SAEP-57 Engineering Procedure Saudi Aramco

SAEP-57

Factory and Site Acceptance Testing Requirements for Medium Gas Metering Systems with USM

Document Responsibility: Custody Measurement Standards Committee

Saudi Aramco DeskTop Standards   

Table of Contents

1 Scope............................................................. 2

2 Conflicts and Deviations................................. 2

3 Applicable Documents.................................... 2

4 Definitions and Acronyms............................... 4

5 Instructions..................................................... 6

6 Factory (Site) Acceptance Test Report.......... 7

7 Responsibilities.............................................. 7

8 Pre-requisites................................................. 7

1 Scope

This procedure specifies the requirements to conduct Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) for the Medium Gas Metering Systems with Ultrasonic Meters as specified by 34-SAMSS-153 and 34-SAMSS-114. Conducting these tests is mandatory as stated in SAEP-21 and SAEP-50.

The purpose of the FAT and SAT is to demonstrate, to the fullest extent possible at the vendor’s facilities and site location, that the subject Medium Gas Metering System meets all requirements of the Job Specification, particularly the Functional Specification Document before being shipped to the site and before commissioning. The test shall include the functionality of the Metering Skid (software, hardware and special application packages).

2 Conflicts and Deviations

2.1 Any conflicts between this procedure and other applicable Saudi Aramco Engineering Standards (SAES’s), Materials System Specifications (SAMSS’s), Saudi Aramco Standard Drawings (SASD’s), or industry standards, codes, and forms shall be resolved in writing by the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this procedure in writing in accordance with SAEP-302 to the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.

2.3 Direct all requests for interpretation of this procedure in writing to the chairman, Custody Measurement Standards Committee for resolution. The Chairman, Custody Measurement Standards Committee shall be solely responsible for determining whether a proposed request meets the requirements of this procedure.

3 Applicable Documents

All referenced Procedures, Standards, Specifications, Codes, Forms, Drawings, and similar material or equipment supplied shall be considered part of this Procedure to the extent specified herein and shall be of the latest issue (including all revisions, addenda, and supplements), unless stated otherwise.

3.1 Saudi Aramco References

Saudi Aramco Engineering

SAEP-50 Project Execution Requirements for Third party Royalty/Custody Metering Systems

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standard

SAES-A-112 Meteorological and Seismic Data

Saudi Aramco Material System Specifications

34-SAMSS-114 Ultrasonic Flow Meter for Gas Custody Measurement

34-SAMSS-153 Medium Gas Metering System with Ultrasonic Flow Meters

34-SAMSS-846 Flow Computers for Custody Transfer Measurement of Hydrocarbon Gases

Saudi Aramco Standard Drawings

AB-036183 Medium Metering Skid (Gas) – Ultrasonic Flow Meter Based

AC-036045 Detail Vent, Drain and Sample Connections

AE-036046 Standard Sample Tube

Saudi Aramco Library Drawings

DC-950040 Pressure Indicators and Switches

DC-950042 Instrument Piping Details – Pressure Instruments

DC-950061 Flow Meter Installations – Gas and vapor service (non-corrosive)

Saudi Aramco Instrument Specification Sheets

SA-8020-153-ENG Medium Gas Metering System with USM

SA-8020-846-ENG Flow Computer

Saudi Aramco Form and Data Sheet

7213-ENG Mechanical Completion Certificate

Saudi Aramco Inspection Form

175-XXXXXX

3.2 Industry Codes and Standards

American Petroleum Institute

API MPMS Ch. 21.1 Electronic Gas Measurement

American Gas Association

AGA 5 Natural Gas Energy Measurement (Report 5)

AGA 8 Compressibility Factor of Natural Gas and Related Hydrocarbon Gases (Report 8)

AGA 9 Measurement of Gas by Multipath Ultrasonic Meters (Report 9)

AGA 10 Speed of Sound in Natural Gas and Other Related Hydrocarbon Gases (Report 10)

4 Definitions and Acronyms

4.1 Definitions

Approve: Review and formal acceptance characterized by the signature of a final authorizing individual or organization.

Buyer: The Company (Saudi Aramco, Aramco Overseas Co., or Aramco Services Co.) actually placing the order for the material. The buyer can be a third party metering system customer.

Buyer's Representative: The person acting on behalf of the Buyer, who may be from the Engineering, Inspection, Purchasing, or User organization.

Company: Refers to a Saudi Arabian Oil Company (Saudi Aramco) and its affiliates.

Construction Contractor: An entity that is responsible for construction of a facility based on the approved project documentation provided by Saudi Aramco.

Custody Transfer Measurement: A specialized form of measurement that provides quantity and quality information used for the physical and fiscal documentation of a change in ownership and/or responsibility of hydrocarbon commodities. This includes measurement of hydrocarbon liquid movements (deliveries or receipts) between Saudi Aramco and its customers, suppliers, joint ventures and transport contractors including VELA ships.

Factory Acceptance Test (FAT): A series of tests conducted at the vendor’s plant to demonstrate compliance of the System with the job specification requirements, to the maximum extent possible in the Contractor's factory environment.

Functional Specification Document (FSD): Provides the technical requirements for the System.

Job Specification: The scope of the work to be performed pursuant to a contract; it describes or references the applicable drawings, standards, specifications, as well as the administrative, procedural, and technical requirements that the Contractor shall satisfy or adhere to in accomplishing the work.

Medium Gas Metering System: A metering system designed to handle gas flow rates between 20 MMSCFD and 200 MMSCFD.

Non-Material Requirements (NMRs): The complete set of documentation required in the electronic form from the Vendor and/or the Contractor during the design and development phase of the project. There are three categories of NMRs:

601 NMRs: Preliminary drawings for review and approval.

602 NMRs: Certified drawings, literature, photographs, and parts data/requirements.

603 NMRs: Operations, maintenance manuals, installation instructions, test certificates, etc.

Pre-FAT: A comprehensive test, completed by the vendor prior to FAT, which ensures that the System can be tested according to FAT procedures without unanticipated delays.

Proponent: The Saudi Aramco organization responsible for signing the Saudi Aramco Form 7213-ENG, Mechanical Completion Certificate. In the context of this document, the Proponent is the Saudi Aramco organization responsible for operating and maintaining the metering facility.

Project Management Team (PMT): The team of Company individuals who are assigned the responsibility of managing the project.

Site Acceptance Test (SAT): A series of tests conducted at the site location on the installed System that demonstrates compliance with all requirements, except availability.

System: is the metering skid system that is procured under the Contract.

Vendor: The party that supplies or sells integrated metering systems, metering equipment, or components sometimes called Integrator.

4.2 Abbreviations

API American Petroleum Institute

CMU Custody Measurement Unit of Process & Control Systems Department

FAT Factory Acceptance Test

FSD Functional Specification Design

GC Gas Chromatograph

MSC Metering Supervisory Computer

MPMS Manual of Petroleum Measurement Standards

SAEP Saudi Aramco Engineering Procedure

SAES Saudi Aramco Engineering Standard

SAMSS Saudi Aramco Material Specification System

SASD Saudi Aramco Standard Drawing

SAT Site Acceptance Test

5 Instructions

The FAT (SAT) Report shall contain the following sections, as a minimum:

a) Identify System and Vendor

b) Include certification statement

c) FAT (SAT) location, start date, completion date

d) Name of Contractor/Vendor representative and signature

e) List of Company representatives and signatures

f) A FAT (SAT) Punch List with description (exception items).

Appendix 1 is the outline of the FAT Procedure and Report. The FAT Procedure shall contain, as a minimum, the information specified and, except for any additions, need to follow the format of the outline.

Appendix 2 is the outline of the SAT Procedure and Report. The SAT Procedure shall contain, as a minimum, the information specified and, except for any additions, need to follow the format of the outline

6 Factory (Site) Acceptance Test Report

Appendices 1 & 2 shall serve as the FAT and SAT reports and when approved by the Company representatives shall be used as the certification that the FAT and SAT has been successfully completed.

Note that as a minimum a cover page, a system acceptance certificate page and the table of contents need to be added to Appendixes 1 & 2 to complete the FAT and SAT reports.

7 Responsibilities

The responsibilities of all Saudi Aramco organizations participating in the FAT and SAT of metering skids are stated in the SAEP-21 and SAEP-50. The assigned Saudi Aramco Project Management Team engineer is responsible for ensuring that the concerned organizations fulfill their responsibilities.

8 Pre-requisites

8.1 The vendor shall ensure that all parts of the metering system with its components have been integrated as per 34-SAMSS-153 and are ready for FAT and SAT.

8.2 All test equipment needed for all aspects of FAT (SAT) shall be identified. Valid calibration certificates of the test equipment shall be available prior to the start of FAT (SAT).

8.3 Provisions have been taken for the commissioning of the GC as per manufacturer procedures and/or by the vendor.

8.4 The Vendor shall conduct a Pre-FAT (SAT). Pre-FAT (SAT) is basically a trial run of all FAT (SAT) procedures to identify and correct any deficiencies that could cause delays during FAT (SAT). The pre-FAT (SAT) is carried out without the presence of Company representatives. The purpose of the pre-FAT (SAT) is to ensure that all hardware, software, and application program deficiencies have been identified and corrected before the official FAT (SAT) (for example: incorrect wiring from the test panel to the I/O points, incorrect wiring inside the equipment, bad I/O modules). A formal, signed pre-FAT (SAT) report shall be submitted to Saudi Aramco before commencement of FAT (SAT), the vendor shall complete Pre-FAT (SAT) utilizing the approved FAT (SAT) procedure/report.

8.5 Utility Requirements

Vendor shall provide all needed utilities to perform the FAT. Some of these utilities are: Control Panel power supply and Instrument air or nitrogen.

8.6 The buyer’s representative or his delegate shall inspect the complete integrated system as per 175-XXXXXX before testing. All the observations and recommendations shall be implemented before the FAT is commenced.

8.7 All documents as per Section 1.3 of Appendices 1 and 2 need to be available.

All documents referenced in the FAT (SAT) Procedure shall be listed with their revision numbers and publication date. Documentation which is part of System and/or is needed during FAT (SAT) shall be available. Specific items typically include User's Manuals, Maintenance Manuals, configuration drawings, connection drawings, database listings, logic drawings, instrumentation loop drawings (ILD), P&IDs.

Thanks and Regards,

PANDIAN

Document Controller ( QA/QC)

Gulf Asia Contracting Co LLC

Haradh and Hawiyah Field Gas Compression Project

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