Sabp X 002

Best Practice
SABP-X-002 3 June 2015

Cathodic Protection Rectifier (Tap Adjustable) Factory Acceptance Tests
Document Responsibility: Cathodic Protection Standards Committee
Saudi Aramco DeskTop Standards

Table of Contents
1 Introduction..................................................... 3
2 References..................................................... 4
3 Definitions....................................................... 4
4 Factory Acceptance Tests.............................. 5
Previous Issue: 26 November 2007 Next Planned Update: TBD

Revised paragraphs are indicated in the right margin
Primary contact: Al-Mahrous, Husain Maki (mahroohm) on +966-13-8809631
Copyright©Saudi Aramco 2015. All rights reserved.

Document Responsibility: Cathodic Protection Standards Committee SABP-X-002
Issue Date: 3 June 2015
Next Planned Update: TBD Cathodic Protection Rectifier (Tap Adjustable) Factory Acceptance Tests
Detailed Index of Contents

1 Introduction ............................................................................................................ 3
1.1 Purpose ................................................................................................................................. 3
1.2 Scope ..................................................................................................................................... 3
1.3 Disclaimer.............................................................................................................................. 3
1.4 Conflicts with Mandatory Standards .................................................................................. 4
2 References ............................................................................................................. 4
2.1 Saudi Aramco References ................................................................................................... 4
2.2 Industry Codes and Standards ........................................................................................... 4
3 Definitions .............................................................................................................. 4
4 Factory Acceptance Tests ...................................................................................... 5
4.1 Rectifier Name Plate Rating Information ............................................................................ 5
4.2 Instructions for Conducting the Factory Acceptance Tests (FAT) ................................. 5
4.3 Component Data Sheets ...................................................................................................... 6
4.4 Performance Data Sheets .................................................................................................... 6
Table A – Factory Acceptance Test Equipment Categories ............................................................ 7
Table B – Design Acceptance Performance Tests .......................................................................... 9
Table C – Routine Production Performance Tests .......................................................................... 9
5 VID Requirements ................................................................................................ 11
 5.1 VID Requirements (Mandatory for FAT approval) ..................................................... 11
 5.2 VID Requirements (Recommended but not mandatory for FAT approval) ............. 11
6 CSD Requirements .............................................................................................. 11
 6.1 New Manufacturer Requirements ............................................................................... 11
 6.2 Installation and Operating Manual .............................................................................. 11
 6.3 Enclosure (Class AA = Dry Air Cooled, Class OA = Oil, Air Cooled) ...................... 11
 6.4 Chassis .......................................................................................................................... 13
 6.5 Instrument Panel ........................................................................................................... 13
 6.6 Labeling ......................................................................................................................... 14
 6.7 Transformers ................................................................................................................. 14
 6.8 Tap Switches and Link Bars ........................................................................................ 14
 6.9 Rectification Components ........................................................................................... 14
 6.10 Meters ............................................................................................................................ 15
 6.11 DC Current Measurement Shunts ............................................................................... 15
 6.12 Fuses .............................................................................................................................. 15
 6.13 Circuit Breaker .............................................................................................................. 16
 6.14 Wires .............................................................................................................................. 16
 6.15 Terminals ....................................................................................................................... 17
 6.16 Lightning and Surge Protection .................................................................................. 17
Page 2 of 18
1 Introduction
1.1 Purpose
The purpose of this Best Practice is to establish guidelines for the Saudi Aramco
RSA or his representative to conduct the Factory Acceptance Test (FAT) required
by 17-SAMSS-004 on each category of Tap Adjustable Cathodic Protection
Rectifier.
1.2 Scope
This Best Practice provides guidelines for evaluating the quality of

workmanship and operating performance characteristics for Tap Adjustable
Cathodic Protection Rectifiers constructed in accordance with 17-SAMSS-004.
Commentary Note:
Cathodic protection rectifiers used in Saudi Aramco facilities use only natural air
cooling (no forced air or pumped oil) and are defined in the standards as:
Class AA: Dry Type Air Cooled
Class OA: Oil Immersed Air Cooled
1.3 Disclaimer
This Best Practice is being provided for the general guidance and benefit of
Saudi Aramco engineers conducting a Factory Acceptance Test (FAT). The use
of this Best Practice during an FAT, however, does not relieve the Manufacturer
from his responsibility or duty to confirm or to verify the accuracy of any
information presented, and does not remove the Manufacturer from his
contractual liability to perform and maintain a conscientious Quality Assurance
program that conforms to Mandatory Saudi Aramco Engineering Requirements.
The use of the information or material contained herein will not guarantee that
the resulting product satisfies the applicable requirements of Saudi Aramco
Standards. Saudi Aramco assumes no responsibility or liability whatsoever for
any reliance on the information presented herein or for a FAT performed by the
Manufacturer in accordance with this Best Practice document. Moreover, this
Best Practice is intended only to provide guidelines for Saudi Aramco engineers
and shall not be considered as a replacement for the Mandatory Saudi Aramco
Engineering Requirements. Saudi Aramco® is a registered trademark of the
Saudi Arabian Oil Company, Copyright, Saudi Aramco, 2004.
Page 3 of 18
1.4 Conflicts with Mandatory Standards
In the event of a conflict between this Best Practice and a Mandatory Saudi
Aramco Engineering Standard requirement, the Mandatory Saudi Aramco
Engineering Standard requirement shall govern.
2 References
Materials or equipment tested with this FAT Best Practice shall comply with the latest
edition of the references listed below unless otherwise noted.
2.1 Saudi Aramco References
Saudi Aramco Materials System Specifications

17-SAMSS-004 Conventional (Tap Adjustable) Rectifiers for
Cathodic Protection
26-SAMSS-059 Specification for Electrical Insulating Oil
2.2 Industry Codes and Standards
National Electrical Manufacturers Association

NEMA ICS 6 Enclosures for Industrial Controls and Systems
National Electrical Code (NEC)
3 Definitions
Design Acceptance Tests: Tests performed by the manufacturer to determine the

adequacy of the design of a particular type, style, or model of equipment and its
component parts to meet its assigned ratings and to operate satisfactorily under normal
service conditions or under special conditions if specified. A design test will also serve
to demonstrate compliance with the respective Saudi Aramco material specification and
referenced industry standards.
Factory Acceptance Test (FAT): A performance and quality assurance test, witnessed
by the Saudi Aramco RSA, and conducted at the factory to assess compliance to the
required performance and quality specifications required for the specific equipment.
Manufacturer: The term “Manufacturer” when used in this document without

additional description, shall pertain to the Saudi Aramco approved cathodic protection
rectifier manufacturer.
Routine Production Tests: Tests performed by the manufacturer on all equipment

being assembled or manufactured for sale purposes, to verify uniformity, quality of
Page 4 of 18
construction, and compliance with the specified routine performance criteria for the
equipment. Routine tests are sometimes referred to as production tests.
4 Factory Acceptance Tests
Factory Acceptance Tests (FAT) for Conventional (Tap Adjustable) Rectifiers for
Cathodic Protection are performed to determine if that the equipment components:
 have been assembled properly in a professional manner, and
 comply with 17-SAMSS-004 and the nameplate rating.
The FAT consists of an evaluation of the Routine Production tests and the Design
Approval tests detailed in 17-SAMSS-004, and other tests as may be applicable in
establishing compliance with the specified Saudi Aramco Material System Specification
and referenced International Standards. The Routine Production tests are required for
all manufactured rectifiers while the Design Approval tests act as a supplement to the
Routine Production tests for a Design approval basis.
4.1 Rectifier Name Plate Rating Information
The RSA or his designate shall copy the Name Plate information from the Name
Plate fastened to the outside of the rectifier enclosure, onto the FAT form sheet
Appendix 1 - Section 2.
4.2 Instructions for Conducting the Factory Acceptance Tests (FAT)
Tests shall be conducted by the Manufacturer and witnessed by the RSA or his
designated representative on a minimum of one of each type, model and design,
as detailed in Appendix 1 - Section 1, Table A.
The Saudi Aramco RSA or designated representative should begin with

Appendix 1 - Section 1 of this Best Practice and fill in all details and checks in
Section 1 through Section 4.
Based on the equipment's compliance with the test criteria, as witnessed by the
Saudi Aramco RSA or designated representative, the Manufacturer's design for
the inspected type and model shall be approved. Section 1 of Appendix 1 shall
be signed by the RSA (or designated representative) to verify and document that
the equipment has successfully completed the FAT and complies with the
requirements of this Best Practice.
The Manufacturer's Quality Assurance Manager shall sign Section 1 of

Appendix 1 of this document to guarantee that equipment applicable to this FAT
that is sold to Saudi Aramco will be manufactured with the same components
and assembly procedures used for the equipment that was tested and approved
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through the FAT. Any future deviations in equipment components or assembly

procedures must be pre-approved by the Saudi Aramco RSA for this equipment.
The Manufacturer is responsible for the quality assurance of the components
used for all future orders, and is responsible for ensuring that the components do
not change from the ones used for the FAT. If a change occurs, it must be
reported to the RSA and retested and re-approved as deemed necessary by the
RSA.
4.3 Component Data Sheets
Data sheets for rectifier components should be reviewed by the RSA or Saudi
Aramco VID. Acceptance of these data sheets is documented by the signatures
on Appendix 1 - Section 1 of this Best Practice.
4.4 Performance Data Sheets
Copies of the data sheets detailing the performance test data as required by
17-SAMSS-004 for the Routine Tests and Design Approval Tests should be
reviewed by the Saudi Aramco RSA or the VID representative. Acceptance of
these data sheets is documented by the signatures on Appendix 1 - Section 1 of
this Best Practice.
Revision Summary
26 November 2007 New Saudi Aramco Best Practice.
3 June 2015 Editorial revision to change tap accuracy tolerance from 10% to15% for T/Rs with less than
30 taps during the routine acceptance test.
Page 6 of 18
Appendix 1 - Section 1
Factory Acceptance Test
Conventional (Tap Adjustable) Rectifiers for Cathodic Protection
Manufacturer
Kit Manufacturer (if applicable)
Rectifier DC Rating Volts Amps
Rectifier AC Rating Volts Amps Ø Hz
FAT Location
Table A – Factory Acceptance Test Equipment Categories

(Enter serial number of Equipment being tested in blank space)
Oil Immersed
AC I/P Rectifier O/P Dry Type Class 1,
Air Cooled
Phase Rated Amperage Air Cooled Div. 2
Not Classified
24 amps and less
25 amps to 50 amps
Single
51 amps to 100 amps
Phase
101 amps to 200 amps
201 amps and greater
24 amps and less
25 amps to 50 amps
Three
51 amps to 100 amps
Phase
101 amps to 200 amps
201 amps and greater
Deficiency Summary (Use page 18 of this Best Practice if more space is needed):
Line Item No. 1
Line Item No. 2
Line Item No. 3
 Not Approved  Approved

Name Signature Date
Saudi Aramco RSA
QA Manager
Plant Manager
Page 7 of 18
Rectifier Name Plate Rating Information
Descriptive Name - “Cathodic Protection Rectifier”
Manufacturer’s Name
Manufacturer’s Address
Manufacturer's Serial Number
Saudi Aramco PO Number
Model Number
Input Rating:
kVA
Nominal Voltage
Current at Rated Output
Phase Rating
Frequency Rating
Output Rating:
kW
DC Voltage
DC Current
Oil Capacity (liters):
Shunt Rating 50 mV Amps
Area Classification: Class Division , or Not Classified
Max. Oper. Temp. (≥55ºC)
Date of Manufacture:
“Meets 17-SAMSS-004“ (revision date)
Page 8 of 18
Table B – Design Acceptance Performance Tests

(Enter  or X in second column to denote pass or fail)
No.  Measured
Value Test Parameter
Output Ripple Voltage (17-SAMSS-004 para. 6.2.2)
B1 %
Less than 30% for 1Ø, Less than 20% for 3Ø
B2
Transformer Temperature Rise (17-SAMSS-004 para. 6.2.3.1)
o
C The rise in transformer temp must be less than 130°C (266°F) above ambient
B3
Class OA, Oil Temperature Rise (17-SAMSS-004 para. 6.2.3.2)
o
C The rise in oil temp must be less than 30°C (86°F) above ambient
(Measure the temp rise inside type AA enclosure above the rectification device)
B4
Rectification Element Temperature Rise (17-SAMSS-004 para. 6.2.3.3)
o
C The rise in rectifier element temp must be less than 40°C (104°F) above ambient
Table C – Routine Production Performance Tests

(Enter  or X in second column to denote pass or fail)
No.  Measured
Value Routine Production Performance Tests for FAT
Max
Tap Increment Test (17-SAMSS-004 para. 6.3.1)
±15% for transformers with 30 or fewer tap adjustment positions
C1 ±20% for transformers with more than 30 tap adjustment positions
Min
Allowable Min volts, Allowable Max volts
Amps
Rated Output Tests (17-SAMSS-004 para. 6.3.2)
Volts
C2 DC output (voltage and current) must equal or exceed rated DC output at rated load with AC
Tap @
input set to 10% below nominal.
Page 9 of 18
No.  Measured
Value Routine Production Performance Tests continued
T/R Efficiency Tests (17-SAMSS-004 para. 6.3.3) including power factor shall be
equal or greater than detailed below (allow 2% reduction in efficiency for every
5 volt increment below 30 volts of rated rectifier output).
Minimum Efficiency
Rectifier Rating
C3 % 1-Phase 3-Phase
10 Amps or less 60 % 60 %
11 to 200 Amps 80 % 80 %
250 Amps 78 % 80 %
300 Amps or greater 75 % 80 %
mA
Dielectric Test (17-SAMSS-004 para. 6.3.4)
Leakage current shall be less than 5 mA, from primary to chassis, from secondary to chassis
C4 mA
and from primary to secondary. Any arcing is unacceptable. Leakage tests on 3 phase
transformers should be conducted on each phase, one phase at a time.
mA
Certificate Welded Seam Test for Class OA Oil Enclosures (17-SAMSS-004 para. 6.3.5)
required
Welded seams for the oil enclosures shall be tested for leakage
C5
Any leakage shall be repaired before galvanizing
Date:
in/hr
Gasket Seal Test for Class OA Oil Enclosures (17-SAMSS-004 para. 6.3.5)
C6 Dust tight seal shall be achieved and verified by pressure test
psi Manufacturer’s Criteria  less than ____ inches drop per hour at ____ psi
1/4” The tightening torque target values shall be witnessed and shall be checked on a
random sampling of each bolt size that carries load current
5/16 Bolt Size Newton-M Inch-Pounds
(inches) Min Max Min Max
1/4 5 6 44 53
C7 3/8” 5/16 8 10 70 84
3/8 11 14 97 123
7/16 15 19 132 167
7/16 1/2 20 24 176 211
1/2’
Page 10 of 18
5 VID Requirements
 5.1 VID Requirements (Mandatory for FAT approval)

 View documentation that confirms that the Quality Control program has been
approved by VID
 Witness and approve T/R Efficiency Test
 Witness and approve Dielectric Breakdown Test
 Witness and approve Oil Temperature Rise Test (for type OA enclosures)
 5.2 VID Requirements (Recommended but not mandatory for FAT approval)
 Witness and approve Output Ripple Voltage Test
 Witness and approve Transformer Temperature Rise Test
 Witness and approve Rectification Element Temperature Rise Test
6 CSD Requirements
 6.1 New Manufacturer Requirements

 Documented operating history for at least 1 year in Saudi Arabia or similar
environment. Kits and components supplied by the following are acceptable:
o IRT (Canada)
o Corrpower (Canada)
o J.A. Electronics (United States)
 If other than the above, supply RSA with user list including contact name and
email address
 6.2 Installation and Operating Manual
 Provided in plastic weatherproof envelope
 Secured in instruction storage holder in instrument enclosure or underside of oil
tank lid for hazardous area rectifiers
 Includes electrical schematics in manual and behind Lexan® sheet (3 mm)
fastened to enclosure door
 Includes fully dimensioned mounting drawings
 6.3 Enclosure (Class AA = Dry Air Cooled, Class OA = Oil, Air Cooled)
 Sunshade provided for Class OA unless noted otherwise on P.O.
 Gasket material is Nitrile rubber or polychloroprene rubber (spec. sheet provided)
 Where adhesives are used to fasten the gasket they are an epoxy adhesive (type
used ___________)
 Gasket fastened mechanically, three side framed, or encapsulating
(except NEMA 3R)
 Gasket for NEMA 4X and NEMA 8 shall be one of the following:
o one piece, or
Page 11 of 18
o interlocked and epoxied or overlapped and epoxied, or

o vulcanized
 Surface coating requirements (measured and witnessed plus RSA written
pre-approval for baked polyester coating):
o galvanizing is 85µm (3.3 mils) , or
o baked polyester over zinc on steel is 170µm (6.8 mils) , or
o aluminum shall be coated with 150 µm (6.0 mils) baked polyester
Note: Test thickness of coating or galvanizing by taking the average of 5 measurements on one
side of the enclosure. The measurements should be taken approximately 20 cm from each
corner and at the center. Record average of measured values above.
 ASTM A36 or A569 (JIS G 3131) 11 gauge (3.038mm nominal) steel or
ASTM B209 Type 5052 aluminum 3.2 mm (0.125 inch) unless NEM ICS6 lists
otherwise (spec. sheet provided plus thickness measured and witnessed).
 Conforms to (enclosure manufacturer’s certificate provided):
o NEMA 3R for Class AA (NEMA 4X or 1 if specified on purchase order)
o NEMA 8 for oil tank for Class OA
o NEMA 4X for instrument enclosure for non-hazardous area Class OA
o explosion proof for instrument enclosure for hazardous area Class OA
 Minimum two quick release latches for all lids and doors
 Latches and hinges are galvanized, 304 SS or 316 SS (spec. sheet provided)
 Series 300 SS nameplate bolted to instrument enclosure or for hazardous area
rectifiers, bolted to oil enclosure or associated fixtures
 Class AA Rectifier Enclosure has:
o mounting hardware suitable for wall/pole and pedestal mounting
o hinged door and two hinged sides, or
o hinged door and tilt out chassis with one hinged side, or
o hinged door and full slide out chassis
o enclosure hinged door is detachable without tools
o three conduit entries plus one for remote monitoring where applicable
o Remote monitoring and less than 50 amps – 25 mm (1”)
o 50 to 150 amps – 38 mm (1.5”)
o 150+ amps – 50 mm (2”)
o threaded water tight hubs on conduit entries
 Class OA Rectifier - Oil Enclosure:
o mounting hardware suitable for pedestal mounting
o oil tank is continuously welded (before galvanizing or coating) on outer seams
and on accessible inner seams (inspect corners on upper lip for cracking)
o oil tank is supported on 100 mm (4 inch) structural members
o oil tanks shall have 4 lifting lugs
o oil tank shall be maximum 132 cm (52 inches) high (_____cm)
o oil tank lid lockable at 100 to 120 degrees with two lid supports
o hot and cold oil levels shown on inside of oil tank
o hot and cold oil levels shown on external sight glass
o sight glass maintains enclosure seal (external sight tubes with vent hole are
Page 12 of 18
unacceptable)
o oil tank fabricated with fitting for removable venting device
o oil tank fabricated with 1.5” fill pipe and threaded cap
o oil tank fabricated with drain valve with kick plate, threaded outlet and plug
 Class OA Rectifier - Control Enclosure (NEMA 4X):
o NEMA 4X
o mounted on one end of the Oil Enclosure
o not bolted directly to Oil Enclosure (no mounting holes in the Oil Enclosure)
o three conduit entries plus one for remote monitoring where applicable
o Remote monitoring and less than 50 amps – 25 mm (1”)
o 50 to 150 amps – 38 mm (1.5”)
o 150+ amps – 50 mm (2”)
o threaded water tight hubs on conduit entries
 Class 1 Div. 2 area rectifiers shall have:
o all control equipment mounted in oil enclosure
o explosion proof meter enclosure with see through face
o externally mounted explosion proof breaker
o continuously welded or threaded water tight (rated for hazardous area
application) conduit hubs
o conduit into hubs supplied with complete seal fittings conforming to NEC
 6.4 Chassis
 Rectifier components for Class AA enclosures shall be mounted on a slide out or
tilt out removable chassis
 Chassis for Class OA shall be constructed with two chassis,
o one with the rectification assembly that is independently removable
o the other with the transformers that shall have minimum two lifting lugs
o all interconnecting wires between the two chassis shall be accessible from the
top of the tank for removal of the chassis
o bolts fastening the chassis to the oil tank shall be above the oil level
 6.5 Instrument Panel
 Non-classified Area Rectifiers
o meters, shunts, fuses and spare fuses mounted on hinged panel with 90 degree
swing capacity (hinged panel not required for rectifiers over 100 amps)
o hinged panels held in place by two knurled or winged nuts
o AC input wiring and DC output wiring does not terminate directly on
instrument panel
o a nut and lock washer offsets every connection from the instrument panel that
may carry current
o panel material for 150 amp and smaller is 105ºC minimum and 5 mm minimum
thickness; for greater than 150 amp is 130ºC minimum and 6 mm minimum
thickness (laminated phenolic or UTR fiberglass reinforced laminate)
Page 13 of 18
 6.6 Labeling
 Terminals and terminal blocks marked for polarity and function with permanent
engraving techniques (labels fastened with adhesive are unacceptable)
 Wire markers are placed with 25mm of each nearest edge of terminal lug
 Each wire has an identification number or letter corresponding to the supplied
schematic drawings
 A schematic drawing is supplied behind a Lexan® sheet (not required for
classified units)
 6.7 Transformers
 Provide full isolation (certificate)
 Finished in baked thermoset varnish (certificate)
 Rated for 180ºC (certificate)
 6.8 Tap Switches and Link Bars
 Tap Switches (required on all three phase and classified area units)
o positive self-centering restraints in each switch position
o rated for minimum of 120% of maximum transformer current at rated output
a) Tap switch current rating = _______amps (from data sheet)
b) Amps through tap switch at rated load = _______ amps (measure with clamp meter)
c) 1.20 x b = ________ (must be less than “a”)
o tap switch control knobs are above oil level
o tap switch contact mechanism is below cold oil level
o tap switch must be rated for oil immersion by switch manufacturer or have
verifiable operating history in oil immersion service
Manufacturers approved by Aramco: Kraus & Naimer______
Entrelec ______
Control Switches International (CSII) ______
ABB_______
 Link Bars (for single phase non-classified area use only)
o fabricated from copper or brass finished in electroless nickel, tin or silver plate
o slotted at one end
o for 50 amp and smaller rectifiers, tightening is achieved by hand with knurled
or plastic nuts, for larger rectifiers, tightening is achieved with a tightening
tool supplied with rectifier (direct hand tightening system is unacceptable)
 6.9 Rectification Components
 Mounted on aluminum heat sinks
 Minimum peak inverse voltage is 1200 volts (data sheet volts)
 Minimum rating for forward current is 50% greater than the average current at
rated rectifier output (average current for single phase is 50% of rated output,
average current for three phase is 33% of rated output)
a) Diode forward current rating = _______amps (from data sheet)
b) Single phase: average current through diode = 0.5 x rectifier rated current =
_______ amps
Page 14 of 18
Minimum acceptable diode rating = 1.5 x b = _____ amps (must be less than “ a ”)
c) Three phase: average current through diode = 0.33 x rectifier rated current =
_______ amps
Minimum acceptable diode rating = 1.5 x c = _____ amps (must be less than “ a ”)
 6.10 Meters
 Two analog or digital meters (one for volts, one for amps)
o located on the instrument panel for non-classified area units
o protected by a glass lens in an explosion proof housing for classified area units
 Analog meters are continuous read
 Digital meters if used for non-classified units may be switch activated
o switch is completely sealed by switch manufacturer
o switch must be spring loaded to return to normally off position after use
 Meters fit into 70 mm (2.75”) round mounting hole (classified units 2.5”)
 Meters are rated for use with 50mV shunt
 Meters have accuracy of ± 2% to rated output at 25ºC and accuracy to 0.85%
error per 10ºC at temperatures 25ºC to 65ºC (spec sheet or witnessed site test)
Site Tested & Approved: Yokogawa (with “FAX” in the Part No.)
 Analog instrument scales are 70 mm (2.75”) minimum length for non-classified

units and 57 mm (2.2”) for classified units
 Scales are marked with a red line or red shading indicating maximum rated output
 Analog meters have a minimum full scale deflection of 120% and a maximum of
150% of the rated output of the rectifier
a) 1.2 x rectifier current rating = _______ , 1.2 x rectifier voltage rating = _______
b) 1.5 x rectifier current rating = _______ , 1.5 x rectifier voltage rating = _______
Full scale deflection of respective meter must be greater than “ a” but less than “b”
 Scales are in even increments and clearly marked with as “VOLTS” or “AMPS”
 Scale face material is aluminum
 6.11 DC Current Measurement Shunts
 50 mV rating
 ±0.25% accuracy
 Mounted on the front of the instrument panel for non-classified area units
 Ampere and millivolt rating stamped or engraved into shunt and visible in the
installed location
 6.12 Fuses
 Semiconductor fuse (see approved list of manufacturers below) labeled and placed
in an accessible location in DC output or transformer secondary
Manufacturers approved by Saudi Aramco: Bussman ______
Edison ______
Gould ______
Littlefuse ______
Page 15 of 18
 The fuse is sized for approximately 120% of the current with the rectifier
operating at rated output
a) Fuse current rating = ______ amps
b) Fuse current at rated rectifier output = _______amps
c) b x 1.2 = _____ amps (must be approximately equal to “a” or nearest commercial size)
 Fuse is located:
o for non-classified area units are on the instrument panel, or on the topside of
the panel in the oil tank above the oil level
o for classified area units, approximately 50 mm to 75 mm (2 to 3 inches) below
the cold oil level
o spare fuse is secured by a clip type holder mounted near the functioning fuse
o fuse fastening hardware for the functioning fuse is copper alloy plated with
silver, tin or electroless nickel
 6.13 Circuit Breaker
 Contains one pole per input line of AC sized to protect the highest current load for
multi-input rectifiers
 Sized for nearest commercial size to hold at 100% at rated rectifier output up to
80ºC and trips at 125% of “Circuit Breaker” rated trip level within 5 minutes at
25ºC (See exception 5.4.7.3 for rectifiers rated below 10 amps)
a) Breaker current rating = ______ amps (from data sheet)
b) Breaker current at rated rectifier output = _______amps (measure with clamp meter)
c) Verify through data sheet or site test that breaker will hold at b and will break at
1.25 x a within 5 minutes
 6.14 Wires
 Wires immersed in oil are rated by the manufacturer for oil immersion at 60ºC or
have been pre-tested and approved in writing by the RSA
Approved cables: Rockbestos Surprenant 110C Exane-125______
Teflon (PTFE) ______
 Wires are sized to comply with ICEA P-46-426 at 65ºC ambient in Type AA
enclosure and 80ºC ambient in Type OA enclosure.
Below table is for Exane-125 with 110ºC rating in transformer oil:
25 A rectifier ≥ #12 AWG (4 mm2) 100 A rectifier ≥ #2 AWG (35 mm2)
35 A rectifier ≥ #10 AWG (6 mm2) 150 A rectifier ≥ #1/0 AWG (50 mm2)
300 A rectifier ≥ #4/0 AWG (120 mm2)
 Parallel conductors to comply with ampacity restrictions are only used for currents
above 100 amps and individual ampacity rating is reduced to 80%
 Wire jacket is labeled by manufacturer except PTFE
 Grounded wires are white, all other wires are not white
 Wire terminations are solderless crimped or tinned and terminated in a captivating
compression type terminal block or lug (except tap stud terminations which may
use one piece soldered brass studs not required to be tinned or plated)
Page 16 of 18
 6.15 Terminals
 Terminal blocks are rated for 600 volts (except instrumentation terminal blocks)
with full insulating barriers
 Terminal block metallic components are tinned or electroless nickel plated
 Maximum of two wires per terminal screw or fitting
 Terminal lugs are not fastened directly against panel (must be offset by a nut and
washer)
 Maximum of two wires between any two nuts on a terminal bolt
 AC input terminals
o for non-classified area units are terminated in a terminal block that is not
mounted on the tilt out instrument panel
o terminals are accessible by instrument probes but not directly touchable by the
operator
o for classified area units, terminals are in an externally operable explosion
proof breaker enclosure fastened to the outside of the oil tank
o for classified area units, the connection of the AC wiring inside the oil tank is
on a terminal block place approximately 50 to 70 mm below the cold oil level
 DC output terminals
o are double post type
o with copper alloy plated or tinned compression lugs
o have a minimum clearance of 25 mm (1”) from all metal parts except lightning
arrestor
o for Class AA enclosures are mounted on a separate fixed panel located near the
bottom of the enclosure a minimum of 200 mm (8”) higher than the conduit entry
o for Class OA enclosures for non-classified area units are mounted on a
separate fixed panel located near the bottom of the control enclosure a
minimum of 200 mm (8”) higher than the conduit entry
o for Class OA enclosures for classified area units are mounted inside the oil
tank at an accessible location approximately 50 to 75 mm (2 to 3”) below the
cold oil level
 6.16 Lightning and Surge Protection
 A surge arrestor rated for a minimum of 750 Joules is connected across the circuit
breaker on the line or the load side and to a ground terminal of rectifier enclosure
or chassis
 A surge arrestor rated for a minimum of 500 Joules is connected across the DC
output
 For classified area rectifiers, the arrestors are located below the cold oil level in
the oil tank
 MOV’s are connected directly across the AC input terminals and DC output
terminals of the diode bridge or rectification element
Page 17 of 18
Inspection Notes:
1
Page 18 of 18

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Best Practice

SABP-X-002 3 June 2015

Saudi Aramco DeskTop Standards

Previous Issue: 26 November 2007 Next Planned Update: TBD

Copyright©Saudi Aramco 2015. All rights reserved.

Detailed Index of Contents

This Best Practice provides guidelines for evaluating the quality of

Class AA: Dry Type Air Cooled

Class OA: Oil Immersed Air Cooled

1.4 Conflicts with Mandatory Standards

2.1 Saudi Aramco References

Saudi Aramco Materials System Specifications

2.2 Industry Codes and Standards

National Electrical Manufacturers Association

National Electrical Code (NEC)

Design Acceptance Tests: Tests performed by the manufacturer to determine the

Manufacturer: The term “Manufacturer” when used in this document without

Routine Production Tests: Tests performed by the manufacturer on all equipment

4 Factory Acceptance Tests

4.1 Rectifier Name Plate Rating Information

4.2 Instructions for Conducting the Factory Acceptance Tests (FAT)

The Saudi Aramco RSA or designated representative should begin with

The Manufacturer's Quality Assurance Manager shall sign Section 1 of

through the FAT. Any future deviations in equipment components or assembly

4.3 Component Data Sheets

4.4 Performance Data Sheets

Table A – Factory Acceptance Test Equipment Categories

 Not Approved  Approved

Rectifier Name Plate Rating Information

Descriptive Name - “Cathodic Protection Rectifier”

Manufacturer's Serial Number

Saudi Aramco PO Number

Oil Capacity (liters):

Shunt Rating 50 mV Amps

Area Classification: Class Division , or Not Classified

Max. Oper. Temp. (≥55ºC)

“Meets 17-SAMSS-004“ (revision date)

Table B – Design Acceptance Performance Tests

Table C – Routine Production Performance Tests

 5.1 VID Requirements (Mandatory for FAT approval)

 6.1 New Manufacturer Requirements

o interlocked and epoxied or overlapped and epoxied, or

 Analog instrument scales are 70 mm (2.75”) minimum length for non-classified

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