Complete Electrical Engineering Services Saudi Arabia for Industrial Infrastructure

Step 1: Factory Acceptance Testing (FAT)

Before any control panel, switchboard, or motor control center ships from the manufacturing floor to your job site, we host formal Factory Acceptance Testing. We simulate field operational inputs using signal injection test rigs, inject nominal currents to confirm trip curves, test automatic transfer switch control sequences during simulated mains outages, and conduct 100% point-to-point wiring continuity verification. Clients receive verified test logs, punch lists, and signed FAT certificates prior to equipment dispatch.

Step 2: Cold Commissioning and Insulation Integrity Verification

Cold testing occurs on unenergized systems to mathematically and physically verify that the electrical network is safe for live voltage application.

• Insulation Resistance (IR) Testing: We apply test voltages up to 5 kV DC using calibrated Megger test sets to measure insulation resistance across phase-to-phase and phase-to-earth boundaries on cables, busbars, and motor windings.
• Contact Resistance (Ductor) Testing: We inject high direct current (typically 100 A) across circuit breaker poles, busbar bolted splices, and isolator contacts to measure micro-ohm resistance drops, identifying loose torque joints that cause destructive hot spots.
• High Potential (Hipot) and VLF Testing: For medium-voltage power cables, we run Very Low Frequency (VLF) AC withstand tests per IEEE 400.2 standards to identify microscopic manufacturing voids or insulation damage sustained during site pulling.
• Earth Grid Resistance Testing: Using the fall-of-potential method with precision earth testers, we measure substation grounding grid impedance to verify that earth step-and-touch potentials remain within safe limits under maximum fault return paths.

Step 3: Secondary Injection and Protection Relay Testing

Protective relays safeguard multi-million-dollar plant assets. We utilize automated secondary injection test sets (such as Omicron test units) to inject controlled currents and voltages directly into numerical protection relays. We test and plot pickup thresholds, trip curves, and operational operating times for overcurrent (50/51), earth fault (50N/51N), differential protection (87T/87M), directional power (32), and undervoltage/overvoltage (27/59) functions against approved protection study settings.

Step 4: Hot Commissioning, Functional Testing, and SAT

Once cold testing is complete and the local utility or facility owner approves power injection, we progress to live hot commissioning under strict lockout/tagout (LOTO) protocols.

• Voltage Phasing and Phase Rotation Verification: We confirm identical phase sequencing across incoming supplies before closing parallel or bus-tie circuit breakers.
• Live Instrumentation Calibration and Loop Checks: We verify live 4-20 mA current loops, HART communications, and field transmitter calibrations against actual process readings, confirming scaling accuracy inside PLC logic blocks.
• Control Interlock and Trip Testing: We systematically force digital inputs and software registers to verify that emergency stop (E-Stop) pushbuttons, transformer gas Buchholz relays, pressure relief valves, and fire alarm interfaces shut down relevant circuit breakers instantly.
• Load Run and Thermal Imaging Surveys: Following plant startup, we use calibrated infrared thermography cameras to inspect loaded switchboards, terminal terminations, and motor starter contactors to spot abnormal thermal signatures before equipment handoff.