Professional Documents
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Complete Quality Manual Vol 2 Rev 2010
Complete Quality Manual Vol 2 Rev 2010
QA / QC MANUAL VOL. 2
CONSTRUCTION PROCEDURES
REV.
0
1
2
3
1
2
3
Prepared By:
CHECKED BY
APPROVED BY
APPROVED BY
APT
YSB
NMZ
SMZ
SIGNATURE/DATE
REVISION HISTORY:
Document Recipients:
1. Gen. Manager
2. Asst. Gen. Manager
3. Business Dev. Manager
4. Project Managers
5. QA/QC Department
6. Project Engineers
REV.
0
QUALITY ASSURANCE/QUALITY
CONTROL MANUAL
MACO-QM-001
VOL. 2
APPROVAL SHEET
Description
Prepared
By:
Name
A. P. Togle
Designation
Signature
Date
Approved
By:
Y.S. Bahrawy
Approved
By:
N. M. Zahrani
Assistant General
Manager
Approved
By:
S. M. Zahrani
General Manager
-i-
MACO-QM-001
QUALITY ASSURANCE/QUALITY
CONTROL MANUAL
MACO-QM-001
VOL. 2
REVISION HISTORY
Revision No.
0
Purpose of Revision
Issue Date
1
2
MACO-QM-001
REV. 0
TABLE OF CONTENTS
QUALITY CONSTRUCTION PROCEDURES
PROCEDURE DESCRIPTION
SL NO.
DOCUMENT NO.
CIVIL WORKS
1
SURVEYING
MACO-QCCP-001
SITE PREPARATION
MACO-QCCP-002
MACO-QCCP-003
MACO-QCCP-004
CONCRETE WORKS
MACO-QCCP-005
GROUTING WORKS
MACO-QCCP-006
MACO-QCCP-007
MACO-QCCP-008
MACO-QCCP-009
10
MACO-QCCP-010
11
MISCELLANEOUS METALS
MACO-QCCP-011
12
MACO-QCCP-012
13
STRUCTURAL STEEL
MACO-QCCP-013
14
JOINT SEALANTS
MACO-QCCP-014
15
PRESSURE TESTING
MACO-QCCP-015
16
THRUST BORING
MACO-QCCP-016
Page 1 of 3
MACO-QCP-TOC
REV. 0
TABLE OF CONTENTS
QUALITY CONSTRUCTION PROCEDURES
SL NO.
PROCEDURE DESCRIPTION
DOCUMENT NO.
MACO-QECP-001
MACO-QECP-002
MACO-QECP-003
MACO-QECP-004
MACO-QECP-005
MACO-QECP-006
MACO-QECP-007
MACO-QECP-008
POWER SYSTEMS
MACO-QECP-009
10
MACO-QECP-010
11
MACO-QECP-011
12
MACO-QECP-012
13
MACO-QECP-013
14
MACO-QECP-014
15
MACO-QECP-015
16
MACO-QECP-016
17
MACO-QECP-017
Page 2 of 3
MACO-QCP-TOC
18
19
REV. 0
MACO-QECP-018
MACO-QECP-019
TABLE OF CONTENTS
QUALITY CONSTRUCTION PROCEDURES
SL NO.
PROCEDURE DESCRIPTION
DOCUMENT NO.
MECHANICAL WORKS
1
MACO-QMCP-001
PIPE SLEEVES
MACO-QMCP-002
MACO-QMCP-003
VIBRATION ISOLATION
MACO-QMCP-004
MACO-QMCP-005
MACO-QMCP-006
MACO-QMCP-007
DUCTWORKS
MACO-QMCP-008
DUCTWORKS ACCESSORIES
MACO-QMCP-009
10
DUCTWORKS INSULATION
MACO-QMCP-010
11
MACO-QMCP-011
12
MECHANICAL IDENTIFICATION
TESTING AND BALANCING OF MECHANICAL
SYSTEMS
13
MACO-QMCP-013
MACO-QMCP-012
-END-
Page 3 of 3
MACO-QCP-TOC
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
SURVEYING
DOCUMENT NO.:
MACO-QCCP-001
Index
10.1.1
10.1.2
10.1.3
10.1.4
10.1.5
10.1.6
10.1.7
Page
Scope
Purpose
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
2
3
4
001
04/09/09
MACO-QCCP-001
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Surveying
Page 1 of 5
MACO-QCCP-001
REV. 0
SURVEYING
1
Scope
This quality procedure covers setting up reference points and bench marks,
vertical and horizontal setting out of all buildings, trench work, utility
installations and other works forming part of the contract.
2
Purpose
References
IFC Drawings :
Definitions
None
Responsibilities
5.1
The QC inspector shall inspect and prepare RFI for Proponent
representative to verify accuracy of gathered survey report/data. He shall
also coordinate with the surveyor on a daily basis to monitor and identify
field changes (if any).
5.2
The surveyor shall perform actual survey and ensure that gathered
survey report/data are accurate, recorded and reported. His responsibility
includes but no limited to:
5.2.1 Performing all surveys for the duration of the contract to
ensure that levels and locations conform to the design drawings, and
shop/working drawings approved by Proponent Representative.
5.2.2 Making formal written requests to Proponent for data on
survey control points related to the project prior to construction.
5.2.3 Verifying the figures on all Proponent furnished data and
documents before laying out the work.
Surveying
Page 2 of 5
MACO-QCCP-001
REV. 0
Procedure
6.1
All horizontal and vertical reference points and monuments shall be
established accurately within a maximum tolerance of 5mm vertically and
10mm horizontally.
6.2
If the validity of any survey monument is threatened, at least three
(3) reference or witness markers shall be placed for each point likely to be
disturbed. Survey notes shall be submitted listing the relative positions of
the reference markers to each other and to the points referencing at least 48
hours prior to disturbing or threatening the validity of the monument.
6.3
All data and grade sheets shall be submitted to Proponent
Representative at least 48 hours prior to construction. The grade sheets shall
show the vertical and horizontal relationships between the stakes and the
design reference points shown on the drawings.
6.4
All survey field notes shall be kept in field at all times for inspection
by Proponent Representative.
6.5
Prior to beginning trenching operations and during the progress of
the work, sufficient stakes shall be set and maintained to show conformance
with the Drawings. All stakes shall be located in such a way that they will
not be disturbed by construction operations.
6.6
Construction stakes shall be placed at each wye connection,
cleanout, and at every 10 meter station.
6.7
All elevations shall be based on Proponent datum scale. Established
survey controls shall be checked regularly against the existing monuments
Surveying
Page 3 of 5
MACO-QCCP-001
REV. 0
Documentation
7.1
Surveying
Form QCCP-001-01-SC
Page 4 of 5
Survey Checklist
MACO-QCCP-001
REV. 0
SURVEY CHECKLIST
QCCP-001-01-SC
Reference:
_______________________
Location:
Project:
_______________________
_________________________
S. NO.
COORDINATES
AS PER
ACTUAL
DRAWING
ELEVATION
AS PER
ACTUAL
DRAWING
DIFF.
DIFF.
REMARKS
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SURVEYOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Surveying
Page 5 of 5
MACO-QCCP-001
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
SITE PREPARATION
DOCUMENT NO.:
MACO-QCCP-002
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
3
3
8
001
04/09/09
MACO-QCCP-002
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Site Preparation
Page 1 of 9
MACO-QCCP-002
REV. 0
SITE PREPARATION
1
Scope
1.1
Clearing and Grubbing works shall include but not limited to: removal of
all vegetation, brush, rubbish, large stones and metallic debris occurring within
the limit of construction.
1.2
Earth work shall include, but not limited to: excavation of soil and rock,
removal and disposal of all unsuitable soil and rock material from the work site,
placing and compacting of fill materials imported from borrow pits, trenching and
trench backfilling and grading the site to the required elevations as shown on the
drawings.
2
Purpose
The purpose of this quality procedure is to provide a procedure for all activities
related to Site Preparation.
3
References
ASTM C136:
ASTM D 3017:
ASTM D 1883:
ASTM D 4253:
ASTM D 4254:
ASTM D 2937:
ASTM D 698:
Site Preparation
02251
02220
MACO-QCCP-002
02221
REV. 0
Construction Specifications:
Definitions
Dewatering removal of excess water from the saturated soil mass.
Imported or Borrowed Fill Material sand or calcareous clay of marine
origin, classified as marl, or combination of both sand and marl. The
maximum particle size shall be 100 mm, or one half the lift thickness
whichever is less.
Select Fill Material inorganic material and shall have 100% passing the
50mm sieve and from 0-20% passing the no. 200 sieve. That portion of
the material passing the No. 40 sieve shall have a maximum liquid limit of
35 and maximum plasticity index of 12. Atterbergs limits are not required
for select fill material with less than 15% fines passing the No. 200 sieve.
Clearing shall consist of satisfactory removal and disposal of all types
of vegetation and debris including grass, brush and rubbish.
Grubbing shall consist of the removal and disposal of slumps and roots
to a depth of 0.5 meters below ground within the limit of construction.
Site Preparation
Responsibilities
5.1
The Civil Supervisor and/or Foreman are solely responsible for the
activities related to Site Preparation. They shall coordinate with the
surveyor for the reference and with the QC Inspector and/or Independent
Testing Laboratory Technician for inspection or testing requirements.
5.2
5.3
Page 3 of 9
MACO-QCCP-002
REV. 0
Procedure
6.1
Surveying
6.1.1 Surveying shall be carried out in accordance to Work Procedure
QCCP-001, Surveying.
6.2
6.3
Earthwork
6.3.1 Excavation
6.3.1.1 Unclassified Excavation work shall be performed to
remove all material which includes soil and rock necessary
for grading and construction in accordance with the lines
and grades shown in the plan.
6.3.1.2 All unsuitable materials encountered during excavation
shall be removed and replaced with suitable materials and
compacted as required. Bottoms of excavation shall be smooth and
free of loose earth or sand.
6.3.1.3 Excavation for structures shall be made accurately to the
lines, grades and elevations shown on the drawings. Trenches and
foundation pits shall be of sufficient size to permit the placement
and removal of forms for the full length and width of structure
footings. The upper 150mm of soil in the bottom of all footing
trenches shall be compacted to the densities required.
6.3.1.4 Excavation work adjacent to the existing utilities as
specified in the Proponent Construction Safety Manual will be
carried out by Hand Excavation.
6.3.1.5 Trenching:
Site Preparation
Page 4 of 9
MACO-QCCP-002
REV. 0
Site Preparation
6.3.2
6.3.3
6.3.4
6.3.5
Side slope of excavations shall be cut true and straight and shall be
graded to the proper cross section. Unsuitable soil slopes shall be
removed and the slopes properly prepared. The bottom of
excavations shall be graded to the elevations and configurations as
shown on the Drawings. Over excavations shall be backfilled with
suitable material and compacted.
6.3.6
6.3.7
6.3.8
MACO-QCCP-002
REV. 0
6.3.10 All general areas (i.e. parking area, paved areas in addition to the
building foot prints) shall be excavated to a minimum depth of
0.6m to remove existing sabkha to minimize the capillary action
resulting in sabkha contamination of the backfilled areas.
6.4
Fill
6.4.1
Site Preparation
Page 6 of 9
MACO-QCCP-002
REV. 0
Site Preparation
Page 7 of 9
of
MACO-QCCP-002
REV. 0
6.5.2.3 Road base and sub-base one test every 2000 ft2.
(180m2.) of base or sub-base.
6.5.2.4 Backfill of trenches one test for every 50 linear ft. (15m)
of each lift.
6.5.2.5 General fill one test every 5000 ft2. (460m2) of
lift.
each
Documentation
7.1
Site Preparation
Page 8 of 9
MACO-QCCP-002
REV. 0
Reference:
_______________________
Location:
Project:
_______________________
_________________________
S. NO.
1
2
3
4
5
6
7
INSPECTION POINTS
ACCEPT
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Site Preparation
Page 9 of 9
MACO-QCCP-002
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
EXCAVATION, TRENCHING, BACKFILLING AND
COMPACTING
DOCUMENT NO.:
MACO-QCCP-003
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
2
3
6
001
03/21/09
MACO-QCCP-003
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 7
MACO-QCCP-003
REV. 0
Scope
Purpose
References
ASTM C136:
ASTM D 3017:
ASTM D 1883:
ASTM D 4253:
ASTM D 4254:
ASTM D 2937:
ASTM D 698:
ASTM D 2292:
ASTM D 1557:
ASTM D 2487:
ASTM D 422:
Page 2 of 7
MACO-QCCP-003
REV. 0
02220
02221
02210
Earth Work
02110
02220
Construction Specifications
Definitions
None
Responsibilities
5.1
The Civil Supervisor and/or Foreman are solely responsible for the
activities related to Excavation, Trenching and Backfilling. They shall
coordinate with the surveyor for the reference and with the QC Inspector
and/or Independent Testing Laboratory Technician for inspection or
testing requirements.
5.2
5.3
Procedure
6.1
Surveying
Page 3 of 7
MACO-QCCP-003
REV. 0
Site Preparation
6.2.1 Earthworks shall be carried out in accordance with Work
Procedure QCCP-002, Site Preparation.
6.3
Excavation/Trenching
6.3.1 Excavation/Trenching shall be performed as indicated on the plans
and standard details in whatever material encountered. All excavations for
structures, utility pipes, appurtenances or cables shall be made to an extent
that will provide sufficient space to work conveniently around the
structure or pipe to be installed.
6.3.2 All unsuitable surplus materials removed during excavation or
trenching shall be removed from site and disposed of at a Government
approved dump site. All materials suitable for backfill shall be used.
6.3.3 Excavation/Trenching over 1.2M deep shall be provided with sides
sloped back to the natural repose of the soil to avoid caving. Sides which
can not be sloped to the natural repose because of adjacent structures or
ground condition shall be shored adequately to resist earth movement and
protect workers.
6.3.4 If required for construction, before excavation, an approved
dewatering system shall be installed and operated when necessary to lower
the groundwater. All excavation and trenches shall be kept dry until the
structures, pipes and appurtenances to be built are completed.
6.4
Page 4 of 7
MACO-QCCP-003
REV. 0
Trench Backfill
6.5.1 The bottom of the trench shall be free of rock, sharp debris or
foreign matter that could cause damage to pipes, cables or other new
construction.
6.5.2 Cables or pipes shall be laid on a clean sand bed compacted to
70% relative density per ASTM D4253 and 4254. The bed shall be
compacted uniformly to provide even bearing for pipes. After pipes have
been laid, tested and approved; fillings shall be placed evenly on both
sides of the pipes and periodically compacted to maintain equal pressure
on the pipe. Backfilling shall be done in 150 mm lifts or half the pipe
diameter whichever is greater until a depth of 300mm of fill over the pipe
is obtained.
6.5.3 The depth of the trench shall be dug deep enough to provide a
minimum ground cover above the top of the pipe and a ground bed of at
least 150mm in depth below the bottom of the pipe.
6.5.4 Fill material shall be placed and built-up in successive layers and
compacted by tamping, until it has reached the required elevation. Each
layer shall be sloped to drain during construction. Layers shall not be
allowed to exceed 200mm in thickness before compaction. Each layer of
material shall be compacted by the use of rollers or other means so as to
secure a dense, stable and thoroughly compacted mass. Where mobile
mechanical equipment cannot be used, the materials shall be thoroughly
compacted by the use of power driven tampers.
Page 5 of 7
MACO-QCCP-003
REV. 0
6.5.5 Cables or pipes shall be embedded all around with at least 150mm
of compacted clean sand unless otherwise indicated, having minimum
70% relative density per ASTM D4253 and D4254.
6.6 Testing
6.6.1 In-place density test shall be performed in accordance with ASTM
D1556, D2922 or D23167 after compaction of each lift to verify that the
specified degree of compaction has been achieved. At least one in-place
density test for every 90m2 of compacted soil shall be performed or for
every layer or fill. Spacing between all test locations shall be
approximately equal.
6.6.2 Should the work in question fail to meet the establish criteria for
testing, remedial work shall be performed and re-tested to the satisfaction
of the Proponent Representative.
6.7
Reinstatement
6.7.1 All trench excavations shall be restored so its surface contour
blends in with the surrounding area. Areas of roadways and pavement
shall be excavated as necessary and restored.
6.7.2 To install pipe, cable or conduits under existing pavement,
pavement of the area shall be saw-cut as needed and restored to the
original condition.
DOCUMENTATION
7.1
Form QCCP-003-01-EP
Excavation Checklist
Page 6 of 7
MACO-QCCP-003
REV. 0
EXCAVATION CHECKLIST
QCCP-003-01-EP
Reference:
_______________________
Location:
Project:
_______________________
_________________________
S. NO.
1
2
3
4
5
6
7
INSPECTION POINTS
ACCEPT
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 7 of 7
MACO-QCCP-003
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
ASPHALT CONCRETE PAVING & BASE COURSE
DOCUMENT NO.:
MACO-QCCP-004
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
3
3
8
001
04/09/09
MACO-QCCP-004
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 9
MACO-QCCP-004
REV. 0
Scope
Purpose
References
ASTM C88:
ASTM C136:
ASTM D1559:
ASTM D1883:
ASTM D2922:
ASTM D4254:
ASTM D4318:
Page 2 of 9
MACO-QCCP-004
REV. 0
Definitions
Primer Coat Homogeneous, medium curing, liquid asphalt MC-70
conforming to Saudi Aramco Standards A973 or MC-250 conforming to
Saudi Aramco Standard A974.
Tack Coat Shall be RC 250 conforming to Saudi Aramco Standards
A971 or RC-800, conforming to Saudi Aramco Standard A972.
Responsibilities
5.1
The Civil Supervisor and/or Foreman are solely responsible for the
activities related to Asphalt Concrete Paving. They shall coordinate with
the QC Inspector for inspection or testing requirements.
5.2
5.3
Procedure
6.1
General Requirements
6.1.1 Job-mix design shall be submitted to the Proponent Representative
for approval prior to start of work, or shall combine the mineral aggregate
and asphalt in such proportion as to produce a mixture conforming the
client specification.
6.1.2 Earthwork shall be performed in accordance with Work Procedure
QCCP-002, Site Preparation.
6.2
Sub-Grade
6.2.1 Existing asphalt or other materials identified to be demolished as
shown on the drawings shall be removed prior to the commencement of
sub-grade cut/fill. Asphalt shall be saw-cut to provide clean, neat vertical
edges that will provide a suitable surface for matching of new asphalt.
Page 3 of 9
MACO-QCCP-004
REV. 0
Base Course
6.3.1 The stone base course and sub-base shall be laid in two layers each
and compacted.
6.3.2 Sub-base course shall be provided only in fill sections where fill
material has a CBR of 5% or less. The sub-base shall have a minimum
CBR of 15% at 95% compaction.
6.3.3 The sub-grade shall be kept drained during the placing and
compacting of the base course or sub-base surface.
6.3.4 Base course material shall not be placed until the sub-grade upon
which it is to be placed has been approved by Proponent Representative.
Base course material shall be placed and compacted in layers not to
exceed 150 mm thickness after compaction.
Page 4 of 9
MACO-QCCP-004
REV. 0
Page 5 of 9
MACO-QCCP-004
REV. 0
6.5
6.6
Page 6 of 9
MACO-QCCP-004
REV. 0
6.8
Reinstatement
Page 7 of 9
MACO-QCCP-004
REV. 0
DOCUMENTATION
7.1
Form QCCP-004-01-CP
Page 8 of 9
MACO-QCCP-004
REV. 0
Reference:
_______________________
Location:
Project:
_______________________
_________________________
S. NO.
1
2
3
4
5
6
7
INSPECTION POINTS
ACCEPT
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 9 of 9
MACO-QCCP-004
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
CONCRETE WORKS
DOCUMENT NO.:
MACO-QCCP-005
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Materials
Procedure
Inspection & Testing
Documentation
2
2
2
2
4
10
10
001
04/09/09
MACO-QCCP-005
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Concrete Works
Page 1 of 14
MACO-QCCP-005
REV. 0
CONCRETE WORKS
1
Scope
1.1 This document covers formworks, rebars, placing, finishing, curing
and joints associated with construction of concrete structures.
Purpose
2.1 The purpose of this procedure is to describe the minimum
requirements in construction of reinforced cement concrete work.
References
ACI 318
Casts-In-Place Concrete
Materials:
4.1
Definitions:
4.1.1 Structural Concrete: All reinforced concrete including
concrete with minimum reinforcement for temperature and
shrinkage control. The 28 day design compressive strength (ASTM
C39) shall be 35 MPa. or as required by design drawing.
4.1.2 Non-structural Concrete: Un-reinforced concrete of no
significant structural value such as lean concrete for sub-slabs,
mass concrete etc. The minimum 28 day compressive strength
(ASTM C39) shall be 14 MPa.
4.2
Water:
4.2.1 Potable water shall be used in the production of concrete,
placement of concrete, production of ice used in concrete
operations, washing aggregates, cooling aggregates, curing
concrete, and cleaning, wetting and cooling the forms.
Concrete Works
Page 2 of 14
MACO-QCCP-005
4.3
REV. 0
Cement:
4.3.1 Portland cement shall conform to ASTM C150, as specified
by the client.
4.4
Aggregate:
4.4.1 Aggregates shall conform to ASTM C33.
4.4.2 Fine and coarse aggregate shall be considered as separate
ingredients and combined gradation shall be the approved mix
design.
4.4.3 Carbonate and dolomite materials shall not be permitted.
4.5
Admixtures:
4.5.1 Chemical admixtures shall conform to ASTM C494 and shall
be used in accordance with manufacturers recommendations. The
admixtures shall not reduce the strength of the concrete.
4.5.2 Silica Fume: Silica fume used as cement replacement shall be
in accordance with ASTM C1240.
4.6
Reinforcing Steel:
4.6.1 Grade for fusion Bonded Epoxy Coated Rebars (FBECR)
and Uncoated Rebars Reinforcement shall be new and to the
following grades:
General reinforcement shall be deformed billet steel
conforming to ASTM A615/A615M, Grade 60 with a
specified yield strength of 414 MPa.
Welded steel wire fabric shall conform to ASTM A185 for
plain fabric and to ASTM A497 for deformed fabric.
Testing of tensile strength, bending and elongation in
accordance with ASTM A370 for each diameter of
reinforcing bars shall be done for every 200 tons of site
delivered steel.
4.7
Curing Materials:
4.7.1 Hessian shall be in accordance with AASHTO M182 and
shall weigh 0.29 kg/m2.
Concrete Works
Page 3 of 14
MACO-QCCP-005
REV. 0
Colored Concrete:
4.8.1 Concrete used for underground duct encasement shall have a
minimum compressive strength of 20 MPa. As required by design
drawing. Aggregate size shall be as per concrete mix design.
4.8.2 Concrete encasement for underground electrical ducts shall
be colored red by adding 1 Kg. of red oxide powder per 100 Kg. of
cement.
4.9
Accessories:
4.9.1 All sleeves, inserts, anchor bolts, water stops and other
embedded items shall be installed in accordance with the design
drawings and supported against displacement.
4.9.2 The coating materials in accordance with the coating system
specifications shall be used.
4.9.3 For critical applications, coating materials from clientapproved manufacturers shall only be used.
4.9.4 The type of abrasive to be used shall be determined by the
degree, of cleanliness and roughness required for the coating
system. Abrasives commonly used are sand, garnet and grit.
Procedure
5.1 GENERAL:
5.1.1 All structural concrete shall be planned mix. Client shall approve
batching plant and the design of the concrete mix to be used.
5.1.2 All plant facilities are subject to random inspection for compliance
with the approved design mix.
5.1.3 The mix design will encompass:
Compressive Strength
Cement Content and Type
Concrete Works
Page 4 of 14
MACO-QCCP-005
REV. 0
5.3 REINFORCEMENT:
5.3.1 All reinforcement fabrication shall be carried out by qualified
craftsmen.
5.3.2 Epoxy coated rebars shall be bent using fiber or plastic mandrels to
prevent damage to coatings.
5.3.3 Any damage coating shall be repaired using epoxy touch up paint
kit.
5.3.4 Place reinforcement as per correct size and spacing. Position,
support and secure reinforcement against displacement using pre-cast
concrete blocks or PVC chairs.
5.3.5 Minimum bend diameter shall be as per the table below (Refer to
Table 7.2 of ACI 318)
Concrete Works
Page 5 of 14
MACO-QCCP-005
Rebar Size
10 mm to 25 mm Dia.
28 mm to 36 mm Dia.
43 mm to 57 mm Dia.
REV. 0
DESCRIPTION
a
b
3 in.
2 in.
1-1/2 in.
1-1/2 in.
in.
1-1/2 in.
in.
in.
Concrete Works
Page 6 of 14
MACO-QCCP-005
REV. 0
Page 7 of 14
MACO-QCCP-005
REV. 0
Concrete Works
Page 8 of 14
MACO-QCCP-005
5.7
REV. 0
JOINTS:
5.7.1 Construction Joint:
Locate construction joint as per design drawings.
Pattern of reinforcement for construction joint and other joints
shall be submitted to Proponent for approval.
Unless otherwise specified, the surface of the previously placed
concrete shall be prepared by exposing aggregate and removing
laitance, loose particles. And damaged concrete.
Immediately before placing new concrete, the joint surface shall be
thoroughly saturated and excess surface water shall be removed.
Reinforcing steel and mesh shall be continued across construction
joints.
5.7.2 CONSTRUCTION JOINT:
Construction joints shall be by saw cutting and location shall be as
per design drawings.
Start cutting as soon as concrete has hardened sufficiently to
prevent dislodgement of aggregates. Saw a continuous slot to a
depth of one-fourth the thickness of the slab.
5.7.3 EXPANSION JOINT:
General:
Width of joints shall be (13 mm) minimum and 1 (25 mm)
maximum.
Sides of joints shall be parallel.
Joints in paving areas shall be spaced not more than 15 meters (50
ft).
Reinforcing Steel:
Reinforcing Steel shall not extend through joints.
Dowels shall be bonded on only one side of the joint.
Water stop shall extend through the joint whenever required.
Sealer Application:
Non-process Areas: Sealer shall be applied as per the
manufacturers recommendations.
Process Areas: Joint surfaces shall be thoroughly cleaned to
remove curing compounds, laitance, sand and dust etc.
Concrete Works
Page 9 of 14
MACO-QCCP-005
REV. 0
Services of client approved third party testing agency shall be utilized for
testing.
6.2
DOCUMENTATION
7.1
Concrete Works
QCCP-005-01-CW
QCCP-005-02-CW
7.3
QCCP-005-03-CW
7.4
Concrete Compressive
Strength Test Form
QCCP-005-04-CW
Page 10 of 14
MACO-QCCP-005
REV. 0
Reference:
_______________________
Location:
Project:
_______________________
_________________________
S. NO.
1
2
3
4
5
6
INSPECTION POINTS
ACCEPT
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 11 of 14
MACO-QCCP-005
REV. 0
QCCP-005-02-CW
Location:
Project:
_________________________
_______________________
CONCRETE TYPE
SLUMP REQUIRED
CONCRETE FOR:
2000 psi
100
Blind
4000 psi
125
OTHERS
150
Paving
175
Walls
200
Pedestal
RCC Structure
BREADTH
QUANTITY (M)
HEIGHT
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Concrete Works
Page 12 of 14
MACO-QCCP-005
REV. 0
Date:
_______________________
Location:
Project:
_______________________
Sample No.
_______________________
Tested By:
_______________________
TEST NO.
_________________________
TRUCK/TICKET
NO.
TIME
BATCHED
HR.
TIME
SAMPLED
HR.
MAX.
TEMP. 0C
SLUMP
REMARKS
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
______________________
SOURCE OF CONCRETE:
___________________________
INDEPENDENT TESTING LAB.
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Concrete Works
Page 13 of 14
MACO-QCCP-005
REV. 0
Date:
_______________________
Location:
Project:
_______________________
Sample No.
_______________________
Tested By:
_______________________
_________________________
TRUCK/TICKET
NO.
TIME
BATCHED
HR.
TIME
SAMPLED
HR.
AIR
CONTENT
%
MIX
TEMP.
0
C
CURING
TEMP. 0C
AIR
TEMP.
0
C
AGE(DAYS)
DIMENSION
SL#
mm
AREA
mm2
WEIGHT
g
DENSITY
Kg/m3
DIAL
Kn
COMPRESSIVE STRENGTH
AGE(DAYS)
DIMENSION
SL#
mm
AREA
mm2
WEIGHT
g
DENSITY
Kg/m3
DIAL
Kn
COMPRESSIVE STRENGTH
AGE(DAYS)
DIMENSION
SL#
mm
AREA
mm2
WEIGHT
g
DENSITY
Kg/m3
DIAL
Kn
COMPRESSIVE STRENGTH
Concrete Works
SLUMP
TEST DATE
Kg/cm2
Psi
MPa
REMARKS
TEST DATE
Kg/cm2
Psi
MPa
REMARKS
TEST DATE
Page 14 of 14
Kg/cm2
Psi
MPa
REMARKS
MACO-QCCP-005
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
GROUTING WORK
DOCUMENT NO.:
MACO-QCCP-006
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Materials
Procedure
Inspection & Testing
Documentation
2
2
2
3
3
4
5
001
04/09/09
MACO-QCCP-006
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Grouting Works
Page 1 of 6
MACO-QCCP-006
REV. 0
GROUTING WORKS
1
Scope
1.1 This document covers the installation of:
Cement Based, Non-Shrink Grout
Epoxy Grout
Purpose
2.1 The purpose of this procedure is intended to describe the minimum
requirement for structural and Equipment Grouting.
Grouting Works
References
ASTM C307
ASTM C413
ASTM C469
ASTM C531
ASTM C579
Test Method for Compressive Strength of ChemicalResistant Mortars, Grouts, and Monolithic Surfacing and
Polymer Concrete
ASTM C580
ASTM C4318
Page 2 of 6
MACO-QCCP-006
REV. 0
GES-013-56
Grouting of Foundation
Materials:
4.1
General Requirements:
4.1.1 Cement Based Non-Shrink Grout and Epoxy Grout for
Structural and Equipment Grouting shall be as per Royal
Commission for Jubail & Yanbu specifications.
4.1.2 Submit manufacturers catalogue to Royal Commission for
Jubail & Yanbu representative for approval before placing order
for materials.
4.1.3 Resin component shall consist of premeasured, prepackaged,
solvent free, epoxy resin specifically formulated for the used grout
system.
4.1.4 The hardener component shall consist of a premeasured,
prepackaged liquid specifically formulated to produce the
specified final properties when mixed with the other component.
4.1.5 The aggregate shall be premeasured, prepackaged blend of
inert, inorganic fillers, such as silica, designed specifically to
provide the proper flow, handling and physical properties required
for the grout product.
4.2
Handling:
4.2.1 Deliver all materials such as resin, hardening component and
other admixture to the job site in original containers.
4.2.2 Keep stored material covered and protected.
Procedure
5.1 General:
5.1.1 All grouting work shall be done as per the drawing details and Royal
Commission for Jubail & Yanbu Specifications.
Grouting Works
Page 3 of 6
MACO-QCCP-006
REV. 0
5.1.2 Epoxy grout shall be installed as per the manufacturers data sheet.
5.1.3 The epoxy grout manufacturers recommendations on maximum
depth of pour and length to width ratio shall be followed.
5.1.4 If the grout pour is 100 mm or deeper, the grout manufacturer
recommendation for installing reinforcement rebar shall be followed.
5.1.5 Safety requirements specified in the grout manufacturers data sheets
shall be followed while application of grout system.
5.1.6 The ratio of aggregate to resin and hardener shall be as per the
manufacturers recommendations.
5.1.7 When type of grout is not specified by Royal Commission for Jubail
& Yanbu, or by the equipment Manufacturer, Cementitious grout shall be
used for any of the following:
i)
ii)
5.1.8 When type of grout is not specified by Royal Commission for Jubail &
Yanbu or by the equipment manufacturer, epoxy grout shall be used for
any of the following:
Equipment with driver horsepower 500 (373 Kw).
Equipment with speed greater than 3600 RPM.
Equipment that has a combined weight (Machine, driver and base
plate) of greater than 2,270 Kg. (5000 Lbs.).
All reciprocating machinery with driver horsepower greater than
50 (37KW).
5.1.9 Cementitious grout shall be cured with potable water for a minimum
period of seven days.
Grouting Works
Page 4 of 6
MACO-QCCP-006
REV. 0
DOCUMENTATION
7.1
Grouting Works
Grouting Checklist
QCCP-006-01-GW
Page 5 of 6
MACO-QCCP-006
REV. 0
GROUTING CHECKLIST
QCCP-006-01-CW
Reference:
_______________________
Location:
Project:
_______________________
_________________________
S. NO.
1
2
INSPECTION POINTS
ACCEPT
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Grouting Works
Page 6 of 6
MACO-QCCP-006
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
PROTECTIVE COATING FOR BURIED CONCRETE
DOCUMENT NO.:
MACO-QCCP-007
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Materials
Procedure
Inspection & Testing
Documentation
2
2
2
2
3
4
4
001
04/09/09
MACO-QCCP-007
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 5
MACO-QCCP-007
REV. 0
Scope:
1.1 This section covers the requirement for materials and application
procedure for the following works:
Surface preparations for buried concrete surfaces.
Coating application for buried concrete surfaces.
Purpose:
2.1 This procedure is intended to describe the minimum requirements for
surface preparation, Coating application for Buried concrete surfaces.
ASTM D 4263
ASTM D 4285
ASTM D 4541
ASTM E 337
09874
Materials:
4.1
General Requirements:
Client approved Coating system specifications or equivalent shall
be used.
Page 2 of 5
MACO-QCCP-007
4.2
REV. 0
Procedure:
5.1
Preparation of Surface:
5.1.1 New concrete shall be allowed to cure for a minimum of 7 days prior
to coating or as per client requirement.
5.1.2 Perform preparation and cleaning procedures in accordance with
paint manufacturers instructions.
5.1.3 For old concrete surface remove oil and greases by mechanical
cleaning.
5.1.4 For old concrete surface remove all loose concrete, sealants and ols
coating by abrasive blasting.
5.1.5 In the case of coating for old concrete surfaces any cracks found
should be prepared as per the concrete repairing procedure.
5.1.6 Expansion and construction joints, if they are to be removed, be
cleaned out and masked off prior to coating. If they are not to be removed,
then they must be masked off. When all coating is complete, remove the
masking and replace with new sealant as required.
5.2
Application:
5.2.1 All filling and coating must be done after sealing.
5.2.2 All below grade concrete surfaces (except the bottom) shall be
coated with Bitumastic 300M by Kop-Coat. The coating shall be applied
per the manufacturers instructions after the concrete is a minimum of
Page 3 of 5
MACO-QCCP-007
REV. 0
seven days old. The dry film thickness of the coating shall be a minimum
of 0.4 mm (16 mils). Coating of vertical surfaces shall extend to 150 mm
(6 inches) above grade.
5.2.3 Finishing coats shall be applied according to the manufacturers data
sheet, taking into consideration the spreading rate requirement.
5.2.4 Any visual pin holes and cracks shall be repaired.
5.2.5 Comply with the recommendations of the product time gap between
succeeding coatings.
5.2.6 Keep brushes and spraying equipment, clean, dry, and free from
contaminants.
5.2.7 Keep brushes and spraying equipment suitable for the finish
required.
5.2.8 Do not apply additional coats until the previous completed coat has
been approved by the client representative.
5.2.9 Provide wet paint signs required to protect newly-painted finishes.
DOCUMENTATION
7.1
Page 4 of 5
QCCP-007-01-BC
MACO-QCCP-007
REV. 0
Reference:
_______________________
Location:
Project:
_______________________
_________________________
S. NO.
1
2
3
4
5
6
7
8
INSPECTION POINTS
ACCEPT
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 5 of 5
MACO-QCCP-007
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
WATERPROOFING, CAULKING AND SEALING
DOCUMENT NO.:
MACO-QCCP-008
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Materials
Procedure
Inspection & Testing
Documentation
2
2
2
2
3
5
5
001
04/09/09
MACO-QCCP-008
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 6
MACO-QCCP-008
REV. 0
Scope:
1.1 This section covers installation of:
Water Proofing.
Caulking and Sealing.
Purpose:
2.1 This procedure is intended to describe the minimum requirements for
water proofing system.
ASTM C 156
ASTM C 920
ASTM E 96
ASTM E 337
Materials:
4.1
General Requirements:
4.1.1 Waterproofing: Membrane shall be preformed, cold applied,
self adhesive, laminated sheet membrane or as per the client
specifications.
Page 2 of 6
MACO-QCCP-008
REV. 0
4.3
Handling:
4.3.1 Deliver materials in original, unopened packages bearing
name of the manufacturer and product identification.
4.3.2 Store materials above the ground, under covered area.
Procedure:
5.1 General:
5.1.1 Waterproofing, Caulking and Sealing shall be done as indicated in
the drawing details and client specifications.
Page 3 of 6
MACO-QCCP-008
REV. 0
Application:
5.3.1 Caulking: Apply caulking as recommended by the sealant
manufacturer or as per the client specifications.
5.3.2 Tool caulking smooth, free from wrinkles and sufficiently convex to
result in flush finish joint when dry.
5.3.3 Sealant: Apply in accordance with manufacturers printed
instructions regarding mixing, surface preparation, application life and
application procedure.
5.3.4 Prime concrete, masonry, wood and other porous surface.
5.3.5 Mask finish surfaces on both sides of the joint cavities to protect
from sealant smears. Remove masking after joints are sealed and tooled.
5.3.6 Fluid Applied Waterproofing:
Apply in accordance with manufacturers printed installation
specifications.
Thin first coat.
Page 4 of 6
MACO-QCCP-008
REV. 0
Perform inspection and testing in accordance with client approved ITP and
client specifications.
DOCUMENTATION
7.1
Page 5 of 6
QCCP-008-01-WP
MACO-QCCP-008
REV. 0
Reference:
_______________________
Location:
Project:
_______________________
_________________________
S. NO.
1
2
3
INSPECTION POINTS
ACCEPT
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 6 of 6
MACO-QCCP-008
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
NON-METALLIC PIPES INSTALLATION
(GRP PIPES)
DOCUMENT NO.:
MACO-QCCP-009
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Materials
Procedure
Inspection & Testing
Documentation
2
2
2
2
2
4
6
001
04/09/09
MACO-QCCP-009
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 6
MACO-QCCP-009
REV. 0
Scope:
1.1 This section covers installation of all types of non-metallic piping.
Purpose:
2.1 The purpose of this procedure is to define and establish necessary
requirement for successful installation of non-metallic piping for
industrial, commercial facilities and buildings.
ASME B31.3
AWWA C950
UPC
Underground Piping
2722
Sewage Systems
Materials:
4.1
Procedure:
The following procedures shall be adopted as per the requirements:
5.1
Page 2 of 6
MACO-QCCP-009
REV. 0
5.1.2 Racks shall confirm to factory shipping packages for each pipe size.
Shelves shall be provided for continuous support of the pipe.
5.1.3 If the loose pipes are stacked on each other, the stack height shall not
exceed 1.5m. Adequate side support shall be provided to prevent slipping
or rolling.
5.1.4 If pipe is stored on racks or bearing boards, the supports shall be at
least 75mm wide. Supports shall be spaced on 3m centers maximum with
first supports 1.5m from the end of the pipe.
5.1.5 All supporting surfaces shall be free of sharp objects.
5.1.6 Thermoplastic and GRP (Glass Fiber Reinforced Pipe) fittings shall
be stored in a building or under a cover that allows free air circulation.
5.1.7 Solvent cement and primer for thermoplastic piping shall be stored
in an air-conditioned building with a maximum temperature of 26.7 Deg.
Centigrade or as specified by the manufacturer.
5.1.8 Gaskets, O-rings, and locking keys shall be stored flat on racks
below 38 0C and out of direct sunlight or as specified by the manufacturer.
5.1.9 Adhesive for GRP piping shall be stored in an enclosure where
temperatures do not exceed 38 0C or as specified by the manufacturer.
5.1.10 Pipe and fittings shall be properly protected from impact, especially
on their ends. They shall not be thrown, dropped, bumped, hit or dragged
and pushed over abrasive surfaces.
5.1.11 Loose thermoplastic or GRP pipe shall be handled by hand or, if
the pipe is too heavy, use nylon or cotton strap spreader slings.
5.1.12 Adhesive and solvent cement containers shall be tightly closed
when not in use, and shall be returned to the storage facilities to
minimized exposure to excessive temperature.
5.1.13 Thermoplastic pipe shall have continuous support along its entire
length when being transported by either truck or pipe trailer. All sharp
edges that could touch the pipe shall be padded with sacks, rubber strips or
other suitable material.
5.1.14 Bearing boards at least 75 mm. wide shall be used to protect GRP
pipe from sharp objects on the truck beds. Rubber tire sections or other
Non-Metallic Pipes Installation
Page 3 of 6
MACO-QCCP-009
REV. 0
Hydrotest.
Page 4 of 6
MACO-QCCP-009
REV. 0
temperature of the piping material or temperature of the test water does not
exceed 40 0C during the test period.
6.3 Potable water (Drinking and raw water) piping systems shall be
hydrotested with fresh potable water.
6.4 No adhesive-bonded GRP piping shall be pressurized until it has cured in
accordance with the manufacturers instructions.
6.5 The test pump shall be placed on firm ground away from the piping. The
pump and the piping system (piping and equipment) shall be protected from
over pressure by relief valves of adequate capacity set at 5% above the test
pressure or a maximum of 170 KPa (25Psig) above the test pressure for pressure
piping systems. The relief valve shall be tested, dated and tagged. Sizing of
relief valve used for testing shall be in accordance to the specifications.
6.6 Requirements of pressure gauges and pressure recorders for pressure
piping systems, calibration intervals, and calibration certificates shall be in
accordance with the client specification. Calibrated and tagged relief valves
may be used as the pressure test instrument upon approval by client.
6.7 The lines whose joints have been backfilled shall be tested as specified by
the client at the following pressures for 24 hours. Lines whose joints have not
been backfilled or are above the ground shall be tested at the following
pressures for 4 hours:
1035KPa (150Psig) or 345 KPa (50 Psig) above the operating pressure,
whichever is greater.
6.8 During hydrotest, all exposed pipe joints fittings, valves and hydrants shall
be carefully examined for leakage.
6.9
6.10 The hydrostatic test shall be repeated after the repair of any defects until
the system is proved satisfactory.
6.11 The piping shall be satisfactory if there is no evidence of leakage or
pressure loss after the specified test period.
DOCUMENTATION
7.1
QCCP-009-01-PI
MACO-QCCP-009
REV. 0
Reference:
_______________________
Location:
Project:
_______________________
_________________________
INSPECTION POINTS
Is trench continuous?
Is trench smooth?
10
11
12
ACCEPT
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 6 of 6
MACO-QCCP-009
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
CONCRETE BATCH PLANT
DOCUMENT NO.:
MACO-QCCP-010
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
2
3
9
001
04/09/09
MACO-QCCP-010
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 4
MACO-QCCP-010
REV. 0
SCOPE
This procedure covers all activities pertaining to Batch Plant Management and
Inspection before and during production of concrete at the Batch Plant.
2.0 PURPOSE
The quality control procedure has been developed in order to highlight the operation
and performance of the batch plant in accordance with the quality control activities
during the course of concrete batch.
3.0
4.0
DEFINITIONS
QA/QC Manual
QCP
ITP
Company
Proponent
SAFETY
The safety Officer is responsible for the overall safety of the construction site. His
responsibilities include site inductions ensuring work permits are valid, accident
reports number of man hours worked and ensuring all works are carried out in the
safest possible manor consistent with good construction practices.
5.0
REFERENCES
SAES-Q-001
SAES-Q-005
Concrete Foundation
09-SAMSS-088
09-SAMSS-097
Page 2 of 4
MACO-QCCP-010
REV. 0
6.0
ASTM-C-33
Concrete Aggregates
ASM-C-94
6.2
6.3
QA/QC Engineer shall verify compliance of aggregates, cement and water for
Ready Mix Concrete per Saudi Aramco standards 09-SAMSS-088 and 09SAMSS-097.
6.4
Calibration certificate of the batch plant shall be checked per Saudi Aramco
specification 09-SAMSS-097 and controlled according to engineering
procedure SAEP-1023.
6.5
Project Engineer or Sit Engineer informs QA/QC Engineer for the concrete
type, quantity and delivery time by internal concrete pouring request form for
each production.
6.6
Before mixing, the QC Inspector shall perform and verify the following items :
6.6.1
6.6.2
6.6.3
6.6.4
Perform the moisture content test of the aggregates and make the
correction of the mixing water.
6.6.5
Make the concrete mixing water analysis for particles and TDS.
Page 3 of 4
MACO-QCCP-010
6.6.6
REV. 0
6.6.7 Check the formula and water/cement ratio of the contents entered into
the computer of batch plant.
6.6.8
6.6.9
6.7 After mixing, the QC Inspector shall perform and verify the following items:
7.0
6.7.1
Check the computer print out after the concrete batching for the actual
quantities and design values.
6.7.2
6.7.3
Make the slump test at batch plant, whether it complies with the
contract specification.
6.7.4
6.7.5
6.7.6
6.7.7
6.7.8
Fill the internal concrete pouring request form ICPR No. HP-01 with
attached related inspection report issued by batch plant.
6.7.9
ATTACHMENTS
QCCP-010-01-CBP
Page 4 of 4
MACO-QCCP-010
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
MISCELLANEOUS METAL
DOCUMENT NO.:
MACO-QCCP-011
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
2
3
9
001
04/09/09
MACO-QCCP-011
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Miscellaneous Metal
Page 1 of 3
MACO-QCCP-011
REV. 0
MISCELLANEOUS METAL
1. SCOPE
This quality procedure will apply for the inspection works for steel.
2. PURPOSE
This quality procedure has been developed in order to describe the main procedure and
performance related to quality control activities during steel works.
3. DEFINITIONS
QMP
QCP
ITP
:
:
:
4. REFERENCES:
NAAMM
ASTM-A269
ASTM-A53
SSPC
SAES-H-101
Industrial-A123
12-SAMSS-007
Schedule Q
:
:
:
:
:
:
:
5. QUALITY PROCEDURE
The civil QC inspector shall verify all delivered materials in the job site to be in good
condition and properly protected against damage to finished surfaces.
Site measurement will be done to ensure that metal fabrication fit surrounding
construction. Clean and strip primed steel items to bare metals where site welding is
required.
Verification of all opening sizes and dimensional tolerances are acceptable
Verification of all supports is properly and correctly positioned.
Installation in accordance with the shop drawings and manufacturers instructions.
Miscellaneous Metal
Page 2 of 3
MACO-QCCP-011
REV. 0
Erection work to ensure square and level, horizontal or parallel to take of steps or
ramp and free from distortion or defects detrimental to appearance or performance.
Expansion joints will be provided as needed to allow for the expansion or contraction.
Installation components plumb and level, accurately fitted, provide anchors, plate
angles required for connecting railings to structure.
Field weld anchors, touchup welds with primer and grind welds smooth.
Conceal bolts and screw whenever possible.
Mechanically cut galvanized finish surfaces. Do not flame cut.
As installation is completed, wash thoroughly using clean water and soap, rinse with
clean water. Do not use acid solution, steel wool or other abrasives.
Remove burrs, weld spatter, weld slag, arc strikes, sharp edges, rust, scale, grease and
foreign matters prior to finishing.
For aluminum items re-anodizing can only be done by removing the part and
returning it to the anodizer.
6. ATTACHMENT
6.1 QCCP-011-01-MM
Miscellaneous Metal
Miscellaneous Metal
Page 3 of 3
MACO-QCCP-011
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DOCUMENT TITLE:
PROCEDURE FOR:
SITE NON-ELECTRICAL UTILITIES
DOCUMENT NO.:
MACO-QCCP-012
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
2
3
9
001
04/09/09
MACO-QCCP-012
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 9
MACO-QCCP-012
REV. 0
Scope
Purpose
The purpose of this quality procedure is to provide a procedure for the installation
of all site Non-Electrical Utilities.
3
References
Definitions
None
Responsibilities
5.1
5.2 The discipline QC Inspectors shall ensure that approved quality control
procedure is implemented throughout the course of the installation.
Inspection shall be done on materials or work, which will be incorporated
to the system. They shall coordinate with Proponent Representative
regarding inspection and testing activities. Documentation of all
inspection and tests made shall also be their responsibility.
6
Procedure
6.1
General Requirements
6.1.1 Thermoplastic and RTR pipes, fittings and accessories shall be
stored and handled in accordance with manufacturers recommendation
and the requirements of Standard Operating Procedure.
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REV. 0
Page 4 of 9
MACO-QCCP-012
6.2
REV. 0
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Thermoplastic Piping
6.2.3.1 Before any pipe or fitting is lowered into the trench it shall
be carefully checked to ensure that it is not cracked or damaged in
any way. Damaged pipe shall either be cut, so that flawless pipe is
obtained with the least possible waste.
6.2.3.2 Joints shall be made in accordance with ASTM D2855.
Solvent cement shall conform to ASTM D2564.
6.2.3.3 After the pipe has been made, the piping shall not be
moved until the drying time listed in Table 3 of SAES-S-070 has
elapsed. To limit movement of a pipe string, the first pipe shall be
backfilled with the joint exposed.
Page 7 of 9
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REV. 0
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REV. 0
Documentation
7.1
None
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DOCUMENT TITLE:
PROCEDURE FOR:
STRUCTURAL STEEL
DOCUMENT NO.:
MACO-QCCP-013
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
2
3
9
001
04/09/09
MACO-QCCP-013
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Structural Steel
Page 1 of 4
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REV. 0
STRUCTURAL STEEL
1. SCOPE
This quality procedure will apply for the fabrication and erection of STRUCTURAL
STEEL in compliance with the contract drawings and specification.
2. PURPOSE
This quality procedure has been developed in order to describe the main procedure and
performance related to quality control activities during fabrication and erection works.
3. DEFINITIONS
QMP
QCP
ITP
:
:
:
4. REFERENCES:
SAES-M-001 :
Basic Criteria for miscellaneous steel structure.
SAES-M-100 :
Saudi Aramco building code.
SAES-H-001 :
Selection requirements for industrial coatings
12 SAMSS-008 :
Miscellaneous steel structure.
Schedule Q
Quality Assurance and Control, Inspection & Testing.
SSEM safety plan
Approved construction drawings.
5. QUALITY PROCEDURE
All structural steel shall be sand blasted and primed with a zinc phosphate or zinc
chromate primer in the shop as per project specification.
Where steel is to receive subsequent top costs the primer shall be from the same
manufacturer as to top coats.
Do not paint surfaces, which are to be welded.
Apply one full coat of paint to surfaces, which are inaccessible after assembly or
erection.
Structural Steel
Page 2 of 4
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REV. 0
Structural Steel
Page 3 of 4
MACO-QCCP-013
REV. 0
Structural Steel
Structural Steel
Page 4 of 4
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REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
JOINT SEALANTS
DOCUMENT NO.:
MACO-QCCP-014
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
2
3
9
001
04/09/09
MACO-QCCP-014
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Joint Sealants
Page 1 of 3
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REV. 0
JOINT SEALANTS
1. SCOPE
This quality procedure will apply for the inspection works for.
2. PURPOSE
This quality procedure has been developed in order to describe the main procedure and
performance related to quality control activities during steel works.
3. DEFINITIONS
QMP
QCP
ITP
:
:
:
4. REFERENCES:
NAAMM
ASTM-A269
ASTM-A53
SSPC
SAES-H-101
Industrial-A123
12-SAMSS-007
Schedule Q
:
:
:
:
:
:
:
5. QUALITY PROCEDURE
The civil QC inspector shall verify all delivered materials in the job site to be in good
condition and properly protected against damage to finished surfaces.
Site measurement will be done to ensure that metal fabrication fit surrounding
construction. Clean and strip primed steel items to bare metals where site welding is
required.
Verification of all opening sizes and dimensional tolerances are acceptable
Verification of all supports is properly and correctly positioned.
Installation in accordance with the shop drawings and manufacturers instructions.
Joint Sealants
Page 2 of 3
MACO-QCCP-014
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Erection work to ensure square and level, horizontal or parallel to take of steps or
ramp and free from distortion or defects detrimental to appearance or performance.
Expansion joints will be provided as needed to allow for the expansion or contraction.
Installation components plumb and level, accurately fitted, provide anchors, plate
angles required for connecting railings to structure.
Field weld anchors, touchup welds with primer and grind welds smooth.
Conceal bolts and screw whenever possible.
Mechanically cut galvanized finish surfaces. Do not flame cut.
As installation is completed, wash thoroughly using clean water and soap, rinse with
clean water. Do not use acid solution, steel wool or other abrasives.
Remove burrs, weld spatter, weld slag, arc strikes, sharp edges, rust, scale, grease and
foreign matters prior to finishing.
For aluminum items re-anodizing can only be done by removing the part and
returning it to the anodizer.
6. ATTACHMENT
6.1 QCCP-014-01-JS :
Joint Sealants
Joint Sealants
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MACO-QCCP-014
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
PRESSURE TESTING
DOCUMENT NO.:
MACO-QCCP-015
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Materials
Procedure
Lay-Up Procedure
Documentation
2
2
2
2
2
5
5
001
04/09/09
MACO-QCCP-015
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Pressure Testing
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REV. 0
PRESSURE TESTING
1
Scope:
1.1 This procedure covers pressure testing of pipelines:
Purpose:
2.1 This procedure is intended to define preparation and method used to
conduct Pressure Testing of pipes as required in the specifications.
Testing Of Piping
Safety:
4.1
4.2
Procedure:
5.1
All materials within the piping system shall be checked to ensure compliance
with the design limit and to verify that the pressure rating meet or exceed the
specified test pressure. The pre-pressure test packages shall be issued to
client for review at an agreed time before the test starts.
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5.2.2 Vents shall be provided at all high points in the system. Drains shall
likewise be provided at all low points in the system.
5.2.3 Piping System being strength tested shall be protected from over
pressure by relief valve of adequate capacity to relieve at 5% above the
strength pressure.
5.3
Test Equipment:
5.3.1 Equipment to be used on the test shall be checked to ensure that
respective pressure ratings are consistent with the test requirements.
Necessary isolation valve rated for manifold pressure between the test
manifold and the system being tested.
5.3.2 Test pump shall be placed on the firm ground and connected at the pipe
having the lowest point or elevations where possible.
5.3.3 A bleed valve shall be provided to protect the piping and equipment
from over pressurization in addition to pressure relief valve. The bleed valve
shall be readily accessible in case immediate depressurization is required.
5.3.4 Pressure gauges shall be calibrated as per client specifications. All
pressure gauges shall have a range such as the pressure is within 30 to 80
percent of the full range.
5.3.5 Gauges calibration interval shall not exceed one (1) month or client
specification.
5.3.6 Calibration certificates shall be made available prior to pressure testing.
5.3.7 Relief valves shall be tested, dated and tagged within one (1) week
prior to hydrotest and sizing of the relief valves shall be in accordance with
the client specifications.
5.3.8 Pressure monitoring gauge shall be installed at the pipe and not at the
pressure pump. Minimum of two (2) pressure gauges whose accuracy shall
be 5% of one another shall be located at the pump manifold and the others on
the system.
5.3.9 Test medium to be used shall be in accordance with the client
specifications. Chloride content of water shall be less than 50 mg/L when
testing stainless steel.
Pressure Testing
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Pressure Testing:
5.5.1 Lines which have not been backfilled or are above the ground shall be
tested for a sufficient time, which shall not be less than 30 min. to determine
that there are no leaks.
5.5.2 Fill the system / sub-system with approved test fluid which shall be
introduced at the lowest point of the system. All vents shall be opened
during filling and closed when entrained air is removed, then build the
pressure slowly.
5.5.3 At 50% of the strength test pressure, pressurization shall be stopped to
check for leaks.
5.5.4 If any leakage is found, the system shall be de-pressurized and then
de-watered. After repair, the system shall be re-filled and pressurization
shall be re-initiated.
5.5.5 After satisfactory preliminary checks for leaks at 50% of strength
test pressure, the pressure shall be increased in steps no greater than onetenth of the strength test pressure with at least 10 minutes hold at each step
to permit inspection for leakage.
5.5.6 If no leaks are discovered during these steps, pressurization shall be
continued up to the required test pressure. The lines shall be considered
satisfactory if there is no evidence of leakage or pressure losses after the
specified test period.
5.5.7 Upon completion, the system shall be bled and the line s shall be
drained. Vents are to be fully opened.
5.5.8 All test manifolds shall be pre-tested separately from the system to at
least 1.2 times the system test pressure but not less than the pump discharge
pressure.
5.5.9 System Valve Testing shall be in accordance with client
specification and approved valve testing procedure.
Pressure Testing
Page 4 of 8
MACO-QCCP-015
Lay-up Procedure:
6.1
Upon completion of final pressure test, the hydro test water shall be drained
completely.
6.2
Compressed air shall be blown until such time the system is thoroughly dried
out.
6.3
DOCUMENTATION
7.1
Pressure Testing
REV. 0
QCCP-015-01-PT
QCCP-015-02-PT
QCCP-015-03-PT
Page 5 of 8
MACO-QCCP-015
REV. 0
PUNCH LIST
QCCP-015-01-PT
PUNCHLIST No.
TEST PACK No.
Item
No.
Drawing
No.
AREA:
SYSTEM:
Category
Action
By:
Description
Originator
Sign.
Date
Comp.
Sign
Date
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Pressure Testing
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REV. 0
QCCP-015-02-PT
TEST PACKAGE:
SYSTEM & SERVICE:
TEST TYPE:
PLANT NO.:
REFERENCE STANDARDS:
S. No.
Drawing No.
Spool No.
S. No.
Drawing No.
TEST PRESSURE:
LAY-UP REQUIRED:
TEST MEDIUM:
TEST DURATION:
Spool No.
EQUIPMENT:
GAUGE No. 01:
Calibration Date:
Expiry Date:
Calibration Date:
Expiry Date:
Calibration Date:
Expiry Date:
REMARKS:
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Pressure Testing
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REV. 0
QCCP-015-03-PT
MANUFACTURER
PRESSURE SEAT
TYPE
:
:
:
TEST No.
TEST MEDIUM
:
:
MANUFACTURER
PRESSURE SEAT
TYPE
:
:
:
TEST No.
TEST MEDIUM
:
:
MANUFACTURER
PRESSURE SEAT
TYPE
:
:
:
TEST No.
TEST MEDIUM
:
:
Item
No.
Royal
Commission
for Jubail &
Yanbu P.O.
No.
PRESSURE
Valve
Identification
Dia.
Rating
BODY
(PSI)
SEAT(A)
(PSI)
SEAT(B)
(PSI)
BACK
SEAT
(PSI)
ACC
REJ
REMARKS:
Pressure Testing
Proponent REPRESENTATIVE
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DOCUMENT TITLE:
PROCEDURE FOR:
THRUST BORING
DOCUMENT NO.:
MACO-QCCP-016
Index
1
2
3
4
5
6
Page
Purpose
Scope
References
Definitions
Procedure
Risk Assessment
2
2
2
2
2
5
001
04/09/09
MACO-QCCP-016
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Thrust Boring
Page 1 of 13
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REV. 0
THRUSTBORING PROCEDURE
1
Scope
This method statement is only applicable to the above works associated with
the construction of the new water main pipeline.
Purpose
The method statement defines the procedures to be adopted and the controls
to be exercised in the placing of the 1200mm dia. steel liner and all associate
works.
References
3.1 Aject Health and Safety Policy
3.2 Site Health Safety Plan
Definitions
PPE Personal Protective Equipment
HAVS Hand Arm Vibration Syndrome
COSHH Control of Substances Harmful to Health
Procedure
5.1
Prior to commencing any work all personnel will have attended the
appropriate Site Induction Training.
5.2
All necessary Permits to Work will have been obtained by the main
contractor and be displayed on site as required.
5.3
Prior to any works commencing, the main contractor shall set out works
in accordance with the latest revised information. Line and control points will
be clearly marked as appropriate for use by AJECT.
5.4
Plant and equipment associated with the works will be delivered to the
site and off loaded in the required pre-determined position suitable for the
works.
Thrust Boring
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5.5
Following completion of the drive pit, shuttering and concreting works
will be required to be carried out for the construction of the thrust wall and
front sealing eye wall.
5.6
Once the shutters are fabricated, mesh reinforcement placed the
required concrete will be called off and delivered and placed using either a
proprietary concrete pump if available or a simple concrete skip in conjunction
with suitable craneage.
5.7
Following completion of the above works and a suitable curing time
period the shutters will be stripped and removed from within the cofferdam.
5.8
The guide slide rails / jacking equipment will be then positioned to the
correct alignment and level to suit the steel sleeve pipe. Once set concrete
haunching will be placed to maintain the position.
5.9
A rubber sealing eye complete with steel plate ring will be attached to
the concrete front sealing eye wall. This ring allows entry of the tunneling
machine while preventing ground loss and bentonite slurry loss.
5.10 The tunnel machine, TBM to be utilized will be an Iseki type machine.
The TBM is equipped with a soft ground cutting head. The head itself is
equipped with carbide tipped tools to cut the entire face of the tunnel. The
machine is a no man entry and consists of a sealed face bulkhead.
5.11 On completion of the above works, the TBM is lowered into the drive
pit onto the guide rails.
5.12 The machine is then jacked forward entering the concrete sealing eye
through the rubber sealing ring. At this point the face of the machine is charged
with water / slurry to provide the necessary face support.
5.13 The sheet piles over the extent of the tunnel entry are then extracted to
a level just above the crown of the tunnel, to allow entry of the TBM into the
ground.
5.14 The machine then commences excavation. The excavated material
passes through the openings in the cutting wheel into the crushing / mixing
chamber. Within the chamber, the rear of the head acts as a conical crusher,
reducing the excavated material to a size suitable for conveying to the surface
settlement tank by use of slurry pumps. Water is injected into the crushing
Thrust Boring
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chamber via nozzles to assist with ground support and to clear the excavated
material.
5.15 The excavated material conveyance is controlled by pressurized feed
and return pumps. The pumps have variable speed controls to adapt to varying
ground conditions and to balance the flow rates and control settlement above
the tunnel line.
5.16 Additionally the machine is fitted with a by-pass valve system which
allows for the washing out of the feed and discharge lines. The system also
isolates the cutting head, thus support can be maintained to the face while the
slurry system is disconnected during the process to place the jacking pipes.
5.17 As stated, the excavated material is conveyed to a settlement tank on
the surface. The feed water is drawn from this tank. The excavated material
settles within the tank and is required to be removed by an excavator at various
intervals during the tunneling process. The water level within the tank will also
require topping up at intervals during the process.
5.18 Control of the tunneling process is via a containerized surface mounted
control cabin / power pack. A CCTV camera in the rear of the machine details
all relevant data the operator requires.
5.19 A laser guidance system is utilized. The laser is set within the drive
shaft and the beam shines along the tunnel length to a target within the rear of
the TBM. This information is also displayed to the operator, who can control
the TBM steering rams to guide the machine to the specified tolerances.
5.20 The TBM will be advanced by utilizing the pit bottom jacking system,
retracting the rams as the full stroke is reached and placing steel spacer units
and continuing the process until there is sufficient space for the first casing
pipe to be lowered.
5.21 At this stage the rams will be extracted and the spacer blocks removed
and the slurry and power cables to the TBM will be disconnected.
5.22 The steel casing pipe (6m long) will be lowered and the pipe welded to
the back of the TBM can. Once welding is completed the TBM services will be
re-established and the jacking process recommenced.
5.23 This process continues until the first casing pipe is fully pushed and the
process repeated lowering the second pipe. The joints between the pipes are
Thrust Boring
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The rubber sealing eye ring will also be removed as described in 5.29.
5.33 The slurry tanks will be emptied of water and excavated material. Main
contractors responsibility.
5.34 All plant and equipment will be stripped and cleaned and prepared for
removal from site.
Thrust Boring
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5.35 An auger pushing rig will then be established within the drive pit to suit
the level of the product pipe.
5.36 The product pipes will be prepared for pushing by having simpler
timber skids attached to the outside to maintain the desired position of the pipe,
once inserted into the casing pipe. The skid / spacer timbers will be secured to
the product pipe using steel band it wire. The timbers will be notched to
prevent the skids from being dislodged during the pushing process.
5.37 The first 6m long pipe will be lowered and pushed into the tunnel to the
desired position to allow welding of the following pipe.
5.38 The second pipe will be lowered and jointing works carried out by the
main contractor. Once the necessary testing and coating works have been
carried out the second pipe will be pushed to the correct position for the
process to be repeated.
5.39 On completion of the pushing process to the required positions the
auger pushing rig will be stripped down and removed from the jacking pit.
5.40 Timber shutters will be constructed to both ends of the tunnel over and
around the inserted product pipe.
5.41 Two pipes will be installed within the top of the shutters to allow for
grouting operations and for the expelled air to exit the void space.
5.42 Grouting and the annulus between the casing pipe and the product pipe
will be undertaken using the specified grout mix. The grout will be placed
utilizing a grout mixing pan and pump. The grout will be placed from the
upper end of the tunnel and will flow through the void space.
5.43 Successful grouting of the void space will be demonstrated when the
grout flows from the upper breather pipes on the down stream end. A header
pipe will also be utilized on the upstream end to allow simple gravity to fill the
remaining void space.
5.44 Once this operation has been completed and the shutters removed the
works shall be handed back to the main contractor for connections and
completion works to be carried out. The pits will then be subsequently
backfilled.
Thrust Boring
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EMERGENCY ARRANGEMENTS:
5.45 Members of the team shall be trained in first aid; the first aid kit is
available at the work area and will be kept with the workforce. Additional
support will be provided by the main contractor.
EMERGENCY PURPOSES:
5.46 All personnel shall be inducted into the main contractors Emergency
and Fire Safety Plan. A tool box talk will be given on the procedures and the
procedures will be displayed on site.
ENVIRONMENTAL ISSUES:
5.47
Environmental spill kits will be available for use at the works location.
Risk Assessment
6.1
Before any work process is undertaken the manager shall ensure a risk
assessment is undertaken for all operations likely to expose persons to any
Thrust Boring
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hazard. Where the hazard cannot be eliminated, risk control measures shall be
identified and the residual risks rating identified.
6.2
A competent person who possesses the necessary training, experience
and expertise has undertaken the risk assessment. It shall be briefed out to all
those involved in the operation and any pertinent feedback incorporated.
6.3
The risk assessment will be reassessed whenever a significant change in
the process, where new equipment or materials are introduced, or when any
person has any knowledge of the assessment being invalid.
Key
L
2 Low
3 Possible
5 Very Likely
Thrust Boring
Risk Rating: R = L x S
Page 8 of 13
MACO-QCCP-016
QA/QC PLAN
ALTERNATE SANITARY WASTEWATER
COLLECTION PIPELINE FROM PS#B2 TO PS#1
DOCUMENT No. MACO-QCCP-016
REV. 0
REF.
Thrust Boring
Hazard
PERSONS
AFFECTED
Initial Risk
Avoidance/Control
Measures
Resultant
Risk
Cranes / Rigging /
Slinging
Banksmen
1
9 Appointed Crane coordinator, Trained
Slingers & Signallers.
Certified Lifting tackle,
visual inspection. Certified
Crane 12 monthly
thorough inspections,
weekly recorded, daily
visual. (6 monthly if used
for manriding). Personal
positioning no standing
under loads.
Manual Handling
All on site
All on site
Visitors
Excavation falls
All on site
Fire
All on site
Personnel
Visitors
8 Assessments to be
undertaken.
Mechanical lifts to be
used wherever practical.
Gloves to be worn.
Good posture to be
maintained whilst lifting.
10 Suitable footwear to be
worn.
Practice good
housekeeping.
Weekly inspections of the
Workplace by competent
person.
15 Excavations or edges of
falls to be guarded.
Daily inspection by
competent person.
Weekly record of
inspection.
15 Fire Plan to be
established.
Trained fire extinguisher
users.
Regular inspection of
equipment.
Regular drills.
Page 9 of 14
MACO-QCCP-016
QA/QC PLAN
ALTERNATE SANITARY WASTEWATER
COLLECTION PIPELINE FROM PS#B2 TO PS#1
DOCUMENT No. MACO-QCCP-016
REV. 0
REF.
Hazard
PERSONS
AFFECTED
Initial Risk
L
Ladders / Scaffold /
Falls from Height
General
Labourers
All site
personnel
Visitors
Disease
General
Labourers
Environmental
Concern
(Contamination of
Controlled Waters)
Environment
10
All on site
11
Noise
All
Thrust Boring
Page 10 of 14
Avoidance/Control
Measures
Resultant
Risk
MACO-QCCP-016
QA/QC PLAN
ALTERNATE SANITARY WASTEWATER
COLLECTION PIPELINE FROM PS#B2 TO PS#1
DOCUMENT No. MACO-QCCP-016
REV. 0
12
Small Tools
13
14
HAVS
Thrust Boring
Operators
All
Operators
Page 11 of 14
Equipment to be
regularly inspected and
maintained.
Post warning signs and
established hearing
protect zones.
9 Only use experienced
operators.
Equipment to be
regularly inspected and
maintained.
Correct PPE to be worn.
6 Minimize operations that
produce flying debris.
Provide respiratory / eye
protection.
Cordon off areas as
appropriate.
9 Use anti-vibration tools
where possible.
Use anti-vibration PPE.
Obtain Particle velocity
reading for equipment
and calculate maximum
working times per 8 hour
shift.
Rotate Operators using
equipment.
Equipment to be
regularly inspected and
maintained.
Provide adequate
welfare facilities.
MACO-QCCP-016
QA/QC PLAN
ALTERNATE SANITARY WASTEWATER
COLLECTION PIPELINE FROM PS#B2 TO PS#1
DOCUMENT No. MACO-QCCP-016
REV. 0
REF.
15
Hazard
Electrocution
PERSONS
AFFECTED
Operators
Avoidance/Control
Measures
Initial Risk
Resultant
Risk
Labour:
Job Function
Supervisor
Engineer
General Labours
Plant Operators
Thrust Boring
Training
PPE
Hard Hat
First Aid
Safety Boots
Induction
High Visibility Clothing
Eye Protection
Hard Hat
First Aid
Safety Boots
Induction
High Visibility Clothing
Use of CAT Detector
Eye Protection
Ear Protection
Hard Hat
Safety Boots
First Aid
High Visibility Clothing
Induction
Eye Protection
Use of Fire Extinguishers
Ear Protection
Anti Vibration Gloves
Hard Hat
Safety Boots
Certified as trained.
High Visibility Clothing
Induction
Eye Protection
Ear Protection
Anti Vibration Gloves
Page 12 of 14
Comments
MACO-QCCP-016
QA/QC PLAN
ALTERNATE SANITARY WASTEWATER
COLLECTION PIPELINE FROM PS#B2 TO PS#1
DOCUMENT No. MACO-QCCP-016
REV. 0
Plant:
Item
Description
Small Tools
Quantity
Variable
Supplier
Hire / AJECT
Certification
Required
No
Crane
1 No.
Manar Arabian
Corp.
Yes
Manrider
1 No.
AJECT
Yes
Variable
Manar
Arabian/AJECT
Yes
Weld Set
1 No.
AJECT
No
Burning
Equipment
1 No.
AJECT
No
Generator
1 No.
AJECT
No
Iseki TBM
1 No.
AJECT
No
Lifting Chains
and
Equipment
Thrust Boring
Page 13 of 14
Special Requirements /
Comments
MACO-QCCP-016
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
WIRES AND CABLES
DOCUMENT NO.:
MACO-QECP-001
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Materials
Procedure
Inspection & Testing
Documentation
2
2
2
2
6
7
8-12
001
04/09/09
MACO-QECP-001
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 12
MACO-QECP-001
REV. 0
Purpose:
1.1 The purpose of this document is to define and establish systematic
method or process to identify laid and test wires/cables, associated
with electrical installation in industrial and non-industrial facilities.
Scope:
The wires/cables covered under this scope are as follows:
2.1 Low voltage jacketed cables rated 600/1000V.
2.2 Low voltage unjacketed insulated wires rated 600V.
2.3 Medium voltage power cables, rated 5KV through 35KV to be used on
system with nominal voltages above 2KV up to 34.5KV.
Material:
4.1 General Requirements
4.1.1
Page 2 of 12
MACO-QECP-001
REV. 0
4.1.1.2 NEC type low voltage cables shall be rated 600V and shall
have minimum temperature rating of 90 Deg. Dry/75 Deg wet and
shall conform to UL standards.
4.1.1.3 IEC 502 type cables shall be rated 600/1000V and shall
have a minimum rating of 85Deg. C.
4.1.1.4 NEC type low voltage unjacketed insulated wires shall be
rated 600V and shall have a temperature rating of 90 Deg. C
dry/75 Deg. C wet.
4.1.1.5 Low voltage unjacketed, SSA 55 type wires shall be rated
450/750V and shall have a minimum rating of 85Deg. C. For
wiring of lighting fixtures, etc., the above minimum temperature is
increased.
4.1.1.6 Power and control conductors shall be stranded copper,
except solid conductors 6mm square (10 AWG) or smaller may be
used in non-industrial locations. Mineral cables and special cables
for pump motor, with solid conductor are permitted.
4.1.1.7 Stranding shall be as per ASTM, but portable cables and
motor leads shall have finer stranding as per UL standard.
4.1.1.8 Cable insulation for interior building wiring shall be
THHN/THWN, except for equipment grounding conductors,
which may have PVC or thermo plastic insulation.
4.1.1.9 Unless otherwise indicated the minimum size of conductor
for power shall be 4mm square and control shall be 2.5mm square.
4.1.1.10 Conductors of multi-conductor control cables shall be
numbered or color coded by colors other than green, green with
yellow stripes, white or gray.
4.1.1.11 The insulation and jacket for direct buried cables shall be
cross linked polyethylene (XLPE) and polyvinyl chloride (PVC)
and outer sheath jacket.
4.1.1.12 The following cables shall be permitted for cable tray
system:
Mineral insulated metal sheathed cable.
Armored cable
Wires and Cables
Page 3 of 12
MACO-QECP-001
REV. 0
Page 4 of 12
MACO-QECP-001
REV. 0
4.2
Manufacturers
Materials are selected purely on the basis of the clients choice,
subjected to compliance with project requirements, installation
methods and the types of race ways used for installation. The
cables/wires from the following manufacturers are used, if the
client is not specific about any material from a particular
manufacturer.
4.2.1 Saudi Cable Company
4.2.2 Riyadh Cable Factory
4.2.3 Middle East Specialized Cable Company
4.2.4 Other Equal manufacturers.
4.3
Material Description
The following types of wires/cables are normally used for different
Electrical installations. These materials shall comply with the
materials and specifications defined in NEC.
4.3.1 Rubber insulated wires and cables.
4.3.2 Thermo plastic insulated wires.
4.3.3 PVC-insulated cable with circular copper conductor.
4.3.4 Thermo plastic insulated cable, 0 to 35KV.
Page 5 of 12
MACO-QECP-001
REV. 0
Procedure:
5.1
All cables and wires are visually inspected for any damage before
installation.
5.2
Identify each wire in junction boxes, terminal boxes, cabinets and
termination boxes by slip-on markers.
5.3
Conductor shall be continuous between outlets, boxes, devices etc.
there shall be no splices or taps within a conduit or conduit body.
5.4
Conductors of light, control and power systems of 120, 208, 220,
380 and 480V shall be permitted to occupy the same enclosure, conduit, or
tray where all conductors are insulated for the maximum nominal circuit
voltage rating of any conductor within the enclosure.
5.5
All phases of a three phase circuit and a neutral wire, if any, and
ground wire shall be located in the same metallic conduit when steel
conduit is used.
5.6
All splices shall be made in junction boxes or splice boxes only.
No splices shall be made in, L or C type fittings. Wire in conduit shall
be continuous
5.7
No wire shall be pulled into conduit that terminates in major
switch gear, control centers, etc., until such equipment has been installed
and permanently secured in place.
5.8
An adequate length of cable or wire shall be left after pulling to
make all necessary splices and terminations.
5.9
Basket grips shall be securely fastened to the cable before pulling.
The area covered by the basket grip shall be removed before termination.
5.10 Cable shall be pulled faster than 50 ft per minute and slower than
15 ft per minute.
Page 6 of 12
MACO-QECP-001
REV. 0
5.13 Single core conductor cables shall be color coded throughout their
length. Ground wire shall always be green strip and neutral shall be white
or gray. Power wires shall be black, red blue, brown, black, yellow etc.
Identify neutral in a multi-conductor cable by tape. Where tape is used, it
shall cover 150mm of the cable.
5.14 Installed splices shall have equal or better mechanical strength and
insulation as the factory insulation.
5.15 When conductors are connected in parallel, in raceways or cable
trays the conductor shall be installed in groups consisting of not more than
one conductor per phase or neutral, to prevent current unbalance due to
inductive reactance.
5.16 Mark wires consistently throughout the system using notation of wire
given.
5.17 Coordinate cable installation with other work.
5.18 Direct buried cables that cross under paved road, railroad etc. shall be
run in duct bank.
5.19 Splicing for medium voltage, (2KV to 35KV) shall be carried out by
trained certified technician. The materials for splicing shall be selected for
the particular type of cable and all related work is performed as per
manufacturers instructions.
5.20 For 2KV to 35KV installations the creepage distance between
terminals are maintained as per relevant standards.
5.21 For medium voltage connections to elbows such as elastimold
connectors, follow manufacturers instructions strictly.
5.22 For higher voltage installation thermo plastic insulating compounds
are not acceptable.
Page 7 of 12
MACO-QECP-001
REV. 0
Associated Documents
7.1
QECP-001-01-WC
7.2
QECP-001-02-WC
7.3
QECP-001-03-WC
7.4
QECP-001-04-WC
Page 8 of 12
MACO-QECP-001
REV. 0
QECP-001-01-WC
CONTRACT:
LOCATION:
CABLE NO:
DRAWING NO.:
S.NO.
1
2
3
4
5
6
7
8
9
10
11
_____________________
_____________________
_____________________
_____________________
REFERENCE:
PROJECT:
SYSTEM:
AMB. TEMP.
INSPECTION POINTS
Check type, size and proper installation.
Check the routing with cable schedule and drawing.
Check the preparation for pulling.
Check the pulling tension as per the specifications.
Wires/cables identified at both ends.
Cable properly supported/trained.
ACCEPT
_________________
_________________
_________________
_________________
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 9 of 12
MACO-QECP-001
REV. 0
QECP-001-02-WC
CONTRACT:
LOCATION:
CABLE NO:
DRAWING NO.:
Equip. Tag
/ Cable No.
Ph. A to G
_____________________
_____________________
_____________________
_____________________
Ph. B to G
Ph. C to G
REFERENCE:
PROJECT:
SYSTEM:
AMB. TEMP.
Ph. A to B
Ph. B to C
_________________
_________________
_________________
_________________
Ph. C to A
REMARKS
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 10 of 12
MACO-QECP-001
REV. 0
QECP-001-03-WC
CONTRACT:
LOCATION:
CABLE NO:
DRAWING NO.:
CABLE NO.
_____________________
_____________________
_____________________
_____________________
REFERENCE:
PROJECT:
SYSTEM:
AMB. TEMP.
CORE
ID/NUMBER
CONTINUITY
YES
NO
_________________
_________________
_________________
_________________
REMARKS
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 11 of 12
MACO-QECP-001
REV. 0
QECP-001-04-WC
CONTRACT:
LOCATION:
CABLE NO:
DRAWING NO.:
_____________________
_____________________
_____________________
_____________________
PHASE
LEAKAGE CURRENT
KV
KV
KV
KV
KV
KV
15 SEC
30 SEC
45 SEC
1 MIN
2 MIN
3 MIN
4 MIN
5 MIN
6 MIN
7 MIN
8 MIN
9 MIN
10 MIN
11 MIN
12 MIN
13 MIN
14 MIN
15 MIN
REFERENCE:
PROJECT:
SYSTEM:
AMB. TEMP.
1-G
MICRO AMPS.
2-G
MICRO AMPS.
_________________
_________________
_________________
_________________
3-G
MICRO AMPS.
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 12 of 12
MACO-QECP-001
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
GROUNDING SYSTEMS
DOCUMENT NO.:
MACO-QECP-002
Index
1
2
3
4
5
6
7
8
Page
Scope
References
Materials
Quality Control
Procedure
Instrument Earthing
Testing
Documentation
2
2
2
2
3
3
4
5
001
04/09/09
MACO-QECP-002
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Grounding Systems
Page 1 of 5
MACO-QECP-002
REV. 0
GROUNDING SYSTEMS
1 SCOPE
This procedure covers the inspection procedure pertaining to the installation
for General Electrical & Instrumentation Earthing System.
This procedure shall be applied to the inspection, method and criteria for
installation work carried out by the Electrical Department.
2 REFERENCE STANDARDS AND CODES
a) SAES-P-100
b) SAES-P-104
c) SAES-B-068
d) SAES-P-111
e) NEC
Lighting
Wiring Methods & Materials
Electrical Area Classification
Grounding
National Electric Code
3 MATERIALS CONTROL
a)
b)
c)
4 QUALITY CONTROL
4.1
a)
b)
c)
Grounding Systems
Page 2 of 5
MACO-QECP-002
d)
e)
f)
REV. 0
5 INSTALLATION
5.1
a)
b)
c)
d)
e)
f)
Grounding Systems
Page 3 of 5
MACO-QECP-002
REV. 0
6 INSTRUMENT EARTHING
Instrumentation and control systems require a clean Clean earth
connection, completely isolated from the plant main earthing system, to
prevent electrical interference on the signals being transmitted.
Where Zener diode barriers are installed in intrinsically safe circuits a
similar isolated, low resistance and path to earth is required.
a)
Instrument ground locations will be checked against relevant layout
drawings to ensure correct positioning and spacing from sources of
interference and installed as in item 1.5.1(b1)(b2)
b)
Instrument earth bars will be checked against the layout drawings and
installation details
c)
Control panel earth reference bars will be megger checked to ensure
they are isolated from the main electrical earthing ground.
d)
Instrument earth cables from the ground rod to the bus bar will be
checked to ensure the earthing facilities and connection is as per the
detailed drawings. Special attention shall be paid to the earthing of
shielded conductors. Continuity throughout will be checked
.Particularly where intermediate junction boxes are installed and single
point earthing will be checked to eliminate the possibility of circulating
currents. Where low power equipment is installed such as
thermocouples ,the earth connected will be checked against the detailed
hook-up drawing
7 TESTING
a)
b)
c)
Grounding Systems
MACO-QECP-002
d)
e)
f)
REV. 0
8 DOCUMENTATION
Form QECP-002-01-GS -Field Inspection Checklist
Form QECP-001-01-GS -Field Test Records
Grounding Systems
Page 5 of 5
MACO-QECP-002
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
LOW AND MEDIUM VOLTAGE
INSTRUMENTATION CABLES
DOCUMENT NO.:
MACO-QECP-003
Index
1
2
3
4
5
Page
Scope
2
References and Codes 2
Material Control
2
Pre-Installation Test 2
Documentation
5
001
04/09/09
MACO-QECP-003
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 4
MACO-QECP-003
REV. 0
SCOPE
1.1 This procedure covers the inspection and test procedures pertaining to the
installation of low and medium voltage test cables
1.2 The procedure shall be applied for inspection, methods and criteria for
installation work carried out by the Electrical Department.
SAES-P-100
SAES-P-104
SAES-B-068
S.A.G.1.2.705
NEC
SAES-J-902
15.5 SAMMS-502
34-SAMSS-913
3 MATERIALS CONTROL
3.1 Ensure that cables are handled in accordance with Electrical Procedures
and Material Control System requirements.
3.2 Check all cables received for conformance with purchase order
/specification requirements and mechanical damage .Any damage or
discrepancies shall be recorded and reported immediately .
3.3 Store all cables in safe place, free from dust and direct sunlight exposure
4
PRE-INSTALLATION TEST
4.1 All cables shall be tested on the reels prior to removal to the work site as
follows :
5-15KV Cables - 5000 Volts DC
0-600V Cables - 1000 Volts DC
4.1.1 The continuity of each conductor shall be checked. Record results on
form.
Page 2 of 4
MACO-QECP-003
REV. 0
INSTALLATION
a)
b)
Nylon cable ties shall be used to fasten cables to tray rungs. Outdoor cable
ties shall be black, resistant to ultra violet radiation.
c)
d)
e)
Throughout the cable pulling process the Site Electrical Supervisor shall
ensure that when a cable winch is used, the manufacturers permissible
pulling tension values will be adhered to.
f)
Where cables of different voltage levels and /or services are run in parallel;
Segregation will be in accordance with the SAES-P-104 & SAES-J-902.
g)
Page 3 of 4
MACO-QECP-003
4.2
REV. 0
TESTING
a)
b)
Medium voltage rated from 5KV to including 15KV shall be (DC high
voltage) tested after completion of jointing, glanding and end terminations in
accordance with SAES-P-104, Section 13, manufacturers recommendations
and 16-SAMSS-502.Results shall be recorded on Proponent Form.
c)
After completion of the tests, the cable ends shall be sealed to prevent ingress
of moisture.
d)
The test result will be checked and signed off by the Engineer, Electrical
Engineer and Proponent project inspection.
e)
Ensure that all test equipment has current calibration certificate issued by
approved testing agency.
5 DOCUMENTATION
a)
b)
c)
d)
e)
Form QECP-003-01-LM
Form QECP-003-02-LM
Form QECP-003-03-LM
Form QECP-003-04-LM
Form QECP-003-05-LM
Page 4 of 4
MACO-QECP-003
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
SWITCHBOARDS / PANELBOARDS
DOCUMENT NO.:
MACO-QECP-004
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Materials
Procedure
Inspection
Associated Documentation
2
2
2
3
3
5
5
001
04/09/09
MACO-QECP-004
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 6
MACO-QECP-004
REV. 0
Purpose:
The purpose of this document is to describe and approve systematic
method for the installation of low voltage switchboards and panel boards
in industrial areas as well as in non-industrial areas.
Scope:
This document covers installation of switchboards and panel boards in
various facilities.
Page 2 of 6
MACO-QECP-004
REV. 0
Material:
4.1 Manufacturers
Materials are selected purely on the basis of client's specification and
choice, subject to compliance whit Project requirement and area of
classification. The products shall be procured from any of the following
Manufacturers, if the client is not advising to use Materials from particular
manufactures.
WESCOSA
Westinghouse Electric Company.
General Electric.
Square D Company.
ABB
Any other Manufacturers approved by the client.
Page 3 of 6
MACO-QECP-004
REV. 0
Enclosure for panelboards shall have the top and bottom wire
bending space sized in accordance with NEC standards.
The minimum distance between bare metal parts, bus switchboards
and so forth shall comply with the NEC.
Lifting device shall be provided in the room where panelboard
and switchboards are installed, if any of the withdraw-type
components weighs more than 20 Kg.
The interrupting rating of equipment shall not be dependant upon
the upstream interrupting device rating.
Voltmeter monitoring the incoming bus system to switchboards
and panelboards shall be connected to the load side of the main
incoming switch or circuit breaker.
LV molded case circuit breaker shall have minimum trip rating of
20A ; however exception is there for smaller trip rating, if
necessary, to meet the motor branch circuit protection requirement
as per NEC article 430.
Procedure:
Page 4 of 6
MACO-QECP-004
Prior to energizing the circuits, test all incoming and out doing cables
for electrical continuity, and for short circuits. Ensure proper
connections with color coding for the 3phase system.
Inspect for proper grounding of the solid neutral to the ground grid.
Inspect for proper grounding of the equipment body grounding.
Check for terminal connections done with proper torque as per
manufacturer's instruction.
Inspection and testing shall be performed in accordance with the
code and client specifications.
Associated Documentation
INSPECTION:
REV. 0
Page 5 of 6
MACO-QECP-004
REV. 0
QECP-004-01-SP
CONTRACT:
LOCATION:
CABLE NO:
DRAWING NO.:
SI. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
_____________________
_____________________
_____________________
_____________________
REFERENCE:
PROJECT:
SYSTEM:
AMB. TEMP.
INSPECTION POINTS
ACCEPT
_________________
_________________
_________________
_________________
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 6 of 6
MACO-QECP-004
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTRUMENT WIRING
DOCUMENT NO.:
MACO-QECP-005
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Materials
Procedure
Lay-Up Procedure
Documentation
2
2
2
2
3
5
5
001
04/09/09
MACO-QECP-005
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Instrument Wiring
Page 1 of 9
MACO-QECP-005
REV. 0
INSTRUMENT WIRING
1
Purpose:
The purpose of this document is to define and approve systematic method
or process to accomplish the electrical wiring system for instrumentation
generally employed in process industries.
Scope:
This document is applicable for electrical wiring of in instruments used in
process industries.
References:
Material:
4.1 Manufacturers
Materials are selected purely on the basis of client's choice, subject to
compliance with Project requirements and standard. The products from the
following Manufacturers are used for instruments wiring, if the client is
not specific about any materials from particular Manufacturers.
4.1.1 Saudi Cable Co.
4.1.2 Riyadh Cable Co.
4.1.3 Middle East Specialized Cable Co.
4.1.7 And other approved Manufacturers
4.2 Materials details & conformance:
Six general groups of cables are used for instrumentation wiring which are
coming under instrumentation and thermocouple cable categories. They
are given below,
Instrument Wiring
Page 2 of 9
MACO-QECP-005
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.9
5.0
Procedure:
5.1
5.2
5.3
5.4
Instrument Wiring
REV. 0
Page 3 of 9
MACO-QECP-005
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
Instrument Wiring
REV. 0
Page 4 of 9
MACO-QECP-005
REV. 0
Instrument Wiring
Associated Documents:
Instrumentation Wiring Check List
Instrument Wiring Test Report
Insulation Resistance Test
Continuity Test Report
Page 5 of 9
QECP-005-01-IW
QECP-005-02-IW
QECP-005-03-IW
QECP-005-04-IW
MACO-QECP-005
REV. 0
QECP-005-01-IW
CONTRACT:
LOCATION:
CABLE NO:
DRAWING NO.:
S.NO
01
02
03
04
05
06
07
08
09
10
11
_____________________
_____________________
_____________________
_____________________
REFERENCE:
PROJECT:
SYSTEM:
AMB. TEMP.
ACCEPT
_________________
_________________
_________________
_________________
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Instrument Wiring
Page 6 of 9
MACO-QECP-005
REV. 0
QECP-005-02-IW
REFERENCE:
PROJECT:
SYSTEM:
EQUIP. NO.
INSULATION MOHM
TERMINAL
CONTINUITY
LINE TO
PANEL NO.
JB TERM. NO.
SPECS
CABLE(1)
CORE
TERMINAL
TAG NO.
ITEM NO.
FIELD INS.
Electl. Signal
Temperature
Alarm interlock
_____________
NOTES
_________________
_________________
_________________
_________________
RESULTS
_____________________
_____________________
_____________________
_____________________
SEALING COMPOUND
CONTRACT:
LOCATION:
PANEL NO:
DRAWING NO.:
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Instrument Wiring
Page 7 of 9
MACO-QECP-005
REV. 0
QECP-005-03-IW
CONTRACT:
LOCATION:
PANEL NO:
DRAWING NO.:
EQUIP.TAG/
CABLE NO.
PH. A TO G
_____________________
_____________________
_____________________
_____________________
PH. B TO G
PH. C TO G
REFERENCE:
PROJECT:
SYSTEM:
AMBIENT TEMP.
PH. A TO B
PH. B TO C
_________________
_________________
_________________
_________________
PH. C TO A
REMARKS
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Instrument Wiring
Page 8 of 9
MACO-QECP-005
REV. 0
QECP-005-04-IW
CONTRACT:
LOCATION:
PANEL NO:
DRAWING NO.:
_____________________
_____________________
_____________________
_____________________
REFERENCE:
PROJECT:
SYSTEM:
EQUIP. NO.
_________________
_________________
_________________
_________________
CONTINUITY
CABLE NUMBER
CORE ID/NUMBER
YES
NO
REMARKS
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Instrument Wiring
Page 9 of 9
MACO-QECP-005
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTRUMENT CONTROL PANELS
DOCUMENT NO.:
MACO-QECP-006
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Materials
Procedure
Lay-Up Procedure
Documentation
2
2
2
2
3
5
5-7
001
04/09/09
MACO-QECP-006
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 6
MACO-QECP-006
REV. 0
Purpose:
The purpose of this document is to describe and approve systematic
method or process to accomplish the installation of instrument control
panels, control cabinets, consoles & marshaling cabinets for locations in
electrically unclassified air conditioned building as well as unclassified
out door locations.
Scope:
This document is applicable in the installation of instrument control
panels, control cabinets, consoles & marshaling cabinets of indoor and
outdoor construction related to process industries.
References:
Material:
4.1 Manufacturers
Control cabinets and marshaling boxes are selected purely on the basis of
client's choice, subject to compliance with Project requirements and
standard. The products from the following Manufacturers are used for
instruments wiring, if the client is not specific about any materials from
particular Manufacturers. Control panels are fabricated with accessories,
components mounted in it and related wirings are carried out as per wiring
diagrams in compliance with specification from approved local
Manufacturers.
4.1.1 Crouse hinds
4.1.2 Hoffman
4.1.3 O.Z. Gegneys
Page 2 of 6
MACO-QECP-006
REV. 0
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.9
4.2.10
4.2.11
4.2.12
4.2.13
Page 3 of 6
MACO-QECP-006
Procedure:
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
REV. 0
Page 4 of 6
MACO-QECP-006
REV. 0
5.17 No more than two wires shall be connected each side of the single
terminal block.
5.18 Plastic wire ducts with removable cover shall be installed in control
panels, cabinet to provide a mean of routing and organize wiring.
5.19 Wiring shall not be threaded through undressed access hole. Glands
or protective grommets shall be used.
5.20 Color coding shall be done as per standards and HKSS cable
Identications procedures.
5.21 Lamps test button shall be installed for all instrument control panel.
5.22 Cable shield shall have continues path to ground.
5.23 Separate, electrically isolated grounding bars shall be provided at
the bottom of the cabinet.
5.24 Cabinet lighting and convenient outlet shall be installed where
practical and necessary as per projects specification.
5.25 When inductive loads are switched, suppression diodes shall be used
for relay installation.
5.26 For the supply voltage of 24 VDC a tolerable 21 28.2 shall be
required for 125 VDC tolerance of 113 141 VDC and 120 VAC
shall be maintained.
5.27 Power supplies outputs shall be individually fused or protected by a
circuit breaker.
5.28 Power supplies shall be identical when ever possible for inter
changeability and spare parts requirement.
5.29 Signal categories shall not be mixed with any signal multi core
cable. 24 VDC digital and 24 VCD 4-20 mA may be run in the same
plastic duct but not in a signal multi core cable.
6.0
INSPECTION:
6.1 Inspection and testing shall be performed in accordance with the code and
client specification.
7.0
7.1
Associated Documents:
QECP-006-01-IC Instrument Control Panel Installation Checklist
Page 5 of 6
MACO-QECP-006
REV. 0
QECP-006-01-IC
CONTRACT:
LOCATION:
CABLE NO:
DRAWING NO.:
_____________________
_____________________
_____________________
_____________________
REFERENCE:
PROJECT:
SYSTEM:
AMB. TEMP.
CHECKS TO BE PERFORMED
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
_________________
_________________
_________________
_________________
YES
COMPLIANCE
NO
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 6 of 6
MACO-QECP-006
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
FIRE ALARM SYSTEM
DOCUMENT NO.:
MACO-QECP-007
Index
1
2
3
4
5
6
Page
Scope
References
Materials
Quality Control
Installation
Documentation
2
2
2
2
5
5
001
04/09/09
MACO-QECP-007
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 3
MACO-QECP-007
REV. 0
SCOPE
a) This procedure covers the inspection and test procedure pertaining
to the installation of Fire Alarm Sensor, Manual Stations, local fire
alarm panels and essential hard wares for the fire alarm system.
b) This procedure shall be applied to the inspection, method and
criteria for installation work carried out by the Electrical
Department.
a)
b)
c)
d)
e)
f)
g)
3
NFPA
ANSI
OSHA
NEC
NEMA
UL
SAMSS
MATERIAL CONTROL
a) All material and equipment shall be protected from damage during handling
and storage. Each piece of equipment shall be tested to ensure proper
operation and conformance with Manufacturers Specification before
delivery.
b) Fire Alarm system shall be ready to use Honeywell, Pyrotronics, Simplex or
equivalent. Co-ordinate the mechanical plans to ensure proper locations of
smoke and duct detectors.
c) Equipment Manufacturer shall furnish wiring diagram and equipment
specification submittals for clients approval prior to installation.
d) All system operation shall be addressable type.
e) The Fire Alarm Panel shall be intelligent, each with its arm microprocessor
and capable of supporting multiple circuits.
f) The Fire Alarm Panel shall provide general purpose inputs for self diagnostic
functions such as low battery or AC failure and all power required for field
devices connected to monitor.
Page 2 of 3
MACO-QECP-007
REV. 0
QUALITY CONTROL
a)
The system shall be installed, connected and tested under the supervision of a
qualified personnel normally engaged in this type of work for at least the past
3 years.
b)
c)
INSTALLATION
a) System wiring shall be installed and run in conduit as required by the
specifications, sizes and test face grounds, open or short circuits.
b) Thermal detectors shall not be installed within 3ft of an HVAC Diffuser.
c) Upon completion of system installation, thorough checking of the fire alarm
system should be done and instruct the clients representatives in the operation
and function of the system.
d) Actual locations of initiating devices signal appliances and smoke detectors
shall be recorded.
6 DOCUMENTATION
a) Field Inspection Checklist.
Page 3 of 3
MACO-QECP-007
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
LIGHTING
DOCUMENT NO.:
MACO-QCCP-008
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Material
Procedure
Inspection & Testing
Documentation
2
2
2
2
2
3
4
001
04/09/09
MACO-QECP-008
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Lighting
Page 1 of 9
MACO-QECP-008
REV. 0
LIGHTING
1.0
Purpose:
The purpose of this document is to define and establish systematic method
or process to install lighting fixtures in industrial and non- industrial
facilities.
2.0
Scope:
The three lighting installations covered under this scope are:
2.1 Outdoor lighting fixtures
2.2 Indoor lighting fixtures
2.3 Emergency lighting fixtures
3.0
References:
4.0
NEC
SAES-P-100
SAES-P-104
SAES-B-068
SAES-P-123
NEMA
IEEE
ANSI
Material:
4.1 general requirements
4.1.1 Fixture Locations
4.1.1.1 All fixtures installed in wet or damp location shall be marked,
"suitable for wet or damp locations." Subject to saturation with water
Lighting
Page 2 of 9
MACO-QECP-008
REV. 0
Lighting
Page 3 of 9
MACO-QECP-008
REV. 0
4.1.1.10.2 Poles for area lighting and street lighting in process area
shall be hot-dipped galvanized steel.
4.1.1.10.3 Poles outside process shall be galvanized steel or aluminum
alloy.
4.1.1.10.4 Aluminum and steel poles shall be provided with a suitable
wiring compartment located at a height of 150 mm or more than 900
mm from the base.
4.1.1.10.5 The use of existing structural steel, equipment structures
and building walls for mounting general area flood light fixture are
desirable.
4.1.1.11 Types of Exterior and interior lighting fixtures generally used are
as follows:
4.1.1.11.1 Mercury vapor
4.1.1.11.2 Metal halide
4.1.1.11.3 High pressure sodium
4.1.1.11.4 Low pressure sodium
4.1.1.11.5 Fluorescent
4.1.1.11.6 Incandescent
4.1.1.12 Applications of exterior lighting fixtures generally required are
as follows:
4.1.1.12.1 Outdoor area lighting
4.1.1.12.2 Outdoor flood lighting
4.1.1.12.3 Outdoor spot lighting
4.1.1.12.4 Outdoor supplementary lighting
4.1.1.12.5 Outdoor landscape lighting
4.1.1.12.6 Outdoor security lighting etc.
4.1.1.13 For office lighting fixtures of surface-mounted, semi direct
fixtures shall be ideal where approximately 10% to 30 % of light
is in 90deg to 180 deg. Zone and 60% in 0 deg. Zone.
Lighting
Page 4 of 9
MACO-QECP-008
REV. 0
4.1.1.14 Always use fixture with overall efficiency of not less than 70%
bare-lamp lumens for office lighting purpose. Construct shielding
assembly of molded virgin acrylic panels in combination with not
less than 20 gauge durable lacquered steel louvers, finished in
high temperature. Backed white enamel, removable louver
assembly with hinges for easy maintenance. The wiring channel,
reflectors, covers and end plates shall be 20 gauge steel and
corrosion resistant baked white enamel.
4.1.1.15 Ballasts and capacitors for fluorescent and HID fixtures shall be
polychlorinated biphenyl (PCB) free.
4.1.1.16 Light fixtures shall be suitable for the environment where they are
installed. The installation shall be in accordance with area
classification.
4.1.1.17 Light fixtures positioned over stairways, platforms, elevated
walkways and landing shall be mounted at a height of 2.03 m.
4.1.1.18 Outside area and street lighting power shall be controlled by
photocells. In 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.
4.1.1.19 Source of emergency lighting power include emergency stand-by
generator and station batteries. The use of Emergency light set,
general purpose shall be self contained, surface/wall mounted with
minimum two lamps and shall have the following features.
4.1.1.19.1 LED indictor light and test switch shall be on front panel.
4.1.1.19.2 When storage batteries are used as a source of emergency
power, minimum duration of emergency during power
failure shall be 1 1/2 half hours.
4.1.1.19.3 Charger shall be fully automatic, solid state type, with
sealed transfer relay and fused output circuit.
4.1.1.20 ' Exit' sign emergency lighting fixtures shall be self contained with
AC or battery illuminated 'exit' sign unit and down light mounted
inside. Sign is illuminated by AC powered lamps under normal
condition. When supply voltage drops to 80 percent of nominal
voltage. Emergency lamp is illuminated by DC power and when
voltage is restored, AC lamps are re lighted.
Lighting
Page 5 of 9
MACO-QECP-008
REV. 0
Procedure:
Lighting
Page 6 of 9
MACO-QECP-008
REV. 0
Lighting
Page 7 of 9
MACO-QECP-008
REV. 0
6.0
7.0
Associated Documents:
7.1 Lighting Installation Check List
7.2 Lighting Circuit Test Record
7.3 Illumination level test
Lighting
Page 8 of 9
(QECP-008-01-LS)
(QECP-008-02-LS)
(QECP-008-03-LS)
MACO-QECP-008
CONTRACT:
LOCATION:
REV. 0
REFERENCE:
PROJECT:
SYSTEM: _____________________
AMB.TEMP: ___________________
S.NO
INSPECTION POINTS
ACCEPT REJECT
01
Check the area classification
Check illumination level is enough for the
02
location as per requirements
Inspect distribution box circuit number, switch
03
rating, safety feature etc
Check exterior pole, foundation strong to
04
withstand wind load
Spot check lamp fitting, spot check wall
05
switches and wall socket etc.
Check ballast noise level for interior fixture
06
installations
Check all lighting are free from dirt, free from
07
finger points and smudges from lenses
Supports, clamps and supports for pendant
08
fixture are in compliance with project
specification
09
Grounding as per specification
10
Lamps are checked for damage
Check the circuit breaker ratings are enough for
11
fixtures
12
Photocell installed as per requirement
N/A
REMARKS: ____________________________________________________________
______________________________________________________________________
MACO QC Inspector
Proponent Representative
Signature
Name
date
Lighting
Page 9 of 9
MACO-QECP-008
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
DC POWER SYSTEMS
DOCUMENT NO.:
MACO-QECP-009
Index
1
2
3
4
5
6
Page
Scope
Purpose
References
Definitions
Responsibilities
Procedure
2
2
2
3
3
7
001
04/09/09
MACO-QECP-009
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
DC Power
Page 1 of 10
MACO-QECP-009
REV. 0
Scope
This quality procedure defines the type and extent of inspections to be carried out to
verify that all operations involved with DC Power Systems, and other associated
installation activities are conducted and complied in accordance with governing
specifications and industry practices.
Purpose
The purpose of this quality procedure is to address paragraph 4.9 of ISO 9002
Process Control for Installation of DC Power Systems, and other associated
installation activities are conducted in accordance with governing specifications and
industry practice.
The quality control test and inspections required and approved for the work are
described in this procedure. Found in the procedure and SATIP section titled
Quality Control Activity is a description of the inspection and test activity to be
conducted by the inspector.
DC Power
References
SAEP-020:
SCHEDULE Q:
SAES-P-100:
SAES-P-103:
SAES-P-104:
SAES-P-111:
Grounding
SAES-P-114:
SAES-T-151:
Page 2 of 10
MACO-QECP-009
REV. 0
SAES-T-795:
17-SAMSS-511:
17-SAMSS-514:
Definitions
QCP:
IFC:
Company:
Proponent
MACO:
IK:
In Kingdom
OOK:
Out of Kingdom
PID:
QA/QC:
RFI:
Responsibilities
The Site or Discipline Engineer In-Charge will be responsible for
the following:
DC Power
Page 3 of 10
MACO-QECP-009
REV. 0
Page 4 of 10
MACO-QECP-009
REV. 0
DC Power
Page 5 of 10
MACO-QECP-009
REV. 0
Quality Records
The fundamental quality records produced for this procedure are the RFI
and the associated SATIP Check Sheet. The check sheet identifies the
quality control activities and all the related information from the SATIP.
The sub-contractor quality control inspector initiates the check sheet for
each RFI. The RFI number is reflected on the check sheet. After the subcontractor completes his inspection, the sheet is copied and attached to the
RFI and given to Manar Arabian Corp. (MACO) discipline quality
inspector. The Manar Arabian Corp. (MACO) quality inspector inspects the
DC Power
Page 6 of 10
MACO-QECP-009
REV. 0
work as required by the surveillance code, signs or initials the check sheet
and the RFI form. Both forms are copied for the records of Manar Arabian
Corp. (MACO) and the sub-contractor, are filed. The original RFI form and
a copy of the check sheet is then given to Royal Commission for Jubail &
Yanbu PMT. SAPMT discipline inspector inspects the work as required by
the surveillance code, signs or initials the check sheet and the RFI Form.
Both RFI and check sheet are then given to HDPIS discipline inspector who
signs the RFI form. The pink copy of the RFI and a copy of the check sheet
are returned to Manar Arabian Corp. (MACO) for record. A copy is made
for the responsible sub-contractor quality files. HDPIS inspector inspects
the work as required by the surveillance code and may sign or initial the
check sheet.
Quality Control Activity
Project quality inspectors will respond to request for inspection (RFI)
throughout every stage of the construction process. This procedure and the
companion Royal Commission for Jubail & Yanbu Test and Inspection Plan
(SATIP) serve as a guide for the inspection work, complete with acceptance
criteria and criteria reference. Paragraph numbering for this section matches
the inspection activity found on the Royal Commission for Jubail & Yanbu
Test and Inspection Plan (SATIP).
Request for Inspection: Requests for Inspection originate with the contractor
Foreman. Information on the form should be complete and legible. Based on
the nature of the work item to be inspected, the inspector shall consult the
SATIP, this procedure and any referenced acceptance criteria to ensure that
the work is inspected for acceptability per the Royal Commission for Jubail
& Yanbu and industry standards.
This format provides for multiple inspection items to be covered by a single
RFI. Example: A single RFI for, listed on the SATIP under that category.
When submitting RFIs to cover multiple items on the ITP, foreman should
reference the QCP/SATIP and applicable inspection item numbers. Check
sheets for the RFI are recommended if repeated inspections for a similar
nature are to be made.
In some certain instances, interim inspections are required. Multiple
Inspection Required is noted in the Quality Control Activity column. The
inspection level for each inspection item is indicated on the Inspection Test
Plan with code key reference found at the bottom of the last page of the
SATIP.
DC Power
Page 7 of 10
MACO-QECP-009
REV. 0
Procedure
Energizing Of Cables or Equipment
The following items are considered to be mandatory inspection hold
points for the Contractor before any cable or equipment is energized:
a) Prior to energizing a cable it is essential to determine that this
cable has been terminated to the correct locations per the approved
installation drawings.
b) The cable should be meggered to ensure insulation resistance
integrity.
c) Prior to energizing, grounding resistance tests should be
conducted in accordance with the requirements of SAES-T-795.
d) It will be mandatory that all personnel involved in the energizing
of this cable are fully briefed as to the time which the event shall
occur. It will be the responsibility of the senior technician to ensure
that all personnel are a safe distance away during the energizing of
these cable at all possible points of hazard for this cable.
Disconnect Switch. Inspect the battery disconnect switch/circuit
breaker to ensure that the cable terminals are adequate for the size
power cable being used, and that the size of the switch enclosure
provides sufficient room for proper cable bending radius.
Stationary Batteries. The following items will be inspected in the
battery room before, during, and after the installation of the batteries.
a) Verify the battery rack is grounded at both ends with green and
yellow grounding wire and that separate sections of the rack are
bonded together. Ensure that safety rails have been provided.
b) Ensure that the battery cables are properly color-coded.
c) After all cable connections are completed verify that the battery
terminals are greased and that battery straps are tightly connected.
d) Ensure that cable lugs are properly sized.
e) Ensure the battery cells are sequentially numbered. The positive
cable to the rectifiers terminates in Cell #1 and the negative cable
terminates in Cell #24.
DC Power
Page 8 of 10
MACO-QECP-009
REV. 0
DC Power
Page 9 of 10
MACO-QECP-009
REV. 0
A1
W1
W2
H
R1
R2
Hold Point Work will be held until the inspection or test has been
satisfactorily completed.
Witness Inspection will be witnessed by inspection QC staff.
Review QC staff will monitor the activity or review the verifying
document records.
6
Documentation
None
DC Power
Page 10 of 10
MACO-QECP-009
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF JUNCTION BOXES AND
DEVICES
DOCUMENT NO.:
MACO-QECP-010
Index
1
2
3
4
5
6
Page
Scope
References
Materials Control
Quality Control
Procedure
Documentation
2
2
2
2
3
3
001
04/09/09
MACO-QECP-010
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 3
MACO-QECP-010
REV. 0
SCOPE
This procedure covers the inspection, method and criteria for
installation of junction boxes and devices.
SAES-P-100
SAES-P-104
SAES-B-068
NEC
NEMA
3
MATERIALS CONTROL
a) Ensure that materials are handled in accordance with General Electric
Procedure and Materials control System.
b) Check all the materials received are in conformance with Purchase order
and Specs. Requirements
c) Check all materials are free from mechanical damage .Any damage or
discrepancies shall be recorded and reported immediately to Materials
dept.
d) Store the materials in a safe place, free from dust and not exposed to
sunlight.
QUALITY CONTROL
a) Check junction boxes for sizes and types in conformance with Specification
& drawings
b) Where junction boxes are to be installed in hazardous areas, particular
attention will be paid to their certification to ensure they are suitable in the
classified areas.
c) Support brackets, posts and stanchions will be checked against the detailed
drawing and located in accordance with the layout drawings.
d) Where industrial or vapor proof fittings are specified, their IP rating will be
checked for suitability.
e) Accessibility for the maintenance will be checked and it will be ensured
that junction boxes do not conflict with other services or equipment
Page 2 of 3
MACO-QECP-010
REV. 0
CONSTRUCTION PROCEDURES
a)
b)
c)
d)
e)
f)
DOCUMENTATION
None
Page 3 of 3
MACO-QECP-010
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF CABLE TRAYS
DOCUMENT NO.:
MACO-QECP-011
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
2
3
3
001
04/09/09
MACO-QECP-011
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 3
MACO-QECP-011
REV. 0
a)
b)
c)
d)
e)
SAES-P-100
SAES-P-104
SAES-B-068
NEC
NEMA
3 MATERIALS CONTROL
Ensure that materials are handled in accordance with General Electric
Procedure and Materials control System.
Check all the materials received are in conformance with Purchase order and
Specs. Requirements
Check all materials are free from mechanical damage .Any damage or
discrepancies shall be recorded and reported immediately to Materials dept.
Store the materials in a safe place, free from dust and not exposed to sunlight.
Cable trays to conform to SAES-P-104 Para 4.4
4
QUALITY CONTROL
Page 2 of 3
MACO-QECP-011
REV. 0
Check that installation of cable trays does not conflict to other services on
equipment.
5 CONSTRUCTION PROCEDURES
a) Cable trays shall be copper free aluminum, ladder type.
b) Cable tray installation shall utilize ventilated, louvered cable tray covers
secure with aluminum cover connector, with a 1220mm (4ft) min interval
.The covers barriers and fittings should be constructed of the same material
as the tray.
c) Cable tray barriers should be solid, continous and non-combustible.
d) Fabrication of steel structures bracket supports shall be in accordance with
detailed drawings.
e) The installed supports shall be inspected to ensure it is level and aligned
vertical and whole assembly is rigid.
f) Where supports are to be welded to structural steel, this shall be done prior
to the application of paint or protective coatings.
g) Where supports are bolted to structural steel, this shall be checked to
ensure all bolts; nuts etc are correctly installed and securely fixed.
h) Earthing bonding jumpers are properly connected and bonded to main
ground grid.
6 DOCUMENTATION
Field Installation Checklist Cable Tray
Page 3 of 3
MACO-QECP-011
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF COMMUNICATION SYSTEMS
DOCUMENT NO.:
MACO-QECP-012
Index
1
2
3
4
5
6
Page
Scope
References
Material Control
Quality Control
Testing
Documentation
2
2
2
3
4
4
001
04/09/09
MACO-QECP-012
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Communication Systems
Page 1 of 4
MACO-QECP-012
REV. 0
SCOPE
a)
This procedure covers the inspection and test procedure pertaining to the
installation f communication system in industrial and process areas. The equipment
covered herein includes telephone and paging system.
b)
This procedure shall be applied to the inspection method and criteria for the
installation work carried out by the electrical department.
REFERENCE STANDARDS
The communication system design, installation and testing shall be in accordance
with applicable section of the latest revision of the codes, standard and regulation of
the organization below and Royal Commission for Jubail & Yanbu standards.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
ANSI
NFPA
NEC
API
NEMA
IEEE
NETA
UL
FM
BICSI
SAES-T-243SAES-T-435
SAES-T-481
SAES-T-622
SAES-T-629
SAES-T-632
SAES-T-633
SAES-T-903
SAES-T-916
Communication Systems
Page 2 of 4
MACO-QECP-012
REV. 0
MATERIAL CONTROL
a) Check / inspect all the material received are in conformance with purchase order and
relevant specification requirement ensure that all the material are handle in
accordance with material control system.
b) Check that telecom equipment & other related associated accessories are free from
mechanical damages. Any discrepancies or parts found defective shall be recorded &
reported immediately to MACO Material Control Department.
c) Store all telecom equipments and other accessories in dust free area and protect them
against atmospheric action and dirt. Most preferably to air- conditioned room to
prevent damages of electronic parts.
4
QUALITY CONTROL
EQUIPMENT INSPECTION
a)
Prior to removal to site, the equipment will be identified and checked against the
data sheets. Where equipment is to be installed in hazardous areas, particular attention
will be paid to their certification to ensure they are suitable for the installation in the
classified area.
b)
Equipment such as telephone / intercom handsets or radio pocket receiver which
are supplied in section, or have accessories supplied loose, will be checked against the
particular inventory.
c)
Unless otherwise stated, all tests shall be conducted by the site electrical QC
inspector.
EQUIPMENT INSTALLATION
A) TELEPHONE & INTERCOM SYSTEMS
1.
P.A.AB.X.S amplifier units, junction boxes and termination racks will be
installed on prepared foundation and or other structural supports as per manufacturing
recommendation.
Prior to installation, the foundation base plates and floor fixing will be checked for
location and level and the fixing points checked against their position on the respective
panels.
Cable sleeves and ducts will be inspected to ensure correct line and location.
2.
Before installing in position, the equipment will be opened up and inspected for
cleanliness to ensure no foreign bodies are present.
3.
Installation will be witness to ensure the equipment is vertical and fixing bolts
tightened. Where equipment consists of a number of panel sections, the assembly shall
commence form the center section. Section on either side of the center shall be alternated,
leveled and shimmed as necessary.
Communication Systems
Page 3 of 4
MACO-QECP-012
REV. 0
4.
The complete assembly will be checked t ensure alignment and level after
tightening of the bolts.
5.
Where equipment is to the wall mounted, the brackets will be checked against the
detail drawing. Wall fixing will be checked to ensure they are secure prior to installation
of the equipment.
6.
Upon installation, the equipment will be inspected to ensure the fixing are secured
properly.
7.
The placement of telephone handsets will be checked against the layout dawning.
8.
Conduits, cable trays and supports will be installed in accordance with approved
drawings.
9.
Cable and wires will be installed in accordance with approved drawings and
Aramco standards.
SEAS-T-916, SAES-T-243, SAES-T-435
B) PARTY PAGING SYSTEM.
1
b)
c)
DOCUMENTATION
Communication system test
Inspection and test report.
Communication Systems
Page 4 of 4
MACO-QECP-012
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF CONDUITS & FITTINGS
DOCUMENT NO.:
MACO-QECP-013
Index
1
2
3
4
5
Page
Scope
References
Materials Control
Quality Control
Documentation
2
2
2
2
3
001
04/09/09
MACO-QECP-013
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 3
MACO-QECP-013
REV. 0
SCOPE
MATERIALS CONTROL
a)
b)
c)
d)
SAES-P-100
SAES-P-104
SAES-B-068
SAES-P-111
NEC
NEMA
NFPA
UL
SAMSS
QUALITY CONTROL
4.1 CHECK FOR THE FOLLOWING
a)
b)
c)
MACO-QECP-013
d)
e)
f)
g)
REV. 0
DOCUMENTATION
Field Inspection Checklist.
Page 3 of 3
MACO-QECP-013
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF DISCONNECT SWITCHES
DOCUMENT NO.:
MACO-QECP-014
Index
1
2
3
4
5
6
Page
Scope
References
Materials Control
Quality Control
Procedure
Documentation
2
2
2
2
3
3
001
04/09/09
MACO-QECP-014
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Disconnect Switches
Page 1 of 3
MACO-QECP-014
REV. 0
SCOPE
a)
This procedure covers the inspection and test procedure pertaining to the
installation of disconnecting switches.
b)
This procedure shall be applied to the inspection, method and criteria for
installation work carried out by the Electrical Department.
SAES-P-116
16-SAMNS-510
NFPA-70.
OSHA
NEC
NEMA
IEEE
SAMSS
MATERIALS CONTROL
a) Ensure that materials are handled in accordance with Royal Commission for
Jubail & Yanbu Procedure and Materials control System.
b) Check all the materials received are in conformance with Purchase order
and Specs. Requirements
c) Check all materials are free from damage .Any damage or discrepancies
shall be recorded and reported immediately to Materials dept.
d) Store the materials in a safe place, free from dust and dirt.
QUALITY CONTROL
a) Switches shall be furnished in NEMA Type 1 general purpose enclosure
and/or NEMA Type 4 stainless steel watertight for outdoor use and wet
locations.
b) Covers for general purpose enclosure shall be of the hinged type provisions
for pad locking covers in the closed positions with defeatable interlocks to
prevent the cover from opening when the operating manhole is in the ON
positions shall be provided.
c) Enclosures shall be fabricated of code gauge steel, with a rust inhibiting
primer and finished on baked enamel. Factory installed ground lugs shall be
provided in each enclosure
Disconnect Switches
Page 2 of 3
MACO-QECP-014
REV. 0
d) All switches shall have switchblades, which are fully visible in the off
position when the cover is open. Removable arc suppressor shall furnish
where necessary to permit access to line-side hinges. Hinges shall be front
removable; all heavy duty switches shall have live terminal shields.
e) Switch mechanism shall be at the quick make, quick back type, with pad
lockable operating handle as an integral part of the enclosure base. Switches
shall have dual cover .Inter locks to prevent unauthorized opening of the
switch when handle is on the ON position or closing of mechanical with
covers in the open position.
5
INSTALLATION PROCEDURE
a) Mount are individually enclosed disconnects rigidly ,and align properly on
the building structure 1(25mm) off the wall and foot 10(1.8m) above
finish floor. Use steel supporting frames as necessary or as shown in
drawings.
b) Provide and install a nameplate shall be engraved in bopt. Arabic & English
indicating the name of the equipment served with circuit or motor number.
c) Nameplate shall be black or white, laminated phenolic, engraved in min.
(6.5mm) high lettering .Provide other or additional information on
nameplates as required .Refer to each specification Sec.16lgt, for complete
requirement for Id plates.
d) Install nameplates to disconnect with appropriate sheet metal screws 6MF
on types and pop-rivet are not acceptable
DOCUMENTATION
Disconnect Switch Inspection Checklist
Disconnect Switches
Page 3 of 3
MACO-QECP-014
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
LOW VOLTAGE MOTOR CONTROL CENTER
DOCUMENT NO.:
MACO-QECP-015
Index
1
2
3
4
5
6
7
Page
Purpose
Scope
References
Materials
Procedure
Inspection & Testing
Documentation
2
2
2
2
2
6
7
001
04/09/09
MACO-QECP-015
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 8
MACO-QECP-015
REV. 0
Purpose:
The purpose of this document is to define and establish systematic method
or process to low voltage motor control centers or replace circuit breakers
and motor starter controllers in existing motor control centers, in industrial
and non-industrial facilities.
Scope:
This document covers installation of low voltage motor control centers
and replace or furnish circuit breakers and motor starter controllers inside
motor control center.
References:
Material:
4.1 General Requirements:
4.1.1 Motor Control Center
Low voltage control gear or motor control centers shall comply
with the following mandatory requirements.
4.1.1.1
4.1.1.2
MACO-QECP-015
4.1.1.3
4.1.1.4
4.1.1.5
4.1.1.6
4.1.1.7
4.1.1.8
4.1.1.9
4.1.1.10
4.1.1.11
4.1.1.12
4.1.1.13
4.1.1.14
4.1.1.15
4.1.1.16
4.1.1.17
4.1.1.18
REV. 0
Page 3 of 8
MACO-QECP-015
4.1.1.19
4.1.1.20
4.1.1.21
4.1.1.22
4.1.1.23
4.1.1.24
4.1.1.25
4.1.1.26
4.1.1.27
4.1.1.28
4.1.1.29
4.1.1.30
4.1.1.31
4.1.1.32
4.1.1.33
4.1.1.34
REV. 0
Page 4 of 8
MACO-QECP-015
4.1.1.35
4.1.1.36
4.1.1.37
4.1.2
REV. 0
Circuit breaker having a frame size of 150 amperes or less shall be molded case
type with thermal magnetic non- inter changeable, trip free sealed trip units.
Breaker contactor material shall be non welding type silver alloy. Breakers shall
have arc- extinguishing chutes.
4.1.3
Starter Units
4.1.3.1 Unless and otherwise stated use combination starter, consisting
of circuit breaker, fusible switch or motor circuit protector and
magnetic starter.
4.1.3.2 Interrupting rating or circuit breaker shall be coordinated with
main bus rating. Coordinate momentary short circuit of starter
units with buses and circuit breakers. Use NEMA size 1
minimum starter capacity.
4.1.3.3 Magnetic starters shall have auxiliary contacts including one
spare N.O and N.C contacts.
4.1.3.4 Provide local control devices, such as start/stop push buttons
hand- off auto switch, indicating lights, control relays and timers
as per the requirement. All starters shall have "red" indicating
light for running and "green" for stop.
4.1.3.5 A minimum of 50 VA control transformer with primary and
secondary fusses are required.
4.1.4
Control Devices
Page 5 of 8
MACO-QECP-015
4.2
REV. 0
Manufacturers
Materials are selected purely on the basis of client's choice, subjected to
compliance with project requirements. For new installation of motor
control centers the product from the following manufacturers are used, if
the client is not specific about any particular manufacturer. For the
installation of breakers or starters selection shall be preferably of the same
manufacturers of the existing motor control centers.
4.2.1 General Electric Co.
4.2.2 Cutler Hammer
4.2.3 Square D
4.2.4 Siemens
4.2.5 WESCOSA
4.2.6 JEDAC
4.2.7 And other approved manufacturers
Procedure:
5.1 Motor Control Centers
5.1.1 Install MCC in accordance with manufacturer's instructions.
5.1.2 Verify all loads on the MCC including the loads of
equipments and devices to be connected. Also verify that
cables and conduits are size for equipment's loads in
accordance with NEC or equivalent standards.
5.1.3 When the main systems of equipments are directly connected
together, the entire bus system shall have the same rating.
5.1.4 If an MCC is fed from a feeder breaker within a switch gear
the switch gear and MCC assembly shall not be physically
connected together.
5.1.5 Keep 1.5 meters in front from the MCC back to back
configuration has two fronts and hence, 1.5 meters on both
fronts shall be kept.
5.1.6 When an MCC is installed in front of a switch gear or another
MCC, the space between the two shall be 2 meters.
5.1.7 Never use cable to extend the main bus of an MCC.
5.1.8 Lifting/handling devices shall be provided for any with-draw
type component weighing over 20 kg.
5.1.9 Panel boards and dry type distribution or lighting
transformers shall not be installed with in an MCC.
5.1.10 Where low voltage MCC is fed from a source with fuse
protection (over head power line), see that all motors be
equipped with single-phasing protection.
Page 6 of 8
MACO-QECP-015
REV. 0
Associated Documentation
7.1
Page 7 of 8
MACO-QECP-015
REV. 0
QECP-007-01-MC
CONTRACT:
LOCATION:
CABLE NO:
DRAWING NO.:
SI. NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
_____________________
_____________________
_____________________
_____________________
REFERENCE:
PROJECT:
SYSTEM:
AMB. TEMP.
INSPECTION POINTS
ACCEPT
_________________
_________________
_________________
_________________
REJECT
N/A
Remarks:
_______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR
Proponent REPRESENTATIVE
Signature:
Name:
Date:
Page 8 of 8
MACO-QECP-015
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF DRY-TYPE TRANSFORMERS
DOCUMENT NO.:
MACO-QECP-016
Index
1
2
3
4
5
Page
Scope
References
Materials
Quality Control
Construction
Procedures
Documentation
2
2
2
3
3
3
001
04/09/09
MACO-QECP-016
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Dry-Type Transformers
Page 1 of 3
MACO-QECP-016
REV. 0
SCOPE
a)
b)
MATERIALS CONTROL
3.1 EQUIPMENT INSPECTION
a) Upon receipt at the storage and handling area, the transformer shall be
inspected for mechanical damage; any damage or discrepancies will be
recorded and reported immediately to MACO.
b) The nameplate will be checked against the transformer specifications
data sheet in conformance with purchase order.
c) Where transformer auxiliaries are shipped loose, these shall be
identified and checked against the equipment delivery.
d) Store the transformer on dust free area and protect them against
atmosphere action and dirt.
e) Ensure those transformers are handled in accordance with this Section
3, Materials Control System.
f) Check that enclosure is suitable for the location where unit will be
installed.
Dry-Type Transformers
Page 2 of 3
MACO-QECP-016
REV. 0
QUALITY CONTROL
CHECK FOR THE FOLLOWING:
a)
b)
c)
d)
e)
f)
CONSTRUCTION PROCEDURE
a)
b)
c)
d)
e)
f)
DOCUMENTATION
a) Form QECP-016-01-DT
b) Form QECP-016-02-DT
Dry-Type Transformers
Page 3 of 3
MACO-QECP-016
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF OIL-FILLED TYPE
DISTRIBUTION TRANSFORMERS
DOCUMENT NO.:
MACO-QECP-017
Index
1
2
3
4
5
Page
Scope
References
Materials
Quality Control
Documentation
2
2
2
3
3
001
04/09/09
MACO-QECP-017
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 4
MACO-QECP-017
REV. 0
SCOPE
a)
This procedure covers the inspection and test procedure pertaining to the
installation of Power Transformer.
This procedure shall be applied to the inspection, method and criteria for
installation work carried out by the Electrical Department.
b)
MATERIALS CONTROL
EQUIPMENT INSPECTION
a)
b)
c)
Upon receipt at the storage and handling area, the transformer shall be
inspected for mechanical damage; any damage or discrepancies will be
recorded and reported immediately to MACO Materials Department
The nameplate will be checked against the transformer specifications
data sheet in conformance with purchase order.
Where transformer auxiliaries are shipped loose, these shall be identified
and checked against the equipment delivery.
Page 2 of 4
MACO-QECP-017
d)
e)
f)
g)
h)
REV. 0
Store the transformer on dust free area and protect them against
atmosphere action and dirt.
Ensure those transformers are handled in accordance with this Section 3,
Materials Control System.
Check that enclosure is suitable for the location where unit will be
installed.
Where oil immerses transformer is delivered oil-filled, the oil level will
be checked to ensure no leakage.
Where an oil conservator with end breather is installed, the silica gel in
the breather will be checked to ensure no ingress of moisture is present.
QUALITY CONTROL
INSTALLATION AND TEST
a)
b)
c)
d)
e)
f)
g)
h)
Page 3 of 4
MACO-QECP-017
REV. 0
TRANSFORMER OIL
a) Transformer insulating oil will be tested using fosters type OTS
60(Auto) or equivalent dielectric test set. Where the transformer has
been supplied pre-filled with oil, sample shall be taken from the lowest
possible point in the tank. Where the insulating oil is supplied
separately, samples shall be taken from the containers prior to filling.
b) The test shall be carried out in accordance with Aramco test procedure
7825 .The oil shall be tested to ASTM D877 and Aramco Standard and
SAES-P-120. The test parameter is shown on Table -013.
c) The test will be conducted by the Site Electrical Supervisor witnessed
and recorded by the Site Electrical QC Inspector
d) After oil filling is complete, the final level and pressure surge devices
will also be checked for completeness. Valves on air lines to radiators,
conservators, air dryers, insulating bushes and flanges will be checked.
The whole system will be inspected to ensure no oil leakages and
reported.
PROTECTION AND CONTROL DEVICES
a) Transformer off-load charger will be inspected for freedom of movement
and locked off at the position specified on the equipment data sheet.
b) Direct mounted indicating gauges shall be inspected for correct
operation.
c) Trip settings of level, temperature and surge pressure devices will be
checked.
d) The results of tests will be recorded. (Final Inspection Record)
DOCUMENTATION
a) Form QECP-017-01-OT
b) Form QECP-017-02-0T
c) Form QECP-017-03-OT
Page 4 of 4
MACO-QECP-017
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF BATTERIES AND CHARGERS
DOCUMENT NO.:
MACO-QECP-018
Index
1
2
3
4
5
Page
Scope
References
Materials
Quality Control
Documentation
2
2
2
3
5
001
04/09/09
MACO-QECP-018
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 5
MACO-QECP-018
REV. 0
SCOPE
a)
b)
This procedure shall be applied to the inspection, method and criteria for
installation work carried out by the electrical department.
REFERENCE STANDARDS
SAES-0111
Power Supplies
SAES-P-100
SAES-P-103
ADP-P-176
NEC
ANSI
NEMA
UL
Underwriters Laboratories
MATERIALS CONTROL
1.3.1
Equipment Inspection
a) Upon receipt at the storage and handling area, the equipment will be
inspected for mechanical damage. Any damage or discrepancies shall be
recorded and reported immediately to MACO Material Department.
b) Check Inspect all the materials received are in conformance with purchase
order and specification requirement. Ensure that equipments are handled in
accordance with Sec. 3 (Materials Control System).
Page 2 of 5
MACO-QECP-018
REV. 0
Store the battery charger dust free area and protect them against atmospheric
action and dirt. Preferably in air-conditioned room to prevent damages of
electronics parts.
QUALITY CONTROL
4.1
Battery Installation
a). Prior to installation, the battery room will be inspected to ensure the floor
finish is complete, clean and free form debris and obstruction. Any floor wall
fixings should be installed.
b). Battery racks ventilation should be complete and functional according to the
contract specification and where installed, eyewash systems will be
functional.
c) Battery racks will be inspected to ensure they are assembled according to
manufacturer instruction and detailed drawings. They should also be stable
and properly fixed.
d) Battery placement will be checked to ensure the arrangement of the positive
and negative terminals as per the connection diagram. The final connection
will be checked to ensure tightness and the correct polarity has been followed.
e) Where batteries are received empty, they will be filled with electrolyte.
Before preparing the electrolyte, the supervisor will ensure the operations
have the correct protective clothing and that a supply of water is available to
wash away any spillage.
Page 3 of 5
MACO-QECP-018
REV. 0
After preparation, the specific gravity of the solution will be checked and
adjusted to the correct value as per the manufacturer instructions.
The filling process will be supervised to ensure the cells are filled to the
correct level giving sufficient time for setting.
f) Where batteries are received filled the electrolyte level will be checked and
topped up as required.
g) When filling is complete the complete arrangement will be checked to ensure
it is clean and free from moisture.
4.2
a) Base plate, floor fixings etc. will be checked for level and location and fixing points
checked against their position on the respective panels. Cable sleeves and ducts will
be inspected to ensure correct line and location.
b) Before installing in position, sections will be opened up and inspected for cleanliness
and ensure no foreign bodies are present. Dust will be removed using a vacuum
cleaner or rags as appropriate.
c) The panel section will be inspected for mechanical damage and megger checked to
ensure that it has no direct connection to earth.
d) Installation will be witnessed to ensure the equipment is vertical and fixing bolts
tightened, where equipment consists of a number of panel section. Sections on either
side of the center shall be alternated, leveled and shimmed as necessary.
e) The complete assembly will be checked to ensure alignment and level after tightening
of the bolts.
4.3
a) Control panels will be inspected to ensure three are no loose connections and the
insulation resistance checked using a 500-volt megger to ensure that it has no direct
connection to earth.
b) The ratings and settings of fuses and protective devices will be checked against the
panel schedule.
c) The control panel will be energized and functionally checked in accordance with the
manufacturer instructions.
Page 4 of 5
MACO-QECP-018
REV. 0
For D.C. battery chargers, the output voltage, float and equalizing charge setting will
be checked.
The operation of all panel indicators will be checked. Fault conditions will be
simulated and the operation of all alarms and annunciators witnessed.
Inverter system will be checked as above and the output voltage and frequency
checked. The operation of the static changeover switch will be checked according to
manufacture instructions.
d) The test will be conducted by the site Electrical Supervisors witnessed and recorded
by the Electrical QC Inspector. The results will be recorded for battery chargers and
for inverse systems.
4.4
Battery Charging
a) Before charging, the battery cell plugs will be loosened and the electrolyte level
rechecked.
b) Connection to the charger will be checked to ensure the correct polarity.
c) The room ventilation system will be checked to ensure it is fully operational.
d) The battery system will be charged according to the manufacturer instructions.
Reading will be taken throughout the charging period. Where a constant voltage rises
will be recorded. Where a constant voltage is applied, the voltage and drop in
charging current will be recorded.
Throughout the charging period the battery temperature shall be checked and the
average value recorded. Attention shall be paid to individual cells with higher
average temperatures.
5
Documentation
a) Form QECP-018-01-BT
Page 5 of 5
MACO-QECP-018
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
ELECTRICAL DUCT BANKS & MANHOLES
DOCUMENT NO.:
MACO-QECP-019
Index
1
2
3
4
5
6
Page
Scope
References
Materials
Quality Control
Procedures
Documentation
2
2
2
2
4
5
001
04/09/09
MACO-QECP-019
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 4
MACO-QECP-019
REV. 0
SCOPE
a) This procedure covers the inspection and test procedure pertaining to the
installation of underground utilities, duct bank, duct bank cables and
conduits.
b) This procedure shall be applied to the inspection ,method and criteria for
installation work carried out by the Electrical Department.
SAES-P-100
SAES-P-104
SAES-B-068
NEC
NEMA
S.A.G.1.2.705
SAES-P-111
3
MATERIALS CONTROL
a) Ensure that materials are handled in accordance with Proponent Procedure
and Materials control System.
b) Check all the materials received are in conformance with Purchase order
and Specs. Requirements.
c) Check all materials are free from mechanical damage. Any damage or
discrepancies shall be recorded and reported immediately to Materials Dept.
d) Store the materials in a safe place, free from dust and not exposed to
sunlight.
QUALITY CONTROL
a) PVC coated 40 mils thick rigid steel jacketed conduit and fitting shall be used
in damp locations, exposed to weather, direct buried under and in conditions
of installations, operation, or maintenance protection from liquids, vapors or
solids.
b) Rigid steel, galvanized conduit shall be used in wet locations, exposed to
weather, in areas subject to mechanical injury defined as less than 2.3 meters
Page 2 of 4
MACO-QECP-019
REV. 0
Page 3 of 4
MACO-QECP-019
REV. 0
CONSTRUCTION PROCEDURES
1. All excavation work shall proceed with care to avoid disturbing existing
underground installations. Hand tools shall be employed exclusively for
investigative digging to minimize disturbances.
a) Cable/Conduit Laying: Before this is done, the bottom of the
trench must have a sand cushion of at least 150mm (6) as per
Proponent Standard Drawings and if cables/conduits or more are to be
laid in the same trench they must comply with SAEP-P-104, Para II.
Any cable/conduit passing or crossing through an existing pipeline or
cable must be as per SAES-B-064.
b) Covering of Cable/Conduit: Cover the cable with a dry sand to a
height of at least 300mm (12), then put a red concrete tile of 50mm
(2) thickness above as per Proponent Standard Drawings.
c) Burying of Cable/Conduit: bedding and covering of sand shall be
packed around the cable /conduit to prevent stone bruises and assist in
heat dissipation. Minimum depth of direct buried cable/conduit from
grade (surface) level to top of the cable/conduit shall be as per
Proponent Standard Drawings.
2. Splicing of conductors shall be kept to a minimum. A maximum of 2
splices be permitted in any one circuit for new installations of cables rated
above 1000V.Splices and terminations of cables rated above 1000V shall be
made by personnel certified in accordance with Proponent G.I.2.705
3. Splicer certification cards shall be submitted to SAPIS for verification and
issuance of the splicer job clearance card (Aramco 8233-22) prior to any
splices of terminations being made on cables rated above 1000V.
4. All buried or concealed connections and splicers for the grounding system
shall be inspected and approved by Proponent before concealment.
DOCUMENTATION
Form QECP-019-01-DB
Form QECP-019-02-DB
Form QECP-019-03-DB
Form QECP-019-04-DB
Duct Manhole
Field inspection Checklist /Electrical Manhole
Underground Cable Duct Bank Test
Under ground Electrical Conduit.
Page 4 of 4
MACO-QECP-019
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
INSIDE BUILDING PIPING AND FITTINGS
DOCUMENT NO.:
MACO-QMCP-001
Index
1
2
3
4
5
6
Page
Purpose
Definitions
Safety
References
Quality Procedures
Documentation
2
2
2
2
3
5
001
04/09/09
MACO-QMCP-001
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 5
MACO-QMCP-001
REV. 0
PURPOSE
This Quality Procedure has been developed in order to ensure the main work operations and
performance of associated Quality Control activities during Piping and Fitting works inside
buildings.
2.0 DEFINITIONS
3.0
QMP
QCP
ITP
SAFETY
3.1
To ensure that work permit is valid, if applicable and all works done in
safest possible manner consistent with good construction practices.
4.0 REFERENCES
SAES A - 004
SAES L - 001
Piping Standards
SAES L 005
Piping Components
SAES L 008
Selection of Valves
SAES L 009
SAES L - 032
SAES L 042
Page 2 of 5
MACO-QMCP-001
5.0
REV. 0
SAES S 050
SAES S 060
SAES S 070
04-SAMSS 001
Gate Valves
04-SAMSS 002
Globe Valves
04-SAMSS 005
Check Valves
04-SAMSS-035
ANSI B 31.9
ASTM D 3311
ASTM D 2729
AWWA C 651
SAES B 067
SAES B 069
SAES B Series
SAES H 200
SAES H 204
SAES H 203
QUALITY PROCEDURES
5.1 Piping Works
5.1.1
Page 3 of 5
MACO-QMCP-001
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.1.10
5.1.11
5.1.12
5.1.13
REV. 0
5.2 Installation
5.2.1
5.2.2
5.2.3
Run piping in straight lines and square with the building. Riser lines to
be plumb. Provide dielectric fittings for connecting dissimilar metals.
5.2.4
Do not route piping over any electrical equipment where the possibility
of damage exists.
Page 4 of 5
MACO-QMCP-001
REV. 0
5.2.5
5.2.6
5.2.7
Place storm drainage pipes, sanitary sewer pipes, waste pipes and drain
pipes at elevation and slopes as per drawing.
5.2.8
5.2.9
Cut pipe ends with pipe cutter only. Hacksaw cutting shall not be
allowed.
6.0
DOCUMENTATION.
Inspection and Test Plan
Inspection and Test Record
Page 5 of 5
MACO-QMCP-001
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
PIPE SLEEVES
DOCUMENT NO.:
MACO-QMCP-002
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedure
Documentation
2
2
2
2
2
3
4
001
04/09/09
MACO-QMCP-002
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Pipe Sleeves
Page 1 of 4
MACO-QMCP-002
REV. 0
PIPE SLEEVES
1
SCOPE
1.1 This covers procedures for inspection to be followed during installation of pipe
sleeves including refrigerant pipes, water, drain and vent pipes passing through floor
slabs, grade beams, walls and roofs.
1.2
This covers the inspection of all aspects of pipe sleeves passing through floor slabs,
grade beams, walls and roofs.
1.3
PURPOSE
a.
To ensure that all items required by this Contract shall conform to Project
specifications and construction drawings.
b.
This procedure shall ensure that the main inspection requirements are met and that
the findings and corrective actions are followed.
c.
DEFINITIONS
Heating, Ventilating and Air Conditioning.
QCP
ITP
SAFETY
4.1
HVAC
To ensure that Work permit is valid, if applicable and all works done in the safest
possible manner consistent with good construction practices.
REFERENCES
SAES-K-001
Pipe Sleeves
Page 2 of 4
MACO-QMCP-002
SAES-K-100
SAES-M-100
SAES-S-060
SAMSS
REV. 0
QUALITY PROCEDURE
6.1 General
6.1.1 All HVAC equipment to be supplied and installed shall have prior approval
from Proponent. All equipment shall meet the project specifications and
suitable for installation as required and in compliance with the manufacturers
recommendations.
6.2
Quality Control
6.2.1 Deliver, store, protect and handle products as per manufacturers and
Proponents requirements.
6.3
Installation
6.3.1 Provide block-outs for pipes passing through walls or slabs. Indicate correct size,
locations and alignment of all sleeves. Provide schedule 40 galvanized steel sleeves
through concrete or masonry. Provide sheet metal sleeves through fire rated
gypsum walls (Plastic sleeves through non rated gypsum walls).
6.3.2 Size of pipe sleeves shall permit placing of pipe, insulation and specified sealing
materials. Seal sleeves through fire walls with approved rated sealant.
6.3.3 Extend sleeves through floor 25 mm (1 inch) above finished floor level unless
otherwise indicated or specified. Caulk Sleeves.
6.3.4 Extend wall and portion sleeves through and cut flush with each surface, unless
otherwise indicated or specified.
6.3.5 Set sleeves in position in form works and provide reinforcements.
6.3.6 Size sleeves large enough to allow for movement due to expansion and contraction.
Provide for continuous insulation wrapping.
Pipe Sleeves
Page 3 of 4
MACO-QMCP-002
REV. 0
6.3.7 Where piping or ductwork penetrates floor, ceiling or walls, close off space between
pipe or duct and adjacent work with fire stopping insulation and caulk. Provide
close fitting metal collar or escutcheon covers at both sides of penetration.
6.3.8 Install chrome plated steel escutcheon at finished surfaces.
6.3.9 After piping has been installed, seal the annular space between piping and sleeves
with specified materials.
DOCUMENTATION
7.1 QMCP-002-01-ITP
7.2 QMCP-002-02-QR
Quality Record.
Pipe Sleeves
Page 4 of 4
MACO-QMCP-002
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
ANCHORS, SUPPORTS AND THRUST BLOCKS
DOCUMENT NO.:
MACO-QMCP-003
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedure
Documentation
2
2
2
2
2
3
4
001
04/09/09
MACO-QMCP-003
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 4
MACO-QMCP-003
REV. 0
1.0
SCOPE
1.1 This covers procedures for inspection to be followed during Installation of supports,
anchors and thrust blocks for HVAC system.
1.2 This covers the inspection of all aspects of supports, anchors and Thrust blocks for
HVAC system including water and drainage pipes.
1.3 This covers the inspection of all aspects of supports, anchors and thrust blocks for
HVAC system including water and drainage pipes.
2.0
PURPOSE
2.1 To ensure that all items required by this Contract shall conform to
project specifications and construction drawings.
2.2 This procedure shall insure that the main inspection requirements
are met and that findings and corrective actions are followed.
3.0
4.0
DEFINITIONS
HVAC
QCP
ITP
SAFETY
4.1 To ensure that Work Permit is valid, if applicable and all works done
in the safest possible manner consistent with good construction practices.
5.0 REFERENCES
SAES-K-001
SAES-K-100
Page 2 of 4
MACO-QMCP-003
SAES-S-070
SAES-S060
SAES-l-011
ASME-B-31.9
UMC
Company
Proponent
REV. 0
General
6.1.1
1
6.2
6.3
Quality Control
6.2.1
6.2.2
6.2.3
Installation
6.3.1
All thrust blocks shall be as per Proponent Standard Drawings. All thrust
blocks shall be designed for maximum working pressure of 1379 kPa (2000
psi).
6.3.2
Thrust blocks shall be cast with not less than 0.02 m. bearing against the
fitting and not less than 0.28 m. bearing against the soil.
6.3.3
Page 3 of 4
MACO-QMCP-003
REV. 0
6.3.4
6.3.5
6.3.6
Provide trapeze hangers for several pipes in parallel and at the same
elevations.
6.3.7
6.3.8
6.3.9
6.3.10 Construct supports of steel members. Brace and fasten with flanges bolt to
structure.
6.3.11 Provide curbs for mechanical roof installation at 300-mm (12-Inch)
minimum high above roofing surface. Flash and counter flash with sheet
metal. Seal watertight.
7.0
ATTACHMENTS
Inspection and Test Plan
Quality Record
Page 4 of 4
MACO-QMCP-003
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
VIBRATION ISOLATION
DOCUMENT NO.:
MACO-QMCP-004
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedure
Documentation
2
2
2
2
2
2
3
001
04/09/09
MACO-QMCP-004
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Vibration Isolation
Page 1 of 4
MACO-QMCP-004
REV. 0
VIBRATION ISOLATION
1.0
SCOPE
1.1
2.0
PURPOSE
2.1
3.0
4.0
6.0
To provide vibration isolators of the appropriate sizes and proper loading to meet
the specified deflection requirements in conformance with manufacturers
recommendations.
DEFINITIONS
3.1
HVAC
3.2
QCP
3.3
ITP
SAFETY
4.1
5.0
This covers procedures and items to be checked and verified for the installation of
vibration isolation of the appropriate sizes and proper loading for HVAC system.
To ensure that Work Permit is valid, if applicable and all works done in the safest
possible manner consistent with good construction practices.
REFERENCES
5.1
SAES-K-001
5.2
SAES-K-100
5.3
ASHRAE
QUALITY PROCEDURES
6.1
Installation.
6.1.1
Vibration Isolation
Page 2 of 4
MACO-QMCP-004
REV. 0
6.1.2
6.1.3
Provide flexible duct connectors between air handling unit or fans and
distribution ductwork.
6.1.4
On closed spring isolators, adjust so side stabilizers are clear under normal
operating conditions.
6.1.5
6.2
Provide pairs of horizontal limits springs on fans with more than 6.0 inch (1.5
kPa) static pressure and on hanger supported, horizontally mounted axial fans.
6.3
6.4
Vibration Isolation
6.4.1
6.4.2
6.4.3
6.4.4
Select 3 hangers closest to vibration source for minimum 1.0 inch (25
mm) static deflection of isolated equipment. Select remaining isolators for
minimum 1.0 inch (25 mm) static deflection or static deflection of
isolated equipment.
Page 3 of 4
MACO-QMCP-004
REV. 0
Minimum operating
Deflection
Isolator
Isolation
Efficiency
-
Neoprene pads
0.2
Neoprene Pads
0.2
Workshop Equipment
7.0
DOCUMENTATION
Inspection and Test Plan
Vibration Isolation
Page 4 of 4
MACO-QMCP-004
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
AIR HANDLING UNIT
DOCUMENT NO.:
MACO-QMCP-005
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Equipment Units
Documentation
2
2
2
2
2
3
5
001
04/09/09
MACO-QMCP-005
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 5
MACO-QMCP-005
REV. 0
2.0
SCOPE
1.1
1.2
PURPOSE
2.1
3.0
To ensure that all items required by this contract shall conform to project
specifications and construction drawings.
DEFINITIONS
3.1 HVAC
4.0
3.2 QCP
3.3 ITP
SAFETY
4.1
5.0
To ensure that Work Permit is valid, if applicable and all works done in the safest
possible manner consistent with good construction practices.
REFERENCE
5.1 17-SAMSS0503
5.2 ARI
5.3
SAES-K-001
5.4
SAES-K-002
Page 2 of 5
MACO-QMCP-005
6.0
REV. 0
5.5 SAES-K-003
5.6
SAES-K-100
5.7
ASHRAE
5.8
NEPA-90A
EQUIPMENT UNITS
6.1
General
6.1.1
6.1.2
6.1.3 Unit shall consist of a fan and coil section, filter section and mixing box
section as indicated on the drawings.
6.1.4
6.1.5
6.1.6
Fan Section
6.2.1
6.2.2
Fan scroll, wheel, shaft, bearing, drives and motor shall be mounted on a
structural steel assembly, which shall be isolated from the outer casing
with factory-installed 2.0 inch deflection spring isolators and vibrationabsorbent fan discharge seal.
Page 3 of 5
MACO-QMCP-005
REV. 0
6.2.3
Hinged access door shall be provided on both sides of unit when supplied
with internal isolation.
6.2.4
Each unit shall have one (1) fan wheel and scroll only.
6.2.5
6.2.6
Fan wheels shall be keyed to the shaft and shall be designed for
continuous operation at the maximum rated fan speed and motor horse
power.
6.2.7
Fan shafts shall be solid steel, Turned, Ground, Polished and coated with
Rust-preventive Oil.
6.2.8
Fan bearing shall be self-aligning, pillow block re-greasable ball or rollertype selected for a minimum average lift of 400,000 hrs.
6.2.9
A motor shall be mounted within the fan section casing on slide rails
having 2 adjusting screws. Fan motor in accordance with specification
section 15170 and equipment schedule.
6.2.10 Fan drive shall be designed for a minimum 1.3 service factory, shall be
constant-speed adjustable pitch. All drives shall be factory mounted with
belts aligned and tensioned.
6.3
Coil Sections
6.3.1
6.3.2
All coils shall be factory tested at 400 psig air pressure while submerged in water.
6.3.3
Page 4 of 5
MACO-QMCP-005
REV. 0
7.0
6.6.1
6.6.2
Access sections shall have a double walled hinged door and 16 gage
floors to protect insulation.
DOCUMENTATION
Inspection and Test Plan.
Inspection and Test Record.
Page 5 of 5
MACO-QMCP-005
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
AIR COOLED CONDENSING UNIT
DOCUMENT NO.:
MACO-QMCP-006
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedures
Documentation
2
2
2
2
2
3
4
001
04/09/09
MACO-QMCP-006
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 4
MACO-QMCP-006
REV. 0
2.0
3.0
SCOPE
1.1
This covers procedures for inspection to be followed during installation of aircooled, direct expansion condensing unit and accessories.
1.2
This covers the inspection of all aspects of air-cooled, direct expansion condensing
unit and accessories.
1.3
PURPOSE
2.1
To ensure that all equipment required by this contract shall conform to project
specifications and construction drawings.
2.2
This procedure shall ensure that the main inspection requirements are met and that
the findings and corrective actions are followed.
2.3
DEFINITIONS
3.1 HVAC
4.0
3.2 QCP
3.3
ITP
3.5 Company
Proponent
SAFETY
4.1
5.0
To ensure that work Permit is valid, if applicable and all works done in the safest
possible manner consistent with good construction practices.
REFERENCE
5.1
17-SAMSS0503
MACO-QMCP-006
6.0
REV. 0
5.2
SAES-K-001
5.3
SAES-K100
5.4
ASHRAE
QUALITY PROCEDURES
6.1
6.2
Quality Assurance
6.1.1
Check the service access, filter access, refrigerant piping and condensate
piping to ensure adequate clearance for the units.
6.1.2
6.1.3
Capacity ratings of the units to be ARI certified and that the unit
constructed according to UL Standards and carry UL label of approval.
6.1.4
6.1.5
Equipment
6.2.1
6.2.2
6.2.3
6.2.4
Page 3 of 4
MACO-QMCP-006
REV. 0
6.3 Installation
7.0
6.3.1
6.3.2
Install condensing unit to allow sufficient clear space of minimum 3.0 ft. all
around for service, maintenance and airflow requirements.
6.3.3
For roof locations, mount units on 6.0 inch concrete pad with 6.0 inch
margin all around equipment base.
DOCUMENTATION
7.1 Inspection and Test Plan
7.2 Quality Record
Page 4 of 4
MACO-QMCP-006
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
PACKAGE AIR CONDITIONING UNIT
DOCUMENT NO.:
MACO-QMCP-007
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedure
Documentation
2
2
2
2
3
3
4
001
04/09/09
MACO-QMCP-007
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 4
MACO-QMCP-007
REV. 0
2.0
3.0
4.0
SCOPE
1.0
This covers instructions for the assigned inspector on procedures and items to
check and verify for the installation of Packaged Air-Conditioning units and
accessories.
1.1
This covers the inspection of all aspects of Package A/C Unit and its electrical
system.
1.2
PURPOSE
2.0
To ensure that all equipment installed shall be in accordance with the project
specifications and manufacturers instructions.
2.1
This procedure shall ensure that the main inspection requirements are met and
that the findings and corrective actions are followed,
2.2
DEFINITIONS
3.1
HVAC
3.2
QCP
3.3
ITP
SAFETY
4.0
5.0
To ensure that Work Permit is valid, if applicable and all works done in the safest
possible manner consistent with good construction practices.
REFERENCES
5.1
SAES-K001
Page 2 of 4
MACO-QMCP-007
6.0
5.2
SAIS-K-100
5.3
ARI
5.4
17-SAMSS-503
REV. 0
QUALITY PROCEDURES
6.0
6.1
6.2
Quality Control
6.0.1
Condenser coil guards shall be provided for all units mounted within reach
of the public.
6.0.2
Cast-in-place roof mounting frame shall also be provided for all units
mounted on the roof including flashings.
6.0.3
Provide OA, return air and relief air dampers in a factory provided
enclosures. All air shall be filtered and bird screens installed.
6.0.4
6.0.5
Roof top units mounted on slabs or other fixed locations shall be provided
with adapters for end discharge and return to the unit.
Installation
6.1.1
Install the unit on the concrete curb as required by the job conditions and
as recommended by the manufacturer and install proper flashing and
counter flashings.
6.1.2
Set the unit in place, taking care to protect the adjacent roofing and
connect the supply and return ductwork.
6.1.3
Make electrical connections, making sure that these do not block access to
any part of the equipment requiring servicing.
6.1.4
Have the factory service person check out the unit and make a written
report.
Operate the unit and check for proper air quantity supply, noise and
correct operations.
Page 3 of 4
MACO-QMCP-007
6.2.2
7.0
REV. 0
Report the airflow, static pressure, voltage and current draw of each item,
refrigerant pressure readings etc. as required by specifications.
DOCUMENTATION
7.1
7.2
Quality Record
Page 4 of 4
MACO-QMCP-007
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
DUCTWORKS
DOCUMENT NO.:
MACO-QMCP-008
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedure
Documentation
2
2
2
2
2
3
5
001
04/09/09
MACO-QMCP-008
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Ductworks
Page 1 of 5
MACO-QMCP-008
REV. 0
DUCTWORKS
1. SCOPE
This covers procedures for inspection to be followed during installation and leak testing of
HVAC Ductworks.
This covers inspection of all aspects of duct works
This procedure shall be used in conjunction with applicable manufacturers instructions.
2. PURPOSE
2.1 To ensure that all items required by this contract shall conform to project
specifications and construction drawings.
2.2 This procedure shall insure that the main inspection requirements are met and
that the findings and corrective actions are followed.
3.
DEFINITIONS
3.1
HVAC
3.2
QCP
3.3 ITP
4. SAFETY
4.1 To ensure that Work Permit is valid, if applicable and all works done in the
safest possible manner consistent with good construction practices.
5. REFERENCES
Ductworks
5.1 SAES-K-001
5.2 SAES-K-100
5.3 SAES-M-100
MACO-QMCP-008
REV. 0
5.5 NFPA 91
5.7 SMACNA
5.8 SMACNA
5.9 UL 181
Structural Steel
Steel Sheets, Carbon and High Strength, Low-alloy Hotrolled and Cold-rolled
Fire Damper Installation Guide
5.13 SMACNA
6. QUALITY PROCEDURES
Ductworks
6.1.1
Perform fabrication in accordance with SMACNA Duct Construction Metal and flexible . Provide duct materials, gauges, reinforcing and
sealing for operating pressures.
6.1.2
Provide T-bends and elbows with radius of not less than 1 times width
of duct on centerline. Provide air foil turning vanes for rectangular
elbows.
6.1.3
6.1.4
6.1.5
Page 3 of 5
MACO-QMCP-008
REV. 0
6.1.6
6.1.7
6.1.8
6.1.9
Connect flexible ducts to metal ducts with adhesive plus tape, draw bands
and sheet metal screw.
6.1.10 All open ductwork must be temporarily closed with metal or taped
polyethylene to prevent ingress of dust during construction.
6.1.11 All flexible connectors shall not be more than one 90 turn and flexible
duct are not allowed to be used in changing of direction.
6.2 Duct Hangers and Supports
6.2.1. All materials shall be galvanized steel band iron.
6.2.2. Wall supports shall be galvanized or fabricated angle bracket.
6.2.3. Arrange hangers to prevent transmission of vibration from piping to the
building structure and allow for expansion and contraction. Clearance for
application of the specified insulation without cutting either pipeline
covering or fitting covering in installation of hangers and fitting shall be
provided.
6.2.4. Flash vents and soil pipes projecting 75-mm minimum above finished roof
surface with lead worked 25-mm minimum in to hub, 200-mm minimum
clearance on sides with 600 x 600-mm sheet.
6.2.5. Flash floor drains in floors with topping over finished areas with lead 250
mm clear on sides with minimum 910 x 910-sheet size.
6.2.6. Seal floor, shower, mop, sink, drains watertight to adjacent materials.
6.2.7. Provide curbs for mechanical roof installations, 300 mm minimum high
above roof surface. Adjust storm collars tightly to pipes with bolts caulk
around top edge. Use storm collars above roof jacks. Screw vertical flange
section to face of curb.
Ductworks
Page 4 of 5
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REV. 0
6.3 Testing
6.3.1
6.3.2
6.3.3
Test shall be done during the night for pressure duct system.
6.4
Cleaning
6.4.1. Duct system shall be clean with force air at maximum allowable velocity
through duct to remove accumulated dust.
6.4.2. Clean all duct system with high power vacuum machines. Protect installed
ducts from dust and dirt. Provide access in to duct work for cleaning
purposes.
7.
ATTACHMENTS
7.1 Inspection and Test Plan
7.2 Quality Record
Ductworks
Page 5 of 5
MACO-QMCP-008
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
DUCTWORKS ACCESSORIES
DOCUMENT NO.:
MACO-QMCP-009
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
References
Definitions
Responsibilities
Procedure
Documentation
2
2
2
2
2
3
4
001
04/09/09
MACO-QMCP-009
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Ductworks Accessories
Page 1 of 4
MACO-QMCP-009
REV. 0
DUCTWORKS ACCESSORIES
1.0
SCOPE
1.1
PURPSOSE
2.1 To ensure that all items required by this contract shall conform to project
specifications and construction drawings.
2.2 This procedure shall insure that the main inspection requirements are met and that
the findings and corrective actions are followed.
3.0
4.0
DEFINATIONS
3.1 HVAC
3.2 QCP
3.3 ITP
SAFETY
4.1 To ensure that Work Permit is valid, if applicable and all works done in the safest
possible manner consistent with good construction practices.
5.0
REFERENCES
5.1 SAES-K-001
5.2 SAES-K-100
5.3 SAES-M-100/UBC
Ductworks Accessories
Page 2 of 4
MACO-QMCP-009
6.0
REV. 0
5.5 SMACNA
5.6 SMACNA
5.7 UL 33
5.8 ASHRAE
QUALITY PROCEDURES
6.1 Material Control
6.1.1 All materials shall be delivered, protected and handled to site in accordance
with the Companys requirements.
6.1.2 Protect dampers from damages to operating linkages and blades.
6.1.3 All data shall be submitted under provisions of the Company.
6.2
Installation
6.2.1
6.2.2
Provide access doors for inspection and cleaning before and after filters,
coils, fans and dampers.
6.2.3
Provide duct test holes where indicated and required for testing and
balancing purposes.
6.2.4
Provide fire dampers where ducts and outlets pass through fire rated
components as required by SAES-M-100/UBC and NFPA 90-A.
6.2.5
6.2.6
Ductworks Accessories
Page 3 of 4
MACO-QMCP-009
REV. 0
6.2.7
6.2.8
7.0 ATTACHMENTS
7.1 Inspection and Test Plan
7.2 Quality Record
Ductworks Accessories
Page 4 of 4
MACO-QMCP-009
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
DUCTWORKS INSULATION
DOCUMENT NO.:
MACO-QMCP-010
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedure
Documentation
2
2
2
2
2
3
4
001
04/04/09
MACO-QMCP-010
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Ductworks Insulation
Page 1 of 4
MACO-QMCP-010
REV. 0
DUCTWORKS INSULATION
1.0
2.0
3.0
4.0
SCOPE
1.1
1.2
1.3
PURPOSES
2.1
To ensure that all ductworks required by this contract shall conform to the project
specifications and construction drawings.
2.2
This procedure shall ensure that the main inspection requirements are met and
that the findings and corrective actions are followed.
2.3
DEFINITIONS
3.1 HVAC
3.2 QCP
3.3 ITP
SAFETY
4.1
5.0
To ensure that Work Permit is valid, if applicable and all works done in the safest
possible manner consistent with good construction practices.
REFERENCES
5.1 SAES-K-001
5.2 SAES-K-100
Ductworks Insulation
Page 2 of 4
MACO-QMCP-010
6.0
REV. 0
5.3 SAES-M-100
5.4 SMACNA
5.5 NFPA
5.6 ASTM-B-209
5.10 ASTM-96
5.11 SMACNA
QUALITY PROCEDURES
6.1 Install material in accordance with manufacturers instructions.
6.2 Insulated ductwork conveying air below ambient temperature.
6.2.1
6.2.2
Finish with tape bands and vapor barrier jacket or stickpins where
applicable for wide ducts.
6.2.3
6.2.4
Ductworks Insulation
6.3.1
6.3.2
Insulate fittings and joints. Where service access is required, bevel and
seal ends of insulation.
Page 3 of 4
MACO-QMCP-010
REV. 0
7.0
DOCUMENTATION
Inspection and Test Plan
Quality Record
Ductworks Insulation
Page 4 of 4
MACO-QMCP-010
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
MECHANICAL IDENTIFICATION
DOCUMENT NO.:
MACO-QMCP-011
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedure
Documentation
2
2
2
2
2
3
5
001
04/09/09
MACO-QMCP-011
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Mechanical Identification
Page 1 of 5
MACO-QMCP-011
REV. 0
MECHANICAL IDENTIFICATION
1.0
2.0
3.0
4.0
SCOPE
1.1
This covers procedures for inspection to be followed during the marking and
identification of materials to identify HVAC equipment.
1.2
PURPOSE
2.1
To ensure that all items required by this contract shall conform to project
specifications and construction drawings.
2.2
This procedure shall insure that the main inspection requirements are met and that
the findings and corrective actions are followed.
DEFINITIONS
3.1 HVAC
3.2 QCP
3.3 ITP
SAFETY
4.1
5.0
To ensure that Work Permit is valid, if applicable and all works done in the safest
possible manner consistent with good construction practices.
REFERENCES
5.1
SAES-K-001
5.2
SAES-B-067
5.3
SAES-M-100
5.4
SAES-K-100
5.5
ASME A-13.1
Mechanical Identification
Page 2 of 5
MACO-QMCP-011
5.6
6.0
UMC
REV. 0
QUALITIES PROCEDURES
6.1
6.2
6.3
6.4
Identify air-handling units, condensing units, exhaust fans and other equipment
with plastic nameplates. Small devices may be identified with tags.
6.4.1
Identify control panels and major control components outside panels with
plastic nameplates.
6.4.2
6.4.3
6.4.4
6.4.5
Identify piping, concealed or exposed with plastic pipe markers. Use tags
on piping (20 MM) and smaller.
6.4.6
6.5
Provide ceiling tacks to locate vales or dampers above T-bar type panel ceilings.
6.6
Service
Abbreviation
Mechanical Identification
DW ( Cold )
Page 3 of 5
MACO-QMCP-011
DW ( Hot )
Utility Water
UW
Fire Water
FW
Compressed Air
CA
6.7
REV. 0
HVAC Equipment
An identification tag or nameplate made of 316 stainless steel shall be attached to each
item of equipment. The tag shall be marked by raised letter as follows :
6.7.1 Purchase Order Number
6.7.2
Manufacturer
Safety Color-Code
The colors red, green, orange and blue shall be reserved for safety uses described herein:
6.8.1Red shall be used as the color indicator for fire protection equipment and piping as
well as emergency stop push button devices and signs.
6.8.2
Green shall be used as the background color indicator for locations of emergency
safety equipment including first aid equipment, safety showers and eye-wash
units.
6.8.3
Orange shall be used as the color indicator for inlet and outlet block valves for
pressure relief valves.
6.8.4
Blue shall be used as the color indicator for chilled water, drinking water and
utility water.
Mechanical Identification
Page 4 of 5
MACO-QMCP-011
7.0
REV. 0
DOCUMENTATION
7.1
7.2
Quality Record
Mechanical Identification
Page 5 of 5
MACO-QMCP-011
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
TESTING & BALANCING OF MECHANICAL
SYSTEMS
DOCUMENT NO.:
MACO-QMCP-012
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedure
Documentation
2
2
2
2
2
2
3
001
04/09/09
MACO-QMCP-012
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 4
MACO-QMCP-012
REV. 0
SCOPE
1.1
2.0
This covers procedures for inspection to be followed during testing, balancing and
adjusting of air moving equipment and air distribution system as per project
specifications and accepted international codes and standards.
PURPOSE
2.1 To conduct airside balancing of HVAC system in accordance with the project
specifications and accepted international codes and standards.
3.0
4.0
DEFINITIONS
3.1 HVAC
3.2 QCP
3.3 ITP
SAFETY
4.1 To ensure that Work Permit is valid, if applicable and all works done in the safest
possible manner consistent with good construction practices.
5.0
REFERENCES
5.1
AABC
5.2
ASHRAE
5.3
5.4
SAES-K100
5.5
ARI
American Refrigeration
5.6
NFPA 90 A
Page 2 of 4
MACO-QMCP-012
6.0
REV. 0
QUALITY PROCEDURES
All HVAC equipment to be supplied and installed shall have prior approval form
SAPMT. All equipment shall meet the project specifications and suitable for installation
as required and in compliance with the manufacturers recommendations.
6.1
6.2
Testing
6.1.1
test all systems and equipment installed under this division to demonstrate
proper operation as per SAES-K-001, Para 6.3 & 6.1. All T & B personnel
shall be quailed as per SAES-K-001, Para 6.2.
6.1.2
6.1.3
Set-up and balance air distribution system. Set air handling unit discharge
temperature as shown in the equipment schedule.
6.1.4
6.1.5
After individual box balancing, set all boxes to full heat and measure zone
flows with flow measuring devices.
6.1.6
6.1.7
Air-Balancing
6.2.1
Adjust fan RFM to design requirements. Record motor full load amperes.
Make pilot tube traverse of main supply ducts and adjust fans to design
airflow rates.
6.2.2
Page 3 of 4
MACO-QMCP-012
6.3
6.2.3
Check air velocity across each duct-mounted smoke detector. Verify that
the minimum velocity recommended by the smoke detector
manufacturers installation instructions is present.
6.2.4
6.2.5
After coil adjustments and VAV box setting, re-check settings as required.
Operation
6.4
6.3.1
Check final air velocity across each duct-mounted smoke detector. Verify
that the minimum velocity recommended by the smoke detector
manufacturers installation instructions is present. If detectors are
equipped with a visual airflow wheel, verify that wheel is operating
properly.
6.3.2
Acceptance
6.4.1
System Balancing
Control System Checkout
Operating Instructions
6.4.1
7.0
REV. 0
DOCUMENTATION
7.1
7.2
Page 4 of 4
MACO-QMCP-012
REV. 0
DOCUMENT TITLE:
PROCEDURE FOR:
WELDING OF STRUCTURAL AND PIPING
DOCUMENT NO.:
MACO-QMCP-013
Index
1
2
3
4
5
6
7
Page
Scope
Purpose
Definitions
Safety
References
Quality Procedure
Documentation
2
2
2
2
2
2
3
001
04/09/09
MACO-QMCP-013
APT
GJR
NZ
ISSUE
NO.
ISSUE
DATE
DESCRIPTION
PREPARED
BY
CHECKED
BY
APPROVED
BY
Page 1 of 3
MACO-QMCP-013
REV. 0
SCOPE
The Quality Procedures shall apply for the welding of structural steel and carbon
steel pipe in compliance with the Contact drawings and specifications.
2.0
PURPOSE
The Quality Procedure has been developed to describe the main works of
operation and performance with the Quality Control activities during welding.
3.0
DEFINITIONS
3.1 QMP
3.2 QCP
3.3 ITP
3.4 COMPANY
4.0
REFERENCES
4.1
4.2
4.3
4.4
5.0
SAES-M-001
12-SAMSS-007
SAES-W-011
SAES-H-001
QUALITY SYSTEM
MACO shall monitor as a minimum some form of Quality system as
means of ensuring that the product conforms to Proponent specification
requirements.
6.0
Procedures.
MACO works shall procure documented procedures and submit for
approval. These Procedures are to make reference to the applicable
specification standards.
Page 2 of 3
MACO-QMCP-013
REV. 0
( a ) Material
The
Procedure
documents.
shall
cover
material
inspections
and
( b ) Welding Procedures
The Procedure is to describe the welding process with
specifications,
type and grade and control during welding depending on the process itself.
( c ) Fit-up / Cutting and Assembly.
The Procedure is to address clearance, dimensions, tolerances, alignment,
tack welds and pre-heat ( if any ).
( d ) Qualifications
The procedure shall not ignore the qualification requirements the
welders, welding inspectors to be as per Saudi Aramco specification
requirement.
(e)
Pre-Heat.
If Pre-heat is required, the procedures shall be produced to cover this
activity. It is to ensure that the temperature rates are monitored according
to Contract specification and applicable standards.
(f)
Calibration
The procedure shall cover the requirement of calibration instruments /
equipment ( Power supply ), ampere, voltage- evidence of valid calibration
shall be maintained as per SAES-W-011, Par 19.2
(g)
Control of Consumables.
Control of consumables shall be followed for the welding activity such as
low hydrogen electrodes to monitor would be storage temperature and
applicable type for particular material as per SAES-W-011.
7.0
DOCUMENTATION
None
Page 3 of 3
MACO-QMCP-013