade and below the lowest power conductor.

*Guys from supporting structures having ungrounded or resistance grounded circuits shall be insulated
with strain insulators.

*For installations where a section of the guy crosses under or over supply conductor circuits connected
to other supporting structures rated in excess of 300 V, or which pass within a 3 m radius of such circuit
conductors, the guy section shall be insulated from ground. The exposed section shall be isolated from
points within 1.8 m of the supporting structure.

Q What type of guy insulators shall be used?

Ans Guy insulators shall have a rated ultimate strength greater than the rated breaking strength of the guy.

*Guy insulators shall not be used with guy strands having ultimate strengths greater than 80 kN.

Q What type of messengers shall be used?

Ans Messengers shall be of the stranded steel type. Messengers shall be sized for the ultimate number of cables
to be installed.

*Insulators are not required for messengers supporting street lighting cables, secondary conductors of
series lighting circuits, and traffic signal conductors.

*Guy and messenger attachment hardware shall be pre‐formed type dead end fittings or automatic guy
grips.

Q What type of anchors are used for overhead line?

Ans Power‐installed screw anchors or rock anchors shall be used, except in hard marl soil where expanding
type anchors are permitted. Anchors shall not be loaded more than 35% of their ultimate allowable
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holding strength. If required for holding in poor soils, other anchor designs may be used with the
concurrence of Coordinator, Electrical Systems Division, CSD.

*Anchors shall not extend above ground in excess of the length necessary for attachment requirements.

Insulator Requirements

Q What is the minimum insulator creepage shall be?

Ans Minimum insulator creepage for components shall be 40 mm per kV line‐to‐line nominal system voltage.

Q What types of insulators shall be used?

Ans Post and suspension type insulators shall be used.

*Pin type insulators shall not be used. Insulator brackets shall be metallic. Semiconducting or resistive glaze
insulators shall not be used.

*Insulator brackets shall be metallic.

*Semiconducting or resistive glaze insulators shall not be used.

Q What requirements shall meet the insulators used on overhead distribution systems?

Ans Insulators used on overhead distribution systems shall meet the requirements of the ANSI C29.

Q What is the load limit for insulators for overhead distribution systems?

Ans Insulators shall not be loaded in excess of 40% of their rated ultimate strength.

Q Where we use the Fog type porcelain suspension insulators?

Ans Fog type porcelain suspension insulators shall be used to terminate overhead circuits at a substation bay or
supporting strain bus. For these applications, an insulating string shall consist of a minimum of 2 units at 13.8
kV and 4 units at 34.5 kV.

Primary Conductors

Q What type of conductors shall be used for overhead distribution systems?

Ans Conductors shall be ACSR/AW per ASTM B549

*Phase rotation shall be x y z (a b c) counterclockwise

ACSR (aluminum clad steel reinforced)

Q What are the normal service conditions?

Ans Normal service conditions are defined as follows:

80°C conductor temperature

50°C ambient temperature

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0.6 m/sec wind velocity

Q What are the emergency service conditions?

Ans Emergency service conditions are defined as follows:

120°C conductor temperature

50°C ambient temperature

0.6 m/sec wind velocity

Q What should be the limit value of conductor tension?

Ans Conductor tension shall not exceed 10% of the conductor ultimate strength.

Q Sag and tension calculations shall be based on what?

Ans Sag and tension calculations shall be based on maximum and minimum ambient temperatures (0°C to 50°C)

*Overhead ground wires terminating on a substation structure shall be connected to an equivalent

cross section copper conductor which is connected to the ground grid or bus.

Accessory Equipment

*Accessories, including terminating devices, shall be rated for application at line‐to‐line system voltages.

Q How transformer primary connections shall be made?

Ans Transformer primary connections shall be made with hot line clamps connected to a bail /stirrup
compressed on the line conductor.

Q What will be the minimum height between any parts of a pole mounted transformer or its mounting bracket
or plate form and grade?

Ans Minimum height between any part of a pole mounted transformer or its mounting bracket or platform and
grade shall be 4.9 m.

Q What should be the minimum stress safety factor for supporting structures for accessories?

Ans Supporting structures for accessories shall have a minimum stress safety factor of 4.0

Q What should be the minimum separation between underground conductors?

Ans Minimum separation between ungrounded conductors shall be

System Clearance mm
Voltage (kV)
4.16 230
13.8 410
34.5 710

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Q Where the load break switches shall be provided?

Ans Load break switches shall be provided at sectionalizing points.

Protective Devices

Q Where the surge arresters shall be installed?

Ans Surge arresters shall be installed at distribution transformer installations, capacitor bank installations, re‐
closer installations, metering installations, and aerial‐to‐underground cable termination points

Q What type of surge arresters shall be and what are the ratings of hem?

Ans Surge arresters shall be of the distribution class, metal‐oxide, gapless type and shall have the ratings as
follows:

System Voltage (kV) Arrester Rating (kV)

4.16 6
13.8 12
34.5 27

Q What type of grounding electrode for surge arrester used and of what dimensions?

Ans The grounding electrode for surge arresters shall be minimum 16 mm diameter and 3 m (10 ft.) long copper
or copper clad ground rod.

The ground rod(s) shall be bonded to the plant or substation ground grid if located within 15 m of the rod.

Q What should be the ground resistance of surge arrester?

Ans The resistance to ground of the surge arrester ground shall not exceed 25 ohms.

Q What is the minimum arrester‐to‐arrester clearance shall be?

Ans Minimum arrester‐to‐arrester clearance shall be

System Voltage (kV) Clearance mm

4.16 230
13.8 410
34.5 710

*Fused cut‐outs shall be provided for transformers fed directly from overhead distribution lines.

*Load break switches and fused cutouts shall be provided for capacitor installations on overhead distribution
lines.

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Motors and Generators

(SEAS‐P‐113)

Q What are the check points for the installation of LV/MV motors?

Ans Acceptance criteria

a) Check motor information rating for its conformation to the data sheet.
b) Inspect physical and mechanical condition of motor.
c) Lifting lugs or eyebolts shall be provided for lifting the motor.
d) Inspect anchorage, alignment, and grounding.
e) Check terminals of motors and proper connections.
f) Check the motor is correctly connected for the available supply voltage.
g) Control circuits and terminals shall be torqued properly.
h) Motors shall be located so that adequate ventilation and space for maintenance is provided.
i) Check the motor is suitable for the area classification.
j) The motor and all of its auxiliary devices shall be suitable for and in accordance with the area
classification system.

Q How to perform the pre‐commissioning of LV motor?

Ans Pre‐commissioning of LV motor

a) Check proper rotation of motor.

b) Perform megger insulation‐resistance test for the motor winding.
c) Measure and record bearing temperatures and the ambient temperature and record temperatures
during testing.
d) Energize the motor and record no‐load starting current and running current in each phase and the
voltage phase to phase.
e) Measure and record motor speed RPM.
f) Measure and record vibration on drive end and non‐drive end bearings.
g) Check the absence of unusual mechanical or electrical noise or signs

Q How many test are performed on motor? How we do pre‐commissioning of motor?

Ans 1) IR Test

2) Continuity Test

3) Winding resistance test/Low resistance test {DLRO‐digital low resistance ohmmeter – MOM micro‐
ohmmeter}

5) No load test / Solo run test (for 4 hours)  To check if voltage or current is dropped, RPM (Techo Meter),
Temperature Test (With Temperature Gun, Assembly+ Bearing+ Shaft+ Non‐Derive End), Vibration Test

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(Vertically, Horizontally, Axially of Frame, Foot and Base with vibration tester), Noise Test (DBA Meter‐at
derive end and non‐derive end)

6) Full load test – Mechanical Run Test (it is performed by operation department to check the capacity of
motor for designed parameters of system for voltage or current)

For MV motors

Q How to perform the pre‐commissioning of MV motor?

Ans Pre‐commissioning of MV motor

a) Check proper rotation of motor.

b) Check that the space heaters are operational.
c) Check that the cooling fans are operational.
d) Check and record the stator winding resistance phase to phase. Perform megger insulation‐resistance
test for the motor winding.
e) Measure and record the heater resistance.
f) Measure and record the bearing temperatures and the ambient temperature and record temperatures
during testing.
g) Energize the motor and record no‐load starting current and running current in each phase and the
voltage phase to phase.
h) Measure and record motor speed RPM.
i) Measure and record vibration on drive end and non‐drive end bearings.
j) Check the absence of unusual mechanical or electrical noise or signs

Q What to do in no‐load test of motor?

Ans Start motor for 4 hour test run

a) Temperature
b) Vibration
c) Voltage
d) Current

4 hour test run

a) Two hours‐ No mechanical load

b) Two hours‐ Mechanically loaded
i) Voltage phase to phase
ii) Current in each phase
iii) Power factor
iv) Speed
v) Winding temperature
vi) Drive end and non‐drive end bearing vibration & temperature

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Q How much voltage applied for IR testing for motor?

Ans

Q What is the limit value for the winding resistance of motor?

Ans Stator winding resistance in micro‐ohms. Measured phase to phase with wye point connected then each
phase is measured with the wye point open and the motor leads separated.

Q What is the minimum insulation resistance values for motors?

Ans

Q Which equipment is used for measuring the resistance of space heater in motor?

Ans Heater resistance measured with a digital high impedance ohmmeter

Q What is the formula of DC Hi‐pot test for MV motor?

Ans DC Hi‐pot test formula Test Voltage is 1.7 x [0.75 (2 x rated voltage + 1kV)]

2300 rated motor test volts 7KV DC

4000 rated motor test volts 11KV DC

13200 rated motor test volts

Q What is the minimum PI Value for motor?

Ans The minimum acceptable polarization index for class B and F insulation is 2.0, however higher values are
preferred.

Q What is the temperature correction formula for winding temperature?

Ans Temperature Correction: To correct to 50°C Rc= Kt x Rt

Rc= insulation resistance corrected to 50°C

Rt= insulation resistance at temperature "t"

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Kt= insulation resistance temperature coefficient at temperature "t"

*Motors and Generators shall comply with 17‐SAMSS‐502, 17‐SAMSS‐503, 17‐SAMSS‐510, 17‐SAMSS‐518,
and 17‐SAMSS‐520

* Motors and generators shall be installed in accordance with NEC.

*Motors and generators used in hazardous locations shall be totally enclosed and meet the requirements of
the NEC

*Increased safety type motors shall not be used in Zone 1 classified areas.

Q What are the specifications of motors used in Zone‐1 hazardous locations?

Ans Motors used in Zone 1 hazardous locations shall be totally enclosed type explosion proof or flameproof.

*Motors for use in Zone 1 hazardous (classified) locations shall meet the requirements of UL 674 or
equivalent international specification, and be certified

Q What are the specifications of motors used in Zone‐2 hazardous locations?

Ans Motors for use in Zone 2 hazardous (classified) locations shall be of the Totally Enclosed type per NEMA, or
Ex‐n per IEC.

*Motors and generators exposed to ambient temperatures shall be rated in accordance with NEMA MG 1
for a 50°C ambient.

*Motors shall be applied and sized based on their 1.0 service factor rating.

*Motors are required to meet the criteria for Class F insulation, with an allowable temperature rise, above
the ambient of 50°C

Diesel‐engine driven generator sets rated 45 kVA (35 kW) through 2500 kVA (2000 kW) shall comply with 17‐
SAMSS‐518. Other type generators shall comply with 17‐SAMSS‐510.

*Special (definite‐purpose) motors shall meet the requirements of NEMA MG 1 or IEC 60034.

*Protective instruments (Temperature, vibration, speed, etc.) for motors shall comply with SAES‐J‐604.

*Motors for submersible pumps for community water well and offshore service shall comply with the
requirements of 31‐SAMSS‐010.

*Motor and generator packages shall meet the noise requirements of SAES‐A‐105.

*Induction and synchronous motor installations shall meet the vibration requirements of 17‐SAMSS‐502 and
17‐SAMSS‐520 when coupled to the driven equipment and run loaded.

Motors for Industrial Facilities

*Motors rated 0.746 kW (1 hp) and above shall comply with 17‐SAMSS‐502, 17‐SAMSS‐503 or 17‐SAMSS‐
520.

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*motors supplied as an integral part of manufacturer's standard packaged parent equipment such as
exhaust fan ventilation assemblies and air conditioning units which meet standards recognized by Saudi
Aramco. Such motors shall have minimum of Class F insulation.

Motors shall be selected in accordance with Table

Table Motor Number of kW (hp) Types

Nominal Nameplate Phases
System Voltage
Voltage
230 220 1 up to 0.25
(0.34)
480 460 3 0.18 (0.25) to Induction
185 (250)
4160 4,000 3 185 (250) to Induction
3000 (4000)
4160 4,000 3 370 (500) to Synchronous
3000 (4000)
6900 6,600 3 750 (1000) to Induction or
6000 (8000) Synchronous

13,800 13,200 3 750 (1000) to Induction or

10500 (14000) Synchronous

13,800 13,200 3 above 10500 Synchronous

(14000)

*Dual voltage 230/460 V are only acceptable for motors up to 30 hp.

*Below 3750 kW (5000 hp) synchronous motors shall only be applied at operating speeds of 1200 rpm and
below.

*Above 1000 kW (1340 hp) the additional level of 6.6 kV is permitted. The use of a 6.6 kV motor plus unit
transformer must be compared with a 13.2 kV motor on the basis of cost.

*Induction motors less than 500 hp with 480 V system are permitted with approval.

*Motors over 30,000 hp are permitted with approval.

Q What are the specifications/requirements for installation of motors less than 1hp?

Ans Motors rated less than 0.746 kW (1 hp) shall comply with NEMA MG 1 or IEC 60034, and the following
additional requirements:

a) Motors for exposed outdoor installation shall be of the totally enclosed type and rated in accordance
with NEMA MG 1 or IEC 60034‐1 for a 50°C ambient and a Class B winding temperature rise.
b) Motors for indoor installation shall be totally enclosed or of the drip proof guarded type.
c) The insulation system shall be Class F minimum.
d) Enclosures and terminal housings shall be metallic.
e) Single Phase Motors shall be provided with a built‐in thermal protective device
f) Fans shall be metallic or reinforced fiberglass, and shall be designed for dual rotation

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Motors for Non‐Industrial Facilities

Q What are the specifications/requirements for installation of motors in non‐industrial facilities?

Ans Motors for Non‐Industrial Facilities Motors shall comply with NEMA MG 1 or IEC 60034 and the following
additional requirements:

1) Larger single phase 115 V, 200 V, and 230 V rated motors may be used as long as the full load current
does not exceed 50 A and larger three phase 200 V and 230 V rated motors may be used as long as the
full load current does not exceed 100 A.
2) Motors for outdoor installation shall be a totally enclosed type.
3) Motors for indoor application shall be totally enclosed or of the drip‐proof guarded type.
4) The insulation system shall be Class F minimum.

Protection

*Within Non‐Industrial Facilities: protection requirements shall be per the NEC unless specified otherwise
within the SAMSS.

*Resistance temperature detectors (RTDs) provided for monitoring stator temperature shall be 100‐ohm,
platinum, and three lead type with a temperature coefficient of resistance equal to 0.00385 ohm/ohm /° C.

*RTDs shall be monitored by the multipurpose motor protection package which shall be set to trip or alarm
on high temperature in accordance with the direction of the facility proponent. Where more than one RTD
per phase is installed, the RTD that shows the highest reading during normal operating conditions shall be
used to provide temperature information for trip and alarm functions.

*Horizontal motors rated 370 kW (500 hp) and above and generators rated 500 kVA and above shall
have bearing temperature monitoring.

*Bearing temperature sensors shall be monitored either by the multifunction motor protection package
or by a separate integrated system protecting the motor and the driven equipment.

Generator Protection

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Power System and Equipment Protection

(SAES‐P‐114)

Q What are the inspection points/ acceptance criteria for cabinets of CT/PT/Relays/ Meter/Recorder?

Ans 1) Check equipment for proper level & arrangement as per layout drawings.
1) Inspect physical and mechanical condition.
2) Check all bolted connections for tightness.
3) Check ratings of MCB's, protection devices, indicators, current transformers etc. against drawings &
specifications requirement.
4) Check earthing connection & other metal structures potentially bonded to main grounding grid.
5) Remove foreign material, moisture, dust etc. from the panel.

Q What is the scope of SAES‐P‐114?

Ans This Standard prescribes minimum mandatory requirements for the design and installation of protective
relaying for power systems and equipment.

General Protection Philosophy

Protective relaying systems shall be applied throughout the power system to detect undesirable or
intolerable operating conditions, and to disconnect the troubled areas or equipment from the other sections
of the power system.

Protection zones shall overlap, to ensure complete protection at the zone boundaries

Protective relays may be used for multiple functions including metering, alarming and control

Main and local back‐up protection of an equipment shall be provided using different protective device
manufacturers

Mandatory Standards and Policies

System and equipment protection shall conform to NFPA 70, as supplemented by this Standard

Protective device function number definitions and applications shall conform to ANSI C37.2

Protection System Design Package Requirements

The design package for protection and control systems shall provide the following information as a
minimum:

1) Relay and Metering One‐Line Diagrams, Saudi Aramco.

2) AC and DC Elementary (Schematic) Diagrams, Saudi Aramco and Vendor.

3) AC Three‐line (Connection) Diagrams, Saudi Aramco and Vendor.

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4) Interconnection Diagrams, Saudi Aramco and Vendor.

5) Panel Wiring Diagrams.

6) Synchronizing Diagrams.

7) Relay and control panel layout drawings, Saudi Aramco and Vendor.

8) Power System Automation package including equipment layout drawings, communication/networking

configuration, architecture, and control logic and ladder diagrams.

Protection System Settings and Coordination Studies

A final protection system settings and coordination study shall be completed and submitted for review
at least two months prior to commissioning of the electrical equipment

The final protection system coordination study shall be completed using ETAP STAR unless otherwise
approved by the Coordinator, Power System Planning & Engineering Department.

The final protection system settings and coordination study review package shall include:

a) A hard and electronic copy of the final protective system coordination study with all required setting
parameters.

b) Recommended final device settings including copy of the device software data files.

c) Protective device data: manufacturer, style, model, type, range, and time characteristic curves. Protective
device and plant data shall refer to the actual devices supplied on the project. General catalog extracts or
typical data are not acceptable, full manuals are required.

d) Nameplate data and ratings of motors, buses, generators, power conductors, instrument transformers,
power transformers, and cables (including cable short‐circuit withstand limits).

e) Data for motors over 100 HP shall include the following: Horsepower rating; Nameplate voltage; Full load
current; Locked rotor current; Acceleration time at 80%, 90%, 100% and Permitted stall time at 80%, 90%,
100%, 110% of rated voltage; Thermal capability curves(Hot/Cold); Number of starts allowed, from cold (cold
start) in first hour and subsequent hours; After running trip (hot start), starts allowed in first hour and
subsequent hours. If acceleration time exceeds permitted stall time, data on speed switch and timers shall
be provided; RTD data.

f) Data for generators shall include: Rating, positive, negative and zero sequence impedances, negative
sequence capability, minimum motoring power, over frequency curves, thermal capability curve, decrement
curve, time constants.

Coordination and Settings of Main Protection

The calculations, settings, and coordination of the main or primary system protection shall be based on the
following two operating conditions:

a) Minimum fault current

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b) Maximum fault current

The maximum fault duration time allowed by the protection shall not exceed the short‐circuit withstand
capability of the protected equipment.

The Coordination Time Interval (CTI) between time‐overcurrent relays shall not exceed 0.35 seconds at
maximum transient fault current.

The CTI between coordination pairs of a time‐overcurrent relay and a trip unit (digital or Solid‐State device),
a fuse or an instantaneous relay shall be 0.25 seconds at maximum transient fault current.

The CTI between coordination pairs of trip unit (digital or Solid‐State device) and fuses shall be 0.1 sec at
maximum transient fault current.

The calculations for sub transient fault currents shall include the contribution from both synchronous and
induction machines, while transient fault calculations shall include synchronous machines only.

Sub transient current values shall be used in calculating the settings and coordination of the following units:

a) Instantaneous relays.

b) Overcurrent relays with less than 0.1 second operating times.

c) Fuses with minimum‐melting times less than 0.1 second.

Transient current values shall be used in calculating the settings and coordination of the following units:

a) Overcurrent relays with 0.1 second or more operating times.

b) Fuses with minimum‐melting times of 0.1 second or more

The settings of instantaneous units that are sensitive to DC offset current shall be based on the
maximum DC offset current in the protected circuit

Generator Protection

Where a generator system is supplied with a molded‐case main circuit breaker, the breaker shall have a
continuous current rating not exceeding 125% of the generator's rated capacity.

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Switchgear and control equipment

(SAES‐P‐116)

General Questions

Requirements for Electrical Installations: NEC Article 110

Demand Load: Electrical load averaged over a specified time period.

Operating Load: one‐hour demand based on plant or facility

Low Voltage: Less than 1000 V.

High Voltage: Voltages greater than 1 kV but less than 100 kV.

AFD: Adjustable Frequency Drive

GIS: Gas Insulated Switchgear

Loop Distribution: equipment having two incoming power connections and multiple outgoing power feeds,
but only one source of power.

Q Define switchgear/control gear/control panel?

Ans In an electrical system, a switchgear/control gear/control panel is the combination of electrical disconnect
switches, fuses or circuit breakers used to control, protect and isolate electrical equipment.

Controlgear:

Controlgear is a collective term for electrical disconnect switches, fuses, and circuit breakers used to control,
protect and isolate electrical equipment. Low and medium voltage controlgear is used in industrial
applications to control and protect equipment, especially electric motors, from surges, earth faults and short
circuits, and to provide basic control functions such as start/stop and ramp up to speed.

Low and medium voltage controlgear is used frequently in motor control centers (MCC). MCCs include
additional components such as branch feeder devices, variable frequency drives, programmable logic
controllers, AC drives, and meters. Also, MCCs are sold as complete solutions with all components pre‐
installed and wired in electrical cabinets. It consists of contactors, relays, breakers etc.

Controlgear protects electric motors against abnormal conditions such as overcurrent or overheating.

Switchgear:

In an electric power system, switchgear is composed of electrical disconnect switches, fuses or circuit
breakers used to control, protect and isolate electrical equipment. Switchgear is used both to de‐energize
equipment to allow work to be done and to clear faults downstream.

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Switchgear in substations are located on both the high‐ and low‐voltage sides of large power transformers.

Switchgear consists of

1) Power conducting components, such as switches, circuit breakers, fuses, and lightning arrestors that
conduct or interrupt the flow of electrical power.
2) Control systems such as control panels, current transformers, potential transformers, protective relays,
and associated circuitry, that monitor, control, and protect the power conducting components.

One of the basic functions of switchgear is protection, which is interruption of short‐circuit and overload
fault currents while maintaining service to unaffected circuits. Switchgear also provides isolation of circuits
from power supplies. Switchgear is also used to enhance system availability by allowing more than one
source to feed a load.

Q What is a control system?

Ans A control system is a device or set of devices, that manages, commands, directs or regulates the
behavior/working of other device(s) or system(s).

Q what is a transfer switch?

Ans A transfer switch is an electrical switch that switches a load between two sources.

Q What is bus bar?

Ans In electrical power distribution, a busbar is a strip or bar of copper, brass or aluminium that
conducts electricity within a switchboard, distribution board, battery bank, or other electrical apparatus.

Q What is an automatic transfer switch (ATS)?

Ans An automatic transfer switch is used to switch a load automatically between two sources.

Q What is the difference between the ATS (Automatic Transfer Switch) and AMF (Auto Man Failure Panel)?

Ans ATS (automatic transfer system panel) will transfer load from main power to emergency load when the
power source drop below 80% or normal voltage while AMF (automatic main failure panel) this will
substitute as main electricity source and reserve the generator if the main supply fail or down.

Q What is PFI panel?

Ans Power factor improvement panel. It controls power factor.

Q What is MCC (Motor Control Center) panel?

Ans MCC (Motor control center) panel is used for distributing power to electric motors. MCC can include variable
frequency drives, programmable controllers, and metering

MCCB stands for Molded Case Circuit Breaker. MCC stands for motor control center motor control center.

RCCB stands for Residual Current Circuit Breaker (RCCB)

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MCB Miniature circuit breaker automatically switches off the power supply during overload and faults and
provide short circuit protection. While RCCB operates, whenever the difference between line and neutral
current (called residual current) becomes more than the set value

MCB” stands for “Miniature Circuit Breakers”, while “MCCB” is “Molded Case Circuit Breaker.” The
main difference between the two is their capacity, with the MCB rated under 100 amps with an interrupting
rating of under 18,000 amps

MCC stands for motor control center. PCC stands for the Power Control Centre, which is a power panel
apparatus used for controlling and distribution of various power sources in the industry.

Q What is electrical enclosure/junction box/terminal enclosure?

Ans An electrical enclosure/junction box/terminal enclosure is a cabinet for electrical or electronic equipment to
mount/install/protect breakers, switches, terminal blocks, knobs and displays and to prevent electrical shock
to equipment users and protect the contents from the environment.

Q What is the junction box?

Ans A box containing the connections and junctions and terminal blocks of wiring cables.

Q what is PCC panel?

Ans There is no difference between PCC (power control center) and PDB (power distribution board). They have
same functions i.e. controlling power feeders.

Q What is distribution board?

Ans A distribution board (panelboard or breaker panel) is a component of an electricity supply system which
divides an electrical power feed into subsidiary circuits, while providing protective fuse or circuit breaker for
each circuit, in a common enclosure.

Q What is switch board?

Ans An electric switchboard is a device that directs electricity/electric power from one or more sources of supply
to several smaller devices of usage.

Q Define DOL circuit?

Ans DOL (direct on line starter) is a circuit used for the starting of the induction motors because the induction
motors draw more starting current during starting. DOL consists a circuit breaker, contactor, and an overload
relay for protection.

Q Define working load?

Ans The maximum load that a machine or other device is designed to bear.

Q What is the testing and commissioning of control panel?

Ans we do the:

a) all wire connections are cleaned and checked for tightness

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b) megger test and continuity test (phase to phase and phase to ground) of control wiring
c) proper clearance between the connections
d) check insulation, insulating tapes and insulated epoxy for damage
e) check the safety and electrical interlocks for correct operation
f) inspect grounding
g) to check if all the components/circuit elements are working by energizing the circuit

Q How we do circuit breaker test? Pre‐commissioning?

Ans The tests/pre‐commissioning includes:

a) trip test/current injection test

b) Contact resistance test
c) megger test and continuity test (from phase to phase and phase to ground)

Q How many test are done on circuit breaker? How we do pre‐commissioning of circuit breaker?

Ans The following test are performed on circuit breaker

1) Contact resistance test {Ductor/DLRO‐to check the contact condition/damage}

2) Current injector test/ Trip Test {primary current injection tests are normally conducted to check the
operation of circuit breaker and their protective relays and devices. The objective of the test is to
identify how the system operates under various levels of current load. By injecting current into the
system we can measure if the breaker will trip or fail. This test is performed with Primary Injections
Tester}.
3) IR test (megger test)

Q How we do contactor test? Pre‐commissioning?

Ans Turn the control switch to ON status to energize the coil in the contractor.
Get the volt ohmmeter and turn it on and make sure that the ohm is positioned in front of the selector
switch. Proceed to testing the L‐side with its corresponding T‐side as L‐1 to T‐1, reading must be 0 ohm.

Q How we do relay testing? Pre‐commissioning?

Ans we do following tests

a) megger test/insulation resistance test

b) test of tripping circuit

Q What is low voltage switchgear?

Ans Low voltage switchgear is that operate within low voltage range.

Q What is disconnecting switch? Define it? How many types are?

Ans Disconnect switch or isolator switch is used to ensure that an electrical circuit is completely de‐energized for
service or maintenance.

a) Center‐break disconnector
b) Double‐side break disconnector
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c) Knee type disconnector

Q What is a switching device?

Ans Device used to make or break the current in one or more electrical circuits.

Q What is the current rating of switchracks?

Ans Maximum switchrack rating is 600A.

*The current rating of a switchrack shall be a maximum of 600A and a minimum of 125% of the switchrack
maximum operating load.

Q What is the current rating of switchboards?

Ans Switchboards shall have a maximum rating of 2000 A.

*Switchracks shall only be used in low voltage applications.

Q What is the current rating of Panelboards?

Ans Panelboards in industrial facilities shall be rated 400A or less. Panelboards in non‐industrial facilities shall be
rated 1000A or less.

Selection

*Transformers with resistance grounded secondaries shall be fed by circuit breakers.

Q Which equipment shall be used for the distribution, switching, protection and control of electrical systems?

Ans Following equipment shall be used for the distribution, switching, protection and control of electrical
systems:

a) Switchgear.
b) Controlgear.
c) Switchracks rated 600A or less.
d) Manually‐operated pad mounted switchgear.
e) Firewater pump controllers.
f) Adjustable frequency drives (AFDs).
g) Panelboards.
h) Switchboards
i) Transfer Switches.
j) Factory Built Assemblies (FBAs).
k) Gas Insulated Circuit Breakers.

*Switchboards shall not be used in industrial facilities.

Q Where is used bus tie breakers?

Ans Bus tie breakers:

a) Shall only be used within switchgear.

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b) Shall be operated normally‐open.

c) Shall consist of a single breaker. (e.g., two breakers in series are not permitted).

*Neutral buses shall not be used within controlgear or switchgear.

*All electrical equipment operating at greater than 240 V shall have an individual switching device intended
to be used for electrical isolation. This switching device shall be equipped with a padlockable lock‐off device.

*Silicone liquids or flammable liquids (such as oils and esters) shall not be used as an insulating or current
interrupting media.

*Main bus systems of different types of equipment shall not be directly connected together.

Q What is the motor controller selection criteria?

Ans Motor controller selection shall be based upon the following criteria:

1) Switchgear shall not be used to control motors.

2) Reduced voltage starters shall not be used.

*Substations operating at 69 kV or above offshore or within 5 km of the coast shall be of the GIS type.

*Busduct shall not be used.

*The interrupting rating shall not be dependent upon upstream interruption devices. (i.e., series rated and
cascade rated protection systems are prohibited).

* Only secondary‐selective switchgear shall be used to feed critical loads.

Installation

*Switchgear, controlgear, switchboards, transfer switches and adjustable frequency drives shall only be
installed in an indoor, air‐conditioned environment.

*Manual transfer switches are allowed outdoors.

*Height and Width of Working Space: The width of the working space in front of the electrical equipment
shall be the width of the equipment or 762 mm (30 in.), whichever is greater. In all cases, the work space
shall permit at least a 90 degree opening of equipment doors or hinged panels.

The work space shall be clear and extend from the grade, floor, or platform to a height of 2.0 m (61⁄2 ) or
the height of the equipment, whichever is greater.

*Dedicated Electrical Space: The space equal to the width and depth of the equipment and extending from
the floor to a height of 1.8 m (6 ft) above the equipment or to the structural ceiling, whichever is lower, shall
be dedicated to the electrical installation. No piping, ducts, leak protection apparatus, or other equipment
foreign to the electrical installation shall be located in this zone.

*Duplex, 3‐wire, 20 A, 120 VAC convenience outlets shall be mounted 1 m above the floor throughout the
substation building. A minimum of one outlet shall be provided for each 6 m of wall space. A minimum of
two outlets per substation shall be provided.

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Q How much unobstructed horizontal space/working space shall be provide for switchgear?

Ans Unobstructed horizontal space shall be provided as follows:

a) 2 meters in front.
b) 1 meter in back and sides.

Q How much unobstructed horizontal space/working space shall be provide for Controlgear, switchboards,
transfer switches and AFD?

Ans Controlgear, switchboards, transfer switches, and floor mounted adjustable frequency drives:
a) 1.5 meters in front.
b) 1 meter on the sides.

*Controlgear mounted in a back‐to‐back configuration has two fronts.

*If controlgear is installed parallel, and in front of switchgear, the space between the front of the switchgear
and the front of the controlgear shall be 2 meters.

Q How much unobstructed horizontal space/working space shall be provided for Panelboards and
switchracks?

Ans Panelboards and switchracks: 1 meter in front.

Q What is the installation requirements for pad‐mounted electrical equipment?

Ans For outdoor installations, pad‐mounted electrical equipment shall be placed on a level concrete pad,
which is elevated a minimum of 100 mm above natural grade. The following minimum clearances shall
apply:

Q How much unobstructed horizontal space/working space shall be provided for outdoor pad‐mounted
electrical equipment?

Ans For outdoor installations, pad‐mounted electrical equipment shall have unobstructed horizontal space
as follows:

a) A minimum working clearance of 2 meters on all sides.

b) A minimum working clearance of 3 meters on the sides of the equipment having doors or access panels.

Q How much clearance/working space is required for pad‐mounted electrical equipment and fences or
walls?

Ans Clearance between pad‐mounted electrical equipment and fences or walls installed for the purpose of
protecting the equipment from unauthorized access is 2 meter and is permitted to be reduced to a minimum
of 1 meter with the concurrence of the proponent, the 3‐meter clearance is maintained for low voltage
equipment doors and access panels, and for medium/high voltage 4.5 meter clearance is maintained.

Q Where will be installed the shutdown device and what are the characteristics/functions/purposes?

Ans All motors are required to have a local, manual shutdown device / padlockable disconnect device.

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1) A manual shutdown device shall be located within sight of each motor or motor location. With the
exception of skid mounted or packaged equipment, each motor shall have a separate, independent
shutdown device. The shutdown device shall have the following characteristics:

a) Operation of the device shall de‐energize the motor and a manual operation must be performed at the
shutdown device location before motor operation is allowed to resume.

b) Shall be either:

i) A fully rated manual main circuit switch, or

ii) A switch/pull/push‐button hard‐wired within the motor control circuit of the main circuit contactor or
circuit breaker. This device shall not be designed, or equipped with features, capable of accepting padlocks.

c) Loss of continuity within the hard‐wired control circuit shall de‐energize the motor

d) The function of the device shall not be dependent upon solid‐state devices and shall be independent
of, and in addition to, any shutdown initiating devices implemented through an emergency shutdown
(ESD) or regulatory control (e.g., DCS) system.

*Field mounted motor operation indicating lights shall be provided if the operation of the motor cannot be
visually determined from the manual shutdown device location. Indicating light system shall have the
following characteristics:

a) Be mounted with, or within, the manual shutdown device.

b) Separate red and green colored lights shall be used to indicate motor operation status. Lights shall be
controlled via the contactor/circuit breaker auxiliary contacts.

c) Fixture design shall be able to withstand the continuous shorting out of the lamp terminals. Under these
conditions, the associated controller shall function normally.

d) Lamp shall be high density LED (Light Emitting Diode) type providing a light intensity similar to an
incandescent fixture.

Q What is the function/operation/characteristics/purpose of space heater?

Ans Motor space heater control equipment shall be provided. This equipment shall have the following
characteristics:

a) Each motor with space heater shall have a separate enclosed contactor to operate all the space heaters in
the motor. This space heater system shall be as follows:

b) A separate branch circuit shall be provided for each motor space heater system.

c) Control voltage shall operate at a maximum of 24 V.

d) Energization of contactor shall energize the space heaters in the motor.

*All motors are required to have a local, padlockable disconnect device.

*Motor Operated Valves (MOVs) are not required to have a local, padlockable disconnect device.
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*Protection and control equipment for high voltage, outdoor SF6 circuit breaker systems 69 kV and above
shall be installed within the air‐conditioned electrical building containing the other electrical equipment
associated with the substation.

Switchgear

Within a room containing high voltage switchgear, portable, manually operated ground and test device shall
be provided.

Each room containing high voltage switchgear shall be equipped with test unit capable of functionally testing
all the circuit breakers within the room.

Passageways shall be unobstructed and shall provide a minimum 2.3 m headroom.

Neutral buses shall not be used within controlgear or switchgear.

LV Switchgear

*In industrial facilities, 480 V switchgear shall not be fed from 4160 V systems if the distance is 500 meters
or less.

*Switchgear shall not be used to control motors.

*Neutral buses shall not be used within switchgear.

*Switchgear shall only be installed in an indoor, air‐conditioned environment.

Pre‐Commissioning

The nameplate on all equipment shall conform with the single line diagrams and schematics.

The switchgear should be properly anchored to its foundation.

All switches, circuit breakers, and other operating mechanisms shall be manually exercised to make certain
that they are properly aligned and operate freely.

An insulation resistance test shall be performed to make sure the switchgear is free from short circuits and
grounds. This test shall be done both phase to ground and phase to phase and with the switches and
breakers both opened and closed.

Switchgear bus shall be tested for insulation resistance with a 1‐minute test (phase to phase and phase to
ground) with 1kV mega‐ohmmeter.

All electrically operated circuit breakers, and other mechanisms shall be electrically exercised (but not under
load), to determine the devices operate properly. An auxiliary source of control power may be necessary to
provide power to the electrical operators.

The settings of the adjustable current and voltage trip mechanisms shall be checked to confirm that they are
at the proper values.

Check PT and CT ratios.

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All instrument transformers shall be tested for insulation resistance with a 1‐minute test with 1 kV mega‐
ohmmeter.

All switching and indicating devices shall be tested for operation. All auxiliary devices and interlocks shall be
tested for operation.

Control wiring insulation resistance should be a minimum of two mega‐ohms.

Controlgear

Controlgear shall only be installed in an indoor, air‐conditioned environment.

Passageways shall be unobstructed and shall provide a minimum 2.3 m headroom.

Panelboards and dry‐type distribution or lighting transformers shall not be installed within controlgear or
low voltage switchgear.

Controlgear in substation buildings containing Distributed Control System (DCS) input/output (I/O) ports may
be specified, and the system designed, so that all DCS control of the controlgear shall be via serial
communication between the DCS communication ports(s) and the controlgear. If this type of design is
specified, the communication protocol and topology shall be as follows:

a) Maximum switching assemblies per topology type shall be as follows:

i) If redundant loop topology: 10 for high voltage controlgear, 50 for low voltage controlgear.

ii) If radial topology; 5 for high voltage controlgear, 20 for low voltage controlgear.

b) Switching assemblies for the operating and standby/redundant/spare loads shall not be on the same
radial or loop service.

c) No intermediate protocol translator shall be installed in the communication circuit between the
controlgear and the DCS (I/O) card.

Low Voltage Controlgear

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1) For low voltage controlgear, the following criteria shall be used for specifying whether a main
disconnector is used within the controlgear and what type it should be:

a) If fed from a circuit breaker within low voltage switchgear:

i) If the controlgear is within the same electrical room as the switchgear from which it is fed, no main
disconnector shall be installed within the controlgear.

ii) If the controlgear is not within the same electrical room as the switchgear from which it is fed,
requirement for main disconnector within the controlgear shall be as shown on the engineering
documents.

iii) In all cases, no intermediate circuit breaker shall be installed between the switchgear breaker and
the controlgear.

b) If fed from a transfer switch, and the controlgear is within the same electrical room as the transfer switch
from which it is fed, no main disconnector shall be installed within the controlgear and the transfer switch
shall be specified as being fully withdrawable.

2) No devices (e.g., circuit breakers, terminal blocks, relays, etc.) shall be field installed within the wireways
of the controlgear.

LV Controlgear Pre‐Commissioning

Perform (continuity test) resistance measurement through bolted connections with low resistance
ohmmeter. The resistance between two parts connected by a bonding conductor shall not be more than 0.1
ohm.

Perform insulation resistance test on each pole, phase‐to‐phase and phase‐to‐ground with starter closed,
and across each open pole for one minute.

Perform insulation resistance test on all control wiring with respect to ground. Applied potential shall be 500
volts dc for 300‐volt rated cable and 1000 volts dc for 600‐volt rated cable. Test duration shall be one
minute.

Insulation resistance values of control wiring shall not be less than two mega‐ohms.

Pre‐Commissioning of MV Controlgear:

Megger and high potential test main bus phase to ground and phase to phase.

Measure bus resistance and joint contact resistance.

Megger contactors and circuit breakers phase to phase and phase to ground.

Measure the contact resistance of each contactor and circuit breaker.

Verify all protective relays and devices for correct operation and settings.

Check to see that space heaters are connected and operable.

Check PT and CT rating, ratio, and insulation resistance, test in accordance with procedure.

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Check calibration of voltmeters and ammeters.

Check relay trip/alarm functions.

Check motor ground fault protection.

Pre‐commissioning of Relays

Perform insulation‐resistance (IR) test on each circuit to frame. IR test on solid state relays shall be
determined from the relay manufacturer’s instructions.

Verify the maximum design voltage and current highest RMS (alternating or direct) at which the equipment
is designed to be energized continuously.

The maximum design voltage or current for protective relays shall be equal to or greater than the rated
voltage and current of the relay.

Test voltage shall be directly applied to the relay terminals through test leads that do not exceed 2 meters in
length.

During the impulse testing, no input or auxiliary energizing quantity shall be applied to the relay.

Three negative and three positive impulses shall be applied. The intervals between each impulse shall be 1
second or greater.

Relays designed to be energized continuously shall withstand the application of the limiting short time
thermal withstand stated by the Manufacturer or values below:

a) Current relays: 1 second

b) Voltage relays: 10 seconds

Switchboards

Switchboards shall only be used to distribute electricity within non‐industrial facilities.

Switchboards shall not be installed in a back‐to‐back configuration.

Switchboards shall only be used for low voltage applications.

Switchboards shall have a maximum rating of 2000 A.

Switchboards shall only be installed in an indoor, air‐conditioned environment.

The minimum spacing between the bottom of enclosure and insulated busbars, their supports or other
obstructions shall be 200 mm (8 in.) and for non‐insulated busbars shall be 250 mm (10 in.)

For other than a totally enclosed switchboard, a space not less than 900 mm (3 ft) shall be provided between
the top of the switchboard and any combustible ceiling, unless a noncombustible shield is provided between
the switchboard and the ceiling.

Control wiring insulation resistance should be a minimum of two mega‐ohms.

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Switchracks

Switchracks shall be fed from switchgear or directly from the secondary of a distribution transformer.

The current rating of a switchrack shall be a maximum of 600A and a minimum of 125% of the switchrack
maximum operating load.

Switchracks shall only be used in low voltage applications.

The switchrack specification applies whether or not the switchrack is completely or partially field assembled
or whether it is installed as a fully assembled unit.

Manually‐Operated Pad Mounted Switchgear

Shall only be used outdoors.

Shall only be used for radial distribution or loop distribution.

Shall not directly feed utilization equipment.

Shall not be used in an automatic transfer configuration.

Shall not be used in industrial facilities.

Shall be limited to a maximum of six (6) switch way positions.

Cablebus/Busduct

Busduct shall not be used.

Cablebus shall be used with power transformers if the forced cooled site rating of the transformer is greater
than 1200 A.
Cablebus shall not be used with pad‐mounted transformers.
If the busduct or cablebus is penetrating a wall with a fire rating, the busduct or cablebus shall be supplied
with a listed internal fire barrier and vapor barrier. The damper/barrier shall have the same, or greater, fire
rating as the wall through which it passes.

Cablebus shall be securely supported at intervals not exceeding 3.7 m (12 ft). Where spans longer than 3.7 m
(12 ft) are required, the structure shall be specifically designed for the required span length.

The individual conductors in a cablebus shall be supported at intervals not greater than 900 mm (3 ft) for
horizontal runs and 450 mm (11⁄2 ) for ver cal runs. Vertical and horizontal spacing between supported
conductors shall be not less than one conductor diameter at the points of support.

Panelboards

Panelboards rated for installation in an electrically classified environment shall be installed completely filled
with breakers and have 20% spare breakers. All other panelboards shall be equipped with a minimum of 10%
spare breakers and a minimum of 10% spare pole spaces. The sizes of the spare breakers shall be
representative of the connected breakers within the panelboards.

Panelboards shall only be used for low voltage applications.

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Panelboards in industrial facilities shall be rated 400A or less.

Panelboards in non‐industrial facilities shall be rated 1000A or less.

Panelboards shall not be installed within controlgear.

The size of Circuit Breaker is the maximum current that can pass through the breaker without tripping the
circuit and causing a loss of power. The breaker controlling a circuit shall be 125% of the continuous load
(maximum current expected).

Busbar bar current rating of a panelboard shall be 120% of the circuit breaker rating.

Q What type of listing/labeling is required for circuit breakers?

Ans Circuit Breaker Listing / Labeling ‐ All main, feeder and branch circuit breakers and enclosures shall be third‐
party tested, and listed or labeled as meeting the requirements of UL standard 489.

Q What type of certification is required for panelboards?

Ans Panelboard Certification ‐ All main, feeder and branch circuit breakers and panelboard enclosure shall be
third‐party tested, and listed or labeled as meeting the requirements of UL standard 67.

Q What are the inspections points/acceptance criteria for panelboards installation?

Ans Panelboards and accessories shall be new and unused. Panelboards and accessories shall be in accordance
with the Saudi Aramco‐approved project‐specific design drawings, diagrams, schedules, lists, databases, and
associated documents. Panelboard short‐circuit ratings and circuit breaker interrupting ratings shall exceed
the available fault current from the system (as calculated). Panelboards and accessories shall conform to all
applicable requirements, standards, and specifications prior to release to be used as part of the work.
Panelboards and accessories shall be identified by using tags, stamps, color coding, stencils or labels. The
location and method of identification shall not affect the function or quality of the materials. Panelboards
and accessories shall be traceable from the manufacturer and supplier through delivery, storage, fabrication,
erection, installation, repair, modification and use. All markings (i.e., voltage and current ratings, number of
phases, including the manufacturer's name and trademark) are correct and easily visible without disturbing
internal parts or wiring after installation. Verify that cabinet and panelboard are installed in accordance with
listing requirements and manufacturer's instructions. Verify that circuit directory located on the face or back
of the panel door conforms to the as‐built drawing and the circuit breakers’ locations in the panel.

*A circuit breaker with a straight voltage rating, such as 240V or 480V, shall be permitted to be applied in a
circuit in which the nominal voltage between any two conductors does not exceed the circuit breaker's
voltage rating. A two‐pole circuit breaker shall not be used for protecting a 3‐phase.

*A circuit breaker with a slash rating, such as 120/240V or 480Y/277V, shall be permitted to be applied in a
solidly grounded circuit in which the nominal voltage of any conductor to ground does not exceed the lower
rating and the nominal voltage between any two conductors does not exceed the higher value of the circuit
breaker's voltage rating.

*The cabinet shall not be located where it will be exposed to ambient temperatures above 40°C (104°F),
corrosive or explosive fumes, dust, vapors, dripping or standing water, abnormal vibration, mechanical

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shock, high humidity, tilting, or unusual operating conditions, unless the cabinet/panelboard combination
has been designed and so identified by the manufacturer for these conditions.

*Mount the cabinet so that there is at least 1/4 inch of air space between the cabinet and the wall or other
supporting surface.

The distance from the lowest overcurrent device to the floor must not be less than 6 inches

The unobstructed working space in‐front of panelboards shall be not less than 1 meter.

Panelboards shall not be installed within a controlgear or low voltage switchgear.

The panelboard cabinet shall not be located against a non‐fireproof ceiling. A minimum clearance of 3 feet
shall be allowed between the ceiling and cabinet unless an adequate fireproof shield is provided.

Explosion‐Proof AC/DC Panelboard

The cabinet shall not be located where it will be exposed to ambient temperatures above 40°C (104°F),
corrosive or explosive fumes, dust, vapors, dripping or standing water, abnormal vibration, mechanical
shock, high humidity, tilting, or unusual operating conditions, unless the cabinet/panel board combination
has been designed and so identified by the manufacturer for these conditions.

Locate or shield the cabinet so as to prevent moisture and water from entering and accumulating therein.
Mount the cabinet so that there is at least 1/4 inch of air space between the cabinet and the wall or other
supporting surface.

Cabinets should be specifically approved for wet locations. Mount the cabinet so that there is at least 1/4
inch of air space between the cabinet and the wall or other supporting surface.

When selecting a location, provide sufficient access and working space around the cabinet. The width of the
working space in front of the panel board should be at least 30 inches and this space should not be used as
storage. The working space should have adequate lighting and a minimum head room of 6 feet 6 inches.

Installations in hazardous locations shall be per the National Electrical Code, with the following additions and
exceptions:

a) IEC or Ex marked equipment meeting requirement of IEC 60079 and certified by one of the agencies in the
Approved IEC Ex Certification Bodies (Ex CBs) under IEC Ex Certified Equipment Scheme is acceptable. Class
and Zone markings are not required on Ex marked equipment but method of protection must be marked and
must correspond with NEC Article 505 requirements for suitable protection method(s) for the hazardous
area where the equipment is applied. Markings based on other schemes or directives such as ATEX are not
acceptable.

b) Equipment suitable for Class 1, Zone 0 locations may be used in Class 1, Division 1 locations.

c) Increased safety (protection type "e") motors and terminal boxes are not permitted in Zone 1 locations.

*Flameproof enclosures EEx d II are permitted in Class I, Division 1 locations as meeting the NEC
requirements for approved enclosures, provided:

i) NEC requirements for cable entry are met;

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ii) the overall enclosure is flameproof EEx d II (explosion‐proof) as a whole (not only its components);

iii) the enclosure is constructed of a conductive metal or has an integral metal bonding device that ensures a
positive low‐resistance bond between conduits or/and cable armors entering or terminating at the
enclosure; and

iv) if used outdoors, the enclosure is rated a minimum of IP54.

*The equipment selection, approval and labeling requirements in the NEC for Division 2 installations also
apply to Zone 2 installations.

Approved sealing fittings shall be installed in each conduit entry into an explosion proof panel board.

Approved sealing fittings shall be installed if conduit is 2 inches or larger of the enclosure.

Conduit seals shall be installed within 450 mm (18 in.) from the enclosure.

Two or More Explosion proof enclosures ‐ Where two or more explosion proof enclosures for which conduit
seals are required are connected by nipples or by runs of conduit not more than 900 mm (36") long, a single
conduit seal in each such nipple connection or run of conduit shall be considered sufficient if located not
more than 450 mm (18 in.) from either enclosure.

Approved sealing fittings shall be installed in each conduit entry into an explosion proof panel board.

If the resistance reads less than 1 mega‐ohm while testing with the branch circuit devices in the open
position, the system may be unsafe and should be investigated. If after investigation and possible correction,
low readings are still observed, the manufacturer should be contacted.

Pre‐commissioning

Q What are the voltage applied during IR test of circuit breakers?

Ans Perform an insulation resistance test at test values specified below:

Voltage Rating Recommended Test Voltage

100 ‐ 250 500 Vdc

251 ‐ 600 1000 Vdc

*Test shall be performed using an Insulation Resistance Test Set (Megohmeter) 1000 V dc minimum.

*Minimum insulation resistance shall be in accordance with manufacturer's published data or as

recommended below:

Voltage Rating Minimum IR Value (MΩ)

250 25

600 100

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Contact Resistance Test/ Ductor Test:

*Perform a contact resistance, millivolt drop test or watt‐loss test from line to load on each phase of a
closed switch with the test points at the line and load lug landings. Test shall be performed using the Digital
Low Resistance Ohmmeter (DLRO ‐ 10 amp unit is sufficient.)

*Perform contact resistance test across main contacts and correct values exceeding 500 micro ohms and
values for one pole deviating by more than 50 percent from other poles

Transfer Switches

Shall only be used in low voltage applications.

Automatic transfer switches shall be installed indoors.
Shall not be used as a substitute for a secondary‐selective substation.
If used for emergency applications, transfer switches shall be automatic and shall be specified to have
switched or overlapping neutral contacts and maintenance bypass switches.
Closed‐transition transfer switches shall not be used.

Adjustable‐Frequency Drives / Variable Speed Derives

Low Voltage AFDs Shall meet the requirements of either:

a) The IEC 60146 and IEC 61136 series of standards.
b) NEMA ICS 7.

High Voltage AFD

*Shall be fed only from switchgear.
*The AFD system supplier shall perform, or directly oversee the commissioning and startup of all drive
systems 2000 kW and larger.

Firewater Pump Controllers

Firewater pumps shall be fed from the most reliable available bus.

Firewater pumps shall be controlled with a firewater pump controller.

For process areas, where multiple firewater pumps are required, between 33% and 50% of the motor driven
firewater pump capacity shall be supplied from a system that can automatically transfer the motors to an
independent power source. These sources can be either two utility, one utility feeder and one generator, or
two generators.

Firewater Pump Controllers shall be installed in accordance with NFPA 20 and NEC Article 695 requirements
except as modified by this standard.

Firewater Pump Controllers shall be fed by switchgear.

Firewater pump controllers shall be specifically listed by UL 218 for electric motor driven firewater pump
service and shall be installed within sight of the firewater pump motor.

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A jockey pump motor shall not be fed from the controller of a firewater pump motor. Jockey pump
controllers are not required to be UL listed.

Substations
(SAES‐P‐119)

*Saudi Aramco defines a substation as any assemblage of electrical equipment which includes a power
transformer rated 751 kVA and larger or switchgear rated 1 kV and higher.

*Saudi Aramco defines a substation as any assemblage of electrical equipment which includes a power
transformer rated 751 kVA and larger or switchgear rated 1 kV and higher.

*Substations shall be located in non‐classified areas.

*Each substation building shall be provided with annunciator/monitor panel indicating the below status
conditions.

Q What information shall be displayed on monitor panel located in workstation?

Ans The following status conditions to be displayed:

a) Loss of circuit breaker tripping supply (Minimum one alarm per bus)
b) Loss of switchgear protection supply (Minimum one alarm per bus)
c) Loss of circuit breaker SF6 gas pressure
d) Low circuit breaker operating air pressure
e) Power transformer combustible gas present
f) Power transformer pressure relief valve operated
g) Power transformer Buchholz relay operated
h) Power transformer high winding temperature
i) Power transformer loss of reference potential on Automatic Voltage Regulator (AVR)
j) Power transformer loss of cooling fan supply voltage
k) Power transformer low transformer oil
l) Power transformer high oil temperature
m) Power transformer low tap changer oil level
n) Power transformer loss of tap changer motor operating supply
o) Power transformer tap changer failure

*Tap changer, automatic voltage regulator, protection and circuit breaker control panels shall be located
inside the substation building when associated equipment is located in an outdoor transformer yard or
switchyard.
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*HV Control and Protection panels shall be arranged as follows for each: Line protection and metering,
Busbar Protection, Feeder Protection and metering, Circuit Breaker Bay Control including Breaker
failure protection, and Automatic voltage regulation. The panels shall be of simplex type having front
door access with relays surface mounted on the door. Circuit breaker control and indication functions
shall be arranged on the circuit breaker control panels to represent the substation configuration (e.g.,
Breaker and half, inverted PI, etc.) and be interconnected by a mimic line diagram indelibly represented
on the surface of the panel with a maximum of one substation bay per panel.

*High voltage disconnect switches shall be manually operated double break, center rotation type
located at the tubular bus level.

Substation Buildings

Q What is headroom clearance for passageways?

Ans Passageways shall be unobstructed and shall provide a minimum 2.3 m headroom.

Q What are the requirements of cable tray installation in substation?

Ans Cable trays shall be installed as follows:

1) Parallel and at right angles to the building walls.

2) Minimum of 200 mm of vertical clearance shall be provided between cable trays.

3) The elevation of the bottom of the lowest interior cable tray shall be a minimum of 2.67 m above the
main substation floor.

Q How will be the entry or exit of conductors in substation?

Ans Conductors shall enter or exit through the building walls.

Q How will be the entry or exit of conductors in the equipments in substation?

Ans Conductors shall enter the equipment from the top.

*Maximum substation building length shall be limited to 50 meters.

Q What type of exterior lighting fixtures shall be used in a substation?

Ans Exterior illumination shall consist of HID high pressure sodium type fixtures controlled by a photo cell. A
Hand‐Off‐Automatic (HOA) selector switch shall be provided for exterior illumination controls.

Q How the interior lighting fixtures will fed from in a substation?

Ans All interior substation lighting shall be fed from different power supplies

Q What type of emergency illumination shall be provided in a substation?

Ans Emergency interior illumination shall be provided by one of the following:

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1) Self‐contained, battery‐powered emergency lighting units, with integral charger, which are automatically
energized upon loss of 120 VAC power.

2) Uninterruptible Power Supply (UPS) system located in the substation.

Q What are the installation specifications for power outlets/receptacles inside the substation?

Ans Duplex, 3‐wire, 20 A, 120 VAC convenience outlets shall be provided throughout the substation
building. A minimum of one outlet shall be provided for each 6 m of wall space at 1 m above the floor. A
minimum of 2 outlets per substation shall be provided.

Q What type of air‐conditioning system shall be provided at substation?

Ans Each substation building shall be provided with a redundant air‐conditioning system

*Unattended substations require a design maximum temperature of 35°C, however, the HVAC for the
battery room is required to maintain 25°C.

*Substation roof drainage shall not be to the transformer yard side of the substation building.

Q What is the height of an elevated/above grade/raised floor substation?

Ans If a substation is to be constructed over existing pipelines, the substation floor shall be elevated a
minimum of 1.8 m above grade.

Q What are the construction characteristics/requirements of an elevated/above grade/raised floor substation?

Ans The space below the elevated substations shall have the following characteristics:

1) The substation floor shall be elevated a minimum of 1.8 m above grade.

2) Be freely ventilated on at least three sides.

3) The ground below the building shall be at or above finished grade.

4) Be enclosed with grillwork suitable for the environmental conditions and a lockable gate to permit access
only to authorized personnel. The grillwork and the gate shall be connected to the substation grounding
system.

5) Shall not drain to the transformer yard side of the substation building.

6) The side of the building adjacent to the transformer yard shall have a solid wall (fire‐rating the same as
the building wall) that separates the space from the transformer yard.

*The concrete floor in front of switchgear shall be flush with the roller level of lower breaker carriage rack
and have a smooth surface to facilitate removal and rolling of breaker. This floor area shall be surface
hardened for rolling stock.

Q What shall be provided underneath switchgear and controlgear to ensure the equipment is maintained on
an even plane?

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Ans Underneath switchgear and controlgear, one of the following shall be provided to ensure the equipment is
maintained on an even plane:

1) Provide leveling steel beams or channels.

2) The floor shall be horizontal in both planes with a maximum surface height variation less than 5 mm per 3
meters.

Q How much shall have fire rating of substation buildings?

Ans Substation buildings shall have a minimum 2 hour fire rating and be constructed

*Substation buildings with single‐ended switchgear shall be designed to accommodate future double‐
ending.

*Substation buildings shall have a telephone and data communications. This shall include connection to
the plant local area network, a dedicated (stand lone) Ethernet network for the power monitoring
system.

*Substation buildings shall have provisions for mounting and protecting as‐built key one‐line diagrams
for ready reference of operating personnel.

*Substation buildings shall have smoke detection systems

*Substation buildings shall have Distributed Control System (DCS) Input/Output (I/O) ports available.
This shall be implemented either by remote I/O racks(s) and/or DCS controllers within the substation.
Design, installation and interconnection to plant DCS system shall be per the applicable SAES‐J series of
standards.

Substation Yard (Outdoor Installations)

Q What is the elevation requirements for outdoor installation/pad‐mounted electrical equipments?

Ans For outdoor installations, pad‐mounted electrical equipment shall be placed on a level concrete pad,
the top of which is elevated a minimum of 100 mm above natural grade.

Q What are the minimum working clearances requirements for outdoor installation/pad‐mounted electrical
equipments?

Ans The following minimum clearances shall apply:

1) Minimum working clearance of 2 meters on all sides.
2) A minimum working clearance of 3 meters on the sides of the equipment having doors or access panels
which can be opened to expose live parts.

*Clearance between pad‐mounted electrical equipment and fences or walls installed for the purpose of
protecting the equipment from unauthorized access is permitted to be reduced to a minimum of 1 meter
with the concurrence of the proponent, provided that the 3‐meter clearance is maintained for equipment
doors and access panels required to be opened for normal maintenance and/or operations.

Transformer clearances and fire barriers shall be as follows:

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Q What are the minimum working clearances requirements for transformer outdoor installation/pad‐
mounted?

Ans Transformer clearances shall be as follows:

1) For transformers containing 7570 liters and less of insulated oil: Clearance from building shall be minimum
of 2 meters on all sides.

2) For transformers containing more than 7570 liter of insulated oil: Separation from buildings: If the
building has a fire rating; 6.1 meters or greater is required.

a) Separation between transformers: If barrier of fire rating is 1 hour; a minimum of 2 meters of clear space
is required (Fig‐1).

b) Separation between transformers: If no fire barrier or barrier fire rating is less than 1 hour; a minimum of
9.1 meters of clear space is required (Fig‐2).

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Fire barrier characteristics shall be as follows:

Q What are the minimum fire barrier characteristics/requirements for substation yard?

Ans Fire barrier characteristics shall be as follows:

a) The height of a fire barrier shall not be less than 300 mm above the height of transformer tank,
conservator, transformer bushing, and pressure relief vents, etc.

b) The fire barrier shall extend at least 600 mm horizontal beyond the line of sight between all points on
adjacent transformers.

Transformer oil containment/drainage shall be as follows:

Q What are the minimum requirements for transformer oil containment/drainage installation in substation
yard?

Ans Transformer oil containment/drainage shall be as follows:

1) For transformers containing 2500 liters or less of oil: No oil containment/drainage is required

2) For transformers containing more than 2500 liters of oil, the following oil containment/drainage system
shall be provided:
a) For power transformers up to 2.5 MVA oil containment shall be in the form of toe walls of sufficient
height and area to contain twice the oil volume of the transformer.
b) For power transformers 2.5 MVA and above oil containment shall be in the form of a concrete pit
constructed around the transformer foundation. The pit shall be equipped with a steel grating covered with
crushed rock to a minimum thickness of 300 mm for fire quenching and have the following characteristics:
i) The crushed rock shall be a minimum sieve size of 25 mm uniformly graded.
ii) The steel grading mesh size shall be less than 25 mm².
iii) A removable section, with a steel lid not covered with crushed rock, shall be provided in a corner of the
steel grating to allow access for cleaning.
iv) A sump shall be provided at a corner of the pit for collection of rain water or oil. The sump shall have
means of drainage either by suitable connection to sewers or other means of fluid removal.
Oil containment shall be designed to accommodate environmental conditions. Pits completely filled with
crushed rock shall not be used since they must be made extremely large to contain the oil volume plus the
crushed rock and they cannot be easily cleaned of wind‐blown sand accumulation.

Q How to install the transformer Neutral Ground Resister (NGR) in the substation yard?

Ans Transformer Neutral Ground Resister (NGR) shall be located in the substation yard.

*NGR shall not be mounted on a transformer.

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Q What will be the thickness of asphalt layer in substation yard?

Ans The substation yard shall be completely paved as a plant area. The thickness of the combined asphalt layers
shall not be less than 100mm/10 cm.

*The high surface resistivity of an asphalt‐aggregate mixture under both wet and dry conditions reduces the
number of ground grid conductors required to obtain safe step and touch potentials during ground faults.

Q What are the method/interval gape of installation of warning signs shall be posted on the fence at
substation yard?

Ans Substation yards shall be enclosed. Warning signs shall be in accordance with Saudi Aramco Standard
Drawing and shall be posted on the fence at intervals not to exceed 6 m.

*120 VAC utility receptacles shall be provided with the following characteristics:

Q What are the installation specifications for power outlets/receptacles inside and outside the substation
building?

Ans 120 VAC utility receptacles shall be provided with the following characteristics:

1) Duplex, 3‐wire, 20 A, 120 VAC, receptacles shall be installed inside and outside the substation building so
that a receptacle is located within 6 m of each power circuit breaker (indoor and outdoor) and each power
transformer.

3) Outdoor units shall be equipped with self‐closing covers which are weatherproof when the covers are
closed.

4) Outdoor receptacles shall be fed from a 20A rated Ground Fault Circuit Breaker (GFCI) with 5 mA
sensitivity. (Receptacles with integral ground fault protection are not acceptable).

Outdoor high voltage substation and switchyard (69 kV and above)

The outdoor high voltage substation and switchyard (69 kV and above) shall be in accordance with the
following:

a) Outdoor Rigid Bus design shall be in accordance with IEEE Guide for Design of Substation Rigid‐Bus
Structures, IEEE 605 ‐ 1998.

b) Bus conductors shall be manufactured from Schedule 40/80 seamless aluminum alloy tubing, temper
6063‐T6.

Q How much will be the vertical bus deflection under maximum loading conditions in outdoor high voltage
substation/switchyards?

Ans Vertical bus deflection under maximum loading conditions, including the weight of vibration damping
measures, shall be limited to 0.5% of span length.

Q How much will be the horizontal span lengths between the bus supports in outdoor high voltage
substation/switchyards?

Ans Maximum horizontal span length between bus supports shall be 10 meters.
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Q How the vibration damping shall be accomplished in outdoor high voltage substation/switchyards?

Ans Vibration damping shall be accomplished by inserting stranded bare conductor inside the rigid bus tubing.
The stranded conductor shall be of the same material as the tubing to prevent corrosion.

Q How the rigid bus shall be joined? How the joints shall be done in bus in outdoor high voltage
substation/switchyards?

Ans The rigid bus shall be joined by welding. Bolted joints in the tubular bus are not acceptable.

Q How the connections to the tubular bus shall be done in outdoor high voltage substation/switchyards?

Ans Connections to the tubular bus shall either be welded or via welded pads providing standard NEMA bolt
pattern.

Q At what lengths of bus runs, the expansion joints shall be provided to bus and in outdoor high voltage
substation/switchyards?

Ans Flexible joints shall be provided to control expansion on bus runs longer than 30 meters.

Q How the grounding lugs shall be provided on the bus in outdoor high voltage substation/switchyards?

Ans Welded grounding lugs shall be provided on the bus tubing for the attachment of safety grounds. The
ground lugs shall be located on the rigid bus on both sides of disconnect switches and circuit breakers.

Q How the connections from bus to circuit breakers shall be done at outdoor high voltage
substation/switchyards?

Ans Connection from rigid bus to circuit breakers shall be via stranded cable jumpers with compression fittings
and NEMA bolt pattern for both the bus and circuit breaker connections.

Q What type of rigid bus supports shall be constructed in outdoor high voltage substation/switchyards?

Ans Rigid bus supports shall be constructed from steel I‐beam, steel pipe or square section steel tubing.

Q What type of insulators shall be used on bus in outdoor high voltage substation/switchyards?

Ans Composite bus support post type insulators shall be used comprising silicone rubber compound external
insulation over a solid fiberglass core with ANSI/IEEE/NEMA bolt patterns.

*Electrical clearances shall be in accordance with ANSI C2 (NESC).

*Exposed equipment insulators, except for surge arresters, shall have a minimum leakage distance of 40 mm
per kV line‐to‐line of the nominal system voltage.

Surge arresters shall have the following characteristics:

Q What are the properties/material of surge arresters used in substation?

Ans Surge arresters shall be of the composite insulation type with silicone rubber compound external insulation
over a hermetically sealed fiberglass core.

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Q What are the voltage rating of surge arresters used at substations?

Ans:

Q At what locations surge arresters shall be installed on systems with operating voltages of 13.8 kV and above?

Ans On systems with operating voltages of 13.8 kV and above, surge arresters shall be installed in substations at
the following locations:

i) At interface points between overhead lines, open bus and underground lines

ii) On power transformer terminals which are connected to overhead lines or open bus.

Q What type of surge arresters shall be used for transformers rated above or below 10MVA?

Ans Intermediate class arresters shall be used for transformers rated 10 MVA and below and station class
arresters shall be used to protect transformers rated greater than 10 MVA.

Q Where the surge arrester grounding terminals shall be connected for grounding purpose in substation?

Ans Surge arrester grounding terminals shall be connected, with minimum bends, directly to the ground bus or
grid or, in the case of surge arresters mounted on transformers, directly to the grounding pad provided on
the transformer.

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Transformers and Reactors

(SAES‐P‐121)

Dry Type Transformers

Q How many types of transformer testing/pre‐commissioning?

Ans Tests of Transformer

a) Transformer winding resistance
b) Transformer winding insulation test
c) Transformer Turns ratio test
d) Temperature rise test
e) On‐load tap‐changer test
f) Vector group test
g) Dielectric absorption test
h) Contact resistance test
i) Core insulation resistance test
j) Continuity test
k) Oil level checking
l) Gauge checking
m) Control and alarm settings on temperature indicators are as specified.

Q How many test are performed on transformer? How we do pre‐commissioning of transformer?

Ans 1) Winding Resistance Test/Low resistance test (DLRO/MOM‐Micro ohmmeter) {the resistance can be
measured by simple voltmeter ammeter method, kelvin bridge meter or winding resistance measurement
kit}

2) Turn ratio test

3) IR Test

4) Continuity Test

5) Oil breakdown test (oil di‐electric strength test, for oil immersed transformer apply 50KV)

6) Vector Group Test

7) Gauge calibration (Pressure and Temperature)

Measured results for individual windings should not deviate by more than 5 percent when comparing with
prior test results.

Perform an insulation resistance test at 1000 Vdc test voltage for 1 minute. Minimum acceptable insulation
resistance value is 100 MΩ.

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Dielectric absorption test shall be for 5 minutes and record the values for every 1 minute. The values
recorded at each one minute interval shall be plotted on log‐log paper with coordinates for resistance versus
time. A good insulation system will have a slope that is a straight line increasing with respect to time. The
characteristic slope of a poor insulation system will be a curve that flattens out with respect to time.

Polarization Index test shall be for 10 minutes and record the values for 1 and 10 minutes intervals. The ratio
of insulation resistance at 10 minutes to insulation resistance at 1 minute value would be 2 or higher, values
between 2 and 1 indicate marginal condition, and values below 1 indicate poor condition.

Measured results for individual windings should not deviate by more than 15 percent on any single
excitation current test, with similar results for the two outer legs of the typical three‐legged core
transformer and lower results for the center leg.

The core insulation resistance shall be measured between the core grounding conductor and the core
grounding lug. Measured core insulation resistance values should be comparable to factory‐obtained results,
but not less than one mega‐ohm at 500 volts dc. Before the core Megger test can be performed, inspect the
transformer and determine whether it has a core ground strap. The copper‐foil ground strap extends out of
the core bottom between the bottom clamps. If the strap is not present, the test is not necessary. If the
strap is present, perform the core Megger test. Disconnect the core ground strap from the flexible jumper,
which attaches the strap to the bottom clamp. Make sure the ground strap is clear from any contact with the
transformer ground to isolate the clamp structure. Take care not to pull the core ground strap out of the
core, attach the hot (‐) lead of a 1000V dc Mega‐ohmmeter to the core ground strap. Attach the ground lead
of the Mega‐ohmmeter to the core clamping bolt, which is next to the core ground strap. Ensure the lead
and core ground strap are not in contact with the ground. A reading of 10 mega‐ohms or greater is
acceptable. Verify with the manufacturer for reading less than 10 mega‐ohms. Record the results in the table
below.

Dielectric absorption test shall be made winding to winding and winding to ground for ten (10) minutes. The
absorption test polarization index should be above 2.0 unless an extremely high value is obtained at the end
of one (1) minute that when doubled will not yield a meaningful value with the available test equipment.

Contact resistance shall be measured using a low‐resistance ohmmeter. Compare bolted connection
resistance measurements to values of similar connections.

Turns ratio shall be performed in accordance with transformer and test instrument manufacturer
recommendations. A turns ratio test shall be performed between windings for all tap positions. The final tap
setting is to be determined by the engineer and set by the test engineer upon completion of the ratio
testing. Turns ratio test results should not deviate more than one‐half of one percent (0.5%) from calculated
ratio.

Pre‐commissioning for Medium Voltage Transformer:

Perform an insulation resistance test at 5000 Vdc test voltage. Remaining tests, procedures and test values
will be the same as for low voltage transformer.

Dry Transformer ‐ LV Xfmr (≤500 kVA)

Q What are the installation inspection points for a transformer?

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Ans Transformer shall conform to all applicable requirements, standards, and specifications prior to release to be
used as part of work.

Transformer shall be in accordance with the Saudi Aramco‐approved project‐specific design drawings,
diagrams, schedules, lists, databases, and associated design documents.

Transformer shall be visually inspected for damage / defects occurred during transportation.

Dry Transformer shall be new and unused.

Transformer assembly shall be in accordance with manufacturer's instructions and design drawings.

The transformer nameplate data shall comply with the latest drawings and specifications. All internal
connections shall be checked with the diagram on the nameplate to make sure they are correct for the
application. Connection of taps are properly done in accordance with manufacturer's guidelines.

Q How much separation is required for dry type transformer from combustible material?

Ans Dry‐type transformers installed indoors and rated 112½ kVA or less shall have a separation of at least 305
mm (12 in.) from combustible material unless separated from the combustible material by a fire resistant,
heat‐insulated barrier.

Exception: This rule shall not apply to transformers rated for 600 volts, nominal, or less that are completely
enclosed, with or without ventilating openings.

Q What is the location requirement for dry type transformer of more tha 112 ½ kVA rating installed indoor?

Ans Dry‐type transformers of more than 112½ kVA rating shall be installed in a transformer room of fire‐resistant
construction. The term fire resistant means a construction having a minimum fire rating of 1 hour.

Exception No. 1: Transformers with Class 155 or higher insulation systems and separated from combustible
material by a fire‐resistant, heat‐insulating barrier or by not less than 1.83 m (6 ft) horizontally and 3.7 m (12
ft) vertically.

Exception No. 2: Transformers with Class 155 or higher insulation systems and completely enclosed except
for ventilating openings.

Q What is the location requirement for dry type transformer of more than 112 ½ kVA rating installed outdoor?

Ans Dry‐type transformers installed outdoors shall have a weatherproof enclosure. Transformers exceeding
112½ kVA shall not be located within 305 mm (12 in.) of combustible materials of buildings unless the
transformer has Class 155 insulation systems or higher and is completely enclosed except for ventilating
openings.

Three‐phase electrical systems shall be grounded at the neutral point of the wye‐connected windings of the
transformers or generators and connected as directly as possible to the grid or grounding electrode. The
system grounding connections shall be made directly to the grounding electrode and be routed separately
from equipment grounding connections.

Exceptions: Three‐phase 120/208 V systems fed from a transformer with a primary voltage less than 600 V
shall be grounded in accordance with NEC rules for separately derived systems. Dry‐type lighting or building
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service transformers in substations, in switchgear rooms, or in equipment rooms may be connected to a

ground bus that is directly connected to the grid or other grounding electrode.

Dry Transformer‐ Medium Voltage‐ MV Xfmr (MV or ≥501 kVA)

Ventilated self‐cooled Class AA or ventilated self‐cooled / forced‐air‐cooled Class AA/FA transformers shall
be utilized indoors.

Sealed self‐cooled, Class GA transformers shall be used outdoors.

Pre‐commissioning

Perform an insulation resistance test at 5000 Vdc test voltage. Remaining tests, procedures and test values
will be the same as for low voltage transformer.

Pad Mounted‐Oil Filled Transformers (35 kV and ≤2.5MVA)

Q How many types of transformer testing/pre‐commissioning?

Ans a) Turns Ratio Tests

b) Polarity Test

c) Winding Resistance (Windings shall be tested primary to ground, secondary to ground, and primary to
secondary)

d) Winding‐Insulation Resistance (Megger test high to low & ground, low to high & ground, high and low to
ground) 500 volts dc

e) Polarization‐Index Test

f) Oil breakdown Test (10‐minute dielectric absorption test)

i) Core‐Ground Inspection and Test (The purpose of measuring the core‐to‐ground insulation is to verify that
the condition of the insulation is satisfactory and that no other core grounds exist). (The test is made by first
disconnecting the core ground strap, which is normally connected to a pad on the underside of the cover
near the manhole or hand hole. The mega‐ohmmeter is then connected between the core ground strap and
the tank ground). (Core Insulation Resistance Test (Core insulation‐resistance values shall not be less than
one mega‐ohm at 500 volts dc)

j) Tank‐Ground Inspection and Test

k) Tap‐Setting Inspection

l) Calibrate Gauges

m) Bushing HV and LV

n) Lightning Arrester

p) Tank Pressure Relief Device

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Check proper operation of all auxiliary devices‐ Tap changer, Liquid level gauges, Winding temperature
gauges, Tap oil temperature gauges, Buchholz relay, Sudden pressure relay, Pressure relief devices, Oil port
sampling.

Check that Oil in the tank is for proper level.

Check condition of silica gel in breather, oil in bath.

Ans Pad‐mounted transformers shall be installed for outdoor application and shall be for mounting on a
precast concrete pad/foundation. Unless otherwise specified, it shall be suitable for continuous
operation at locations up to an altitude of 1000 meters.

Ans Pad‐mounted transformers supplied under this specification shall be suitable for use in locations that are
subject to sand and dust storms, fog, and airborne contaminants, including NaCl (Sodium Chloride) to 300
ppm and MgCl (Magnesium Chloride) to 50 ppm.

Ans The floors of vaults in contact with the earth shall be of concrete that is not less than 100mm (4 in.) thick.

Ans The walls and roofs of vaults shall be constructed of materials that have adequate structural strength for the
conditions with a minimum fire resistance of 3 hrs. Fire rating of 2 hours is for substation walls.

Ans Nameplates of transformers shall be in the English language, shall be abrasion‐resistant, stainless steel, and
attached with stainless steel hardware. Entries shall be marked by etching, engraving or other permanent
marking method.

Ans The transformer tank cover shall be welded or bolted. When bolted, the gasket shall be neoprene type or
equivalent.

Ans Frames of equipment (motors, generators and transformers) operating at 1000 V or greater shall have two
connections to a supplementary grounding electrode.

Ans The high‐voltage and low‐voltage portions of the compartment shall be located side‐by‐side on one side of
the transformer tank. When viewed from the front, the low‐voltage portion shall be on the right.

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Ans Access to the termination compartment shall be provided by a single door or by individual compartment
doors. If individual compartment doors are provided, they shall be so constructed as to provide access to the
high‐voltage portion of the compartment only after the door to the low‐voltage portion of the compartment
has been opened.

Ans High‐voltage separable insulated connectors shall be provided for connection to the distribution system. The
high‐voltage connectors shall consist of either bushing wells, bushing wells with bushing inserts, or integral
bushings, as specified.

Ans The low‐voltage neutral shall be either a blade connected directly to the tank or a fully insulated terminal. If
a fully insulated terminal is used, a ground pad shall be provided on the outer surface of the tank. One or
more removable ground straps suitably sized for the short‐circuit rating of the transformer, shall be provided
and connected between the low‐voltage neutral terminal and the ground pad.

Ans Forced‐air cooling fans and controls shall be provided on all transformers rated 2500 kVA or larger and shall
not be supplied on transformers rated less than 2500 kVA.

Ans For transformers with OA ratings of 90 MVA or larger two stages of forced cooling are acceptable. The forced
cooling may be forced‐air (FA) and/or forced‐oil‐air (FOA). Two stages of cooling shall not be supplied on
transformers less than 90 MVA.

Ans All transformers shall be shipped filled with insulating oil. The oil shall be virgin hydrocarbon mineral oil
specifically manufactured for use as electrical insulating oil. The oil shall contain no additives and shall meet
IEC 60296 Class 1 or ASTM D3487 Type 1. The transformers shall be supplied with labels stating that they are
PCB free.

Ans Fuses shall be provided on the high voltage (HV) primary side of all control or instrument transformers rated
34.5 kV and below.

Ans Current transformers (CTs) used for revenue metering shall be ANSI accuracy Class 0.3

Ans Where the same disconnecting device feeds more than one transformer, a loadbreak disconnecting means
shall be provided to permit de‐energizing each transformer separately.

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Ans CTs connected to time overcurrent relays shall have a protective relay accuracy class rating which will ensure
that the CT does not saturate at the calculated fault level with the connected relays set on lowest tap. The
CT ratio shall be chosen so that the secondary current will never exceed the short time rating of any relay or
device connected in the secondary circuit.

CT secondary wiring shall not be spliced.

Ans The protection required for a pad‐mounted distribution transformer rated 750 kVA or less shall be phase and
ground overcurrent relays at the high side circuit breaker.

Ans Exciting current for each winding shall be measured using a Doble power factor test set.

Ans Insulating oil shall be tested for ‐ Dielectric breakdown voltage, Water content, Acid neutralization number,
Specific gravity, Interfacial tension, Visual condition, Color, Power factor tests.

Ans When transformers operated in parallel, the total circulating current shall not exceed 10% of the rated
current of the lowest kVA rated transformer.

Ans The installation testing should be performed just prior to energizing the transformer. There should never be
a delay of more than 1 month between testing and energizing the transformer (less if possible).

Ans The values from transformer turns ratio (TTR) tests shall not deviate more than 1/2 (0.5) percent from either
the adjacent coils or the calculated ratio.

Ans Transformers are designed to be either additive or subtractive. The polarity can be determined by the
connection diagram or the vector symbol given on the nameplate.

Ans The standardized rules of the industry state that the high‐voltage leads brought outside the case are to be
marked H1, H2, etc. and the low‐voltage leads X1, X2, etc.

Ans A simple test can be conducted to determine the transformer polarity.

Place a jumper between the H1 terminal and the X terminal located on the same side.
Apply a voltage to terminals H1 and H2
With a voltmeter connected between H2 and the other X terminal, obtain a reading.

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If the reading is more than the applied voltage, the transformer is additive. A voltage of less than the applied
voltage would indicate a subtractive unit.
Polarity of transformers will be verified to confirm agreement with the nameplate and specifications.

Ans The protection required for a pad‐mounted distribution transformer rated 750 kVA or less shall be phase and
ground overcurrent relays at the high side circuit breaker.

Power Transformers (≥35 kV or >2.5 MVA)

General

*Transformers: NEC Article 450

Q how many type of transformer are used in field?

Ans Power Transformer, Dry‐Type Power Transformer, Overhead‐Type Distribution Transformer, Pad‐
Mounted Distribution Transformer, Instrument Transformer, Current Transformer (CT), Voltage
Transformer (VT), Control Transformer, Current‐Limiting Reactor

Q How the connections will be done on supply and load side?

Ans Power transformers and Distribution transformers shall be the two‐winding type. Normally, two‐winding
power and distribution transformers shall be delta‐connected on the supply side and wye‐connected on the
load side.

*Generator Step up transformer shall be delta‐connected on the generator (low voltage) side and wye‐
connected on the transmission (high voltage) side.

*Three winding transformer shall not be used.

Intertie transformers that may carry power flow in either direction shall be provided with a HV load tap
changer.

Dry‐Type Transformers:

Q What are the characteristics of dry‐type transformer?

Ans Transformers shall have the following characteristics:

a) Windings and all main circuit conductors shall be copper.

b) Windings shall be encapsulated with solid insulation or vacuum pressure impregnated.

c) Shall fully comply with either of the following: i) IEC 60726, ii) UL listed which requires the transformer be
manufactured in accordance with applicable NEMA, ANSI, UL and IEEE standards.

d) Enclosure material and protection are 3R type.

Sizing

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The minimum ONAN self‐cooled kVA rating of each ONAN/ONAF transformer shall be equal to the maximum
operating load plus projected future load.

Captive transformers shall be limited to motors rated 7500 HP and larger. Captive transformers rating shall be
selected by the motor vendor.

For transformers that are self‐cooled only, a 10% load growth factor shall be added to the calculated load
(maximum operating load plus projected future load).

The forced‐cooled ONAF site rating of each transformer serving a double‐ended substation shall be capable of
feeding the entire operating load of both buses with the bus‐tie breaker closed.

Forced‐air cooling fans and controls shall be provided on all transformers rated 2500 kVA or larger, and shall
not be supplied on transformers rated less than 2500 kVA

For transformers with ONAN ratings of 90 MVA or larger two stages of forced cooling are acceptable. The
forced cooling may be forced‐air ONAF and/or forced‐oil‐air (OFAF). Two stages of cooling shall not be
supplied on transformers less than 90 MVA.

The self‐cooled kVA rating of power transformers shall be de‐rated for continuous operation at higher than
usual ambient temperatures in accordance with ANSI loading guides.

All attachments and accessories such as bushings, instrument transformers, and surge arresters shall be
compatible with the site ambient temperatures and not limit the transformer kVA rating at site temperatures.

When transformers are operated in parallel, the total circulating current shall not exceed 10% of the rated
current of the lowest kVA rated transformer.

The Generator Step‐Up (GSU) transformer selection and application shall be in accordance with IEEE 57.116
guidelines and the following:

a) Shall be sized to carry the maximum generator output establish by the capability curves and site conditions
for all possible tap positions.

b) GSU MVA rating shall never limit the generator MW output for any expected turbine output.

c) Shall be capable of absorbing without damage an energy amount equal in value and time to the energy
dissipated in a fault at the generator terminals.

Instrument and Control Transformers:

Current transformers (CTs) used for revenue metering shall be ANSI accuracy Class 0.3

Installation

The Field erection and testing of oil‐immersed transformers rated 10 MVA or larger shall be in accordance
with ANSI C57.12.11. The design of all transformer installations shall be in accordance with the NESC and NEC.

Dry‐type transformers shall be installed in accordance with the NEC and ANSI C57.94.

Where the same disconnecting device feeds more than one transformer, a loadbreak disconnecting means
shall be provided to permit de‐energizing each transformer separately.
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Instrument and Control Transformers

Fuses shall be provided on the high voltage (HV) primary side of all control or instrument transformers rated
34.5 kV and below.

CTs connected to time overcurrent relays shall have a protective relay accuracy class rating which will
ensure that the CT does not saturate at the calculated fault level with the connected relays set on lowest
tap. The CT ratio shall be chosen so that the secondary current will never exceed the short time rating of
any relay or device connected in the secondary circuit.

CT secondary wiring shall not be spliced.

Protection (Relays)

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Lighting
(SAES‐P‐123)

International standards for lighting: IESNA. IEC, NEC

*IESNA: illuminating Engineering Society of North America

Ambient Temperature: Average temperature of air or another medium in the vicinity.

Operating Temperature: Ambient temperature range within which a system works safely.

Luminaire: Apparatus which distributes, filters or transforms the light emitted from one or more lamps
and which includes all the parts necessary for fixing and protecting the lamps and connecting them to
the electric supply.

The words “luminaire” and “lamp system” are often assumed to be synonymous. For the purposes of
this standard, the word “luminaire” is restricted to apparatus used for distributing light in general
lighting, while “lamp system” implies use of lamps in other than general lighting applications.

Luminaire Lifetime: Length of time during which 70% of the measured initial luminous flux value are
provided, as a function of maximum operating temperature range. The luminaire lifetime of the module
is expressed in hours.

Lumen Maintenance: Value of the luminous flux at a given time in the life of a luminaire divided by the
initial value of the luminous flux of the luminaire and expressed as a percentage x of the initial luminous
flux value. The lumen maintenance of a luminaire is the effect of decrease of lumen output which is
sometimes referred to as depreciation or lumen loss factor.

Luminaire Efficacy: Quotient of the luminous flux emitted by the power consumed by the luminaire.
The efficacy is expressed in lm/W.

*Requirements for residential lighting are found in the IESNA Lighting Handbook.

*Security lighting requirements shall be in accordance with the SAES‐O‐204.

*For high structures and stacks, special obstruction luminaires and warning luminaires shall be provided in
accordance with SAES‐B‐063.

Piers, offshore platforms and similar structures extending into navigable waters must be furnished with
obstruction lighting as required by SAES‐M‐005.

Lighting Requirements

*Design components for lighting energy management shall be per considerations in IESNA LEM‐3.

Q Lighting design should be according to which standard?

Ans Lighting design shall be in accordance with IESNA RP‐7

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Q Lighting standard for parking facilities shall be in accordance with which standard?

Ans Lighting design for parking facilities shall be in accordance with IESNA RP‐20.

Q For photometric measurements of sports which standard we follow?

Ans Photometric measurements of sports lighting, when required shall be performed as per the IESNA LM‐5.

Q For photometric measurements of parking areas which standard we follow?

Ans Photometric measurements of parking areas, when required shall be performed as per the IESNA LM‐64.

Q What shall be the continuous current rating of direct control switches and switching contacts used on
lighting circuits?

Ans Direct‐control switches and switching contacts used on lighting circuits (other than fluorescent luminaires)
shall have a continuous current rating of at least 1.5 times the steady‐state current of the lighting load.

Q What shall be the continuous current rating of direct control switches and switching contacts used on
fluorescent lighting?

Ans Direct‐control switches and switching contacts used on fluorescent lighting circuits shall have a
continuous current rating of at least 2 times the steady‐state current of the lighting load.

Q How the outdoor non‐plant area and street luminaires shall be controlled? On/Off

Ans Outdoor non‐plant area, street luminaires shall be individually controlled by a photocell –or other
controller/sensor‐ mounted on the fixture.

Q What type of photocell switches shall be for street luminaries?

Ans Outdoor/outside plant, photocell switches shall be of the twist‐lock type and shall incorporate an inherent
time delay to prevent spurious operations.

Outside area and street lighting shall be controlled by photocells.

Plant areas, photocell control of area and street lighting shall be through a lighting contactor with a
hand‐off‐automatic switch and provisions for remote operation.

Q What is ambient temperature for continuous operation of photocell switches?

Ans Photocell switches shall be suitable for continuous operation in an ambient temperature above 40°C.

Q At which location of steel towers for flood lights, steel service platforms shall be located.

Ans Where floodlights are installed on steel towers, the towers shall be equipped with steel service platforms
located 1.5 m below the fixtures.

Q What are the acceptance requirements for poles in lighting areas and street lighting?

Ans Poles for area lighting and street lighting shall meet the following requirements:

(1) Poles used in process areas shall be hot‐dipped galvanized steel.

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(2) Poles outside process areas shall be hot dipped galvanized steel or seamless aluminum alloy.

Q At what height of aluminum, steel, and fiberglass poles for area lighting and street lighting wiring
compartment shall be located?

Ans Aluminum, steel, and fiberglass poles shall be provided with a suitable wiring compartment located at a
height of not less than 150 mm nor more than 900 mm from the base.

*Poles and foundations shall be designed to withstand wind loading due to a basic wind speed value of a 3‐
second gust and a gust factor of 1.3 acting on the effective projected area of the pole, bracket, and
luminaires.

Q Lighting poles installed within how many meters from roads shall have breakaway bases?

Ans Lighting poles installed within 5 meters from roads having a speed limit in excess of 50 km/h and up to 65
km/h shall have breakaway bases. Poles with breakaway bases shall not have traffic guards.

Q Can we use the existing structural steel, equipment structure and building walls for mounting area floodlight
fixtures?

ANS The use of existing structural steel, equipment structure and building walls for mounting general area
floodlight fixtures is allowed.

Q What type of certification requirements are for acceptance of luminaires?

Ans Luminaires shall be marked, listed or labeled by an independent third party laboratory the associated
certificate shall state either that the luminaires meet appropriate designated standards or have been tested
and found suitable for use in a specified manner.

Luminaires shall be suitable for the environment where they are installed. Luminaires installed outdoor shall
be approved as weather proof and dust tight.

The luminaire manufacturer shall provide certificate issued by third party agency verifying the luminaire’s
performance including declared luminaire lifetime and lumen maintenance based on the operating
temperature range specified in this standard.

IEC, NEAM, and UL may have differences in classifying and defining weather proof, rainproof, wet locations,
etc. The intention of this requirement is to have luminaire suitable for the application.

Q What type of lamps are used in lighting fixtures for offices, control buildings, and in industrial areas?

Ans Energy‐efficient type T5 or T8 and compatible energy efficient electronic ballasts having less than 10% THD
(voltage total harmonic distortion) shall be used in luminaires for offices, control buildings, and in industrial
areas. Efficacy of Compact fluorescent lights (CFL) shall not be less than 80 Lumen / Watt.

Ballasts and capacitors for fluorescent and HID luminaires shall be Polychlorinated Biphenyl (PCB) free.

Q What type of fixtures are used for outdoor area illumination?

Ans High‐pressure sodium (HPS) luminaires shall be used for outdoor area illumination, except for sports and
recreational facilities.

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Q What type of fixtures are used for high‐bay or low‐bay indoor industrial applications?

Ans High‐pressure sodium (HPS) or Metal Halide (MH) fixtures shall be used for high‐bay or low‐bay indoor‐
industrial applications.

Q What type of fixtures are used in workshops, repair shops and maintenance shops?

Ans Metal halide (MH) fixtures shall also be permitted in workshops, repair shops and maintenance shops where
a high Color Rendering Index (CRI) is essential.

Q What type of energy‐efficient fixtures shall be used?

Ans The use of energy‐efficient luminaires like High Pressure Sodium (HPS), Metal Halide, and LED shall be
maximized. Mercury vapor luminaires and incandescent luminaires shall not be used.

Use of efficient luminaries such as fluorescent, compact fluorescent or LED shall be maximized to phase out
or eliminate in‐efficient lighting.

Exception: Incandescent luminaires rated below 40 Watts are allowed.

Q What type of lighting fixtures shall be used for battery rooms?

Ans Battery rooms shall be provided with enclosed and gasketed (vapor‐tight) corrosion‐resistant lighting
fixtures.

Q How the luminaires shall be tagged/marked?

Ans Luminaires shall be marked (tagged) with circuit number and panel board number.

LED Luminaires

Q What shall be the properties/features of LED luminaires?

Ans LED luminaire lifetime shall not be less than 80,000 hours associated with the following conditions:

1) Ambient temperature of 56°C and operating temperature range between ‐15°C to 65°C with direct sun
exposure for outdoor applications.
2) Failure rate not more than 3% for the entire luminaire lifetime period.

Additional Requirements for LED

1) The LED circuitry shall prevent flicker perceptible to the unaided eye over the voltage range specified as
per IEC 61000‐3‐3 or IEEE 1453.
2) All LED components to be designed to tolerate between ‐20°C and +80°C at 100% Relative Humidity (RH)
during non‐operating/daytime.
3) Voltage THD induced into an AC power line by a luminaire shall not exceed 10%.
4) Thermal management shall be passive by design. The use of fans or other mechanical devices shall not
be allowed.

Q What safety shall be provided in LED luminaires to control the glare and harmful light spectrum to safe level?

Ans Reflectors or filters shall be provided to control the glare and harmful light spectrum to safe level.
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Plant Lighting

Q For street lighting design which standard is used? Street lighting design shall be in accordance with which
standard?

Ans Street lighting design shall be in accordance with IESNA RP‐8

*As a minimum requirement, lighting shall be provided at all street intersections in plants.

*Series street lighting shall not be used.

Q What is the height of light fixtures positioned over stairways, platforms, elevated walkways and landing?

Ans Light fixtures positioned over stairways, platforms, elevated walkways and landings shall be positioned at a
height of 2.03 m (2030mm)

*Lower mounting height shall be permitted for stanchion mounted luminaires provided the luminaire is
positioned outside the handrail vertical plane. The mounting height shall be measured from the bottom of
the luminaire to the floor directly beneath.

*To determine suitability of luminaires for use in hazardous areas where the maximum daily ambient
temperature exceeds 40°C, the temperature code (T‐rating) shall be based on an ambient test temperature
of 50°C or higher. The installation shall be in accordance with NEC and the area classification drawings.

Task Lighting

Definition: Task lighting is lighting directed to a specific surface or area to provide illumination for visual
and/or manual tasks.

*When general area lighting provides the required illumination on a visual task, it shall be considered as task
lighting.

*Local supplementary luminaire(s) shall be required when a specific amount or quality of lighting cannot
readily be obtained by general lighting.

*In outdoor areas where tasks are not required to be performed at night, task lighting is not required.

Emergency Lighting

*In the event of a power failure, emergency lighting must be provided to enable operating personnel to
follow planned operating and shutdown procedures.

*Sources of emergency lighting power include emergency stand‐by generators; station batteries, where
available, providing 125‐volt DC; battery‐operated self‐contained floodlights (these are the most economical
for general lighting); battery‐operated luminaires.

Q What is the minimum time duration of normal power failure for emergency lighting?

Ans Minimum duration of emergency lighting in the event of normal power failure, shall be 1‐1/2 hours.

Q What is the minimum emergency illumination level in manned switchgear rooms and control room?

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Ans In manned switchgear rooms and control rooms where essential activities continue during failure of the
normal lighting, a minimum emergency illumination level of 100 lux (10 fc) shall be provided at 760 mm
above the floor.

Q Where the normal and emergency task lighting should be provided?

Ans Normal and emergency task lighting of at least 200 lux (20 fc) shall be provided for the following:

A. In plant areas to illuminate equipment required for use in emergencies, such as: emergency telephones,
shutdown and emergency isolation stations, fire water pump areas, central foam concentrate mixing
areas, fire control panels and stand‐by generators.
B. In evacuation assembly areas and in off‐shore platform escape capsule areas and boat landings

Q Illuminated exit sign shall be manufactured and installed in accordance with which standard?

Ans Illuminated exit signs shall be manufactured and installed in accordance with NFPA 101 requirements.

Q Where the emergency egress lighting shall be provided?

Ans Emergency egress (exit) lighting shall be provided for the following:

1) Control Rooms
2) Process Areas
3) Switchgear Rooms
4) In‐Plant Buildings
5) Offshore Platforms

A means of egress is an unobstructed path to leave buildings, structures and spaces i.e. exit.

Q What is the emergency lighting illumination minimum and maximum lux value?

Ans Emergency lighting facilities shall provide initial illumination that is no less than 10 lux (1 fc) and a minimum
at any point of 1 lux (0.1 fc) measured along the path of egress (exit) at floor level.

*A maximum to minimum illuminance uniformity ratio of 40:1 shall not be exceeded.

Building Lighting

Office lighting shall be designed as per IESNA RP‐1.

Offices containing computer visual display terminal (VDT) shall be designed as per IESNA RP‐24.

Luminaires installed in the control room shall provide shadow less illumination.

Luminaires shall be installed to minimize reflections and glare at operating screens.

Q What type of luminaires shall be provided for offices, computer rooms, interface rooms and general service
area?

Ans General illumination for offices, computer rooms, interface rooms and general service areas shall be
provided by fluorescent, CFL, or LED luminaires.

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Q How to install the luminaires for suspended ceilings?

Ans Luminaires for suspended ceilings shall be recessed mounted and shall be self‐supporting in accordance to
NEC (NFPA 70).

Q How the luminaires for offices and equipment rooms shall be controlled?

Ans Luminaires for offices and equipment rooms shall be controlled by manual switches located at the entrance
to every room.

Luminaires Performance

Efficiency Requirements: allowable minimum efficiency is as follows

Color Rendering Index (CRI) and Correlated Color Temperature (CCT) Requirements

Q What is the efficiency and color rendering index of fluorescent lamps?

Ans The fluorescent lamps shall have 82.5 lumens per‐watt efficacy and a color rendering index (CRI) of 82 at a
correlated color temperature of 3,500 K or higher

*Incandescent spot fixtures with dimmers to provide variable illumination of up to 1,000 lux shall be used for
supplementary task lighting in work areas within the control room as required.

Q What is the measurement requirements of Flood Lights installed on steel tower with steel platform from
lights to platform?

Ans 1.5 Meter

Q What type material being used for Lighting Poles in a process Area?

Ans Hot‐Dipped Galvanized Steel

Q What is the international reference standard for Lighting design?

Ans IESNA RP‐7

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Q What is the international reference standard for lighting design of parking facilities?

Ans IESNA RP‐20

Q What are the voltages required designs for single phase 3 wires lighting system?

Ans 230V/400V

Q What are the Lighting pole wiring compartment height requirement from the base?

Ans 150 mm nor more than 900 mm

Q What is the Installation distance of Lighting Poles installed from roads having speed limit access of 50 km/h
and up to 65 km/h?

Ans 5 Meters

Q What is the minimum time duration of emergency lighting?

Ans 1½ Hrs.

Light Pole Assembly and Installation

*Conductors on poles shall have a separation of not less than 300 mm (1 ft) where not placed on racks or
brackets

*Luminaires (fixtures) and lamp holders shall be securely supported. A luminaire (fixture) that weighs more
than 3 kg (6 lb) or exceeds 400 mm (16 in.) in any dimension shall not be supported by the screw shell of a
lamp holder.

Hung Ceiling, Surface / Flush Mounted Light Fixtures/ HID ‐ Low / High‐bay Light Fixtures

All luminaires (fixtures) shall be marked with the maximum lamp wattage or electrical rating, manufacturer’s
name, trademark, or other suitable means of identification.

A luminaire (fixture) requiring supply wire rated higher than 60°C (140°F) shall be marked in letters not
smaller than 6 mm (¼ in.) high, prominently displayed on the luminaire (fixture)

Branch‐circuit conductors within 75 mm (3 in.) of a ballast shall have an insulation temperature rating not
lower than 90°C (194°F) unless supplying a luminaire (fixture) listed and marked as suitable for a different
insulation temperature.

A fixture weighing more than 50 pounds (22.7 kg) (including lamps) shall be provided with means for support
that will be independent of the outlet box.

Bushing having holes 7 mm (9/32 inch) in diameter shall be permitted for use with plain pendant cord and
holes 11 mm (13/32 inch) in diameter with reinforced cord.

The labeling, listing, or certification of Lighting Fixture required to be approved for use in hazardous
locations shall be based on the latest version of the following standards or procedures:
a) UL standards (for approved enclosures and fittings: UL 886), or
b) FM procedures or

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c) CSA standards, or
d) IEC standards, or
e) ISA standards

Pole‐Mounted Light Fixtures

Lighting system power supplies consisting of 120/240 volt, single‐phase, three‐wire; 208/120 volt, three‐
phase, four‐wire; 480/277 volt, three‐phase, three‐wire or four‐wire; and 480 volt, two‐wire shall be
acceptable. The choice of voltage and distribution system for lighting installations shall depend on the area
to be supplied and the required lighting load.

When base & fixture is installed adjacent to sidewalk, locate light base within 150mm of edge of sidewalk.

Security Light Fixtures (Fence, Area, and Checkpoint Lighting)

Where floodlights are installed on steel towers, the towers shall be equipped with steel service platforms
located 1.5 m below the fixtures.

Cables for security lighting (perimeter and area lighting) shall be armored or metal clad, installed
underground and rising inside the lighting poles.

Lighting poles shall typically be 5 m high, spaced 20 m apart and be installed in the area allocated for
lighting.

Area lighting deployed for security related requirements shall have an average illuminance of 5 lux. Poles
used for area lighting shall be between 10 m to 30 m in height.

Lights used for checkpoint Lighting shall have a Color Rendering Index (CRI)>50 as defined by the Illuminating
Engineering Society of North America (IESNA) handbook.

Gate House interior lighting shall provide adequate task level lighting with illuminance at the countertop
level, inside the gate house, at least 300 lux (30 fc). It shall be controlled by a dimmer mounted inside the
gatehouse.

Aviation / Obstruction Light Fixtures

For aviation/obstruction lighting fixtures, only marking and lighting equipment and systems which meet the
technical standards established by the United States Federal Aviation Administration (FAA) shall be used.

Flashing red beacons and steady‐burning obstruction lights shall be used during the hours of darkness,
during periods of limited daylight illuminance and/or reduced meteorological visibility. Aviation orange and
white paint should be used for day time marking.

High intensity flashing white obstruction lights during daytime with automatically selected reduced
intensities for twilight and nighttime operations shall be used on structures greater that 150 m AGL.

Dual lighting systems are used to reduce environmental concerns in highly populated areas. This system
consists of a combination of flashing aviation red beacons and steady‐burning red lights for night time
operation and flashing white lights for day time operation.

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As the height of the structure exceeds each level at which permanent obstruction lights will be required, two
or more lights of the type specified in the determination shall be installed at that level.

To ensure the proper luminous intensity for fixtures with incandescent lamps, the voltage provided to the
lamp filament shall not vary more than plus or minus 3% of the rated voltage of the lamp.

Only lamps of the type supplied with FAA approved equipment and those recommended by the
manufacturer as original or replacement lamps shall be used in the light fixture.

A single red steady‐burning obstruction light (L‐810) may be used when more than one obstruction light is
required and where maintenance can be accomplished within a reasonable time.

Red obstruction lights shall be operated by a satisfactory control device (e.g., photo cell, timer, etc.) adjusted
so the lights will be turned on when the northern sky illuminance reaching a vertical surface falls below a
level of 645 lux but before reaching a level of 367 lux.

Structures 60 m AGL or Less: Two or more steady‐burning L‐810 lights shall be installed in a manner to
ensure an unobstructed view of one or more lights by a pilot.

If a rod, antenna, or other appurtenance 6 m or less in height is incapable of supporting a red flashing
beacon, then it may be placed at the base of the appurtenance. If the mounting location does not allow
unobstructed viewing of the beacon by a pilot, then additional beacons shall be added.

Appurtenances Exceeding 6 m: If a rod, antenna, or other appurtenance exceeding 6 m in height is incapable

of supporting a red flashing beacon, a supporting mast with one or more beacons shall be installed adjacent
to the appurtenance. Adjacent installations shall not exceed the height of the appurtenance and be within 6
m of the tip to allow the pilot an unobstructed view of at least one beacon.

Structures 105 m AGL or Less: Two or more steady‐burning (L‐810) lights shall be installed on diagonally or
diametrically opposite positions.

Structures Exceeding 105 m AGL: Install steady‐burning (L‐810) lights on each outside corner of each level.

Structure Exceeding 105 m AGL: At intermediate levels, two beacons (L‐864) shall be mounted outside at
diagonally or diametrically opposite positions of intermediate levels. The lowest light shall not be less than
60 m AGL.

Number of Light Units for Chimneys, Flare Stacks, and Similar Solid Structures:

1) 5 m or Less: Three light units per level.

2) Exceeding 5 m But Not More Than 30 m: Four light units per level.

3) Exceeding 30 m But Not More Than 60 m: Six light units per level.

4) Exceeding 60 m: Eight light units per level.

Structures 60 m AGL or Less: Double obstruction lights (L‐810) shall be installed horizontally at regular
intervals at or near the top.

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Structures Exceeding 60 m AGL: At least three L‐864 beacons shall be installed horizontally at regular
intervals at or near the top.

Chimneys, Cooling Towers, and Flare Stacks lights may be displayed as low as 6 m below the top to avoid the
obscuring effect of deposits and heat generally emitted by this type of structure. It is important that these
lights be readily accessible for cleaning and lamp replacement.

Structures exceeding 180 m AGL shall have a second level of light units installed approximately at the
midpoint of the structure and in a vertical line with the top level of lights.

For Structures Exceeding 60 m AGL: At least three flashing (L‐864) beacons shall be installed on each level in
a manner to allow an unobstructed view of at least one beacon.

Structures 45 m or Less in Any Horizontal Direction, If the structure/extensive obstruction is 4 m or less

horizontally, at least one steady‐burning double light (L‐810) shall be displayed on the highest point at each
end of the major axis of the obstruction. If this is impractical because of the overall shape, display a double
obstruction light in the center of the highest point.

If the structure/extensive obstruction exceeds 45 m horizontally, display at least one steady‐burning double
light for each 45 m, or fraction thereof, of the overall length of the major axis. At least one of these lights
shall be displayed on the highest point at each end of the obstruction. Additional lights shall be displayed at
approximately equal intervals not to exceed 45 m on the highest points along the edge between the end
lights. If an obstruction is located near a landing area and two or more edges are the same height, the edge
nearest the landing area shall be lighted.

Structures Exceeding 60 m Vertically AGL, Steady‐burning red double obstruction lights (L‐810) shall be
installed on the highest point at each end. At intermediate levels, steady‐burning red lights shall be
displayed for each 45 m or fraction thereof. The vertical position of these lights shall be equidistant between
the top lights and the ground level as the shape and type of obstruction will permit. One such light shall be
displayed at each outside corner on each level with the remaining lights evenly spaced between the corner
lights.

Where icing is likely to occur, metal grates or similar protective ice shields shall be installed directly over
each light unit to prevent falling ice or accumulations from damaging the light units. The light shall be
mounted in a manner to ensure an unobstructed view of at least one light by a pilot approaching from any
direction.

High‐intensity flashing white obstruction lights during daytime with automatically selected reduced
intensities for twilight and nighttime operations shall be used on structures greater that 150 m AGL. When
this lighting system is used, aviation orange and white paint may be omitted.

Flash‐tube Replacements, The flash‐tubes in a light unit should be replaced when the peak effective daytime
illumination falls below 200,000 candelas.

The beacon intensity is controlled by a device that changes the beacon intensity when the ambient light
changes. The system shall automatically change intensity steps when the northern sky illumination in the
Northern Hemisphere on a vertical surface is as follows:

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(a) Day‐to‐Twilight: This shall not occur before the natural illumination drops to 645 lux, but shall occur
before it drops below 375 lux. The illuminance sensing device should, if practical, face the northern sky in the
Northern Hemisphere.

(b) Twilight‐to‐Night: This shall not occur before the natural illumination drops below 50 lux, but shall occur
before it drops below 20 lux.

(c) Night‐to‐Day: The intensity changes listed in (a) and (b) above shall be reversed when changing from the
night‐to‐day mode.

Effective high intensity white light system shall be:

a) Day Mode ‐ no less than 200,000 candelas;

b) Twilight mode ‐ approximately 20,000 candelas;

c) Night mode ‐ approximately 4000 candelas.

All light units shall flash simultaneously at 40 pulses per minute.

Light Units per Level

1‐ 5 m or Less: Three light units per level.

2‐ Exceeding 5 m But Not More Than 30 m: Four light units per level.

4‐ Exceeding 30 m: Six light units per level

Where terrain, nearby residential areas, or other situations dictate, the light beam shall be further elevated
above the horizontal. The main beam of light at the lowest level shall not strike the ground closer than 5 km
from the structure. If additional adjustments are necessary, the lights may be individually adjusted upward,
in 1 degree increments, starting at the bottom.

Where two structures are situated within 150 m of each other and the light units are installed at the same
levels, the sides of the structures facing each other need not be lighted.

When a structure lighted by a high intensity flashing light system is topped with an antenna or similar
appurtenance exceeding 6 m in height, a medium intensity flashing white light (L‐865) shall be placed within
6 m from the tip of the appurtenance.

When objects within a group of obstructions are approximately the same overall height above the surface
and are located not more than 45 m apart, the group of obstructions shall be considered an extensive
obstruction. Install light units on the same horizontal plane at the highest portion or edge of prominent
obstructions. Light units shall be placed to ensure that the light is visible to a pilot approaching from any
direction. These lights may require shielding, such as louvers, to minimize the adverse impact on local
communities. Extreme caution in the use of high intensity flashing white lights shall be exercised when
installed near populated areas.

If the Obstruction is 60 m or Less in Either Horizontal Dimension: Install three or more light units at the
highest portion of the structure in a manner to ensure that at least one light is visible to a pilot approaching

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from any direction. Units may be mounted on a single pedestal at or near the center of the obstruction. If
light units are placed more than 3 m from the center point of the structure, use a minimum of four units.

If the Obstruction Exceeds 60 m in One Horizontal Dimension, but is 60 m or less in the other: Two light units
shall be placed on each of the shorter sides. These light units may either be installed adjacent to each other
at the midpoint of the edge of the obstruction or at (near) each corner with the light unit aimed to provide
180 degrees of coverage at each edge. One or more light units shall be installed along the overall length of
the major axis. These lights shall be installed at approximately equal intervals not to exceed a distance of 30
m from the corners or from each other.

If the Obstruction Exceeds 60 m in Both Horizontal Dimensions: Light units shall be equally spaced along the
overall perimeter of the obstruction at intervals of 30 m or fraction thereof.

Offshore Light Fixtures

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Power System Automation

(SEAS‐P‐126)

Overall System MTBF of not less than 60,000 hours.

PSA within individual substations shall have a maintenance interval of not less than 45,000 hours.

Cathodic Protection
(SAES‐X‐400, SAES‐X‐600)

Q What is CP and how we do it?

Ans Cathodic protection (CP) is a technique used to control/prevent the corrosion of metal by making it cathode
of an electrochemical cell.

Q Which standard we follow for the “cathodic protection of buried pipelines”?

Ans SAES‐X‐400

Q Where we use SAES‐X‐600?

Ans SAES‐X‐600 is used for “cathodic protection of plant facilities”.

Q How many types of CP are used?

Ans There are two types of CP; 1) Galvanic Cathodic Protection 2) Impressed Current Cathodic Protection

Q What are the contents of permanent CP?

Ans CP transformer rectifier, High silicon cast iron (HSCI) anode, DC cables/ separate negative leads, bonding box

Q What is galvanic/temporary cathodic protection, define it with diagram.

Ans In galvanic cathodic protection, a galvanic anode, a piece of a more electrochemically active metal, is
attached to the required metal surface. The galvanic anode continues to corrode, consuming the anode
metal until it must be replaced.

Q What is impressed current cathodic protection (ICCP), explain it with diagram.

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Ans Impressed current cathodic protection (ICCP) systems consist of anodes connected to a DC power source,
often a transformer‐rectifier.

An ICCP system for pipeline consist of a DC power source, often an AC powered transformer rectifier and an
anode or array of anodes buried in the ground (the anode groundbed). The DC power source would typically
have a DC output of up to 50 amperes and 100 volts, but this depends on several factors, such as the size of
the pipeline and coating quality. The positive DC output terminal would be connected via cables(25 mm2/ #4
AWG) to anode array, while another cable would connected from the negative terminal of the rectifier to the
pipeline, preferably through junction boxes to allow measurements to be taken. Anodes can be installed in a
groundbed consisting of a vertical hole (50ft/15m minimum) and backfilled with conductive coke (a material
that improves the performance and life of the anodes) or laid in a prepared trench, surrounded by
conductive coke and backfilled. The choice of groundbed type and size depends on the application, location,
and soil resistivity.

Q What types of anodes are used in galvanic/temporary cathodic protection and impressed current cathodic
protection?

Ans For galvanic cathodic protection magnesium, zinc and aluminium anodes are used.

For galvanic cathodic protection mostly magnesium anodes are used (for dry, sandy, rocky areas 60lbs
prepackaged Mg anode is used and for buried mechanical fittings 32 lbs prepackaged Mg anode is used and
for wet, subka areas 100 lbs bare‐not prepackaged Mg anode is used) and sometimes zinc anodes also used.

For impressed current cathodic protection mostly High Silicon Cast Iron (HSCI) anodes are used and
sometimes Mixed Metal Oxide (MMO) are also used (only for use in subka)

Q What is the purpose of temporary cathodic protection?

Ans The purpose of cathodic protection (CP) is to control the corrosion of new pipeline by making it the cathode
of an electrochemical cell.

Q For how much length of pipelines the permanent CP is required?

Ans Production pipelines that extend more than 25km

Q Within how many days need to provide a temporary/permanent CP?

Ans Within 30 days of burial.

Q How to know that temporary CP is working is properly?

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Ans Potential survey data shall be submitted monthly to verify that temporary CP is providing proper protection.

Q For how long time the potential survey data should be submitted?

Ans Pipe‐to‐soil potential survey data verifying that the temporary system is providing proper protection shall be
submitted to the CP proponent monthly for 6‐months, and every 6‐months thereafter.

Q What is bond cable?

Ans A cable installed between two metallic structures to provide electrical continuity to bring them on same
potential.

Q What is calcined petroleum coke breeze?

Ans A carbonaceous backfill used as a conductive backfill media for impressed current anodes in soil.

Q What does mean CP?

Ans Cathodic Protection

Q What is Cross Country Pipeline?

Ans A pipeline between; two plant areas, another cross‐country pipeline and a plant area, or between two cross‐
country pipelines.

Q What is CSD?

Ans Consulting Services Department

Q What is Deep Anode Bed?

Ans Anodes connected to a common CP power supply installed in a vertical hole, (typically 25 cm diameter) with
a depth more than 15 m (50 ft.).

Q What is Design Agency?

Ans The organization or company contracted by client for the design of a system.

Q What is Drain Point?

Ans The location on the cathodically protected structure where the negative cable from the rectifier or junction
box is fastened.

Q What are Galvanic Anodes/Sacrificial anodes?

Ans Anodes fabricated from materials such as magnesium, zinc or aluminium that are connected directly to the
buried structure to provide cathodic protection. Galvanic anodes are also called sacrificial anodes.

Q What is Negative Cable?

Ans A cable that is electrically connected to the negative output terminal of a cathodic protection (CP
rectifier).

Q What is Positive Cable?

Ans A cable that is electrically connected to the positive output terminal of an ICCP power supply, including
impressed current anode cables.
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Q What is Reference Electrode?

Ans An electrode used as a common reference potential for cathodic protection measurements.

A copper/copper sulfate (Cu/CuSO4) reference electrode is typically used for soil applications.

A silver/silver chloride (Ag/AgCl/0.6M Cl) reference electrode is typically used for aqueous applications.

Q What is GOSP and WIP?

Ans Gas and Oil Separation Plant, Water injection plant

Q What is thermite weld/ Cad Weld?

Ans An exothermic process to make electrical connections between two metals.

Q What is the content of the cad weld?

Ans Mold, powder, steel plate, fire gun or lighter

Q With one mold how many cad welds are allowed?

Ans Fifty (50) CAD Welds are allowed.

Q How we will verify that CAD Weld powder is okay to use?

Ans It shall be of same number as mentioned on mold, and CAD weld powder & mold shall be from same
manufacturer and shall be UL listed.

Q What are the dimensions for surface cleaning for CAD Welds?

Ans Shall be cleaned 100 mm sq including 50 mm sq white cleaned and in case if two adjacent cad welds or
failure of cad welds the distance will be 75mm apart.

Q What shall be the weight of the hammer to test cad weld?

Ans It shall be one pound.

Q How much value is for open circuit potential for galvanic anodes?

Ans Magnesium anodes shall have an open circuit potential of ‐1.7 volts.

Q What is project proposal package? And what shall it provide?

Ans The Project Proposal package shall provide all general design considerations that can be developed
without requiring measurement of field data. The Project Proposal package should include:

a) A scope of work including a specific statement that clearly identifies any additional requirement to
provide CP for any existing pipeline.
b) Proposed locations of new cathodic protection systems on an overall CP system layout drawing,
including proposed anode type(s) and estimated output ratings of the proposed cathodic protection
power source.
c) Information on spare cathodic protection capacity (from nearby or adjacent pipelines) along the
route of the proposed pipeline.

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d) Information on all locations where the proposed pipeline will be mechanically connected to other
facilities (plants, pipelines etc.) with clear details on whether these other facilities will be electrically
isolated.

Q At which locations the electrical isolation or supplemental cathodic protection is mandatory?

Ans Electrical isolation or supplemental cathodic protection is mandatory at

(a) Valve stations and scraper traps

(b) Motor operated vales (MOVs)
(c) Metallic supports
(d) Pipelines between GOSPs, WIPs, or other production facilities
(e) Product pipeline to bulk plant transitions

Q What are the bonding requirements for buried pipelines?

Ans Bonding shall be provided at the following locations

(a) At every 10 km intervals (at all negative drain points for ICCP power supplies) between the parallel
pipelines wherever pipelines are parallel within 50 meters
(b) At all buried pipeline crossings
(c) All the negative drain points for ICCP power supplies
(d) Within 500m start and end of parallel segment

*Bonding is required between the crossing pipelines and parallel pipelines, provided adjacent pipelines are
not more than 50 meters apart.

Q Which kind of anode shall install for temporary CP?

Ans Install galvanic anode of Mg for temporary CP system using 3‐pin test station.

Q What is the size of cables used for CP bonding?

Ans 10 mm sq. and 16 mm sq. (8‐AWG & 6‐AWG)

Q What is the minimum size for the primary positive and negative DC cables from the rectifier?

Ans The minimum size for the primary positive and negative DC cables from the rectifier shall be 25 mm2 (# 4
AWG)

Q What is the size of bond conductor in Aramco standard?

Ans The minimum bond conductor size shall be 16 mm2 / 6AWG

Q How many anodes are installed at buried mechanical fitting?

Ans One 32 lbs prepackaged anode in installed

Q (1) How many anodes are installed at full thrust anchors?

(2) How many anodes are installed at trust bored road crossings?

Ans Two 60 lbs prepackaged Mg anodes at each end, total of 4 anodes.

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Q At thrust anchor anode installation, how much distance is required from anodes to pipeline & thrust anchor?

Ans Four anodes are installed at thrust anchor two at each side, distance from pipe to anode shall be
1000mm/1m and 600mm apart from thrust anchor and 900mm deep.

Q How many anodes are installed at camel crossings?

Ans One 60 lbs prepackaged anode per pipe, plus one additional 60 lbs prepackaged anode, i.e. one pipe requires
2 anodes and two pipes requires 3 anodes.

Q How many anodes are installed for open road cut?

Ans 2 anodes, one at each side for the open cut road.

Q How many anodes shall install at thrust anchor located inside the fence or plant area?

Ans 2 magnesium anode, one at each side.

Q What is the mini length for the pipe line to be treated as cross country pipe line?

Ans As per SAES‐X‐400, the minimum length for the cross country pipe line is 25‐KM. if pipeline is more than 25
km it shall be call or treated as cross country pipe line.

Q What is the voltage value of CP cable holiday test?

Ans 18 KV ‐ DC

Q What the minimum life is of impressed current and galvanic anode system?

Ans As per the SAES‐X‐600, the minimum design life of impressed current and galvanic anodes shall be 20 years.

Q What the minimum life is of temporary CP system?

Ans The minimum design life of temporary CP system shall be 2 years.

Q What is the capacity/rating of power source is required for ICCP?

Ans 50V & 100 Amps

Q At what locations test station should be provided on pipelines?

Ans Test station shall be provided at

(a) At kilometer marker (1‐pin)

(b) At anode locations (3‐pin)

Q Within how many days of pipeline burial there should be installed 1‐pin and 3‐pin test stations?

Ans Within 1‐week of berming completed.

Q What shall be the height of test station from grade level?

Ans It shall be 1200mm/1.2m

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Q What is the purpose of test station?

Ans The purpose of the test station is to take the pipe‐to‐soil potential measurements.

Q What is the average current density of galvanic anodes for buried pipelines?

Ans Average current density for bare pipelines is 20 mA/m2

Average current density for coated buried pipelines is 0.1 mA/m2 (design criteria) and 0.005 mA/m2
(temporary criteria)

Q What is the maximum current density of impressed current anode?

Ans For HSCI anode maximum current density is 0.7 mA/cm3

Q What is the mini currents density value for bare buried steel?

Ans Minimum current density for bare steel buried is 20 mA/m2

Q What is the mini current density value for copper ground rod?

Ans Minimum current density for copper ground rod is 50 mA/m2

Q What is the minimum and maximum voltage for buried pipeline?

Ans According to SAES‐X‐400 minimum voltage 1.V and maximum 3 V with the reference to a copper /copper
sulfate electrode.

Q What types of reference electrodes are used for taking voltage potential value from pipe‐to‐soil?

Ans Copper‐copper sulfate (Cu‐CuSO4) reference for soil, and silver‐chloride (Ag/AgCl) electrode for aqueous
applications.

Q How much depth require for installation of Anode for ICCP protection and galvanic cathodic protection?

Ans For ICCP anode bed, minimum depth requirement is 15 meters (50 ft.) and for galvanic 900mm.

Q How much depth require for installation galvanic Anode?

Ans For galvanic anode the required depth is 900 mm/ 90 cm from the ground level and in rocky areas it should
be 300 cm/ 30 cm, the clearance between pipeline and anode should be 600 mm/ 60 cm.

*When parallel piping runs prohibit 600 minimum clearance, anodes shall be buried a minimum of 600
below pipe (except 300 min. in rocky areas).

Q What should be the minimum distance between two anodes installed side by side?

Ans There should be 1.5 m distance between two anodes.

Q What should be the clearance/ distance between pipeline and anode in CP?

Ans The clearance between pipeline and anode should be 600 mm/ 60 cm

Q What is the minimum HSCI anode bed distance from the buried pipe line or structure?
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Ans SAES‐X‐400 says minimum distance 35 meter and maximum 225 meter.

Q What are the depth requirements for direct buried CP cable Trench?

Ans For sand or subka area

Total 750mm is required including 150mm sand bedding and then after warning tap 450mm sand cover.

For Rocky Area

Total 300mm is required including 75mm sand bedding and then 125mm cement backfill.

For Sand and Rock Area

Total 450mm is required including 75mm sand bedding and after warning tap 150mm crushed marl backfill.

Over the pipeline crossing

Total 600mm required including 150mm sand bedding (distance between cable and pipe) and 450mm sand
cover.

Q What is the width of CP cable trench?

Ans It is 200mm.

*Cathodic protection Junction Boxes and Bond Boxes shall be manufactured in accordance with 17‐
SAMSS‐008.

Q What is the difference between the bonding box and junction box?

Ans Bonding box is used in bonding two wires, while junction box in instrumentation for connection of
instrument wires.

Q What is the difference between distribution board and junction box?

Ans Junction box contains terminal blocks and is used for termination and joining of cables. While distribution
board contains breakers for distribution of electricity to one or more power circuits.

*Do not install the D.C power supply in hazards location

*Do not use DC power supplies with rated output voltage greater than 100 volts

*Do not install isolating devices in areas classified as hazardous locations.

*Do not install isolating devices in any buried or submerged portions of a pipeline.

*Install the rectifiers in non‐hazardous areas where possible and use oil‐immersed rectifier units inside
hydrocarbon plant areas.

*Conduct soil resistivity or soil conductivity measurements at 10‐meter intervals over the full length of the
proposed remote surface anode bed location.

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*The number and size requirements for the anodes shall be determined based on providing a sufficient
potential gradient over the entire length of the respective pipeline to achieve the protection criteria.

*If impressed current anodes are placed within 50 meters of a thrust anchor, then two additional impressed
current anodes shall be installed within 15 meters of the anchor, and placed on opposite sides of the anchor.
If impressed current anodes are installed, galvanic anodes are not required for the thrust anchor.

*Use 27.2 kgs (60 lbs) magnesium anodes for soil resistivities greater than 500 ohm‐cm.

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