saep-136

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Engineering ProcedureSAEP-136 16 September 2008Saudi Aramco Management ofElectric Equipment Obsolescence Program

Electrical Substations Equipment Standards Committee MembersIshwait, Basel A., Chairman

Ghamdi, Mohammed Ahmed, Vice Chairman

Fayez, Hamad Abdullah

Gopal, Uarutharaja

Hartman, Ralph August

Helfrich, Cory Allan

Maghrabi, Ibrahim Mohammad

Nazzawi, Abdullah Omar

Ojan, Jawad Ali

Ramadhan, Mohammad Jafar

Refai, Jobran AliRumaih, Waleed A.

Carlson, Ron W.

Sheef, Jaafar Abdullah

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 22 Applicable Documents................................... 23 Terms and Definitions.................................... 24 Program Components.................................... 45 Program Description...................................... 56 Responsibilities.............................................. 77 Electrical Obsolescence Flowchart.............. 10

Appendix A - Equipment Manufacturer Survey.. 11Appendix B - Obsolescence Criteria

and Scoring Procedure........................ 12

Previous Issue: 30 June 2004 Next Planned Update: 1 July 2009Revised paragraphs are indicated in the right margin Page 1 of 20Primary contact: Qahtani, Ali Mohammed on 963-3-876-0323

CopyrightSaudi Aramco 2008. All rights reserved.

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Document Responsibility: Electrical Substations Equipment SAEP-136Issue Date: 16 September 2008 Saudi Aramco Management ofNext Planned Update: 1 July 2009 Electric Equipment Obsolescence Program

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1 Scope

This SAEP describes the implementation and administration of the Saudi Aramco

Electrical Equipment Obsolescence program. The purpose of this program is to monitorand report on the state of Electrical Equipment obsolescence at all Saudi Aramcofacilities. In itself, the result of the obsolescence measurement does not constitutejustification, inclusion or approval of a project in the Capital Program.

2 Applicable Documents

The requirements contained in the following documents apply to the extent specified inthis procedure.

Saudi Aramco References

Saudi Aramco Engineering Standards

SAES-P-100 Basic Power System Design Criteria

SAES-P-103 Direct Current and UPS Systems

SAES-P-116 Switchgear and Control Equipment

Saudi Aramco Materials System Specifications

16-SAMSS-502 Metal-Enclosed Low-Voltage Assemblies

16-SAMSS-503 Indoor Controlgear - Low-Voltage

16-SAMSS-504 Indoor Metal-Clad Switchgear - 1 to 38 kV

16-SAMSS-506 Indoor Controlgear - High Voltage

16-SAMSS-507 High Voltage Motor Controller - Outdoor

16-SAMSS-508 SF6 Gas Insulated Circuit Breakers, Outdoor -

34.5 kV through 230 kV

16-SAMSS-510 Manually Operated Pad Mounted SF6 Switchgear

16-SAMSS-519 Indoor Switchboard

17-SAMSS-514 Battery Charger/Rectifier

17-SAMSS-516 Uninterruptible Power Supply (UPS) Systems

3 Terms and Defini tions

3.1 Terms

Approved Third Party Supplier: A spare parts supplier, other than theOriginal Equipment Manufacturer, who has the license to supply spare
http://standards/docs/SAES/PDF/SAES-P-100.pdfhttp://standards/docs/SAES/PDF/SAES-P-103.pdfhttp://standards/docs/SAES/PDF/SAES-P-116.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-502.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-503.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-504.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-506.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-507.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-508.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-510.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-519.pdfhttp://standards/docs/SAMSS/PDF/17-SAMSS-514.pdfhttp://standards/docs/SAMSS/PDF/17-SAMSS-516.pdfhttp://standards/docs/SAMSS/PDF/17-SAMSS-516.pdfhttp://standards/docs/SAMSS/PDF/17-SAMSS-514.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-519.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-510.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-508.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-507.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-506.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-504.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-503.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-502.pdfhttp://standards/docs/SAES/PDF/SAES-P-116.pdfhttp://standards/docs/SAES/PDF/SAES-P-103.pdfhttp://standards/docs/SAES/PDF/SAES-P-100.pdf

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parts/upgrades for a specific device. Approval of such a supplier needscomplete type test data, performed on the equipment, for evaluation.

BI-19 project: A special Master Appropriation in the Capital Budget. Itprovides funds for construction or purchase of miscellaneous assets withminimum capital value of $10,000 and maximum total project cost of$2,000,000.

Capital Projects: A project with a value over $2,000,000 and documented inthe annual budget as separate budget items.

Controlgear: Equipment manufactured to either 16-SAMSS-503(Low VoltageControlgear), 16-SAMSS-506(High Voltage Controlgear) or 16-SAMSS-507(High Voltage Motor Controller - Outdoor).

Critical loads: Loads for which a single contingency failure could cause a lossof power which would create an immediate hazard to human life or cause asignificant reduction in Saudi Aramco production, or loads which cannot beshut-down for a minimum of one day annually for scheduled maintenance onupstream power supply equipment. Examples of critical loads are: majorcomputer centers, critical care areas in clinics and hospitals, major officebuildings, process units in major gas plants, major GOSPs, Terminals, andprocess units in refineries.

DC Power System: Consists of batteries, battery chargers and outputdistribution Panel boards, built to 17-SAMSS-514.

Electrical Equipment: Equipment used to transmit and distribute electricity.Major Electrical Equipment are listed in section 4.1.1.

Electrical Master Plan: A survey of all facilities, headed by FPD, to plan forall expected future projects, including the replacement of obsolete equipment.

High Voltage: Voltages 1000 V or greater unless otherwise designated in aspecific MSAER or referenced international standard, as defined inSAES-P-100.

Low Voltage: Voltages less than 1000 V, unless otherwise designated in a

specific MSAER or referenced international standard, as defined inSAES-P-100.

Obsolete Equipment: No longer useful, i.e. when the function(s) performed bythe equipment or system is physically or economically unsupportable.

Obsolescence: Obsolescence is defined as the process of becoming obsolete.Obsolescence can be used to describe the process through which Electrical
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equipment (technology/system/component) transitions during its life cycle fromthe 'original state' (design/installation) towards a state of being obsolete. Thecircumstances and parameters contributing to obsolescence have been identified

in the 8 Obsolescence Criteria contained in Appendix B of this procedure.

Redundant System: A system where a load is supplied by two power sources;such as a double ended switchgear, or where two loads exist with the samefunction; such as run and standby pumps.

Spare Parts: For purposes of determining obsolescence, spare parts for majorequipment shall be limited to components of type tested assemblies. This doesnot include items such as relays, fuse blocks, CTs, etc.

Switchgear: Equipment manufactured to either 16-SAMSS-502(Low Voltage

Switchgear) or 16-SAMSS-504(High Voltage Switchgear).

UPS System: Consists of batteries, battery charger/rectifiers, inverters, statictransfer switch, bypass line (bypass transformer and maintenance bypassswitch), and output distribution Panelboards, built to 17-SAMSS-516.

3.2 Abbreviations

AOC Aramco Overseas Company

ASC Aramco Services Company

BOE Board of Engineers

CSD Consulting Services Department

DC Direct Current

EPI Engineering Program Item

FPD Facilities Planning Department

MSAER Mandatory Saudi Aramco Engineering Requirements

MSO Material Supply Organization

OEM Original Equipment Manufacturer

PDD Power Distribution Department

SAES Saudi Aramco Engineering Standards

SAMSS Saudi Aramco Material Specification System

UPS Uninterruptible Power Supply
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4 Program Components

The Electrical Equipment Obsolescence Program was developed in 2003 in response to

a BOE request to measure and track the status of obsolescence of Saudi AramcoElectrical Equipment. The main objective is to ensure the continued availability of asafe and reliable power supply system. The Obsolescence Program currently consists ofthe following components:

DATABASE: A Company-Wide database of Electrical Equipment information,accessible to all Business Lines, Admin. Areas and Departments that will bemaintained in an up-to-date manner as prescribed by this document.

CRITERIA: An eight point Obsolescence Criteria and scoring system withguidelines that are intended to provide an objective measure of obsolescence for

existing Electrical Equipment. The Criteria will be periodically applied using thedatabase to determine and track equipment obsolescence.

REPORTS: Upon completion of the Criteria evaluation, the results will be archivedand obsolescence reports will be generated with flags highlighting specific areas ofobsolescence risks and concerns.

FPD PLANNING: Electrical Equipment Obsolescence Reports shall be provided toFacilities Planning Department (FPD) as an input to the development of the businesscase analysis for new project submittals by Proponents, and shall be used for futureupdates of the Electrical Master Plan.

5 Program Description

This section provides an overview of the management requirements of the ElectricalEquipment Obsolescence Database, Obsolescence Criteria, Scoring, and ReportingSystems.

5.1 Database

The database contains detailed information on the Electrical Equipment for eachSaudi Aramco facility. The database tracks the following equipment types:

Low voltage and high voltage Switchgear as defined in 16-SAMSS-502and16-SAMSS-504.

Low voltage and high voltage Circuit Breakers as defined in 16-SAMSS-502and 16-SAMSS-504.

Low voltage and high voltage control gear as defined in16-SAMSS-503and16-SAMSS-506.
http://standards/docs/SAMSS/PDF/16-SAMSS-502.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-504.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-502.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-504.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-503.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-506.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-506.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-503.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-504.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-502.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-504.pdfhttp://standards/docs/SAMSS/PDF/16-SAMSS-502.pdf

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Outdoor motor controllers, as in 16-SAMSS-507.

Low voltage and high voltage outdoor switches, as defined by

16-SAMSS-508and 16-SAMSS-510.

Low voltage Switchboards, as defined by 16-SAMSS-519.

UPS systems as defined by 17-SAMSS-516.

Battery Chargers as defined by 17-SAMSS-514.

5.1.1 Database Information Gathering

Database contains fields of data originating from the Proponent, CSD,FPD, MSO, and the Vendor. Each organization will be responsible for

performing its own information gathering.

5.1.2 Database Access

The Obsolescence Database will be shared over the Company intranet tothe assigned Proponent, CSD, MSO, and FPD representatives withpassword access.

5.2 Electrical Equipment Obsolescence Criteria

5.2.1 Criteria Description

The Electrical Equipment Obsolescence Criteria consists of 8 individualcriterions, which are questions selected to fully cover all obsolescenceaspects. When scored and summed, they produce an objective measureof that equipment obsolescence. Additionally, threshold values for eachcriterion have been established, those criteria that are at or below thethreshold value will be flagged. These measurements provide for a morein-depth indication of the condition of the equipment. See Appendix B:Obsolescence Criteria and Scoring Procedure for a detailed list of theObsolescence Criteria and instructions for their use.

5.2.2 Electrical Equipment Obsolescence Criteria Application and Scoring

5.2.2.1 The Electrical Equipment Obsolescence Criteria are to bescored utilizing the information retained in the database. TheCriteria require careful and deliberate evaluation using the bestinformation and data available, therefore application of theCriteria will not be automatic and will require specificindividual scoring for each plant.
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5.2.2.2 The Electrical Equipment Criteria are to be applied and scoredfor each piece of equipment, identified in section 5.1, withineach plant. Each criterion has a 0-10 scoring, with 0 being the

lowest score. Each criterion has a weighting (1.25). The scoremultiplied by the weight produces the composite criterion score.All 8 criteria summed make the Equipment Obsolescence rating.A rating of 40 or less, out of 100, will be the hurdle rate at whichan item of equipment may be considered obsolete.

5.2.2.3 Additionally, each criteria question is assigned a FlagThreshold. If the numeric evaluation score is equal to or belowthe threshold value a "Flag" is set for that criteria question.This provides additional indicators as to the condition of theElectrical Equipment.

5.3 Obsolescence Reporting

An obsolescence report will be generated and affected users will be notifiedwhen criteria scoring falls below the threshold score.

5.4 Implementation Plan

The Electrical Equipment obsolescence condition, as measured through thisSAEP, is one of the inputs to developing the business case justification forElectrical Equipment upgrade or replacement projects. In itself, the result of theobsolescence measurement does not constitute justification, inclusion or

approval of a project in the Capital Program. Following are general guidelinesthat shall be used to plan for obsolete equipment identification and replacement:

5.4.1 Obsolete equipment whose failure would constitute a safety hazard shallbe rectified immediately under a BI-19 project, or submitted to FPD forintroduction into the capital plan as a safety priority. These items will beassigned a ranking of 1.

5.4.2 Projects for the replacement/retrofitting of all other obsolete equipmentshall be submitted to FPD for assessment and potential inclusion into thecapital plan, based on Business Case Analysis.

6 Responsibilities

Administration of the electrical obsolescence program shall be as follows:

6.1 Proponent Responsibilities

The Proponent Departments shall ensure that the Electrical Equipment data

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exists, for the various systems at their facilities. To this end, each Proponentshall select their coordinator and identify him to both FPD (InformationTechnology and Electrical Facilities Planning Division) and CSD (Electrical

Equipment Unit). This Coordinator is responsible for access to the Databasewithin his organization. The Proponent coordinator shall:

6.1.1 First consult the obsolescence database to verify the status of theequipment before approaching MSO.

6.1.2 In partnership with MSO, confirm equipment spare parts status with thevendor, using the vendor questionnaire in Appendix A.

6.1.3 Update the database, provide all related documentation and populate itwith new equipment, with the assistance of the maintenance

organizations and PDD.

6.1.4 Proponent Coordinators will be the single point contact for allinterdepartmental Obsolescence communications.

6.2 MSO Responsibilities

The MSO Department will be required to supply data to the ObsolescenceDatabase. To this end, MSO shall identify an Obsolescence Coordinator fromSupplier Development & Registration Unit of Purchasing Department. ThisCoordinator is responsible for contacting vendors, using the questionnaire ofAppendix A. The MSO coordinator will be responsible for access to the

database and providing input for the Obsolescence Scoring evaluation.Coordinators will be the single point contact for all interdepartmentalObsolescence communications.

6.3 CSD Responsibilities

6.3.1 Standards Coordinator shall be the responsible for ownership of thisSAEP.

6.3.2 If the proponent confirms information other than that in the database,CSD shall verify this information.

6.3.3 CSD is responsible to assist with all technical matters associated withthis effort.

6.4 FPD Responsibilities

6.4.1 FPD maintains its traditional role of business case and project alternativeanalysis and the development of project justifications consistent with the

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Capital Programs investment policies and requirements of CorporatePlanning and Finance.

6.4.2 FPD will utilize Obsolescence criteria evaluations to identify businessopportunities and assist in the development of migration, upgrade andreplacement Programs and Planning Strategies via updates of theElectrical Master Plan.

6.4.3 FPD shall issue a bi-annual reminder to all proponent organizations toupdate the database, as part of the Electrical Master Plan.

6.4.4 FPD shall discuss the issue of Electrical Obsolescence during any futureElectrical Master Plan meeting with the proponents.

Proponent and FPD are responsible for assessing and scoring equipmententered into the database using the ranking criteria.

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7 Electrical Obsolescence Flowchart

Check database for current

status on equipment

Database Flagging aparticular equipment for re-

evaluation based on its

score

Use SAEP questionnaire, incontacting manufacturer

Update database bsed on new

findings, and entering new

equipment

Scoring Cycle of2 years during the

Electrical Master Plan

Operational, maintenanceand spare part concerns

identified by user

Perform criteria evlauation

scoring

Confirm findings

Issue allert to facilitiesand notify FPD

No alert, wait for next

scoring cycle

Take action

Project evaluation and

submittal

Score < 40 Score > 40

Yes

No

Proponent

Standardization with

the asistance of the

Proponent

Proponent

CSD

CSD

FPD and

Proponent

Revision Summary30 June 2004 New Saudi Aramco Engineering Procedure.16 September 2008 Editorial revision to replace the Electrical Substations Equipment Standards Committee

Chairman and Vice Chairman.

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Appendix A Equipment Manufacturer Survey

Manufacturer

Equipment Type

Survey Questions:

1 Are spare parts available Yes No

2 Are the available spare parts complete or limited

3 Are these original equipment spare parts new or refurbished?

4 How many years will these parts be available

5 Is there a minimum quantity of parts required to process an order?Specify.

6 What is the average delivery time for non-stocked spare parts?

7 Do you have an existing spare parts agreement with Saudi Aramco?

8 Is there a factory-built direct replacement/retrofit for the equipment?

9 Is design test data available for this direct replacement/retrofitequipment?

10 Can you refurbish/recondition this equipment?

11 Where is the refurbishment work done?

12 What is the warranty period for new/reconditioned/refurbished equipment

13 Please provide contact information (name or position, complete address,telephone number, fax number and e-mail)

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Appendix B Obsolescence Criter ia and Scor ing Procedure

The obsolescence evaluation criteria are listed below and described in more detail later:

Criterion 1

Rate the criticality of the fed load.

Criterion 2

Rate the redundancy of Supply/Load.

Criterion 3

Rate the availability of spare parts from the OEM or an approved third-party supplier.

Criterion 4

Rate the years of vendor support.

Criterion 5

Rate the speed of spares delivery.

Criterion 6

Rate the cost of spares.

Criterion 7

Rate the failure incident rate since last PM.

Criterion 8

Rate the equipment condition and age.

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Appendix B Obsolescence Criter ia and Scoring Procedure (Cont 'd)

Obsolescence Criterion 1

Rate the criticality of the fed load

Criterion Clarification:

"Loads for which a single contingency failure could cause a loss of power which wouldcreate an immediate hazard to human life or cause a significant reduction in SaudiAramco total production, or loads which cannot be shut-down for a minimum of oneday annually for scheduled maintenance on upstream power supply equipment.Examples of critical loads are: major computer centers, critical care areas in clinics andhospitals, major office buildings, process units in major gas plants, major GOSPs,Terminals, and process units in refineries."

This definition is extracted from SAES-P-100.

Data Source:

Proponent shall provide information on the criticality of the load based on the abovedefinition and utilizing:

Single line diagrams

Process and Instrumentation Diagrams

Guideline for scoring:

Score Load Criticality

0 Critical

10 Not critical
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Rate the redundancy of Supply/Load


The load can be fed from two power sources (such as a double ended switchgear).

There are two or more loads performing the same duty (such as running and standbymotors on process pumps).

Data Source:

Proponent shall provide information on the redundancy of the load based on the abovedefinition and utilizing:

Single-line diagram

Process and Instrumentation Diagrams


Score Redundancy

0 Not redundant

10 Redundant

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Rate the availability of spare parts from the OEM or an approved third-party

supplier


Are spares available within the Saudi Aramco system?

Are spares available from the Original Equipment Manufacturer?

Are spares available from an approved third party supplier?

Data Source:

Proponent in collaboration with MSO shall provide information on the availability ofspare parts through:

Saudi Aramco spares system

Vendor questionnaire


Score Spares Availability

0 No spares available

3Limited spares available within Saudi Aramco system,the OEM or the approved third party supplier (FLAG)

7Only normal consumable spare parts available withinSaudi Aramco system, the OEM or the approved thirdparty supplier

10All spares available within Saudi Aramco system, theOEM or the approved third party supplier

A flag is triggered on a score of "3" or less.

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Rate the years of vendor support


This score should be based on the years of stated support available.

Data Source:

Information on the years of support can be found from the Vendor questionnaire.


Score Years of Support

0 No support available

2 Support available for only 2 years

5 Support available up to 5 years (FLAG)

8 Support available from 5 to 10 years

10 Support for 10 years or more


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Rate the speed of spares delivery


This score should be based on the time required for the delivery of spare parts from anysource.

Normal lead time for one complete unit could take up to 1 year.

Data Source:

Vendor questionnaire

Recent proponent purchase orders


Score Delivery time

0 Greater than six months

2 Within 6 months4 Within 4 months (FLAG)

6 Within 2 months

8 Within 1 month

10 Within 1 week

A flag is triggered on a score of "4".

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Rate the cost of spares


This score should be based on the cost of the equipment spare parts in comparison to acomplete equipment replacement.

Data Source:

Proponent in collaboration with MSO shall provide information on spare part costcompared to new equipment cost.


Score Cost of Spares

0 More than 60% of equipment value (FLAG)

3 40% of equipment value

7 25% of equipment value

10 10% or less of equipment value

A flag is triggered on a score of "0".

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Rate the failure incident rate since last PM


This score should be based on the number of failures that have occurred since the lastPreventive Maintenance (PM) on a specific piece of equipment. Failures caused byhuman error shall not be considered.

Data Source:

Equipment Proponent (i.e. Plant or PDD) shall provide information on the equipmentrate of failure between consecutive PM (maintenance records).


Score Failure rate

0 More than 2 failures since last PM

3 2 failures since last PM (FLAG)

7 1 failure since last PM

10 No failures since last PM


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Rate the equipment condition and age

Clarification:

This score should be based on the equipment physical condition and age.

Data Source:

Equipment Proponent shall provide information on equipment age and physicalcondition.


ConditionAge

Good Fair Poor

0-10 10 7 4

10-15 9 6 3

15-20 8 5 2

20-25 7 4 1

25+ 6 3 0


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