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PROCEUDRE FOR CABLE GLAND

CARBON DIOXIDE CAPTURE AND


INJECTION FACILITIES

SG2425-CST-022

SEAL AND CONDUIT SEAL

REV. No.

INSTALLATION

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TABLE OF CONTENTS

1.

PURPOSE

2.

SCOPE

3.

REFERENCE

4.

RESPONSIBILITIES

5.

GENERAL REQUIREMENTS

6.

PROCEDURE

7.

HANDLING AND STORAGE

18

8.

INSPECTION

19

9.

SAFETY

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PROCEUDRE FOR CABLE GLAND


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INJECTION FACILITIES

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1. PURPOSE
This procedure is to establish in which the general guidelines to be followed for the
cable gland sealing and conduit seal installation in accordance with good working
practice as per Samsung / Saudi Aramco job Specification and Standards.

2. SCOPE
This procedure defines the requirements for cable gland seal and conduit seal
installation which are to be installed in CO2 project. And this procedure is not
applicable for Electrical installation

3. REFERENCE
3.1 Saudi Aramco Engineering Standards (SAES)
Document Title

Document no.
SAES-P-100

Basic Power System Design Criteria

SAES-P-101

Regulated Vendors List for Electrical Equipment

SAES-P-104

Wiring Methods and Materials

SAES-P-111

Grounding

SAES-J-902

Electrical System for Instrumentation

SAES-B-068

Electrical Area Classification

15-SAIP-50

Inspection Procedure for Conduit and Cable Seal

3.2 International Standard


Document No.

Document Title

ANSI/NFPA 70

National Electrical Code (NEC)

NESC

National Electrical Safety Code

NFPA

National Fire Protection Association

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IEC

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International Electro-Technical Commission

3.3 Saudi Aramco Typical Inspection Plan (SATIP)


Document No.

Document Title

SATIP-P-111-01

Grounding and Bonding

SATIP-P-104-01

Low Voltage Cable and Wire

SATIP-P-104-04

Boxes (Junction, Terminal & Pull) Wire Troughs, and Wire


ways

SATIP-P-104-05

Above Grade Conduit, Fittings and Accessories

3.4 Saudi Aramco Inspection Checklist


Document No.

Document Title
Hazardous Location Conduit and Cable Sealing Special

SAIC-P-3004

Work Procedure
General Boxes and Enclosures Class 1, Division 1, or

SAIC-P-3016

Zone 1 Installation and Pre-Commissioning


General Boxes and Enclosures Class 1, Division 2 or

SAIC-P-3017

Zone 2 Installation and Pre-Commissioning


Hazardous Location Conduit / Cable Seal Fitting

SAIC-P-3209

Installation and Sealing


Conduit Hazardous Location GRS and LT Flex Conduit

SAIC-P-3321

System (Class 1, Zone or Division 2), Installation and PreCommissioning


Conduit Hazardous Location GRS and EXP Flex Conduit

SAIC-P-3322

Systems (Class 1, Zone or Division 2), Installation and


Pre-Commissioning

4. RESPONSIBILITIES

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4.1 Site Manager


4.1.1 Controlling the overall construction activities.
4.2 Electrical/Instrument Manager / Engineer
4.2.1 Delivering the relevant documentation and issue the required materials to the
Subcontractor to used on the construction activities.
4.2.2 Ensure relevant permits are raised and received prior to commencement of work,
with full compliance by all associated craftsman to the requirements of this
procedure, reference drawings, and Specification for the cable gland and conduit
sealing activity.
4.3 Supervisor and Foreman
4.3.1 Execution and implemented the approved working procedure for a proper
execution of the works with regards to safety, quality and productivity.
4.3.2 Shall arrange all the necessary manpower, tools and equipments.
4.4 Safety Supervisor
Check the work area for any unsafe conditions ensure that all safety requirements have
been adequately addressed and the work is carried out in accordance with Samsung /
Saudi Aramco Project Safety Procedure.

5.

GENERAL REQUIREMENTS
5.1 Ensure that all drawings / documents are latest revision and available at site.
5.2 Check the materials for damage before transporting to the work area. All materials with
doubtful condition or quality shall be immediately segregated from the job site.
5.3 Ensure safety barriers are erected at designated work areas.
5.4 For high elevation installation, ensure adequate scaffold ladders and access way
erected at the work location.
5.5 Ensure that all materials and tools/equipment needed to complete the work are
available at work areas.
5.6 The location of conduit seal installation shall be as per approved Electrical Area
Classification drawings.
5.7 Prior to proceeding the conduit sealing the cable shall be completely tested.

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PROCEDURE
6.1 Pre-installation Activities
6.1.1 Verify / check the cable gland sealing materials as per Aramco / Manufacturer
specifications.
6.1.2 Before glanding and sealing the cable, ensure that cables are completely tested,
inspected and accepted and the manufacturers instruction shall available at site.
6.1.3 Dressed the cable as per required and install the cable gland as per
manufacturer procedure.
6.1.4 Conductor separation and drain wire when required shall be performed in
accordance with the Saudi Aramco specification and NEC Articles 501 & 502.
6.1.5 For cables entering enclosures which requires to be sealed, they shall be sealed
by means of using the barrier type cable sealing glands, utilizing sealing
compound (e.g. explosion proof glands).
6.1.6 Cable entry into the control building, penetration on the wall of the building
shall via short horizontal PVC conduits (sleeves) encased into the wall, sealed
inside of the sleeves with the approved brand of sealing materials to provide fire
retardancy on the building interior side.
6.5.7 Multi conductor penetration shall be made with intact cable jackets.

6.2 Assembly Instruction for Cable Gland Type


6.2.1 Cable Gland Preparation
1. Back nut
2. Middle nut
3. Reversible Armour Clamping Ring (RAC)
4. Armour Spigot
5. Rubber Pot

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6. Entry (with captive deluge seal)

6.2.2 Strip the cable to suit equipment as shown above and the
expose the armour / braid I removing all cable fillers.
I = 20mm for cable gland sizes Os to A
I = 25mm for cable gland sizes B to C2
I = 32mm for cable gland sizes D to F
II = to suit equipment, if required fit shroud

6.2.3 Push the cable through the armour spigot 4. Spread


armour/braid over the armour spigot 4 until the end of the
armour / braid is up against the shoulder of the armour
cone. Position the armour clamping ring 3.

6.2.4 Remove the rubber pot 5 from the entry 6, place the
entry 6 over the armour spigot 4. Move the sub-assembly
1 and 2 up to meet the entry 6.

6.2.5 Hold the entry 6 in position with a spanner wrench or


monkey plier to prevent rotation. Hand tighten the
middle nut 2 onto the entry 6 and turn a further to
of a turn with a spanner / wrench.

6.2.6 Unscrew the middle nut 2 and visually inspect that the
armour / braid has been successfully clamped
between the armour spigot 4 and the armour
clamping ring 3 if armour / braid not clamped repeat
assembly.

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6.2.7 Remove the entry 6, spread the cable cores out for
the compound packing. Pack the compound between
the cores.

6.3 Epoxy Compound Preparation


6.3.1 When handling this materials, the gloves supplied must be worn. The epoxy
compound is supplied in the form of a two part package, these should be mixed
into the ratio of 1:1 until both colours have blended into one, without any streaks.
Rolling and folding is the most satisfactory method of obtaining an even blend.
6.3.2 Once mixed the compound must be used within 30 minutes, after this time it will
begin to stiffen. The compound should be kept at an ambient temperature of no
less than 200C prior to using, at lower temperatures it becomes difficult to mix.
6.3.3 Any Compound come into contact with the skin it should be cleaned off with skin
cleaner and not allowed to dry on the skin. Only compound for immediate
termination should be mixed.
6.3.4 The mixing and installation of the compound at an ambient temperature below
40C is not recommended due to extended curing periods.

6.3.5 With all gaps and voids filled, bring the conductors
Back together and pack more compound around the
outside of the conductors, tape the conductors
together to prevent disturbance of the compound
seal, pass the rubber pot 5 over the armour spigot 4
and removed any surplus compound from the top of
the rubber pot 5 and joint face as indicated.

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6.3.6 Replace the entry 6 over the rubber pot 5 ensuring


that compound does not cover the end of rubber pot 5
6.5.7 Locate and hand tighten the sub-assembly 1 and 2 to
the entry 6. The conductor must not be moved for a
minimum of four hours.

6.5.7 Allow the compound to cure (See below 6.3.10 for curing
times). Un tighten the sub-assembly 1 and 2 from the
entry 6 to enable inspection. The rubber pot 5 may be
removed for inspection to ensure that the packing is
satisfactory, add further compound if necessary.

6.5.7 Re-assemble the rubber pot 5 and the entry 6, hand


tighten the sub-assembly 1 and 2 to the entry 6 and add
half a turn with a spanner / wrench. Tighten the back nut
1 to form a seal around the cable, then tighten a further
full turn using a wrench / spanner. Ensure that the
middle nut 2 does not rotate when tightening the back
nut, ensure that deluge seal is pulled down into position.
Locate the shroud over the cable gland if applicable.

6.5.7 The compound may be adversely affected by some


solvent vapours, if such vapours are likely to be
present in the vicinity of the cable gland in service,
suitable precautions may be necessary. The
compound cures at a shore D hardness of 85 when
it can be handled, the compound when fully cured
is suitable for use at a temperature range of -60oC
to +80oC.

6.5.7 The Os and O size cable gland when used with braid is only suitable for use
with fixed apparatus (See the Table) the cable for which must be effectively

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clamped elsewhere to prevent pulling or twisting, the cable gland has an


operating temperature of -60oC to +80oC. A seal must be formed between the

equipment and the cable gland to maintain the appropriate degree of protection
against ingress of dust, solid objects and water.

6.5.7 Accessories: before carrying out the cable gland assembly or stripping of
the cable gland assembly, consideration should be given to any cable gland
accessories that may be required, such as.
6.5.7.2 Shroud, to offer additional corrosion protection.
6.5.7.2 Lucknut, to secure cable glands into position.
6.5.7.2 Sealing washer, to offer additional ingress protection of the enclosure
At the cable gland entry.
6.5.7.2 Earthtag, to provide an external armour / braid bonding point.
6.5.7.2 Serrated washer, to dampen any vibrations that may loosen the
lucknut or cable gland assembly.

6.4 Conduit System Installation


6.4.1 Conduit installation shall be completed between outlet, junction box or splicing
points prior to the installation of conductors.

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6.4.2 Bends of GRS conduit shall be made so that the conduit is not damage and the
internal diameter of the conduit is not effectively reduce.
6.4.3 Conduit shall be cut using a saw or pipe cutter. Care should be taken to ensure
a straight cut.
6.4.4 All cut ends shall be reamed or otherwise finished to remove rough edge.
6.4.5 There shall not be more than the equivalent of four quarters bends (360 degress
total) between pull points, for example, conduit bodies and boxes.
6.4.6 GRS conduit shall be securely fastened within 900mm (3ft) of each outlet box,
junction box, device box, cabinet, conduit body or other conduit termination.
Fastening shall be permitted to be increase to a distance of 1.5m (5ft) where
structural members do not redily permit fastening within 900mm (3ft).
6.4.7 Conduit shall be supported at intervals not exceeding 3m (10ft). Process piping
shall not be used to support conduits, except with the company approval.
6.4.8 Flexible Metallic Conduit (FMC) can be used in exposed or concealed location
where conditions of installation, operation or maintenance required flexibility.
6.4.9 FMC shall not be installed in wet locations unless the conductors are approved
for the specific conditions and the installation is such that liquids is not likely to
enter raceways or enclosures to which the conduit is connected.
6.4.10 FMC shall be securely fastened in place by an approved means within 300mm
(12inches) of each box, cabinet, conduit body or other conduit termination and
shall be supported and secured at intervals not to exceed 1.4m (4-1/2 ft).
6.4.11 Horizontal runs of FMC supported by openings through framing members at
intervals not greater than 1.4m (4-1/2ft) and securely fastened within 300mm
(12inches) of termination points shall be permitted.
6.4.12 FMC angle connectors shall not be used for concealed raceway installation.
6.4.13 Liquid tight flexible conduit (LFMC) can be installed exposed or concealed
where conditions of installation, operation or maintenance required flexibility or
protection from liquids, vapors or solid, and can be direct burial where listed
and marked for the purpose.

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6.4.14 LFMC conduit shall be securely fastened in place by an approved means within
300mm (12in.) of each box, cabinet, conduit body or other conduit termination
and shall be supported and secured at intervals not exceed 1.4m (4-1/2ft).
6.4.15 LFMC conduit connectors, angle connectors shall not be used for concealed
raceways installations.

6.5 Cable and Conduit Seal Installation


6.5.1 Class 1 location is those in which flammable gases or vapors are or may be
present in the air in quantities sufficient to produce explosive or ignitable
mixtures. Class 1 Division 1 location is as follows.
6.5.1.1 In which ignitable concentrations of flammable gases or vapors can exist
under normal operating conditions.
6.5.1.2 In which ignitable concentrations of such gases or vapors may exist
frequently because of repair or maintenance, operations or because of
leakage.
6.5.1.3 In which breakdown or faulty operation of equipment or processes might
release ignitable concentrations of flammable gases or vapour and might
also cause simultaneous failure of electrical equipment in such a way as
to directly cause the electrical equipment to become a source of ignition.
6.5.2 Class 1, Division 2 location is as follows
6.5.2.1 In which volatile flammable liquids or flammable gases are handled
processed, or used, but in which the liquids, vapors or gases will
normally be confined within closed containers or closed system from
which they can escape only in case of accidental rapture or breakdown
of such containers or systems or in case of abnormal operation of
equipment.
6.5.2.2 In which ignitable concentrations of gases or vapors are normally
prevented but positive mechanical ventilation and which might become
hazardous through failure or abnormal operation of the ventilating

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equipment.

6.5.2.3 The adjacent to Class 1, Division 1 location, and to which ignitable


concentration of gases or vapors might occasionally be communicated
unless such communication is prevented by adequate positive-pressure
ventilation from a source of clean air and effective safeguards against
ventilation failure are approved.
6.5.3 Seals are provided in conduit and cable system to minimize the passage of
gases and vapors and prevent the passage of flames from one portion of the
electrical installation to another through the conduit.
6.5.4 Class 1, Division 1 conduit seal location
6.5.4.1 In each conduit entry into an explosion proof enclosure where either of
the following apply.
6.5.4.1.1 The enclosure contains apparatus such as switches, circuit
breakers, fuses, relays, or resistors that may produce arcs,
sparks, or high temperatures that are considered to be an
ignition source in normal operation. The entry is metric
designator 53 (trade size 2) or larger and the enclosure
contains terminals, splices or taps.
Exception:
A. Are enclosed within a chamber hermitically sealed against
the entrance of gases or vapors.
B. Are immersed in soil.
C. Are enclosed within factory sealed explosion proof chamber
located within the enclosure, identified for the location, and
marked factory sealed or equivalent, unless the enclosure
entry is metric designator 53 (trade size 2).
D. Are in non-inductive circuit.
6.5.4.2 In each conduit entry into a pressurized enclosure where the conduit is

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not pressurized as part of the protection system. Conduit seals shall be


installed within 450mm (18 in.) from the pressurized enclosure.
6.5.4.3 Where two or more explosion proof enclosures for which conduit seals
are connected by nipples or by runs of conduit not more than 900mm
(36in) long, conduit shall be considered sufficient if located not more
than 450mm (18in.) from either enclosure.
6.5.4.4 In each conduit run leaving a Class 1, Division 1 location, the sealing
fitting shall be permitted on either side of the boundary of such location
within 10 ft (3.05 m) of the boundary and shall be designed and
installed so as to minimize the amount of gas or vapour within the
Division 1 portion of the conduit from being communicated to the
conduit beyond the seal. Except for listed explosion proof reducers at
the conduit seal, there shall be no union, coupling, box or fitting
between the conduit seal and the point at which the conduit leaves the
Division 1 location.
Exception :
A. Metal conduit containing no unions, coupling, boxes or fittings that
pass completely through a Class 1, Division 1 location with no
fittings less than 12 inches (305 mm) beyond each boundary shall
not required a conduit seal, if the termination point of the un-broken
conduit are in un-classified location.
B. For underground conduit installed where the boundary is beneath the
ground, the sealing fitting shall be permitted to be installed after the
conduit leaves the ground, but there shall be no union, coupling, box
or fitting, other that listed explosion proof reducers as the sealing
fitting, in the conduit between the sealing fitting and the point at
which the conduit leaves the ground.
6.5.5 Class 1, Division 2 conduit seal location
6.5.5.1 A conduit seal shall provided for connections to enclosures that are
required to be explosion proof.

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6.5.5.2 In each conduit run passing from a Class 1, Division 2 location into an
un-classified location. The sealing fitting shall be permitted on either
side of the boundary of such location within 10ft (3.05 m) of the
boundary. Rigid metal conduit shall be used between the sealing fitting
and the point at which the conduit leaves the Division 2 location, and the
threaded connection shall be used at the sealing fitting. Except for listed
redeucers at the conduit seal, there shall be no union, coupling, box or
fitting between the conduit seal and the point at which the conduit leaves
the Division 2 location.
Exception :
A. Metal conduit containing no unions, coupling, boxes or fittings that passes
completely through a Class 1, Division 2 location with no fittings less than
12in. (305 mm) beyond each boundary shall not be required to be sealed if
the termination points of the unbroken conduit are in unclassified locations.
B. Conduit systems terminating at an unclassified location where a wiring
method transition is made to cable tray, cable bus and ventilated bus way.
6.5.6 Class 1 Division 1 cable seal location
6.5.6.1 Cable shall be sealed all terminations. Cables with a gas / vapor tight
continuous metallic sheath and an overall jacket of suitable polymeric
material shall be sealed with a listed fitting after removal of the jacket
and any other covering so that the sealing compound surrounds each
individual insulated conductor in such a manner as to minimized the
passage of the gases and vapors.
Exception :
Shielded cables and twisted pair cables shall not require the removal of
the shielding material or separation of the twisted pairs, provided the
termination is by an approved means to minimize the entrance of gases
or vapors and prevent propagation of flame into the cable core.

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6.5.6.2 Cables in conduit with a gas / vapor tight continuous sheath capable of
transmitting gases or vapors through the cable core shall be sealed
after removing the jacket and any other covering so that the sealing
compound will surround each individual insulated conductor and the
outer jacket.
Exception :
Multi-conductor cables with a gas / vapour tight continuous sheath
capable of transmitting gases or vapors through cable core shall be
permitted to be considered as a single conductor by sealing the cable in
the conduit within 450 mm (18 in.) of the enclosure and the cable end,
within the enclosure by an approved means to minimize the entrance of
gases or vapors and prevent the propagation of flame into the cable
core. For shielded cables and twisted pair cables, it shall not be
required to remove the shielding material or separate the twisted pair.
6.5.6.3 Each multi-conductor cable in conduit shall be considered as a single
conductor if the cable is incapable of transmitting gases or vapors
through the cable core. These cables shall be sealed.
6.5.7 Class 1, Division 2 cable seal location
6.5.7.1 Cables entering enclosures that are required to be explosion proof shall
be sealed at the point of entry.
Exception :
A. Cables passing from an enclosure or room that is un-classified shall not
require a seal at the boundary.
B. Shielded cables and twisted pair cables shall not require the removal of the
shielding material or separation of the twisted pairs, provided the
termination is by an approved means to minimize the entrance of gases or
vapors and prevent propagation of flame into the cable core.

6.5.7.2 Cables that have gas / vapour tight continuous sheath and do not

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transmit gases or vapors through the cable core in excess of the


quantity permitted for seal fittings shall not be required to be sealed.
6.5.7.3 Cables with a gas / vapor tight continuous sheath capable of
transmitting gases or vapour through the cable core shall not be
required to be sealed, unless the cable is attached to process
equipment or devices that may cause a pressure in excess of 1,500
pascals (6 in. of water) to be excerted at a cable end, in which case a
seal, barrier, or other means shall be provided to prevent migration of
flammables into an un-classified location.
Exception :
Cables with an un-broken gas / vapor tight continuous sheath shall be
permitted to pass through a Class 1, Division 2 location without seal.
6.5.7.4 Cables that do not have gas / vapour tight continuous sheath shall be
sealed at the boundary of the Division 2, and un-classified location in
such a manner as to minimize the passage of gases or vapor into an
un-classified location.

6.6 Conduit and Cable Seal Application


6.6.1 Using fiber, make a dam in each conduit hub, leaving a sufficiently sized pour
hole, so that fluid sealing compound cannot leak from the sealing chamber.
Proceed as follows to pack proper fiber dam.
A. Position the conductor forward so they do not impede the work.
B. Pack fiber into each conduit hub behind the conductors.
C. Position the conductors backward and spread them apart.
D. Pack fiber between and around the conductors in each conduit hub.
E. Pack fiber into each conduit hub in front of conductors.
Caution: Remove all excess fibers from the sealing chamber and
conductors. The complete dam and conduit stop shall be level.
F. If the conduit is a type or size that has a separate work opening, this should
be closed by its cover before pouring the seal.
6.6.2 Compound : Follow these instruction to apply.
A. Use clean mixing container for every batch.

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B. The manufacturers specified proportions by volume compound and clean


water shall be strictly followed.
C. Do not mix more than the quantity that can be poured in 15 minutes after
water is added.
D. Stir immediately and thoroughly.
E. Fill conduit sealing compound to the level recommended by the
manufacturers instructions.
6.6.3 Specific Instructions:
A. Conduits seal shall only be poured at temperatures between 35 85
degrees Fahrenheit.
B. If a batch has started to set, do not attempt to thin it by adding water or by
stirring.
C. Discard partially set material and take up fresh batch.
D. After pouring, immediately close the pouring opening.
E. All poured conduit seal fittings shall be painted red.
6.6.4 Rectification if sealing fails
A. Clean the sealing area by removing the sealing compound which is fails
secure the cable that it will not be damage.
B.Check the inner sealing compound that are poured that it was failed if failed
removed totally the failed sealing compound.
C. Apply by sealing compound as per 6.6.2

7. HANDLING AND STORAGE


7.1 All electrical materials shall be inspected upon receipt at job site. If any defect or
damage is found, it shall be segregated and will subject for replacement.
7.2 Loading and Unloading of electrical equipments and materials shall be properly
controlled by using guide ropes and proper lifting procedures. Straps, slings and ropes
shall be used, manual loading and unloading can also be done for small electrical
items.
7.3 The materials shall be handled at all times in a manner that prevents damage to the
electrical equipment and its associated components.
7.4 All electrical equipment shall be adequately protected during transit from warehouse to
installation area.

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8. INSPECTION
8.1 Upon completion of the installation, Construction Engineer/Subcontractor shall notify
the Contractor QC Inspector for pre-inspection and the Contractor QC Inspector will
notify the ARAMCO SGPIU (by RFI) for the required inspection to assure correct
installation as per requirements.
8.2 The inspection result shall be documented on the related reports/checklist
8.3 All stages of work shall be inspected in accordance with approved Project Quality
Control Inspection Plan.

9. SAFETY
9.1 Electrical works and testing involves working on electrical equipment and system where
voltages and or mechanical movement exist or may suddenly occur Safety Engineer or
Officer shall follow strictly the governing safety program.
9.2 Barricades (safety warning tapes) shall be provide whenever required for any related
works that invite hazard to working personnel.
9.3 Safety Engineer / Officer in conjunction with the Site Supervisor or Foreman shall
physically check and conform that all safety requirements had been provided and
implemented.