Complete Quality Manual Vol 2 Rev. 2010 PDF

THIS QUALITY MANUAL IS THE ONLY
CONTROLLED AND VALID VERSION.

ALL OTHER VERSIONS ARE
CONSIDERED TO BE
UNCONTROLLED AND MAY NOT BE
USED FOR WORK CONTROLLING
PURPOSES.
DOCUMENT NO. MACO-QM-001
th
01 April 2009
QA / QC MANUAL VOL. 2
CONSTRUCTION PROCEDURES
KINGDOM OF SAUDI ARABIA
P.O. BOX 10257, DAMMAM 31433

Tel. No. +966 3 8417007
Fax. No. +966 3 8423281
REV.
DOCUMENT NO. MACO-QM-001 0
THIS QUALITY MANUAL IS THE ONLY
CONTROLLED AND VALID VERSION.
ALL OTHER VERSIONS ARE
CONSIDERED TO BE
UNCONTROLLED AND MAY NOT BE
USED FOR WORK CONTROLLING
PURPOSES.
DOCUMENT NO. MACO-QM-001
th
01 APRIL 2009
QA/QC MANUAL VOL. 2

CONSTRUCTION PROCEDURES
P.O. BOX 10257, DAMMAM 31433

Tel. No. +966 3 8417007
Fax. No. +966 3 8423281
1 ISSUED FOR APPROVAL Prepared By: CHECKED BY APPROVED BY APPROVED BY
2 QA/QC Quality Manual APT YSB NMZ SMZ

3 SIGNATURE/DATE
REVISION HISTORY: Document Recipients:
1 Revision 1 April 1, 2009 1. Gen. Manager 4. Project Managers
2 2. Asst. Gen. Manager 5. QA/QC Department
3 3. Business Dev. Manager 6. Project Engineers
REV.
DOCUMENT NO. MACO-QM-001 VOL. 2 0
QUALITY ASSURANCE/QUALITY CONTROL
MANUAL
Doc. No. MACO-QMP-001
Rev. 0
QUALITY ASSURANCE/QUALITY
CONTROL MANUAL
MACO-QM-001
VOL. 2
APPROVAL SHEET
Description Name Designation Signature Date
Prepared QA/QC Senior Engineer

A. P. Togle
By: Manar Arabian Corp.
Approved
Y.S. Bahrawy Projects Gen. Manager
By:
Approved Assistant General

N. M. Zahrani
By: Manager
Approved
S. M. Zahrani General Manager
By:
-i-
Quality Manual Vol. 2 MACO-QM-001

QUALITY ASSURANCE/QUALITY CONTROL
MANUAL
Doc. No. MACO-QMP-001
Rev. 0
QUALITY ASSURANCE/QUALITY
CONTROL MANUAL
MACO-QM-001
VOL. 2
REVISION HISTORY
Revision No. Purpose of Revision Issue Date
0 Submitted for Approval. April 01, 2009
-ii-
Quality Manual Vol. 2 MACO-QM-001

QUALITY CONTROL/ASSURANCE MANUAL
Quality Construction Procedures
DOCUMENT No. MACO-QM-001 REV. 0
TABLE OF CONTENTS
QUALITY CONSTRUCTION PROCEDURES
SL NO. PROCEDURE DESCRIPTION DOCUMENT NO.
CIVIL WORKS
1 SURVEYING MACO-QCCP-001
2 SITE PREPARATION MACO-QCCP-002

EXCAVATION, TRENCHING, BACKFILLING &
3 COMPACTING MACO-QCCP-003
4 ASPHALT CONCRETE PAVING & BASE COURSE MACO-QCCP-004
5 CONCRETE WORKS MACO-QCCP-005
6 GROUTING WORKS MACO-QCCP-006
7 PROTECTIVE COATING FOR BURIED CONCRETE MACO-QCCP-007
8 WATERPROOFING, CAULKING AND SEALING MACO-QCCP-008
9 PIPE INSTALLATION PROCEDURE MACO-QCCP-009
10 CONCRETE BATCH PLANT MACO-QCCP-010
11 MISCELLANEOUS METALS MACO-QCCP-011
12 SITE NON-ELECTRICAL PROCEDURE 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
TABLE OF CONTENTS
ELECTRICAL WORKS/INSTRUMENTATION WORKS
1 WIRES AND CABLES INSTALLATION PROCEDURE MACO-QECP-001
2 GROUNDING SYSTEMS PROCEDURES MACO-QECP-002

LOW & MEDIUM VOLTAGE CABLES INSTALLATION
3 PROCEDURE. MACO-QECP-003
4 SWITCH BOARDS AND PANEL BOARDS PROCEDURE MACO-QECP-004
5 INSTRUMENT AND WIRING PROCEDURE MACO-QECP-005
6 INSTRUMENT CONTROL PANEL PROCEDURE MACO-QECP-006
7 FIRE ALARM SYSTEMS MACO-QECP-007
8 INSTALLATION OF LIGHTING SYSTEM MACO-QECP-008
9 POWER SYSTEMS MACO-QECP-009
10 INSTALLATION OF JUNCTION BOXES AND DEVICES MACO-QECP-010
11 INSTALLATION OF CABLE TRAYS MACO-QECP-011
12 INSTALLATION OF COMMUNICATION SYSTEMS MACO-QECP-012
13 INSTALLATION OF CONDUITS AND FITTINGS MACO-QECP-013
14 INSTALLATION OF DISCONNECT SWITCHES MACO-QECP-014
15 LOW VOLTAGE MOTOR CONTROL CENTER MACO-QECP-015
16 INSTALLATION OF DRY-TYPE TRANSFORMERS MACO-QECP-016
17 INSTALLATION OF OIL-FILLED TYPE TRANSFORMERS MACO-QECP-017
18 INSTALLATION OF BATTERIES AND CHARGERS MACO-QECP-018

UNDERGROUND ELECTRICAL DUCT
19 BANKS/MANHOLES MACO-QECP-019
TABLE OF CONTENTS
MECHANICAL WORKS
1 INSIDE BUILDING PIPING AND FITTINGS MACO-QMCP-001
2 PIPE SLEEVES MACO-QMCP-002
3 ANCHORS, SUPPORTS AND THRUST BLOCKS MACO-QMCP-003
4 VIBRATION ISOLATION MACO-QMCP-004
5 AIR HANDLING UNIT MACO-QMCP-005
6 AIR COLLED CONDENSING UNIT MACO-QMCP-006
7 PACKAGE AIR CONDENSING UNIT MACO-QMCP-007
8 DUCTWORKS MACO-QMCP-008
9 DUCTWORKS ACCESSORIES MACO-QMCP-009
10 DUCTWORKS INSULATION MACO-QMCP-010
11 MECHANICAL IDENTIFICATION MACO-QMCP-011

TESTING AND BALANCING OF MECHANICAL
12 SYSTEMS MACO-QMCP-012
13 WELDING OF STRUCTURAL AND PIPING MACO-QMCP-013

-END-
Construction Procedures
DOCUMENT TITLE:
PROCEDURE FOR:
SURVEYING
DOCUMENT NO.:
MACO-QCCP-001
Index Page
10.1.1 Scope 2
10.1.2 Purpose 2
10.1.3 References 2
10.1.4 Definitions 2
10.1.5 Responsibilities 2
10.1.6 Procedure 3
10.1.7 Documentation 4
001 04/09/09 MACO-QCCP-001 APT GJR NZ
ISSUE ISSUE PREPARED CHECKED APPROVED

DESCRIPTION
NO. DATE BY BY BY
Surveying Page 1 of 5 MACO-QCCP-001

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
The purpose of this quality procedure is to provide a documented procedure for

all activities related to Surveying.
3 References
IFC Drawings : Site Plot Plan
4 Definitions
None
5 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.

5.2.4 Informing Proponent Representative if the validity of any

survey monument is threatened, and take the necessary steps.
5.2.5 Obtaining approval of Proponent Representative if any

survey control points will be disturbed or destroyed by construction
activities.
5.2.6 Maintaining all Proponent established reference points and

bench marks at all times during construction. Under the direction of
Proponent Representative, replace any survey monuments damaged
or disturbed by construction activity.
5.2.7 Preparing accurate as-built survey and submission drawings.
6 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

prior to layout of new structures/utilities. Sufficient stakes shall be set and

maintained before and during the progress of the work.
7 Documentation
7.1 Form QCCP-001-01-SC Survey Checklist

SURVEY CHECKLIST
QCCP-001-01-SC
Contract No.: _________________________ Reference: _______________________
Location: _________________________ Project: _______________________
Drawing No: _________________________
COORDINATES ELEVATION
S. NO. AS PER DIFF. AS PER DIFF. REMARKS
ACTUAL ACTUAL
DRAWING DRAWING
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SURVEYOR Proponent REPRESENTATIVE

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
SITE PREPARATION
DOCUMENT NO.:
MACO-QCCP-002
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Definitions 2
5 Responsibilities 3
6 Procedure 3
7 Documentation 8

DESCRIPTION
NO. DATE BY BY BY
Site Preparation Page 1 of 9 MACO-QCCP-002

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: Sieve Analysis of Fine and Coarse Aggregate
ASTM D 3017: Test Method for Moisture Content of Soil and Soil
Aggregate
ASTM D 1883: Test Method for CBR of Laboratory Compacted Soil
ASTM D 4253: Test Method for Maximum Index Density
ASTM D 4254: Test Method for Minimum Index Density
ASTM D 2937: Test Method for Density
ASTM D 698: Test Method for Moisture Index Density
Royal Commission Specifications:
02251 Compaction and Testing of Earthwork
02220 Structure Excavation and Backfill

02221 Trenching, Bedding, Backfilling and Compacting
Construction Specifications:
4 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.
5 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 The QC Inspector shall inspect and prepare RFI for Proponent
representative to witness/inspect tests related to backfilling and
compacting. He shall also coordinate with the surveyor on a daily basis to
monitor and identify field changes.
5.3 The Independent Testing Laboratory Technician shall be responsible for

all necessary tests in the field. He shall also be responsible in recording all
test results and generate reports of all tests conducted.

6 Procedure
6.1 Surveying
6.1.1 Surveying shall be carried out in accordance to Work Procedure

QCCP-001, Surveying.
6.2 Clearing and Grubbing
6.2.1 All types of vegetation and debris including grass, brush and
rubbish within the limit of construction shall be satisfactorily removed and
disposed.
6.2.2 Stumps and roots to a depth of 0.5 meters below the ground within
the limit of construction shall also be removed and disposed.
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:

6.3.1.5.1 Trenches shall be excavated with sufficient width to

provide free working space at both sides of the trench and around
the installed items as required for joining, backfilling and
compacting.
6.3.2 Excavation of building foundations shall be carried out in

accordance with foundation design drawings up to 2.5M depth to
remove sabkha materials.
6.3.3 Select fill material shall be used within 0.6m of bottom of

elevation of foundations, spread footings, or slabs on grade.
6.3.4 During excavation and compaction, ground water table shall be

lowered to minimum 0.6m below the surface under compaction
using Well Point System of dewatering. Dewatering shall be
carried out in accordance to Method Statement submitted by
Dewatering Sub-Contractor and approved by Proponent
Representative.
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 All excavated materials that are unsatisfactory for use as fill or
backfill shall be disposed of at a location designated by Proponent.
6.3.7 Unsuitable material encountered below grade shall be removed and

replaced with suitable fill material and compacted to density
requirements, unless the Geotechnical Report or Proponent
Representative stipulates another procedure. Bottoms of
excavations shall be smooth and free of loose earth or sand. Any
soft or loose areas of insufficient bearing, as determined by
Proponent Representative, shall be compacted to the density
requirements.
6.3.8 Excavation for structures shall be made accurately to the lines,

grades and elevations shown in the drawings. Foundation pits shall
be of sufficient size to permit the placement and removal of forms
for the full length and width of structure footings and foundations
shown. Rock or other hard material shall be cleaned of loose debris
and cut to a firm surface, either level, stepped, or serrated, as
shown or as directed. Loose disintegrated rock and thin strata shall

be removed. When concrete or masonry is to be placed in an

excavated area, special care shall be taken not to disturb the
bottom of the excavation. Excavation to the final grade level shall
not be made until just before the concrete or masonry is to be
placed.
6.3.9 Excavation works adjacent to the existing utilities shall be carried

out by hand.
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 Before placement of fill or backfill material, the following shall be

observed:
6.4.1.1 Areas to receive fill shall be free of roots, trash, or other

foreign material.
6.4.1.2 All areas to receive fill shall have the in-site soil proof
rolled and inspected, after clearing and grubbing, for soft spots or
loose zones.
6.4.1.3 All observed soft spots or loose zones shall be

compacted in-place or excavated to firm soil and replaced with
properly compacted fill.
6.4.2 Surface protection shall be provided where clean sand or dune

sand is used for fill/bedding material. A cap layer of compacted cohesive
material 150 to 300mm in thickness will be placed. Capping material shall
have a maximum size of one-half lift thickness or 75mm, whichever is
less, and shall have between 11-35% passing the No. 200 sieve. The
capping material shall have a maximum liquid limit of 35 and maximum
plasticity index of 12, as per ASTM D4318. Final slope shall be protected
from erosion.
6.4.3 Fill materials shall be placed in successive horizontal lifts or layers

not to exceed 200 mm in depth. Each layer, before starting the next, shall
be leveled and smoothed by means of power driven graders, bulldozers or
other suitable equipment. Hauling and spreading equipment shall be
operated over the full width of each layer.

6.4.4 Each layer of fill material shall be moistened or dried to uniform

moisture content suitable for maximum compaction and then thoroughly
compacted by rolling with tamping or pneumatic tired rollers or through
wheel power rollers. At least one roller shall be operated continuously for
each 100 cm, or fraction thereof, per hour. When several embankments,
each of small area, are so isolated from each other that one roller cannot
compact them satisfactorily, additional rollers shall be provided. All fills
shall be compacted to 85% relative density as defined by ASTM D4253
and ASTM D4254 for cohesion-less materials, or 95% of the maximum
density as determined by ASTM D1557 for cohesive materials.
6.4.5 Backfilling adjacent to structures shall be placed and compacted

uniformly in such manner as to prevent wedging action or eccentric
loading upon or adjacent to the structures. Slopes bounding or within areas
to be backfilled shall be stepped or serrated to prevent sliding of the fill.
During backfilling operations and in the formations of embankments,
equipment that will overload the structure in passing over and compacting
this fill shall not be used.
6.4.6 Prior to importing borrow materials and/or transporting fill

material to Work site areas requiring fill, Proponent Representative
reserves the right to inspect and test the fill material for conformity with
the Specifications. Fill material which does not meet the requirements of
Specifications shall not be used and, if on the worksite, shall be removed
from the worksite.
6.5 Compaction and Testing
6.5.1 Prior to compaction of fill, a field test section using the intended
compaction equipment shall be performed to determine the proper lift
thickness to achieve the necessary density requirement.
6.5.2 In-place density and moisture content of soils shall be determined

by the sand cone method per ASTM D1556, nuclear method per ASTM
D2922, the rubber balloon method per ASTM D2167, or the drive-
cylinder method per ASTM D2937. Acceptance testing of in-place density
and moisture content (field density testing) on compacted fill will be
performed at the following rates:
6.5.2.1 Under all foundations one test every 1000 ft2. (90 m2.) of
each lift.
6.5.2.2 Under area paving one test every 2000 ft2. (180m2.) of
each lift.

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 each
lift.
6.5.3 As a minimum, at least one in-place density test shall be performed

on every lift of fill and further placement shall not be allowed until the
required density has been achieved.
6.5.4 The number of tests shall be increased if a visual inspection

determines that the moisture content is not uniform or if the compacting
effort is variable and not considered sufficient to attain the specified
density.
7 Documentation
7.1 Form No. QCCO-002-01-SP Site Preparation Checklist

SITE PREPARATION CHECKLIST

QCCP-002-01-SP
Drawing No: _________________________
S. NO. INSPECTION POINTS ACCEPT REJECT N/A
All backfilling layer should be as of

1
indicated in the contract drawing.
Select fill is of Clint Specification or as
2
approved by the client.
Do not allow layers to exceed 300mm in
3
thickness before compaction.
Compact each layers in accordance with
4 Royal Commission for Jubail & Yanbus
Standards.
The bottom of the trench shall be free of
5
sharp or loose rock, debris or foreign matter.
Cable or pipe shall be laid on a 150mm thick
6
clean sand bed.
The bed should be compacted uniformly to
7
provide even bearing for pipes.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
MACO SUPERVISOR Proponent REPRESENTATIVE

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
EXCAVATION, TRENCHING, BACKFILLING AND
COMPACTING
DOCUMENT NO.:
MACO-QCCP-003
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Definitions 2
6 Procedure 3
7 Documentation 6

DESCRIPTION
NO. DATE BY BY BY
Excavation, Trenching, Backfilling and Compacting Page 1 of 7 MACO-QCCP-003

EXCAVATION, TRENCHING, BACKFILLING AND

COMPACTING
1 Scope
1.1 This procedure covers the trenching, excavation, backfilling and

compacting building and other structures and utility lines; water and sewer pipes,
drainage pipes, which also includes manholes, cleanouts and boxes, removal and
disposal of excess excavation material and importing required bedding and fill
material, installation of cable tiles and warning tapes.
2 Purpose
The purpose of this quality procedure is to provide a documented procedure for

all activities related to Excavation, Trenching, Backfilling and Compacting.
3 References
ASTM C136: Sieve Analysis of Fine and Coarse Aggregate
ASTM D 3017: Test Method for Moisture Content of Soil and Soil
Aggregate
ASTM D 1883: Test Method for CBR of Laboratory Compacted Soil
ASTM D 4253: Test Method for Maximum Index Density
ASTM D 4254: Test Method for Minimum Index Density
ASTM D 2937: Test Method for Density
ASTM D 698: Test Method for Moisture Index Density
ASTM D 2292: Nuclear Test Method for Soil Moisture Density
ASTM D 1557: Test Method for Moisture Density Relations
ASTM D 2487: Classification of Soil for Engineering Purpose
ASTM D 422: Particle Size Analysis of Soils

Royal Commission Specifications:
02251 Compaction and Testing of Earthwork
02220 Structure Excavation and Backfill
02221 Trenching, Bedding, Backfilling and Compacting
02210 Earth Work
02110 Clearing and Grubbing
02220 Structure Excavation & Backfill
Construction Specifications
4 Definitions
None
5 Responsibilities
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.
representative to witness/inspect tests related to backfilling and
compacting. He shall also coordinate with the surveyor on a daily basis to
monitor and identify field changes.

6 Procedure
6.1 Surveying

6.1.1 Surveying shall be carried out in accordance to Work Procedure

QCCP-001, Surveying.
6.2 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 Structure Fill and Backfill
6.4.1 Compaction shall have a minimum of 70% relative density (ASTM

D4253/4254) or 95% standard proctor density (ASTM D698) whichever is
applicable and gives the greater density.
6.4.2 Fill and backfill under structures shall be select fill or coarse
aggregate and fine aggregate when indicated or specified for use under
structures, and conforming to requirements for coarse and fine aggregate.
6.4.3 Fill material shall be placed in lifts not exceeding 150 mm in

thickness. Unless otherwise indicated or specified, each layer shall be
compacted to 95% of the maximum density as determined by ASTM

D698 for cohesive material and within 1 % optimum moisture content or

70% relative density as determined by ASTM D 4253/4254 for cohesion
less material.
6.4.4 Backfill against or on structures shall not be placed until they have
attained sufficient strength to support the loads (including construction
loads) to which they will be subjected, without distortion, cracking, or
other damage. Special leak tests shall be provided, if required, as soon as
practicable after structures are structurally adequate and other necessary
work has been done. Backfilling shall be promptly started after
completion of tests. Unequal soil pressure shall be avoided by depositing
material evenly around structure.
6.4.5 The sides of all concrete foundations shall be primed and top
coated with asphalt emulsion damp-proofing prior to backfilling.
6.5 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.

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.
7 DOCUMENTATION
7.1 Form QCCP-003-01-EP Excavation Checklist

EXCAVATION CHECKLIST
QCCP-003-01-EP
Drawing No: _________________________
All backfilling layer should be as of

1
indicated in the contract drawing.
Select fill is of Clint Specification or as
2
approved by the client.
Do not allow layers to exceed 300mm in
3
thickness before compaction.
Compact each layers in accordance with
4 Royal Commission for Jubail & Yanbus
Standards.
The bottom of the trench shall be free of
5
sharp or loose rock, debris or foreign matter.
Cable or pipe shall be laid on a 150mm thick
6
clean sand bed.
The bed should be compacted uniformly to
7
provide even bearing for pipes.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
ASPHALT CONCRETE PAVING & BASE COURSE
DOCUMENT NO.:
MACO-QCCP-004
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Definitions 2
6 Procedure 3
7 Documentation 8

DESCRIPTION
NO. DATE BY BY BY
Asphalt Concrete Paving and Base Course Page 1 of 9 MACO-QCCP-004

ASPHALT CONCRETE PAVING AND BASE COURSE
1 Scope
1.1 This procedure includes, but is not limited to sub-grade preparation,

aggregate base coarse, prime coat, tack coat, asphalt concrete paving, sampling
and testing for the new construction of roads, driveways and parking areas as
indicated in the Drawings.
2 Purpose
2.1 The purpose of this quality procedure is to provide a documented

procedure for all activities related to Base Course application and construction of
Asphalt Concrete Paving.
3 References
ASTM C88: Test Method for Sounding of Aggregate by Use of Sodium

Sulfate or Magnesium Sulfate
ASTM C136: Test Method for Sieve Analysis of Fine and Course
Aggregate
ASTM D1559: Test Method for Resistance to Plastic Flow of Bituminous
Mixture
ASTM D1883: Test Method for CBR (California Bearing Ratio) of
Laboratory Compacted Soil
ASTM D2922: Test Method for Density of Soil and Soil Aggregate in
Place by Nuclear Methods (Shallow Depth)
ASTM D4254: Test Method for Maximum Index Density and Unit Weight
of Soil and Calculation of Relative Density
ASTM D4318: Test Method for Liquid Limit, Plastic Limit, and Plastic
Index of Soil
Royal Commission Standards:
02555 Asphalt Concrete Pavement

4 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.
5 Responsibilities
activities related to Asphalt Concrete Paving. They shall coordinate with
the QC Inspector for inspection or testing requirements.
representative to witness/inspect tests related to Asphalt Concrete Paving.
He shall also coordinate with the Independent Testing Laboratory
Technician for inspection and testing requirements.

6 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.

6.2.2 Unless otherwise specified, sub-grade shall be compacted to 95%

of the maximum dry density per ASTM D1557 or AASHTO T180 method
D) while within 1.5% of the optimum moisture content or to 85% of
relative density determined by ASTM D4253 and D4254.
6.2.3 All holes, ruts, soft places, and other defects shall be corrected. In
no case shall the sub-base or base course be placed on soft or unstable
material, or over areas that are not drained.
6.2.4 If the sub-grade is dusty or muddy, operations shall be delayed

until it is in a condition satisfactory to the Proponent Representative.
6.2.5 Prior to delivery of materials for the base course, the road bed
surface shall be prepared by sprinkling, blading, rolling and lightly
scarifying where necessary, until the proper crown is obtained. When
compacted and ready for base course construction, the road bed shall be
well compacted, smooth hard and uniform, all irregularities having been
bladed out and rolled smooth.
6.2.6 After the road bed has been prepared, it shall be maintained true to
cross section and grade until the base course is completed. The road bed of
the entire project shall be maintained from the time the work is started
until covered with the base course.
6.2.7 The sub-grade shall be offered for inspection and approval by the
Proponent Representative, prior to starting construction of the sub-base or
base course on any portion of the work.
6.3 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.

6.3.5 While at optimum moisture (1-%) the sub-base or base

materials shall be compacted with equipment capable of obtaining the
desired density to the full depth of the respective layer. The rolling shall
continue until the base and sub-base are compacted to not less than (100%
for the base and 95% for the sub-base) of the maximum laboratory dry
density as determined by ASTM D1557, or AASHTO T180. In-place
density shall be measured by ASTM D2922 or ASTM D1556 or other
approved methods. Testing shall be conducted at a rate of one test every
2000 ft. (180m) of base or sub-base.
6.3.6 Following the construction of the aggregate base, the compacted

base course shall be maintained by blading, brooming and otherwise
maintaining the base, keeping it free from raveling, and other defects until
such time as the bituminous prime coat or other surface is applied. Water
shall be applied at such time and in such quantities as directed by the
Proponent Representative.
6.4 Prime Coat Application:
6.4.1 The prime coat shall be applied and shall consist of the MC-70
conforming to the Saudi Aramco Standard A-973 or MC-250 conforming
to Saudi Aramco Standard A-974. A prime coat shall consist of the initial
application of liquid asphalt into the surface of non-asphalt base course.
6.4.2 Immediately before applying the primer bituminous material, the

surface shall cleaned of all loose dirt and other objectionable materials
with a power broom, hand broom, or blower. If so ordered by the
Proponent Representative, the surface shall be lightly bladed and rolled
immediately prior to the application of the bituminous material, in which
case brooming or blowing will not be required. A light application of
water shall be lightly applied, if required, just before the application of
bituminous material.
6.4.3 Prime coat shall be applied only when the surface to be treated is
dry and when the temperature in the shade is 8C and rising. Prime coat
shall not be applied when the weather is foggy or rainy or in a sand storm.
Bituminous material shall be applied by means of a distributor at a rate
between 0.65 and 1.75 liters/M and at a temperature between 50C to
80C. If the material is applied in two lanes, there shall be an overlap of at
least 200 mm. Any prescribed application may be divided in two
applications to prevent plowing of the surface and additional bituminous
material shall be applied where surface conditions indicate it is required.
6.4.4 The primed surface shall be kept free from all traffic and in a clean
condition pending placement of the covering asphaltic concrete pavement.

A minimum period of 24 hours shall be allowed for the absorption and

curing of the prime coat prior to placement of covering pavement.
6.4.5 Surfaces of manhole cover and frames shall be coated with oil to
prevent bond with asphalt pavement. These surfaces shall not be bonded
with primer or tack coat.
6.5 Tack Coat Application:
6.5.1 The asphalt binder course shall be laid in two layers as per SAES-
Q-006.
6.5.2 The tack coat shall be of RC-250 conforming to Saudi Aramco

Standard A-971 or RC-800, conforming to Saudi Aramco Standard A-972.
6.5.3 Tack coat shall be applied to all concrete surfaces that will be in
contact with asphalt concrete pavement. Tack coat applications shall take
place prior to the paving operations and will include contact surfaces of
concrete gutters and other drainage structures.
6.5.4 Tack coat shall be applied between the binder course and the
surface course; new and old asphalt surface, and vertical cut of adjacent to
new asphalt. If application of the surface is delayed by more than 3 days,
or if dirt, sand or other impurities have contaminated the tack coat, then a
new tack coat shall be applied after the original one has been swept clean.
6.5.5 The bituminous material shall be applied on the binder course by

means of a bituminous distributor at a maximum rate of 0.25 liters/M or
as directed by the Proponent Representative. A hand broom shall be used
for application of the tack coat to concrete surfaces not covered by the
bituminous distributor.
6.5.6 Tack coat shall not be placed during rainy weather, or when the
moisture on the surface to be paved would prevent proper bond.
6.5.7 Tack coat shall be applied to contact surfaces of curbs, gutters and
berm walls.
6.6 Placement of Asphaltic Concrete
6.6.1 Asphalt shall be petroleum asphalt cement, Grade 60-70

penetration, conforming to Saudi Aramco Standard A-970.

6.6.2 Asphaltic concrete material shall not be accepted unless it is

covered with tarpaulins until unloaded, and unless it has a temperature of
at least 139C at the time of spreading and compaction.
6.6.3 Placement and compaction of the bituminous mixture shall

progress in sections not more than 90M in length. The bituminous mixture
shall be spread, shaped and finished with the power machine with
automatic adjustable grade controlled by a ski or a straight line. The
mixture shall be placed one-half width or one traffic lane at a time. After
the first width has been compacted, the second width shall be placed,
finished and compacted as specified for the first width. Asphaltic concrete
shall not be placed when the atmosphere temperature is below 10C, nor
during fog, rain, wind or other unsuitable conditions.
6.6.4 Asphaltic concrete material shall be spread in a manner which

requires the least handling. When thickness of finished pavement will be
60 mm or less, material shall be spread in one layer. Maximum thickness
of layer shall not exceed 120 mm in loose measurement.
6.6.5 After a layer has been placed the full width, the surface shall be
rolled. Rolling shall be longitudinal, and shall commence at the outer edge
of the road overlapping it and progress towards the center. Rolling shall
continue until the surface is of uniform texture and degree of compaction
is achieved, and is true to grade and cross section. Under no circumstances
shall the center of the surface course be rolled first.
6.6.6 Asphalt Compaction Density requirement shall be equal to or

greater than 96% of the Marshall Density of each day production per
ASTM D1559.
6.7 Inspection and Testing:
6.7.1 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.
6.7.2 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.
6.8 Reinstatement

6.8.1 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.
6.8.2 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.
7 DOCUMENTATION
7.1 Form QCCP-004-01-CP Base Course and Asphalt Concrete Paving

Checklist

BASE COURSE & ASPHALT CONCRETE PAVING CHECKLIST

QCCP-004-01-CP
Drawing No: _________________________
Sub-grade shall be compacted as per the

1
Base course shall be compacted as per the
2
Prime Coat shall be applied as per the client
3
specification.
Tack Coat shall be applied as per the client
4
specification.
Placement of Asphalt Concrete shall be
5
applied as per the client specification.
Thickness Tolerance: Measurement of any
6 core shall not be deficiently by more than
10mm or 15% of the design thickness.
Asphalt Concrete Mixture shall be applied as
7
per the client specification.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
CONCRETE WORKS
DOCUMENT NO.:
MACO-QCCP-005
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Materials 2
5 Procedure 4
6 Inspection & Testing 10
7 Documentation 10

DESCRIPTION
NO. DATE BY BY BY
Concrete Works Page 1 of 14 MACO-QCCP-005

CONCRETE WORKS
1 Scope
1.1 This document covers formworks, rebars, placing, finishing, curing

and joints associated with construction of concrete structures.
2 Purpose
2.1 The purpose of this procedure is to describe the minimum

requirements in construction of reinforced cement concrete work.
3 References
ACI 318 Building Code Requirements of Structural Concrete
03348 Casts-In-Place Concrete
4 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.

4.3 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.

4.7.2 Impervious Sheeting shall be polyethylene, and in

accordance with ASTM C171.
4.8 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 client-

approved 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.
5 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

Fine and Coarse Aggregates

Water Cement Ratio
Air Content
Slump
Admixtures if any.
5.2 FORM WORKS:
5.2.1 Comply with provisions of ACI 347-78 Recommended Practice for

Concrete Formwork for design and construction.
5.2.2 Formwork will be inspected for the following:
Dimensional Accuracy as per drawings.

Line and level with tolerances.
Metal embeds and inserts are at accurate positions.
Firmness of forms and supports.
Form surfaces must be clean and coated with approved form
release agent.
Chamfer strips to be used on exposed corners.
Inside of forms must be cleared of all debris before placing
concrete.
Install and properly tighten all form ties or clamps as specified. All
threads should fully engage the nut or coupling.
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)

Rebar Size Minimum Dia. Of Bend

10 mm to 25 mm Dia. 6 times diameter of bar.
5.3.6 Adequate cover over reinforcement as required by codes is needed

for protection of steel and long term durability of the concrete. The
following minimum concrete cover shall be provided for reinforcement,
unless otherwise shown in the construction drawings:
COVER
DESCRIPTION
INCH
Clear cover concrete in contact with soil (all
a 3 in.
Substructures.)
b Concrete exposed to weather:
i) 18mm to 57mm dia. bar 2 in.
ii) 16mm and below 1-1/2 in.
Concrete not exposed to weather or in contact with
c
ground:
i) Slab, wall and joists
43 to 57mm 1-1/2 in.
36mm and below in.
ii) Beam and Column: Primary reinforcement,
1-1/2 in.
ties, stirrups, spirals.
iii) Shells, folded plate numbers
18mm dia. and more in.
16mm dia. and lower in.
5.3.7 Minimum splice length shall be as shown on the drawings.
5.3.8 Hooks and bends, including minimum extensions, shall be made in

accordance with the approved shop drawings.
5.3.9 When rebar details are shown on the design drawing marked Issued
for Construction the reinforcing steel shall be fabricated in accordance
with these schedules.
5.3.10 Reinforcing steel, at the time of placing in the forms and prior to
concrete pour, shall be free from mud, oil, or other deleterious coatings
that will reduce the bond.

5.3.11 Welding of crossing bars shall not be permitted for assembly of

reinforcement unless authorized by the client.
5.3.12 Handling and fabrication of epoxy coated reinforcement shall be in

accordance with ASTM A775 Appendix and concrete reinforcing steel.
5.4 CONCRETE PLACING:
5.4.1 Concrete placement is accomplished with buckets, hoppers, chutes,

drop pipes, conveyor belts or pumps as required, in accordance with
ACI304-R.
5.4.2 All structural concrete shall pour over lean concrete along with
vapor barrier.
5.4.3 Deposit concrete continuously and at such a rate that the underlying
concrete is still plastic.
5.4.4 The method of holding water stop in the forms should ensure that it
cannot bend to form cavities during concreting.
5.4.5 Bars and embedded items should be held securely in the proper
position by suitable supports and ties to prevent displacement during
concreting.
5.4.6 Ensure proper vibration. Over vibration should be avoided to prevent

segregation.
5.4.7 Vibrators are not to be used to transfer concrete inside forms. Any
movement of concrete is to be by hand shovel. Re-tempering of concrete
is not allowed.
5.4.8 Vertical drop of concrete shall not exceed 1.5 meters.
5.4.9 Dampen the sub-grade and forms to prevent moisture loss at the base
of the slab prior to pouring.
5.5 HOT WEATHER CONCRETING:
5.5.1 Hot weather may lead to problems in mixing, placing and curing
hydraulic cement concrete that can adversely affect the properties and
serviceability of the concrete. Most of these problems relate to the
increase rate of cement hydration at higher temperature and the increase
evaporation rate of moisture from the freshly mixed concrete. The rate of
cement hydration is dependent upon concrete temperature, cement

composition and fineness, and admixtures used. Preparations and

procedures are required to reduce the undesirable effects of hot weather
concreting in general type of construction. Generally, if concrete strengths
are satisfactory and curing practices are sufficient to avoid undesirable
drying of surfaces, durability of hot weather concrete should not be greatly
different from similar concrete placed at normal temperature.
5.5.2 The following list of practices and measures to reduce or avoid the
potential problems of hot weather concreting:
Use concrete materials and proportions with satisfactory records in

field use under hot weather conditions.
Use cool concrete.
Use a concrete consistency that permits rapid placement and
effective consolidation.
Transport, place, consolidate and finish concrete with least delay.
Plan the job to avoid adverse exposure of the concrete to the
environment; schedule placing operations during times of the day
or night when weather conditions are favorable.
Protect the concrete against moisture loss at all times during
placing and during its curing period.
Protect freshly placed concrete from premature drying.
5.6 CONCRETE CURING AND PROTECTION:
5.6.1 Protect freshly placed concrete from premature drying. In extremely

dry and hot weather, fogging of the surrounding area may be required.
5.6.2 Water for curing shall be sweet water.
5.6.3 Start curing as soon as the concrete surface has hardened

sufficiently. Curing of concrete shall strictly continue as per ACI/RC
Specifications.
5.6.4 A plasticized sheet vapor barrier shall be placed beneath slabs on

grade. Outdoor sidewalks are exempted from this requirement.
5.6.5 A plasticized sheet vapor barrier or lean concrete shall be placed

beneath concrete foundations. Lean concrete thickness shall be as per
conceptual drawings/scope of work. i.e. 100mm.
5.6.6 All concrete surfaces in direct contact with earth shall be coated with
two (2) coats of coal.

5.7 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.

A plastic foam backer shall be inserted in to the joint to provide a

depth as per the manufacturers recommendations.
Sealer shall be mixed and applied as per the manufacturers
recommendations.

6 INSPECTION AND TESTING:
6.1 Services of client approved third party testing agency shall be utilized for
testing.
6.2 Perform all tests and inspection in accordance with the client
specifications and ITPs.
6.3 Independent Testing Laboratory shall be employed to perform field and

laboratory testing which shall include compressive tests of molded concrete
cylinder tests, slump, unit weight, air content (where air entrapment is required)
and fresh concrete temperature. The minimum required number of concrete tests
cylinders for strength tests shall be 3, for 3,7 and 28 days.
7 DOCUMENTATION
7.1 Concrete Work Checklist QCCP-005-01-CW
7.2 Concrete Request Form QCCP-005-02-CW
7.3 Concrete Slump Test Form QCCP-005-03-CW
7.4 Concrete Compressive

Strength Test Form QCCP-005-04-CW

CONCRETE POURING CHECKLIST

QCCP-005-01-CW
Drawing No: _________________________
Concrete mix shall be as per the client

1 specification or as approved by client
representative.
Test sample shall be taken as per the client
2
specification and requirement.
Set form to the required grade, lines, rigidly
3
braced and secure.
4 Anchor bolt size, type and location.
Provide expansion/Contraction joint as

5
shown in the drawing.
Locate, place and support reinforcement as
6
per the drawing details and specifications.
7 Ensure proper placement and vibration.
Perform concrete finishing as required by the

8
client.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:
CONCRETE REQUEST FORM

QCCP-005-02-CW
Contract No.: _________________________ Time & Date of Pour: _________________
Drawing No: _________________________
CONCRETE TYPE SLUMP REQUIRED CONCRETE FOR:

2000 psi 100 Blind
4000 psi 125 Cable Box/Man Hole
OTHERS 150 Paving
175 Walls
200 Pedestal
RCC Structure
SIZE OF FORM WORK

NOS. QUANTITY (M)
LENGTH BREADTH HEIGHT
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

SLUMP & TEMPERATURE TEST REPORT

QCCP-005-03-CW
Contract No.: _________________________ Date: _______________________
Drawing No: _________________________ Sample No. _______________________
Sample By: ___________________________ Tested By: _______________________
TIME TIME
TRUCK/TICKET MAX.
TEST NO. BATCHED SAMPLED SLUMP REMARKS
NO. TEMP. 0C
HR. HR.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
______________________ ___________________________
SOURCE OF CONCRETE: INDEPENDENT TESTING LAB.

Signature:
Name:
Date:

COMPRESSIVE TEST REPORT

QCCP-005-04-CW
Contract No.: _________________________ Date: _______________________
Drawing No: _________________________ Sample No. _______________________
Sample By: ___________________________ Tested By: _______________________
TIME TIME AIR MIX AIR

TRUCK/TICKET CURING
BATCHED SAMPLED CONTENT TEMP. TEMP. SLUMP
NO. 0 TEMP. 0C 0
HR. HR. % C C
AGE(DAYS) TEST DATE

DIMENSION AREA WEIGHT DENSITY DIAL COMPRESSIVE STRENGTH
SL# Kg/cm2 REMARKS
mm mm2 g Kg/m3 Kn Psi MPa
AGE(DAYS) TEST DATE

SL# Kg/cm2 REMARKS
AGE(DAYS) TEST DATE

SL# Kg/cm2 REMARKS

DOCUMENT TITLE:
PROCEDURE FOR:
GROUTING WORK
DOCUMENT NO.:
MACO-QCCP-006
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Materials 3
5 Procedure 3
7 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Grouting Works Page 1 of 6 MACO-QCCP-006

GROUTING WORKS
1 Scope
1.1 This document covers the installation of:

Cement Based, Non-Shrink Grout
Epoxy Grout
2 Purpose
2.1 The purpose of this procedure is intended to describe the minimum

requirement for structural and Equipment Grouting.
3 References
ASTM C307 Test Method for Tensile Strength of Chemical-Resistant

Mortars, Grouts, and Monolithic Surfacing
ASTM C413 Test Method for Absorption of Chemical-Resistant

Mortars, Grouts, and Monolithic Surfacing
ASTM C469 Test Method for Static Modulus of Elasticity and Poisons
Ratio of Concrete in Compression
ASTM C531 Test Method for Linear Shrinkage and Coefficient of

Thermal Expansion of Chemical-Resistant Mortars, Grouts,
and Monolithic Surfacing
ASTM C579 Test Method for Compressive Strength of Chemical-

Resistant Mortars, Grouts, and Monolithic Surfacing and
Polymer Concrete
ASTM C580 Test Method for Flexural Strength and Modulus of

Elasticity of Chemical-Resistant Mortars, Grouts, and
Monolithic Surfacing and Polymer Concrete
ASTM C4318 Test Method for Compressive Creep of Chemical-Resistant

Polymer Machinery Grouts

GES-013-56 Grouting of Foundation
4 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.
5 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.

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
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) For Rotating Equipment that satisfies all of these requirement:
Driver horsepower less than 500 (373KW).

3600 RPM or less.
Combined weight of machine, driver and base plate up to
2,200 Kg. (5,000 Lbs.)
ii) Grouting for structural base plates, anchor bolts, columns and
precast members, i.e. wall panels beams etc.
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.

6.1 Ensure grouting is as per the drawing details and specifications.

6.2 Follow the maximum depth of pour and length to width ratio is as per
6.3 Follow the safety requirements specified in the grout manufacturers data
sheets.
6.4 If the grout pour is 100mm or deeper, install reinforcement as per

6.5 The ratio of aggregate to resin and hardener shall be as per the
7 DOCUMENTATION
7.1 Grouting Checklist QCCP-006-01-GW

GROUTING CHECKLIST
QCCP-006-01-CW
Drawing No: _________________________
Ensure grouting is as per the drawing details

1
and Specifications.
Follow the maximum depth of pour and
2 length to width ratio is as per manufacturers
recommendations.
If the grout pour is 100mm or deeper, install
3 reinforcement as per manufacturer
recommendation.
The ratio of aggregate to resin and hardener
4 shall be as per the manufacturers
recommendations.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
PROTECTIVE COATING FOR BURIED CONCRETE
DOCUMENT NO.:
MACO-QCCP-007
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Materials 2
5 Procedure 3
7 Documentation 4

DESCRIPTION
NO. DATE BY BY BY
Protective Coating for Buried Concrete Page 1 of 5 MACO-QCCP-007

PROTECTIVE COATING FOR BURIED CONCRETE
1 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.
2 Purpose:
2.1 This procedure is intended to describe the minimum requirements for

surface preparation, Coating application for Buried concrete surfaces.
3 References and Standards:
ASTM D 4263 Standard Test Method for Indicating Moisture in Concrete

by the Plastic Sheet Method.
ASTM D 4285 Standard Test Method for Indicating Oil or Water in

Compressed Air.
ASTM D 4541 Standard Test Method for Pull-Off Strength of Coatings

Using Portable Adhesion Testers.
ASTM E 337 Standard Test Method for Measuring Humidity with a

Psychrometer
09874 Protective Coating and Lining System
4 Materials:
Client approved Coating system specifications or equivalent shall

be used.

4.2 Paint manufacturers: Unless otherwise specified, manufacturer

mentioned below shall be preferred.
4.2.1 Hempel Industrial Coatings. P.O. Box 1077 Dammam
4.2.2 Sigma Paints P.O. Box 7509 Dammam
4.2.3 Saudi Industrial Paint Co. P.O. Box 2549 Riyadh
4.2.4 Arabian Danish Co. Ltd.
4.2.5 Jotun Saudia Co. Ltd.
5 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

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.
6.1 Inspection and Testing shall be performed in accordance with ITP and
client specifications.
7 DOCUMENTATION
7.1 Protective Coating for Buried Concrete Checklist QCCP-007-01-BC

PROTECTIVE COATING FOR BURIED CONCRETE CHECKLIST

QCCP-007-01-BC
Drawing No: _________________________
1 Only approved products shall be used.
Perform preparation and cleaning procedures in

2
accordance with paint manufacturers instructions.
Examine surfaces scheduled to receive paint and
3 finishes for conditions that will adversely affect
execution.
Protect all the hardware accessories, machined
4 surfaces, plates etc., prior to surface preparation and
painting operation.
For old concrete surface, remove all loose concrete, oil,
5
grease and other contaminants sealants and old coating.
Expansion and construction joints, if they are to be
6 removed be cleaned out and masked off prior to
coating.
Cracks and holes shall be repaired as per old concrete
7
repairing procedure.
8 Previous completed coat has been approved.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
WATERPROOFING, CAULKING AND SEALING
DOCUMENT NO.:
MACO-QCCP-008
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Materials 2
5 Procedure 3
7 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Waterproofing, Caulking and Sealing Page 1 of 6 MACO-QCCP-008

WATERPROOFING, CAULKING AND SEALING
1 Scope:
1.1 This section covers installation of:
Water Proofing.
Caulking and Sealing.
2 Purpose:
2.1 This procedure is intended to describe the minimum requirements for

water proofing system.
ASTM C 156 Test Method for Water Retention by Concrete Curing

Materials
ASTM C 920 Standard Specification for Elastomeric Joint Sealant
ASTM E 96 Standard Test Method for Pull-Off Strength of Coatings

Using Portable Adhesion Testers.
ASTM E 337 Test Method for Water Vapor Transmission of Materials
07110 Membrane Water Proofing of Underground Concrete

Structures
4 Materials:
4.1.1 Waterproofing: Membrane shall be preformed, cold applied,

self adhesive, laminated sheet membrane or as per the client
specifications.

4.1.2 Caulking: The compound shall be elastomeric, single or

multi-component, non-sag, paintable, and have zero
moisture/vapor permeability or as per the client specification.
4.1.3 A ready mixed sealant shall have a consistency suitable for

easy mixing with a light hand mixer and easy application by a
manual or an air operated gun in a temperature range of 50C to
500C or as per the client specifications.
4.1.4 If required, Manufacturers approved primer shall be

provided with the sealant.
4.1.5 Bound Breakers: Polyethylene tapes or as recommended by

the sealant manufacturer or as per the client specifications.
4.1.6 Vapor Barrier: 8-Mil polyethylene sheeting, having an

ASTM E 96 vapor permanence not exceeding 0.50 per m and
having ASTM C 156 loss water not exceeding 0.055 g/cm2 of
structure or as per the client specifications.
4.1.7 Vapor Barrier Joint Sealant: Hot or cold applied mastic or

plastic cement provided by sheeting manufacturer or as per the
4.2 Manufacturers: Manufacturer shall be as per the client

specifications. Unless otherwise specified, manufacturer
mentioned below shall be preferred.
4.2.1 Fosam Company Ltd. Dammam
4.2.2 Saudi Industrial Company Ltd. Dammam
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.
5 Procedure:
5.1 General:
5.1.1 Waterproofing, Caulking and Sealing shall be done as indicated in

the drawing details and client specifications.

5.1.2 Unless otherwise indicated in general use:
Sealants in Joints exposed to exterior.
Caulking in joints exposed to interior.
Caulk and seal joints between frames in masonry opening and the
masonry in or against which they are set.
5.2 Preparation:
5.2.1 Waterproofing: Ensure the surfaces are clean, dry and free from dust
and dirt, and otherwise prepared as recommended by the material
manufacturer.
5.2.2 Caulking and Sealant: Ensure that surfaces and joint cavities are
clean, dry and free from loose particles, oil, grease, asphalt tar, dirt, rust
and other materials that may result in the loss of bond.
5.3 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.

Apply second coat to produce a minimum dry fill thickness of 10

mils.
5.3.7 Vapor Barrier: Place polyethylene sheeting as indicated in drawing.
Lap sheet 150 mm (6 in.) with the top sheet placed in the direction
of concrete placement.
Turn sheeting up at the walls and seal all lap joints.
6.1 Perform inspection and testing in accordance with client approved ITP and
7 DOCUMENTATION
7.1 Water Proofing, Caulking & Sealing Checklist QCCP-008-01-WP

WATERPROOFING, CAULKING AND SEALING CHECKLIST

QCCP-008-01-WP
Drawing No: _________________________
1 Only approved products shall be used.
Perform preparation and cleaning procedures in

2
accordance with sealant manufacturers instructions.
Examine surfaces scheduled to receive sealant and
3 finishes for conditions that will adversely affect
execution.
Surfaces and joint cavities are clean, dry and free
4 from loose particles, oil, grease, asphalt tar, dirt, rust
and other materials that may result in the loss of bond.
Tool caulking smooth, free from wrinkles and
5 sufficiently convex to result in flush finish joint when
dry.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
NON-METALLIC PIPES INSTALLATION
(GRP PIPES)
DOCUMENT NO.:
MACO-QCCP-009
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Materials 2
5 Procedure 2
7 Documentation 6

DESCRIPTION
NO. DATE BY BY BY
Non-Metallic Pipes Installation Page 1 of 6 MACO-QCCP-009

NON-METALLIC PIPES INSTALLATION
1 Scope:
1.1 This section covers installation of all types of non-metallic piping.
2 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 Chemical Plant and Petroleum Piping
AWWA C950 Fiber Glass Pressure Pipe
UPC Uniform Plumbing Code
2650 Underground Piping
2722 Sewage Systems
4 Materials:
4.1 The piping materials and fittings manufactured in accordance to

the ratings and specifications as specified in the scope or by the
client.
5 Procedure:
The following procedures shall be adopted as per the requirements:
5.1 Storage and Handling:
5.1.1 Pipe shall be stored out of direct sunlight in a building or under a

cover that allows free air circulation.

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

suitable material shall be attached to the bearing boards. Support spacing

and height limits shall be followed as specified above, except that the end
support shall not be more than 1m from ends of the pipe.
5.1.15 Thermoplastic and GRP pipes shall be secured with cotton or nylon
straps.
5.1.16 Solvent cement primer and adhesive containers shall be protected

from direct sunlight.
5.2 Inspection Prior To Installation:
5.2.1 Each piece of pipe and fittings shall be examined for cuts, scratches,
gouges, kinks, buckles and ultra-violet (sun) damage. Damaged lengths of
pipe shall be cut out and discarded. Damage fittings shall be discarded.
GRP Pipes and fittings which show ultra-violet damage and weathering
effects shall not be used.
5.2.2 All GRP pipes and fittings shall be visually inspected for scratches,
damaged ends, cracks, de-lamination, crushing, weathering and cracked
O-rings and gaskets. Damaged pipes and fittings shall not be used.
5.2.3 Pipe and fittings shall be cleaned before installation.
5.2.4 Any primer, solvent cement, or adhesive that is beyond the stamped
expiration date shall be discarded. Solvent cement that has gelled or
thickened shall be discarded. Leaking or opened containers shall also be
discarded.
5.3 Underground GRP Piping Installation:
5.3.1 For Underground pipe installation, follow attached AMIANTITS

GUIDE for installing underground pipe.
Following tests are applicable depending upon the requirements:
6.1 Hydrotest.
6.2 Unless prevailing conditions or regulations require full backfilling of the

piping prior to the hydrotest, under ground piping shall be partially backfilled
with all joints exposed during the hydrotest. The exposed joints shall be shaded
from direct sunlight, and the hydrotest shall be performed so that the

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 Leaking pipes, joints and fittings shall be replaced.
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.
7 DOCUMENTATION
7.1 Non-Metallic Piping (GRP) Installation Checklist QCCP-009-01-PI

NON-METALLIC PIPING (GRP) INSTALLATION CHECKLIST

QCCP-008-01-WP
Drawing No: _________________________
1 Visual inspection for pipe fittings.
2 Is pipe fitting cleaned before installation?
3 Is ground prepared with sand bed?
4 Is trench continuous?
5 Is trench smooth?
6 Is trench free of rocks?
7 Is necessary shoring provided?
8 Are sleeves installed in the road crossings?
9 Are fittings, valves and joints accepted?
10 In trench, is thrust block provided?

Is backfilling and pavement completed as per the
11
requirement?
12 Is hydrotest successfully completed?
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
CONCRETE BATCH PLANT
DOCUMENT NO.:
MACO-QCCP-010
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Definitions 2
6 Procedure 3
7 Documentation 9

DESCRIPTION
NO. DATE BY BY BY
Concrete Batch Plant Page 1 of 4 MACO-QCCP-010

CONCRETE BATCH PLANT
1.0 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 DEFINITIONS
QA/QC Manual Quality Assurance/Quality Control Manual
QCP Quality Control Procedure
ITP Inspection and Test Plan
Company Proponent
4.0 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 Criteria for Design and Construction of Concrete structure.
SAES-Q-005 Concrete Foundation
09-SAMSS-088 Aggregates for Concrete
09-SAMSS-097 Ready Mixed Portland Cement Concrete
Approved Construction drawings

Technical Specification for Civil Works
ITP Batch Plant Management
MACO Safety Plan
ASTM-C-33 - Concrete Aggregates
ASM-C-94 - Ready Mixed Concrete
6.0 QUALITY CONTROL PROCEDURE
6.1 Vendor/Supplier shall be approved by Proponent prior to supply concrete to

the project.
6.2 Concrete mix Design shall be approved prior to the start of concrete
production and in compliance with the technical specification and 09-SAMSS-
097.
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 09-
SAMSS-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 Check the Mix Design and Quality.
6.6.2 Check the concrete type at the silo by the manufacturers certificate.
6.6.3 Check approve admixture quality and quantity.
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.

6.6.6 Check the cleanliness of the aggregates by verifying the washed water
TDS in compliance with contract specification.
6.6.7 Check the formula and water/cement ratio of the contents entered into
the computer of batch plant.
6.6.8 Verify/Check the periods whether the physical tests on concrete

aggregates have been done by batching plant laboratory per Saudi
Aramco specification 09-SAMSS-088.
6.6.9 Verify the Batch Plant test equipment calibration status.
6.7 After mixing, the QC Inspector shall perform and verify the following items:
6.7.1 Check the computer print out after the concrete batching for the actual
quantities and design values.
6.7.2 Check fresh concrete temperature.
6.7.3 Make the slump test at batch plant, whether it complies with the
contract specification.
6.7.4 Record the slump and temperature reading at the concrete dispatch
ticket and sign it.
6.7.5 Take a set of sample (Cylinder) for compressive strength test.
6.7.6 Witness / Review the compression test.
6.7.7 Authorize the concrete delivery
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 QC Inspector shall use quality record form QCCP-010-01-CBP as

checklist as fill it as summary weekly performed inspections.
7.0 ATTACHMENTS
QCCP-010-01-CBP - Concrete Batching Plant Daily Monitoring.

DOCUMENT TITLE:
PROCEDURE FOR:
MISCELLANEOUS METAL
DOCUMENT NO.:
MACO-QCCP-011
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Definitions 2
6 Procedure 3
7 Documentation 9

DESCRIPTION
NO. DATE BY BY BY
Miscellaneous Metal Page 1 of 3 MACO-QCCP-011

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 : Quality Management Procedure

QCP : Quality Control Procedure
ITP : Inspection and Test Plan
4. REFERENCES:
NAAMM : Architectural Metal Manufacturer.
ASTM-A269 : Stainless steel Tubing for General Services.
ASTM-A53 : Hot-Dipped and seamless steel pipe.
SSPC : Steel structure painting.
SAES-H-101 : Requirements for industrial coatings.
Industrial-A123 : Zinc Coating in Iron and steel
12-SAMSS-007 : Miscellaneous steel structure
Schedule Q Quality Assurance and Control, Inspection & Testing.
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.

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

DOCUMENT TITLE:
PROCEDURE FOR:
SITE NON-ELECTRICAL UTILITIES
DOCUMENT NO.:
MACO-QCCP-012
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Definitions 2
6 Procedure 3
7 Documentation 9

DESCRIPTION
NO. DATE BY BY BY
Site Non-Electrical Utilities Page 1 of 9 MACO-QCCP-012

SITE NON-ELECTRICAL UTILITIES
1 Scope
This quality procedure applies to the installation of Fire/Raw Water, Drinking

Water, Sanitary Sewer, piping, fittings, accessories, bedding and connections.
2 Purpose
The purpose of this quality procedure is to provide a procedure for the installation
of all site Non-Electrical Utilities.
3 References
Construction Specifications & IFC Drawings.
4 Definitions
None
5 Responsibilities
5.1 The discipline supervisors and/or foremen are responsible for the
installation activities assuring all works being implemented are in
conformance with specifications and approved drawings.
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
6.1.1 Thermoplastic and RTR pipes, fittings and accessories shall be

stored and handled in accordance with manufacturers recommendation
and the requirements of Standard Operating Procedure.

6.1.2 Concrete requirements shall be in accordance with work

procedure MACO-QCCP-005, Concrete Works.
6.1.3 Excavation, Trenching, Backfilling and Compacting shall be

carried out in accordance with work procedure MACO-QCCP-003,
Excavation, Trenching, Backfilling and Compacting, and as herein
specified.
6.1.3.1 All excavations shall be restored so its surface contour

blends in with the surrounding area. All existing pavements
(asphalt and concrete) disturbed during trenching operation shall
be restored to their original condition or better.
6.1.3.2 No construction shall start until the design of the

dewatering system (if required) has been approved by the
Proponent Representative. Dewatering shall be carried out in
accordance to Method Statement submitted by Dewatering Sub-
Contractor and approved by Proponent Representative.
6.1.3.3 The bottom of the trench shall be dry before pipe is

installed.
6.1.3.4 At the end of every work shift, personnel performing the

pipe installation shall ensure that the pipe ends are capped to
prevent the egress of foreign material and the piping are anchored
to prevent floatation.
6.1.3.5 The depth of the trench shall be dug deep enough to

provide a minimum ground cover above the top of the pipe, as
required in Table 2 of SAES-S-070, and a ground bed of at least
150 mm in depth below the bottom of the pipe.
6.1.3.6 The width of the trench should be wide enough to allow

room for jointing, but in any case not less than shown in Table 1 of
SAES-S-070.
6.1.3.7 The ground bed shall provide uniform and adequate

support and drainage along the entire length of the piping. In
subkha areas, a base support layer of crushed stone base material
150 mm deep 38 mm maximum size shall be provided. The
crushed stone base material shall be compacted to at least 95% of
ASTM D698.

6.1.3.8 A bedding layer of clean sand, 150 mm in depth is required

for all trenches. The sand shall be free of debris and rocks and
compacted to at least 70% relative density, or 95% proctor density
as per ASTM D698, whichever gives the greater density.
6.1.3.9 The trench bottom shall be continuous, smooth, free of

rocks, and to the line and grade shown on the installation
drawings. The pipe shall have essentially continuous support and
not rest on the joint. For RTR piping, the trench contour shall not
cause the joint angular deflection or the pipe-bending radius to
exceed the manufacturers limit.
6.1.3.10 The minimum trench width from the bottom to 300 mm

above the top of the pipe shall be as shown in Table 1 of SAES-S-
070.
6.1.3.11 Trenches maybe excavated wider than the trench width

above the LNTL (Line of Narrow Trench Limit), if necessary.
6.1.3.12 Sheeting or shoring shall be in accordance with the

Proponent Construction Safety Manual, Section II. All
underpinnings, bracings, and shoring shall be provided as
necessary to protect and preserved all existing buildings, fences,
walls, utilities, and other structures.
6.1.3.13 The minimum cover over the top of the pipe shall be as
shown in Table 2 of SAES-S-070 unless noted otherwise.
6.1.3.14 Piping shall have steel sleeves at government road

crossings and railroad crossings in accordance with Saudi Aramco
Standard Drawing AC-036660 or AB-036880.
6.1.3.15 If it is impossible to achieve the minimum cover as

specified in this Standard, the piping shall be protected by a
reinforced concrete slab, or metallic casing in accordance with
SAES-L-046.
6.1.3.16 The trench bottom shall be continuous, smooth, free of

rocks, and to the line and grade shown in the installation drawings.
The pipe shall have essentially continuous support and not rest on
the joint. For RTR piping, the trench contour shall not cause the
joint angular deflection or the pipe-bending radius to exceed the
manufacturers limit.

6.2 Assembly and Installation
6.2.1 All pipes shall be installed in accordance with IFC Drawings,

Construction Specification and applicable provisions of SAES-S-
010, SAES-S-040, SAES-S-060, and SAES-S-070 as herein
specified.
6.2.1.1 Pipes and fittings shall be inspected before installation to

detect defects. Defective materials shall be marked with paint and
promptly removed from the site.
6.2.1.2 When placing pipe in the trench, fabric slings shall be

used. The pipe shall not be dragged along the bottom of the trench,
nor humped, and it shall be supported by the sling while being
fitted to the adjacent pipe. No metal tools or heavy objects should
be permitted to come into unnecessary contact with the pipe or
fittings.
6.2.1.3 The pipe shall be laid at the level and gradient stipulated,
on a prepared bed 150 mm deep with special hollows made for the
joints. The pipe shall be aligned carefully in both the horizontal
and vertical planes. Pipe shall be uniformly bedded throughout its
length.
6.2.1.4 Every precaution shall be taken to prevent foreign matter

from entering the pipe or fittings. During laying operations, no
debris, tools, cloth or other materials are to be allowed to enter the
pipe.
6.2.1.5 Deflection at joints shall not exceed the maximum

recommended by the manufacturer.
6.2.1.6 As the work progresses, interior of the pipe shall be cleared

of dirt and other foreign material.
6.2.1.7 The bottom of the trench shall be dry before pipe is

installed.
6.2.1.8 At the end of every work shift, pipe ends shall be sealed by
temporary watertight plugs to prevent the egress of foreign
material.
6.2.1.9 The minimum clear distance between raw and drinking

water lines, if installed in the same trench, shall be 300 mm.

6.2.1.10 All water supply piping shall have a minimum cover of 24

in. (610 mm) for all pipes 3 in. (90 mm OD) diameter and larger;
and 12 in. minimum cover (305 mm) for smaller than 3 in. (90 mm
OD) pipes.
6.2.1.11 Underground parallel water supply and fire water piping

shall have a minimum horizontal clear distance of 12 in. (305
mm).
6.2.1.12 A branch piping of a raw/firewater combined distribution

system, serving firewater systems of a building or a facility shall
be connected upstream of the isolation valve of the raw water
supply piping.
6.2.2 RTR Piping
6.2.2.1 The installation of RTR piping shall be done by personnel

trained in the proper handling and usage of applicable materials
and equipment.
6.2.2.2 Adhesive-bonded RTRP Joints shall be assembled in

accordance with the manufacturers procedures. Heating blankets
shall be used to cure adhesive bonded RTRP joints.
6.2.2.3 RTR piping of 250 mm nominal pipe size and less may be
assembled next to, or in the trench. Piping larger than 250 mm
nominal pipe size shall be assembled in the trench.
6.2.2.4 For trenches 2 M deep or less, pipe assembled next to the

trench shall not be moved within three pipe lengths of an uncured
joint. The pipeline shall be lowered into the trench progressively to
avoid excessive joint angular deflection.
6.2.2.5 For trenches deeper than 2M, pipe shall be assembled in

the trench.
6.2.2.6 Pipe and fittings shall not be dropped into trench. Protect
from all types of impact and excessive overheating causing
deformation or permanent damage to pipe.

6.2.2.7 Bedding in the pipe zone should be clean sand. Sand

bedding under the pipe should be a minimum of 150 mm in
thickness.
6.2.2.8 Sand shall be uniformly compacted around the pipe with

particular care given to the bedding beneath the haunches of the
pipe. Sand may be compacted by hydraulic methods if the native
soil in which the trench is excavated is free draining. If trench is
not free draining, placement of damp sand will facilitate
compaction. Sand bedding and backfill should extend a minimum
of 300 mm above the pipe.
6.2.2.9 Backfill shall be deposited in 150 mm maximum layers to a

point at least 600 mm above the top of the pipe, each layer being
compacted as required.
6.2.2.10 In-place tests of soil density shall be made in accordance

with ASTM D1556 or ASTM D2167.
6.2.2.11 Mechanical compactors may be used provided harmful

shock loads are not transmitted to the pipe. Maintaining a space of
at least one foot between tamping feet and pipe wall should avoid
damage to the pipe wall.
6.2.2.12 The minimum earth cover above the pipe crown shall be
900 mm (3ft).
6.2.3 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.

6.2.3.4 Pipe shall not be exposed to direct sunlight and provisions

shall be made for shading any pipe which is left in the open or
uncovered in trenches.
6.2.3.5 Sewer pipe shall be laid beginning at the low point of the
system, true to the grades and alignment indicated with unbroken
continuity of invert. Pipes shall be placed with bell ends facing
upstream.
6.2.4 Water, Sewer Location and Crossing
6.2.4.1 No sewer main shall be located closer in a horizontal

direction, than 3M to a water main.
6.2.4.2 Where a sewer main or lateral cross below a water main or

water service line, the sewer line shall in all cases be installed at
least 30cm below the water line.
6.2.4.3 Where the water main, or service line crossing above the
sewer line or lateral has less than 30cm vertical distance, the sewer
pipe shall be fully encased with 150mm thick of concrete all
around for a distance of 3M each side of the crossing (measured
perpendicular from the water main or service line).
6.2.4.4 The sewer main or laterals may cross above a water main
or water service line with the approval of Proponent
Representative. In such a case, the sewer pipe shall be fully
encased with concrete.
6.2.4.5 Where a water or sewer line crosses electrical or telephone

cables, approval from the concerned authorities shall be obtained.
6.2.4.6 The minimum crossing or parallel clearance between direct

buried cables or conduits and underground piping, including
hydrocarbon pipelines that fall outside of the scope of SAES-B-
064, shall be 30cm (12 in.).
6.2.4.7 Sewer lines passing through roads and pavements having

cover less than 900mm shall be sleeved or concrete encased.
6.2.4.8 Parallel building sewers and water service lines, if

necessary, may be laid in a common trench provided that all of the
following requirements are met:

6.2.4.8.1 The bottom of the water pipe(s), at all points, shall be at

least 12 in. (305mm) above the top of the sewer line.
6.2.4.8.2 The side(s) of the water pipe(s), at all points, shall be at

least 12 in. (305mm) clear horizontally from the side of the sewer
line.
6.2.4.8.3 The water pipe(s) shall be placed on a solid shelf of the

common trench, or the water line shelf be of select backfill
compacted to a minimum of 95% density as per ASTM D698.
6.2.4.9 Proponent Representative shall be notified before any

connection is made to the existing system. Elevation of existing
pipes shall be field verified at tie-in points prior to construction.
6.2.4.10 Adapter coupling/flange shall be provided at tie-in points

as required.
6.3 Pressure Testing
6.3.1 Pressure Testing, inspection and repair in case of any leakages

during hydrotest shall be carried out in accordance with Work Procedure
MACO-QCCP-010, Pressure Testing.
6.3.2 Underground piping shall be partially backfilled with all joints

exposed during the hydrotest. The exposed joints shall be shaded from
direct sunlight, and the hydrotest shall be performed so that the
temperature of the thermoplastic piping material or the temperature of the
test water does not exceed 400C during the test period.
7 Documentation
7.1 None

DOCUMENT TITLE:
PROCEDURE FOR:
STRUCTURAL STEEL
DOCUMENT NO.:
MACO-QCCP-013
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Definitions 2
6 Procedure 3
7 Documentation 9

DESCRIPTION
NO. DATE BY BY BY
Structural Steel Page 1 of 4 MACO-QCCP-013

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
performance related to quality control activities during fabrication and erection works.
3. DEFINITIONS

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.
SSEM safety plan
Approved construction drawings.
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.

Touch up all primer where damaged during erection.
Fabricate in accordance with SAES-M-100 or as indicated on approved shop

drawing.
Shearing, flame cutting and chipping shall be dimensionally true to achieve indicated
lengths and fitting requirement.
Develop required camber for members.
Welded connections shall comply with AWS D1.1 procedures, appearance, testing
and quality of welds and for method used in correcting welded work. All welds shall
be pre-qualified or shall be tested and qualified in accordance with AWS D1.1
Connections shall be as shown on the contract drawings.
Drill or punch holes at right angles to surface metal, do not enlarge by burning.
Punched holes shall be clean cut without torn or ragged edges.
ASTM A325 bolted connections shall conform to the requirements of the

specification for structural joints using ASTM A325 or A490 bolts. Friction type
bolts shall be installed with load indicator washers in accordance with the
manufacturer recommendations.
Plate washers and additional lock nut shall be used in all slotted connections.
Deliver, unload and handle all structural steel in such a manner as not to distort or
damage. Replace damaged or distorted materials with approved materials without
additional cost to Saudi Aramco.
Place column setting plates and beam bearing plates at required elevations and pack
grout under plates to provide a bearing plate surface, which is fully supported, flat
and level at the correct elevation.
Make allowance for thermal expansion of length of members when installing

members.
Use bolts for field fastening of steel to concrete, masonry and steel to steel
connections. Use field welding only when indicated on drawings. Notify Proponent
representative for inspection.
Provide all bracing, temporary bracing and accessories required for complete
erection.

Drifting to enlarge holes is prohibited.
Burning of hole prohibited.
Installation and tightening of A325 bolts will comply with section 7 of RCSC
specification.
Gas cutting is prohibited on major members.
Cutting, fitting, drilling and tapping of materials as required for proper and complete
installation work.
After erection cleaning will be done.
Touch up with same paint for the exposed steel will be done.
6. ATTACHMENT
6.1 QCCP-013-01-SS : Structural Steel

DOCUMENT TITLE:
PROCEDURE FOR:
JOINT SEALANTS
DOCUMENT NO.:
MACO-QCCP-014
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Definitions 2
6 Procedure 3
7 Documentation 9

DESCRIPTION
NO. DATE BY BY BY
Joint Sealants Page 1 of 3 MACO-QCCP-014

JOINT SEALANTS
1. SCOPE
This quality procedure will apply for the inspection works for.
2. PURPOSE
performance related to quality control activities during steel works.
3. DEFINITIONS

4. REFERENCES:
NAAMM : Architectural Metal Manufacturer.
ASTM-A269 : Stainless steel Tubing for General Services.
ASTM-A53 : Hot-Dipped and seamless steel pipe.
SSPC : Steel structure painting.
SAES-H-101 : Requirements for industrial coatings.
Industrial-A123 : Zinc Coating in Iron and steel
12-SAMSS-007 : Miscellaneous steel structure
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.

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

DOCUMENT TITLE:
PROCEDURE FOR:
PRESSURE TESTING
DOCUMENT NO.:
MACO-QCCP-015
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Materials 2
5 Procedure 2
6 Lay-Up Procedure 5
7 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Pressure Testing Page 1 of 8 MACO-QCCP-015

PRESSURE TESTING
1 Scope:
1.1 This procedure covers pressure testing of pipelines:
2 Purpose:
2.1 This procedure is intended to define preparation and method used to

conduct Pressure Testing of pipes as required in the specifications.
15053 Testing Of Piping
4 Safety:
4.1 All necessary work permits shall be obtained prior to hydro

testing.
4.2 Hydro test shall be performed in accordance with the client approved
procedure only.
5 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.
5.2 Pipe Joint and Fittings:
5.2.1 Underground process piping shall be tested prior to backfilling. The test
pressure shall be maintained for a minimum of 2 hours while the joints are
inspected for leakage. If for justifiable safety reasons the line must be
backfilled, then the joints shall remain exposed during testing, otherwise the
test shall be a 24 hour recorded test. The test pressure shall be in accordance
with client specifications.

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.

5.4 Sectionalizing System may be separated in to sub-system for testing. A

diagram shall show the limit and method of isolation for systems or sub-systems
shall be prior to testing.
Test pressure shall be as specified in the project line list.
5.5 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 one-
tenth 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.

6 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 Open air inlet and exit point to dry the system.
7 DOCUMENTATION
7.1 Pre-Test Punch List QCCP-015-01-PT
7.2 Pressure Test Certificate QCCP-015-02-PT
7.3 Valve Test Certificate QCCP-015-03-PT

PUNCH LIST
QCCP-015-01-PT
PUNCHLIST No. AREA:

TEST PACK No. SYSTEM:
Item Drawing Action Originator Comp.
Category Description Date Date
No. No. By: Sign. Sign
Category A: To be corrected before pressure test.
Category B: To be corrected before or after pressure test.

Signature:
Name:
Date:

PRESSURE TEST CERTIFICATE

QCCP-015-02-PT
TEST PACKAGE: TEST TYPE:

SYSTEM & SERVICE: PLANT NO.:
REFERENCE STANDARDS:
S. No. Drawing No. Spool No. S. No. Drawing No. Spool No.
TEST PRESSURE: LAY-UP REQUIRED:
TEST MEDIUM: TEST DURATION:
EQUIPMENT:
GAUGE No. 01: Calibration Date: Expiry Date:
GAUGE No. 02: Calibration Date: Expiry Date:
RELIEF VALVE No.: Calibration Date: Expiry Date:
REMARKS:

Signature:
Name:
Date:

VALVE TESTING RECORD

QCCP-015-03-PT
MANUFACTURER :
PRESSURE SEAT : TEST No. :
TYPE : TEST MEDIUM :
MANUFACTURER :
MANUFACTURER :
Royal PRESSURE
Commission
Item Valve BACK
for Jubail & Dia. Rating BODY SEAT(A) SEAT(B) ACC REJ
No. Identification SEAT
Yanbu P.O. (PSI) (PSI) (PSI)
No. (PSI)
REMARKS:
MACO QA/QC INSPECTOR Proponent REPRESENTATIVE

DOCUMENT TITLE:
PROCEDURE FOR:
THRUST BORING
DOCUMENT NO.:
MACO-QCCP-016
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Definitions 2
5 Procedure 2
6 Risk Assessment 5

DESCRIPTION
NO. DATE BY BY BY
Thrust Boring Page 1 of 13 MACO-QCCP-016

THRUSTBORING PROCEDURE
1 Scope
This method statement is only applicable to the above works associated with
the construction of the new water main pipeline.
2 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.
3 References
3.1 Aject Health and Safety Policy

3.2 Site Health Safety Plan
4 Definitions
PPE Personal Protective Equipment

HAVS Hand Arm Vibration Syndrome
COSHH Control of Substances Harmful to Health
5 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.

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

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

fully butt welded. On completion of the welding, the process as described

above is repeated until the drive is completed.
5.24 Prior to the tunnel works being completed the reception pit will have
been prepared for receiving the TBM. A suitable level base will have been
constructed. This may be either stone or concrete depending on the conditions
encountered.
5.25 A similar sealing eye will have been constructed previously within the
reception pit. A block work wall will have been constructed within the sealing
eye void, the void space between the blocks and the profile of the sheet piles
will be filled with bentonite slurry.
5.26 The block work wall will be supported with timbers and steel work to
prevent the wall from being pushed out by the TBM.
5.27 As the TBM reaches the position of the reception pit entry, the required
sheet piles will be extracted to just above the tunnel crown level to allow
passage of the machine.
5.28 The machine then cuts through the block work wall and enters the
reception pit onto a set of either steel rails or heavy duty timbers placed to the
underside of the TBM to prevent it from dropping and to allow for smooth
pushing into the pit.
5.29 The TBM is then pushed through the entry eye to a position within the
pit where it can be removed.
5.30 The rubber sealing ring within the reception pit can be removed,
placing a cement grout to the annulus between the concrete eye and the casing
pipe as necessary.
5.31 Within the drive pit the casing pipe will be cut to the correct position to
allow for the threading of the actual product pipe.
5.32 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.

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.

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.
5.48 AJECT will be informed of all necessary procedures by Manar Arabian

Corp. and will be provided any equipment necessary to allow conformity.
OTHER WORKS:
5.49 All instructions given by the banksman must be followed and works
cease as appropriate.
5.50 AJECT will be notified of any particular other safety issues within site
inductions. Any equipment to conform to any particular site rules which are
not specifically contained within this method statement will be provided by the
main contractor.
5.51 AJECT will be informed of any other works being carried out within
the general working area which may affect our operations.
5.52 The main contractor is responsible for obtaining any permits required
during the sub-contract works including all access and hot works permits that
may be required and the provision of any equipment required by the issuing of
the said permits; for example fire fighting equipment.
6 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

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 The likelihood of an incident occurring

1 Very Low 2 Low 3 Possible 5 Very Likely
S The level of severity if the incident occurs in terms of injury, illness or

damage.
1 Minor Injury, damage or sickness 2 First aid injury or Lost time illness
3 Reportable injury or illness, substantial damage 4 Major injury, amputation or long term
absence 5 Fatal Injury or catastrophic damage
R Risk Rating: R = L x S

QA/QC PLAN
ALTERNATE SANITARY WASTEWATER
COLLECTION PIPELINE FROM PS#B2 TO PS#1
DOCUMENT No. MACO-QCCP-016 REV. 0
PERSONS Avoidance/Control Resultant

REF. Hazard Initial Risk
AFFECTED Measures Risk
L S R L S R
1 Cranes / Rigging / Banksmen 3 3 9 Appointed Crane co- 1 3 3
Slinging ordinator, 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.
2 Manual Handling All on site 4 2 8 Assessments to be 2 2 4

undertaken.
Mechanical lifts to be
used wherever practical.
Gloves to be worn.
Good posture to be
maintained whilst lifting.
3 Slips, Trips and Falls All on site 5 2 10 Suitable footwear to be 2 2 4
Visitors worn.
Practice good
housekeeping.
Weekly inspections of the
Workplace by competent
person.
4 Excavation falls All on site 3 5 15 Excavations or edges of 1 5 5
falls to be guarded.
Daily inspection by
competent person.
Weekly record of
inspection.
5 Fire All on site 3 5 15 Fire Plan to be 1 5 5
Personnel established.
Visitors Trained fire extinguisher
users.
Regular inspection of
equipment.
Regular drills.

QA/QC PLAN

L S R L S R
6 Ladders / Scaffold / General 4 3 12 Correct use of ladders 2 3 6
Falls from Height Labourers footed or tied.
Correct angle of rake.
Correct erection and use
of scaffold / trained
personnel.
7 Crushing by plant and All site 3 4 12 Trained operators. 1 4 4
equipment personnel High visibility clothing.
Visitors Planned traffic routes.
Banksmen for unsighted
operations and reversing
wagons.
8 Disease General 3 5 15 Practice good hygiene. 1 5 5
Labourers Provide good welfare.
Induction and awareness
of Weils Disease.
9 Environmental Environment 3 2 6 All diesel plant and tanks 2 2 4
Concern to be bonded.
(Contamination of Fuel stored to be locked
Controlled Waters) against vandalism.
Drip trays to be used.
Settlement tanks to be
used.
Spill kits to be provided.
10 Dermatitis, skin burns All on site 2 2 4 COSHH Assessments to 1 2 2
Health Impact be made and briefed out
Ensure safe / secure
storage and disposal of
materials.
Ensure fire and first aid
facilities are available.
Wear PPE as dictated by
COSHH assessment.
Provide hand Protection.
Provide adequate
welfare facilities,
cleansing materials and
barrier creams.
11 Noise All 2 2 4 Ear protection to be worn 2 1 2
when working with or
near noisy equipment or
as determined by noise
assessments.
Select silenced
equipment where
possible.

QA/QC PLAN
Equipment to be
regularly inspected and
maintained.
Post warning signs and
established hearing
protect zones.
12 Small Tools Operators 3 3 9 Only use experienced 2 2 4
operators.
Equipment to be
maintained.
Correct PPE to be worn.
13 Flying Debris / Dust All 3 2 6 Minimize operations that 2 1 2
produce flying debris.
Provide respiratory / eye
protection.
Cordon off areas as
appropriate.
14 HAVS Operators 3 3 9 Use anti-vibration tools 2 2 4
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
maintained.
Provide adequate
welfare facilities.

QA/QC PLAN

L S R L S R
15 Electrocution Operators 3 3 9 Only trained welders to 2 2 4
use welding equipment
and carry out welding
operations.
Ensure adequate and
correct grounding is
utilized prior to operating
welding units.
Ensure all power cables
are connected by trained
electricians and all
connection points are
locked off.
Wear rubber gloves when
handling any TBM
connection cables during
pipe change-overs.
Protect all connection
sockets from water during
pipe change overs.
7 Labour and Plant
Labour:
Job Function Training PPE Comments

Hard Hat
First Aid Safety Boots
Supervisor
Induction High Visibility Clothing
Eye Protection
Hard Hat
First Aid Safety Boots
Engineer Induction High Visibility Clothing
Use of CAT Detector Eye Protection
Ear Protection
Hard Hat First Aid Training to be
Safety Boots given to 1 in 10 persons.
First Aid
High Visibility Clothing Use fire Extinguishers,
General Labours Induction
Eye Protection training to be given to 1 to
Use of Fire Extinguishers
Ear Protection 10 persons.
Anti Vibration Gloves
Hard Hat
Safety Boots
Certified as trained. High Visibility Clothing
Plant Operators
Induction Eye Protection
Ear Protection
Anti Vibration Gloves

QA/QC PLAN
Plant:
Item Quantity Certification Special Requirements /

Supplier
Description Required Comments
Daily inspection before use.

Weekly recorded inspection.
Small Tools Variable Hire / AJECT No
Vibration tools regularly
maintained.

Weekly recorded inspection.
12 monthly thorough
Manar Arabian
Crane 1 No. Yes examination.
Corp.
6 months if used for manriding
Height restrictor where
required.

Manrider 1 No. AJECT Yes Weekly recorded inspection.
6 monthly thorough
examination.
Lifting Chains Daily inspection before use.

Manar
and Variable Yes Weekly recorded inspection.
Arabian/AJECT
Equipment 6 monthly thorough
examination.
Weld Set 1 No. AJECT No
Burning
1 No. AJECT No
Equipment Daily inspection before use.
Generator 1 No. AJECT No
TBM checked before delivery
Iseki TBM 1 No. AJECT No to site, all electrical connection
to be checked prior to use.

DOCUMENT TITLE:
PROCEDURE FOR:
WIRES AND CABLES
DOCUMENT NO.:
MACO-QECP-001
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Materials 2
5 Procedure 6
7 Documentation 8-12
001 04/09/09 MACO-QECP-001 APT GJR NZ

DESCRIPTION
NO. DATE BY BY BY
Wires and Cables Page 1 of 12 MACO-QECP-001

WIRES AND CABLES
1 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.
2 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.
Codes and Standards:
Comply with all applicable codes and standards including, but not limited
to, those listed below:
NEC (National Electrical Code)

Royal Commission Standards
4 Material:
4.1.1 Low voltage cables/wires.
4.1.1.1 Low voltage jacketed cables shall comply with NEC or

IEC 502.

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

Metal clad cable

Power limited tray cable
Multi conductor service entrance cable
Power and control tray cable
Non metallic sheathed cable, XLPE insulated type
Other multi conductor control, signal or power
cables, approved for installation in cable trays.
4.1.1.13 Cable shall be marked at intervals not exceeding 24

inches indicating the maximum working voltage, type of
insulation, size and number of conductors.
4.1.1.14 The instrumentation and signaling cables shall be copper

conductor, aluminum shielded & polyethylene insulated type.
4.1.2 Medium Voltage Power Cables
4.1.2.1 Medium voltage power cable shall be manufactured and

tested in accordance with standard IEC60502-2.
4.1.2.2 Insulation material shall be cross linked polyethylene

(XLPE) or ethylene propylene rubber (EPR).
4.1.2.3 Conductor and insulating screening is required for all

cable.
4.1.2.4 Conductor screening shall be easily removable from the

conductor and shall consist of a layer of extruded semi conducting
compound.
4.1.2.5 The extruded semi-conducting conductor shield, the

insulation and the semi conducting insulation shield shall be
applied by simultaneous triple extrusion.
4.1.2.6 The metallic part of the insulation screen shall consist of

copper tape, 5mil thickness applied with 20% overlap.
4.1.2.7 Fillers shall be used in order to render the cable free from
voids.
4.1.2.8 All cables shall have continuous overall outer nonmetallic

sheaths. The outer sheath shall be PVC and rated for 90oC
maximum temperature.

4.1.2.9 The cable shall meet the flame retardant test.
4.1.2.10 Cable shall be suitable for direct burial, above grade rigid
steel conduit and cable trays.
4.1.2.11 The nominal thickness of insulation and field test voltages

of 5, 15, & 35KV are given below:
System Voltage, KV Nominal Ins. Thickness Field Test Voltage, KV

(4.6) 5 3.4 mm 36
(13.8) 15 5.5 mm 64
(34.5) 35 9.0 mm 100
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.

4.3.5 Cross linked thermosetting polyethylene wire and cable for

the transmission and distribution of electrical energy.
4.3.6 Ethylene-propylene rubber insulated wire and cable for the

transmission and distribution of electrical energy.
5 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.

5.11 Cables shall be continuously trained into the duct or conduit in

such a manner that the cable will not drag on the edge of the conduit.
5.12 Lubricant shall be applied as necessary to reduce pulling friction.
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.

6 Inspection & Testing:
6.1 Low voltage cables (600, 450/750, 600/1000 V rated) including splices
shall be 500/1000V megger tested after installation and prior to placing in
service.
6.2 Medium voltage cables (5-35KV) and splices shall be 5KV megger tested
and then DC higher potential tested after installation and prior to placing in
service. The test voltage for different systems shall conform to NEC standards.
6.3 Inspection and testing shall be performed in accordance with the code and
7 Associated Documents
7.1 Wires/Cables Installation Checklist QECP-001-01-WC
7.2 Insulation Resistance Test QECP-001-02-WC
7.3 Continuity Test Report QECP-001-03-WC
7.4 Hipot Test for Medium Voltage Cable QECP-001-04-WC

WIRES/CABLES INSTALLATION CHECKLIST

QECP-001-01-WC
CONTRACT: _____________________ REFERENCE: _________________

LOCATION: _____________________ PROJECT: _________________
CABLE NO: _____________________ SYSTEM: _________________
DRAWING NO.: _____________________ AMB. TEMP. _________________
S.NO. INSPECTION POINTS ACCEPT REJECT N/A

1 Check type, size and proper installation.
2 Check the routing with cable schedule and drawing.
3 Check the preparation for pulling.
4 Check the pulling tension as per the specifications.
5 Wires/cables identified at both ends.
6 Cable properly supported/trained.
7 All conductors of phase and neutral in the same raceways.
8 Enough length is left for splicing and terminations.
Total number of wires pulled in raceways conform as
9
per specifications.
For medium voltage cable laying and termination
10
creepage distance.
11 Color coding done as per standard.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

INSULATION RESISTANCE TEST

QECP-001-02-WC

CABLE NO: _____________________ SYSTEM: _________________
Equip. Tag
Ph. A to G Ph. B to G Ph. C to G Ph. A to B Ph. B to C Ph. C to A REMARKS
/ Cable No.
Test Instrument details: _________________________________________________________
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

CONTINUITY TEST REPORT

QECP-001-03-WC

CABLE NO: _____________________ SYSTEM: _________________
CORE CONTINUITY
CABLE NO. REMARKS
ID/NUMBER YES NO
Test Instrument details: _________________________________________________________
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

HIPOT TEST REPORT (DC) FOR MEDIUM VOLTAGE CABLE

QECP-001-04-WC

CABLE NO: _____________________ SYSTEM: _________________
PHASE 1-G 2-G 3-G

LEAKAGE CURRENT MICRO AMPS. MICRO AMPS. MICRO AMPS.
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
Rated Voltage of Cable: _________________________________________________________

Remarks: _______________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
GROUNDING SYSTEMS
DOCUMENT NO.:
MACO-QECP-002
Index Page
1 Scope 2
2 References 2
3 Materials 2
4 Quality Control 2
5 Procedure 3
6 Instrument Earthing 3
7 Testing 4
8 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Grounding Systems Page 1 of 5 MACO-QECP-002

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 - Lighting
b) SAES-P-104 - Wiring Methods & Materials
c) SAES-B-068 - Electrical Area Classification
d) SAES-P-111 - Grounding
e) NEC - National Electric Code
3 MATERIALS CONTROL
a) Ensure that materials and equipment are handled in accordance with

SAES-1023.
b) Checked all supplied materials are in conformance with Purchase Order
any discrepancies shall be reported immediately to MACO Materials
Dept.
c) Store all grounding materials for terminations, splicing etc. on a safe
place, free from dusts and protected against atmosphere action and dirt.
4 QUALITY CONTROL
4.1 CHECK/INSPECT FOR THE FOLLOWING
a) Grounding conductors shall be soft drawn copper unless specified on

detailed drawings. Direct buried grounding conductors connecting to
the equipment to the ground grids maybe un-insulated or green PVC
insulated.(these grounding conductors do not substitute grounding
conductors required by SAEP-P-111 Para 6.3,ReferenceSAEP-P-
111,Para 5.1 & 5.2)
b) Grounding grid conductors shall be a minimum of 70 sq. mm.
(#2/0AWG) bare copper conductors shall be used whenever soil
resistivity is less than 70 ohmmeter. Ref SAES-P-111,Para.4.2.1
c) All exposed non-current carrying metal parts of equipments and other
sizeable metallic objects such as fences, piping, piping supports,

motors, electrical panels , switchgears, MCCs , fixtures, grounding

terminals of each receptacle, conduit metal tanks and pumps ,shall be
potentially bonded to grounding grids accordingly.
d) Conduits, cable tray, cable wire armour, or cable shields shall not be
the sole means of grounding equipment. Separate grounding conductors
shall be installed within the same conduit, cable tray or otherwise shall
accompany with the power conductors. Metallic conduits cable trays
shall be grounded at both ends of points. Reference SAES-P-111,Para
6.3
e) Check that installation of materials does not conflict with other services
or equipment and installed as per Manufacturers recommendations.
f) All buried or concealed connection and splices for the grounding
system shall be inspected and approved by Saudi Aramco Inspector
before concealment
5 INSTALLATION
5.1 EARTHING OF ELECTRICAL EQUIPMENT
a) Installation shall be in accordance with ANSI/NFPA 70 and the site soil

resistivity shall be measured in accordance with IEEE 81, and in
conformance with SAES-P-111.
b) Ground rods locations will be checked against the layout drawings to
ensure correct positioning
1)Where rods are to be Hand driven ,the procedure will be witnessed
to ensure the correct depth or Refusal is achieved .Where rods to be
installed in pre-drilled bore holes, the bore holes will checked to ensure
the correct depth is achieved and the backfill materials are as per
specification.
2) Upon completion, the installation of the earth pit and the ground rod
termination and disconnect facilities will be checked against the
installation details.
c) The location of the earth bus bars will be checked against the layout
drawings and the assembly checked to ensure the fixings is secure.
d) Underground based joints or cad welds connections will be inspected
to ensure good mechanical and electrical bonding
e) Equipment will be inspected to ensure the earth bonding facilities are
installed and located as per the drawings. Particular attention will be
paid to equipment, such as floating roof tanks, which require special
devices. The bonding points on gates etc., which are subject to frequent
movement ,will be inspected to ensure the fixing is secure
f) The termination of the earth cables will be inspected to ensure the
crimpling thermite welding and/or bolting is secure and where
applicable, protected against corrosion

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) The earth electrode resistance will be checked by the fall-of

potential method, using megger type DET 3 or equipment hand
cracked test instrument.
b) The apparent ground resistance shall be obtained by means of a made
electrode. The electrode should be installed specifically for grounding
purposes. Industrial locations ,ground resistance of the made electrode
shall not exceed 2 ohms for system above 600 and shall be determined
in accordance with touch and step potentials as defined by
IEEE80.Reference SAES-P-111,Para 4.1.4
c) The test method as specified for the above instrument for individual
and electrode networks will be applied as follows:
1) Prior to testing the electrode system will be disconnected from the
ground network.
2)The current spike will be driven to 1meter depth at a point 50mts
from the perimeter of the electrode network and the potential spike
driven midway, in a straight line between the current and the
connection to the electrode network.
3) The terminals C1 and P1 of the instrument will be connected to the
electrode system
4) Terminal C2 will be connected to the remote current spike.
5) Terminal P2 will be connected to the remote potential spike.

6) The first megger reading R1 is recorded.

7) The potential spike will be moved to the point 6 meters closer to the
electrode network and the reading R2 recorded.
8) The potential spike will be moved to the point 6 meters further away
from the electrode network and the reading R3 recorded.
9) The potential spike will be compared and providing they have
reasonable agreement the average value will be calculated to network
earth resistance value
d) For large ground works, it may be necessary to locate the current and
potential electrodes in considerable distance from the connection to the
network .In this instance, the current and potential electrodes can be
placed at a minimum angle of 90 degrees. The test will be conducted as
in item (c) with the following electrode spacing:
1) The current and potential electrodes will be driven at a distance of
300 meters from the connection to the earth network and the
reading recorded
2) The current electrode will be removed out in 30meters steps and
the resistance value measured until the same reading is obtained at
three successive locations.
e) The results obtained will be compared to those specified; the following
will be used as a guide
Plant earthing system with - Less than 1ohm extensive network
Individual electrical equipment
Or small networks - Less than 4 ohms
Lighting and static discharge
Networks - Less than 7 ohms
f) The test will be conducted by the Site Electrical Supervisor, witnessed
and recorded by the Site Electrical QC Inspector
8 DOCUMENTATION
Form QECP-002-01-GS -Field Inspection Checklist

Form QECP-001-01-GS -Field Test Records

DOCUMENT TITLE:
PROCEDURE FOR:
LOW AND MEDIUM VOLTAGE
INSTRUMENTATION CABLES
DOCUMENT NO.:
MACO-QECP-003
Index Page
1 Scope 2
2 References and Codes 2
3 Material Control 2
4 Pre-Installation Test 2
5 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Low and Medium Voltage Instrumentation Cables Page 1 of 4 MACO-QECP-003

LOW AND MEDIUM VOLTAGE INSTRUMENTATION CABLES
1 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
2 REFERENCE STANDARDS & CODES
a) SAES-P-100 - Basic Power System Design Criteria

b) SAES-P-104 - Wiring Methods and Materials
c) SAES-B-068 - Electrical Area Classification.
d) S.A.G.1.2.705 - (For splicing /Terminations)
f) SAES-J-902 - Electrical Systems for Instrumentation
g) 15.5 SAMMS-502 - MV Power cable 5 KV-35KV
h) 34-SAMSS-913 - Instrumentation and Thermocouple Cable
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.

4.1.2 The insulation resistance between conductors and between

individual conductors and shield armoring if applicable shall be
checked. Record only the minimum reading for each use the following
test voltage.
4.2 The results shall be recorded on form checked against the values shown in
Table.
4.3 After completion of test, the ends of the cables shall be sealed to prevent
the ingress of moisture.
4.4 The test will be conducted by the Electrical Supervisor witnessed by the
QC Inspector; Checked and signed by the QC Supervisor and Electrical
Engineer; and reviewed by the Proponent Inspection.
4.5 Certificate issued by the approved testing agency

4.6 Ensure that all testing equipment has a current calibration.
4.1 INSTALLATION
a) Prior to installing cables in trenches ,dust banks ,cable trays or conduits,

ensure that these have been thoroughly inspected ,respective ITPs complied
with documentation completed.
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) A suitable pulling compound shall be used while cables being installed in

conduits or ducts.
d) Wiring shall be identified at termination points by the use of permanently

embossed wire markers of heat shrinkable on Slip-on type. Wrap around rigid
Snap-on or adhesive type markers are not permitted.
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) Splicing , glanding and terminating of medium voltage cables will be carried

by cable splicers to Proponent Standards.

4.2 TESTING
a) On completion of cable pulling and, where installed in trenches, prior to

backfilling all cables will be tested for continuity and insulation resistance
and the results recorded on form.
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) Form QECP-003-01-LM
b) Form QECP-003-02-LM
c) Form QECP-003-03-LM
d) Form QECP-003-04-LM
e) Form QECP-003-05-LM

DOCUMENT TITLE:
PROCEDURE FOR:
SWITCHBOARDS / PANELBOARDS
DOCUMENT NO.:
MACO-QECP-004
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Materials 3
5 Procedure 3
6 Inspection 5
7 Associated Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Switchboards and Panelboards Page 1 of 6 MACO-QECP-004

SWITCHBOARDS & PANELBOARDS
1 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.
2 Scope:
This document covers installation of switchboards and panel boards in

various facilities.
NEC (National Electrical Code) ( NFPA 70 )
ANSI American National Standards institute
Saudi Aramco Engineering Standards ( SAES )
Saudi Electric Company Engineering Standards ( SES )
SAES - B 068 Electrical Area classification

SAES - P 100 Basic power System design criteria
SAES - P 104 wiring Methods and Materials
SAES - P 114 Power System and Equipment protection
SAES - P 116 Switchgear and Control Equipment
SES - B 119 Basic Design Aspects
Saudi Aramco Material System Specifications ( SAMSS )
Saudi Electric Company Material System ( SMSS )
16- SAMSS-518 Low Voltage Panel Boards.
16- SAMSS-519 Industrial Switchboards, Low Voltage.
31- SMSS Low Voltage Panel and Enclosures.

4 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.
4.2 General Requirements / Materials specifications :
Conductors and busbars in switchboards and panel boards shall be

located so as to be free from physical damage and shall be held
firmly in place.
The arrangement of busbars and Conductors shall be such as to
avoid overheat due to inductive effects.
Each switchboards or panel boards, if used as service equipment ,
shall be provided with a main bonding jumper size in accordance
with NEC standards placed within the service disconnect section
for connecting the grounded service conductor on its supply side to
the switchboards or panel boards frame in switchboards or
panelboards loud terminals for field wiring shall be located so that
it is not necessary to reach across or beyond a non- insulated
ungrounded line bus.
The phase arrangement on three phase buses shall be A,B,C from
front to back, top to bottom or left to right as viewed from the front
of the panelboards or switchboards.
The panels of or switch boards shall be made of moisture resistant,
non-combustible Materials.
Busbars shall be insulated or bare and shall be rigidly mounted.
Component parts like switches, fuses and fuse holder used on
panelboards shall comply with requirement as per NEC article 204
and 404.

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.
5 Procedure:
Unobstructed horizontal space in front, for switchboards and

panelboard shall be 1.5 meter and 1 meter respectively.
Cable shall not be used to extend the main bus of switch boards and
panel boards.
Switch boards that have expose live parts shall be located
permanently in dry location and accessible only for qualified persons
for supervisions.
When Switch boards and panelboard are installed in wet location or
outside of the building, they shall be enclosed in a weather proof
enclosure.
Switch boards and panelboard shall only be used for low voltage
applications.
Switch boards shall only be used to distribute electricity with non-
industrial facilities.
Switch boards shall not be installed in a back to back configuration.
Switch boards shall only be used for a current rating of maximum
2000 amps.
Never install more over current device than that the number for
which the panelboard was designed, rated and approved.
Panelboard shall be equipped with a minimum of 10% space &
spare breakers.
Not more than forty-two over current devices (other than the
provided for mains) of lighting and appliance branch circuit
panelboard shall be installed in any one cabinet.

Panelboard used in industrial facilities shall be rated maximum of

400 Amps or less.
The total load on any over current device located in a panel board
shall not exceed 80 percent of the rating of it.
Panelboard in damp or wet locations shall be installed to comply
with relevant NEC standards.
All circuit details shall be legibly identified on a circuit directory
located on the face or inside of the panel door in the case of a
Panelboard, and at each switch on a switchboard.
For other than totally enclosed switch board, a space not less than
900mm shall be provided between the top of the switch board and
any combustible ceiling.
Instruments, meters and instrument transformers located on switch
board shall be grounded as per NEC article 250-170 to 178.
Panelboards shall be mounted in cabinets, cut out boxes or
enclosures designed for the purpose and shall be dead-front. As
externally operable type shall be permitted where access is only for
qualified persons.
6 INSPECTION:
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.
7 Associated Documentation
Switchboard / Panelboard installation Check List QECP-004-01-SP

SWITCHBOARDS AND PANEL BOARDS

QECP-004-01-SP

CABLE NO: _____________________ SYSTEM: _________________
SI. NO. INSPECTION POINTS ACCEPT REJECT N/A

Confirm the material as per Project
1 Requirement and see any Damage.
Check panelboard/ switchboard and enclosures
2 Comply with area of classification as per standard
3 Check size of main incoming feeder cable.
4 Check size of branch circuit cables.
5 Wires/cables identified by tagging at terminations
Check for proper grounding connection to the
6 ground grid
7 Check for equipment body grounding
Check for protective devices connected in the up
8 stream side as per drawing.
Check for updated panel board schedule ( circuit
9 directory ) affixed on the equipment door
Check in front of panel board/ switch board empty
10 space for easy access
Check branch circuit space and spares, for a
11 minimum of 10%
Total numbers of over current devices not to exceed
12 42 (for lighting and appliance branch circuit
panelboards )
Check wire bending space in terminal& top and
13 bottom gutters
Check connected load are 80% of over current
14 device rating
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
INSTRUMENT WIRING
DOCUMENT NO.:
MACO-QECP-005
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Materials 2
5 Procedure 3
7 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Instrument Wiring Page 1 of 9 MACO-QECP-005

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.
2 Scope:
This document is applicable for electrical wiring of in instruments used in

process industries.
3 References:
Comply with all applicable codes and standards including, but not
limited to, those listed below:
3.1 NEC (NATIONAL ELECTRICAL CODE)
3.2 MACO-QECP-001 Wire & Cables
4 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,

4.2.1 Group-1, single twisted pair/Triad, unshielded. Stranded circular

copper conductor, 16 AWG size, XLPE insulation, 300 V type
PLTC cables, 600 V for type TC cable, color coded, black- white
for pair, black white and red for triads, with PVC jacket material.
4.2.2 Group-2 single twisted pair/Triad shielded, with all specifications
of group-1 plus shielded material of Aluminum foil bonded to non-
hygroscopic polyester tapes.
4.2.3 Group-3 multi pair/triad, unshielded, with or without overall
shield, same specifications of Group-1&2 and multi pair/triad.
4.2.4 Group-4 multi pair/triad, individual and over all shield, all
Specifications of group 1,2 and 3 and added overall shield material
of aluminum foil bonded to Mylar tape.
4.2.5 Thermo couple extension wire, 16 AWG for single pair and 18
AWG for multi pair, primary insulation of XLPE & XLPO,
voltage rating 300 V, with individual shield and over all shield of
aluminum foil bonded to Mylar tape with PVC jacket.
4.2.6 Group-6 fire proof cable. When the instrument installation is
required to be fire proofed, silicon dioxide magnesium oxide
insulated cables, as well as fire resistant polymer alloy jacketed
cable meeting the fire test shall be considered.
4.2.7 For direct buried use manufacturers certification for direct burial is
required.
4.2.8 For oil resistant purpose manufacturer shall certify that all cable is
resistant to hydro carbon oil.
4.2.9 Cables outer jacket shall be marked conductor size, number of
pairs, voltage rating, type of cable, listing, sun light resistant and
direct burial etc.
5.0 Procedure:
5.1 All instrument wiring shall be done as per projects dawning and
comply with electrical standards and suitable MACO electrical
procedures.
5.2 All connections at the field instrument shall made on terminal
blocks. Instrument with integral terminal blocks shall be connected
directly to the field cable.
5.3 The outer jacket of individual twisted pair/triad cables shall be left
intact up to the point of termination. Drain wires and Mylar shield
shall be cut and insulated with heat shrink sleeve at field
instruments.
5.4 Multi twisted pair/triad cable shall be cut to the appropriate length to
minimize looping and flexing of the cable with in the junction box.

5.5 Each shield drain wire shall be insulated using an insertion jacket
from the point where the outer jacket is removed, up to the point of
termination.
5.6 The outer jacket individual shielded twisted pair shall be lift intact
up to the point of termination. One inch of heat shrink tubing shall
be applied over the Mylar shield at the terminated end to prevent the
Mylar unraveling.
5.7 All process control instrumentation, PLCs, enunciators, ESD
systems shall be powered by UPS system. UPS power and utility
power shall not share the same cable or be routed in the same
conduit.
5.8 Splices are not permitted in instrumentation wiring, when wiring
shall be extended, connections shall be made via terminal blocks in
a junction box.
5.9 Twist-on wire nut connectors shall not be used for making any
electrical instrumentation connections.
5.10 The minimum size of multi paired triad cable shall be 18 AWG and
single pair cable shall be 16 AWG. The maximum voltage drop shall
not exceed 5%.
5.11 ITC cable shall not be installed on power limited circuits operating
at the more than150 volts.
5.12 The use of single cable tray or conduit for primary and back-up data
link is not acceptable.
5.13 Protection against reverse EMF shall be provided for inductive loads
such as relays solenoids etc. this may be accomplished by installing
a diode across the coil for DC loads.
5.14 Data link, including fiber optic cables, shall be specified and
installed per manufactures recommendations. Data link cables shall
not be routed in the same conduit, duct, or cable tray with other
instrument cable.
5.15 Single twisted pair cable shall be installed in steel conduits from
field instruments to the field junction box. Low point drain and
breather shall be installed. The armored cable shall be routed
independently of existing over head tray system. The unsupported
end of the cable at the instruments should not exceed tow feet.
5.16 All signal wiring shall go to marshaling box panel terminal strip.
5.17 All spare pair cables shall be terminated at both the field junction
bon and the marshaling panel. Drain wires for spare shielded pair
shall also be individually terminated.
5.18 Emergency shut down system (ESD) and fire detection system shall
have dedicated cabling, junction boxes and marshaling cabinets.
5.19 Cables entering the marshaling cabinets shall be cut to the
appropriate length. Coiling extra cable beneath the box is not
acceptable.

5.20 Instrumentation cables installed beneath computer type floors in

control room shall be placed in ladders, trough or solid bottom cable
tray.
5.21 Different signal categories shall be routed via segregated cabling
and shall not share the same cable, conduit, junction box or try.
Minimum separation requirements between various instrumentation
cables shall be as per manufactures recommendations.
5.22 Signal wiring shall be installed in a manner that will minimize
unwanted and unnecessary distortion of the signal. Unwanted
voltages are imposed on electrical signal transmission system by
inductive, capacitive or coupling with other circuits by leakage
current.
5.23 Shielded cable shall be used to reduce electro static noise. The
Shield shall be grounded at one point only at the marshaling panel.
Cable shields must have a single continuous ground path.
5.24 Twisted pair/triad cables shall be used on all instrument loops to
reduce spurious signals resulting from induced voltage.
5.25 Terminals for AC, DC current service shall be grouped together but
physically separated by means of dividers.
5.26 Terminals for 120VDC and 120 VAC power for field contacts shall
be segregated from other system.
5.27 Terminal strip for ESD system wiring shall be completely separated
from other wiring power control and instrumentation.
5.28 All wire shall be tagged at both ends. Cables entering junction box
shall be marked cable numbers.
5.29 The metal equipment and enclosures with in a panel or series of
panels shall be bonded with bonding jumpers and connected with
safety ground bus with copper wire of 4 mm square cross sectional
area. Grounding shall be done as per HKSS grounding procedure.
6.0 INSPECTION:
6.1 inspections and tasting shall be performed in accordance with the code and
7.0 Associated Documents:
7.1 Instrumentation Wiring Check List QECP-005-01-IW

7.2 Instrument Wiring Test Report QECP-005-02-IW
7.3 Insulation Resistance Test QECP-005-03-IW
7.4 Continuity Test Report QECP-005-04-IW

Instrument Wire/Cable Installation Checklist

QECP-005-01-IW

CABLE NO: _____________________ SYSTEM: _________________
S.NO ACCEPT REJECT N/A

01 Check the cable routing with cable schedule and drawing
02 cable routing clean and free from debris
03 Check type and size of cable
04 Cable is identified at both ends
05 Check the cable pulling tension as per the specification.
06 Check the cable preparation for pulling.
07 UPS power and Utility power pulled in different raceways
08 Data link and fiber optic cable pulled separate.
09 ESD and fire detection cables shall have dedicated conduits
10 Spare cables terminated
11 Mylar shielding properly cut, copped & terminated
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

Instrument Wiring Test Report

QECP-005-02-IW

PANEL NO: _____________________ SYSTEM: _________________
DRAWING NO.: _____________________ EQUIP. NO. _________________
Electl. Signal
JUNCTION BOX: ____________________________________________ Temperature
Alarm interlock
CABLE NO. & SPEC. _________________________________________ _____________
CONTROL
FIELD INS. CABLE(1) INSULATION MOHM
SEALING COMPOUND
RESULTS
NOTES
ROOM
CABLE (2) WIRE
LINE TO
JB TERM. NO.
CONTINUITY
PANEL NO.
TERMINAL
TERMINAL
TAG NO.
ITEM NO.
SPECS
CORE
NO.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

Insulation Resistance Test

QECP-005-03-IW

PANEL NO: _____________________ SYSTEM: _________________
DRAWING NO.: _____________________ AMBIENT TEMP. _________________
EQUIP.TAG/
PH. A TO G PH. B TO G PH. C TO G PH. A TO B PH. B TO C PH. C TO A REMARKS
CABLE NO.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

Continuity Test Report

QECP-005-04-IW

PANEL NO: _____________________ SYSTEM: _________________
DRAWING NO.: _____________________ EQUIP. NO. _________________
CONTINUITY
CABLE NUMBER CORE ID/NUMBER REMARKS
YES NO
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
INSTRUMENT CONTROL PANELS
DOCUMENT NO.:
MACO-QECP-006
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Materials 2
5 Procedure 3
7 Documentation 5-7

DESCRIPTION
NO. DATE BY BY BY
Instrument Control Panels Page 1 of 6 MACO-QECP-006

INSTRUMENT CONTROL PANELS
1 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.
2 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.
3 References:
Comply with all applicable codes and standards including, but not
limited to, those listed below:
3.1 NEC (NATIONAL ELECTRICAL CODE)
3.2 MACO-QECP-001 Wires & Cables
4 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

4.1.4 Himmel Cabinets

4.1.5 ABD other approved equal Manufacturers
4.2 Materials details & conformance:
4.2.1 All control cabinet equipment and wiring shall be designed for
continuous operation at 50 deg C and relative humidity 80%
maximum and 20% minimum.
4.2.2 The cabinet shall be rigid and self supporting. The cabinet shall be
floor or wall mounted.
4.2.3 Indoor cabinet shall be NEMA type 1 and out door type shall be
NEMA 4, 4X, 3, & NEMA 7 etc. depending area of classification
and environment.
4.2.4 Cabinet requiring heat dissipation shall be convection ventilated
and shall be provided with readily accessible removable filter
screens.
4.2.5 Fan may be used with in cabinet for power supplies to assist in
heat removal and for over temperature provision shall be made for
external alarm annunciation.
4.2.6 Cabinet support bracing shall not restrict maintenance access to
chassis, modules or components.
4.2.7 Each cabinet shall be provided with removable lifting rings.
4.2.8 All doors of cabinet must be capable of swinging at least 90 deg
open at the installed location.
4.2.9 A minimum of primer under coat and finishing coat of enamel or
lacquer is required. Interior cabinet color shall be white or of a
light color.
4.2.10 Where ever name plate abbreviations are avoided. Name plates
shall be made from laminated plastic, information engraved into
the back core.
4.2.11 No spare cut outs shall be provided unless specified. Spare panel
space shall be left accessible for future installation of instruments.
4.2.12 Air piping material to the control panel shall be stainless steel and
tube fitting shall be stainless steel and shall be compression type.
4.2.13 Equipment which is not enclosed or hermetically sealed, but is
situated off shore or near shore shall be protected from corrosion
and wind born sea water spray or accumulation of wetted salt.

5 Procedure:
5.1 Control panels shall be fabricated as per project drawing and shall
conform to relevant standards and appropriate for environmental
conditions.
5.2 All components, accessories mounted inside the panel shall be as
per client requirement and project construction drawing.
5.3 No process piping of any kind shall be installed in a control cabinet.
They only fluid allowed in instrument air.
5.4 For out door installation the panels, materials and equipments
required for electrical wiring and installation within the control
panel be suitable for use in specified area.
5.5 For explosion proof cabinet conduit shall have a removable blank
gland plate.
5.6 Elevated outdoor control cabinets shall normally have conduit entry
from the bottom.
5.7 For outdoor classified location install only hermetically sealed
relays.
5.8 Push buttons, pilot lights and switches shall be heavy duty and oil
tight.
5.9 All process instruments shall be powered from instrument- circuit
power distribution panel. Each distribution panel shall be dedicated
to single voltage level. These panels shall not give power to non
instrumentation wiring.
5.10 Power wiring for field instruments, two-wire analog transmission
loops field switch contacts etc. shall be individually fused and
provided a means of disconnecting the power without distributing
terminated wiring.
5.11 Wiring connected to I/O modules or interfaces containing individual
current limiting do not required fuses and also low level signal
wiring connected directly to I/O.
5.12 Exposed electrical connections with voltage greater than nominal 48
volts AC/DC shall have removable transparent insulating plastic
cover.
5.13 Terminal strip spacing shall allow ample room for plastic wire ducts
and shall permit training and lacing of cables. Each terminal strip
shall be labeled above or below with the terminal numbers.
5.14 Terminal strip for ESD wiring shall be completely separate from all
other wiring including power and control.
5.15 Wiring for a given instrument loop shall be terminated on adjacent
terminals on the terminal strip in order to organize and group all
loop wiring.
5.16 Terminals of various types of general wiring, enunciator points and
single wiring shall be separated by dividers.

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
7.1 QECP-006-01-IC Instrument Control Panel Installation Checklist

INSTRUMENT CONTROL PANEL INSTALLATION CHECKLIST

QECP-006-01-IC

CABLE NO: _____________________ SYSTEM: _________________
COMPLIANCE
CHECKS TO BE PERFORMED YES NO N/A
1. Check the enclosures of panels for area classification.
2. Control panels components are as per standard and approved list.
3. Wiring diagrams are being followed properly.
4. Power wiring fused properly.
5. For outdoor type relays hermetically sealed.
6. Wires spares provided, and also spare terminal strips.
7. General wiring and signal wiring segregated
8. For outdoor type push buttons switches heavy duty.
9. Cabinets supports adequate and as per standard.
10. The only fluid connected to the panel is air.
11. Grounding is provided as per standards.
12. Signal and digital are not taken in common cable.
13. Proper label tags & nomenclature.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
FIRE ALARM SYSTEM
DOCUMENT NO.:
MACO-QECP-007
Index Page
1 Scope 2
2 References 2
3 Materials 2
4 Quality Control 2
5 Installation 5
6 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Fire Alarm System Page 1 of 3 MACO-QECP-007

FIRE ALARM SYSTEM

1 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) NFPA - National Fire Protection Association.

b) ANSI - American National Standard Institute.
c) OSHA - Occupational Safety and Health Institute.
d) NEC - National Electrical Code
e) NEMA - National Electrical Manufacturers Association
f) UL - Underwriters Laboratories
g) SAMSS - Saudi Aramco Material Systems Standards
3 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.

g) Fire Alarm switches shall allow authorized personnel to initiate a general

alarm condition ,Silence the local audible ,silence the alarm signal , disable
the signal to the central fire monitor, reset all zones after all zones have
returned to normal condition. Test all Leos without affecting any zone
condition: estimate a device mismatch condition by changing the device type
and fan shut down of HVAC within designated zones.
h) All manual pulls station must be non coded spring loaded contact, non- break
glass type that lock when actuated and to be normally released.
i) Bell/Horn shall include an integral flashing stroke light with white

polycarbonate lens and red Fire lettering.
4 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) Determine the work to be performed .Provide the type and amount of

materials and equipments necessary to place the work in proper location.
Complete installation, wire tested and ready to use.
c) Check installation conforming to manufacturers installation instruction
5 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.

DOCUMENT TITLE:
PROCEDURE FOR:
LIGHTING
DOCUMENT NO.:
MACO-QCCP-008
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Material 2
5 Procedure 2
7 Documentation 4

DESCRIPTION
NO. DATE BY BY BY
Lighting Page 1 of 9 MACO-QECP-008

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:
NEC - NATIONAL ELECTRICAL CODE

SAES-P-100 - Basic Power System Design Criteria
SAES-P-104 - Wiring Methods and Materials
SAES-B-068 - Electrical Area Classification.
SAES-P-123 - Grounding System
NEMA - National Electrical Manufacturers
Association
IEEE - Institute of Electrical & Electronics
Engineers
ANSI - American National Standard Institute
4.0 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

or other liquids, location exposed to weather and un protected and

vehicle washing areas etc. are wet locations.
4.1.1.2 Fixtures installed in corrosive locations shall be of a type suitable

for such locations.
4.1.1.3 Fixtures shall be permitted to be installed in cooking hoods of non

residential occupancies.
* Fixtures shall be identified for the use and the temperature limit of
the materials shall not be exceeded.
* All exhaust vapors, grease, oil or cooking vapor shall be excluded
from the lamp and wiring department.
* wiring methods and material supplying the fixtures shall not be
exposed with in cooking hood.
4.1.1.4 No parts hanging fixtures or pendant shall be located with in a

zone measured 3 feet horizontally and 8 feet vertically from the top of
the path tub rim.
4.1.1.5 Fixtures installed over highly combustible material shall be of the

un switched type. Unless an individual switch is provided for each
fixture, lamp holders shall be located at least 8 feet above the floor or
shall be so located or guarded that the lamps cannot be removed or
damaged.
4.1.1.6 Externally wired fixtures shall not be used in a show window.
4.1.1.7 Lighting systems shall be designed for energy efficient operation.
4.1.1.8 Direct control switches and switching contacts used on in

candescent lighting circuits shall have a continuous rating of at least
1.5 times the steady state current of the lighting load.
4.1.1.9 Direct control switches and switching contacts used on

fluorescent lighting circuits shall have a continuous rating of at least
twice the steady state current of the lighting load.
4.1.1.10 Lighting poles and supports.
4.1.1.10.1where flood light are installed on steel towers, the tower

shall be equipped with steel service platform located 1.5 meters below
the fixture.

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.

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.

4.1.1.21 Lighting for control rooms shall be designed for maximum

flexibility to permit flicker free variation of illumination levels.
Fluorescent and incandescent fixture installed in control rooms
shall provide shadow less illumination.
4.1.1.22 Fixtures for suspended ceilings shall be recessed shall be recessed

mounted type and shall be self supported.
4.1.1.23 Fixtures having exposed ballasts or transformers shall be installed

such that the ballasts or transformers will not be in contact with
any combustible material.
5.0 Procedure:
5.1Exterior Lighting Fixtures
5.1.1 Install exterior lighting fixtures at locations and heights as

indicated in accordance with fixture manufacturer's instructions,
applicable requirements of NEC and with recognize industry practice
to ensure that lighting fixture fulfill requirements.
5.1.2 Fasten electrical lighting fixtures and brackets securely to the

structural supports including poles.
5.1.3 Ensure that installed fixtures are plumb and level.
5.1.4 Poles and foundations shall be strong enough to withstand wind

loading.
5.1.5 Lighting pole installed within 5 meters from roads having a

speed limit above 50 Km/h and up to 65 Km/h shall have a breakaway
bases as per standard. Poles with breakaway bases shall not have
traffic guards.
5.1.6 Provide equipment grounding connections as per drawing and in

conformance with the grounding specifications.
5.1.7 Clean all lighting fixtures upon completion of installation.
5.1.8 Replace the lamps in exterior lighting fixture which are observed
to be noticeably dimmed after testing, if client requests.
5.1.9 Upon completion of installation, apply electrical energy to

circuitry to demonstrate the capability and compliance with
requirement.

5.2 Interior lighting fixtures
5.2.1 The interior lighting fixtures shall be installed as per

architectural drawings and specifications. Verify ceiling types,
modules, suspension systems for compliance with the requirements
and specifications.
5.2.2 Verify the installations are carried out, in such a way to dampen
ballast generated noise.
5.2.3 Equip the lighting fixtures with plaster frame for installation in
plaster or gypsum board ceiling and proper trim for installations in
suspended acoustic tile ceilings.
5.2.4 Provide fixtures and/or fixture outlet boxes with hangers to

properly support fixtures weight.
5.2.5 Install flush mounted fixtures to eliminate light leakage between

fixture frame and finished surface.
5.2.6 Provide plaster frames for recessed fixtures installed other than
suspended grid type acoustical ceiling systems. Brace frames
temporarily to prevent distortion during handing.
5.2.7 Fasten fixtures securely to structural supports and ensure that

pendant fixtures are plumb and level. Provide individually mounted
pendant fixtures longer than 2 feet with stem hangers with clams.
5.2.8 Support surface mounted fixtures, greater than 2 feet in length, at

a point in addition to the outlet box fixture stud.
5.2.9 Tighten connectors and terminals including screws and bolts in

accordance with the equipment manufacturers torque tightening value.
Provide equipment grounding connections.
5.2.10 upon completion of installations, clean interior lighting fixtures

of dirt and constructions.
5.3 Emergency lighting fixtures

5.3.1 Set units plumb, square and level with ceiling and walls and
secure in accordance with manufacturer's instructions and approved
shop drawing.

5.3.2 Mount heights specified or indicated.
5.3.3 Recessed and semi recessed fixtures may be supported from

suspended ceiling systems. Support with 4 rods or wires per fixture
and locate not more than 6 inches from fixture corner.
5.3.4 Do not support fixtures by ceiling acoustical panels.
5.3.5 Where fixtures smaller than the ceiling grid are indicated to be
centered in the acoustic panel, support fixtures independently with at
least two3/4 inch metal channel spanning secured to ceiling tees.
Install support clip for recessed fixtures. Securely fastened to grid
members.
5.3.6 Coordinate with other electrical installations as appropriate for

proper installation of emergency lighting fixtures.
5.3.7 Clean emergency unit light set upon completion of installation.

Adjust focusable fixtures to provide light intensities in egress path.
5.3.8 Ground non-current carrying parts of the equipments.
5.3.9 Apply and interrupt electrical energy to demonstrate proper

operation. Test all lamps and if mal functions any lamp replace them.
6.0 INSPECTION & TESTING
6.1 Installation resistance test is conducted before and after

connection of fixtures and equipment.
6.2 Perform electrical continuity test for the wires.
6.3 Perform the illumination level test.
6.4 Inspection and testing shall be performed in accordance with

code and client specifications.
7.1 Lighting Installation Check List (QECP-008-01-LS)

7.2 Lighting Circuit Test Record (QECP-008-02-LS)
7.3 Illumination level test (QECP-008-03-LS)

CONTRACT: REFERENCE:
LOCATION: PROJECT:
CONDUIT NO. : __________________ SYSTEM: _____________________

DRAWING NO. : _________________ AMB.TEMP: ___________________
S.NO INSPECTION POINTS ACCEPT REJECT N/A

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
REMARKS: ____________________________________________________________
______________________________________________________________________
MACO QC Inspector Proponent Representative

Signature
Name
date

DOCUMENT TITLE:
PROCEDURE FOR:
DC POWER SYSTEMS
DOCUMENT NO.:
MACO-QECP-009
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Definitions 3
6 Procedure 7

DESCRIPTION
NO. DATE BY BY BY
DC Power Page 1 of 10 MACO-QECP-009

DC Power Construction Quality Control Procedure
1 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.
2 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.
3 References
SAEP-020: Equipment Inspection Schedule
SCHEDULE Q: Quality Assurance and Control, Inspection and

Testing
SAES-P-100: Basic Power System Design criteria
SAES-P-103: Direct Current and UPS Systems
SAES-P-104: Wiring Methods and Materials
SAES-P-111: Grounding
SAES-P-114: Power System and Equipment Protection
SAES-T-151: Communication DC Power System

SAES-T-795: Communications Facility Grounding Systems
17-SAMSS-511: Stationary Storage Batteries
17-SAMSS-514: Battery Charger Rectifier
National Electrical Code
National Fire Protection Association (NFPA)
Standards of the National Electrical Manufacturers Association (NEMA)
Saudi Government Safety and Security Directives SSD 12, 14, and 17
Applicable DC Power Drawings as identified in the project Drawing Index
4 Definitions
QCP: Quality Control Procedure
IFC: Issued for Construction
Company: Proponent
MACO: Manar Arabian Corp. (MACO)
IK: In Kingdom
OOK: Out of Kingdom
PID: Project Inspection Department
QA/QC: Quality Assurance/Quality Control
RFI: Request for Inspection
5 Responsibilities
The Site or Discipline Engineer In-Charge will be responsible for

the following:

To ensure that construction/erection is carried out to the

required Job Specifications and Approved
Construction/Erection Plans.
To ensure that the work is complete and ready for

inspection and to initiate the required internal application
form for inspection.
Will be responsible for ensuring that all parties required

to conduct joint inspection or tests are informed as to the
construction program. Request for inspection originate
with the field foreman through their respective discipline
engineers.
Upon completion of the installation activities ensure that

any mark-ups to the approved drawing(s) have been
completed and reflect the installed equipment properly.
The Quality Assurance Manager will be responsible for the

following:
Inform the Company Representatives by the official

Request for Inspection (RFI) Form SA-6717-ENG when
various operations are being performed. Contractor
representatives will issue this form when various stages
of the work are complete or in progress and can be
witnessed/inspected by the Company.
Ensure that approved discipline inspectors are informed

of inspection schedules and are available to support the
construction schedule.
Ensure that the complete inspection records are

maintained and filed by the organization responsible for
the work
Will review all relevant documentation, test reports, and

Certificates, and prepare all handing over documents and
clearing out all pending non conformance items.
Will coordinate with discipline Quality Control

Inspectors to ensure that all other discipline activities
requiring inspection within the construction program
have been inspected and cleared.

Will sign and obtain signatures from Company

representatives for document review per the various
Royal Commission for Jubail & Yanbu Test and
Inspection Plan (SATIP) thereby confirming that all the
attachments and Inspection signatures per the various
SATIPs are properly executed before the preparation of
the handover documents.
Organizing and allocating the various inspection tasks to

the Quality Control Inspectors or in some cases,
discipline engineers.
At the completion of an integral part of the work, as

defined by the Mechanical Completion Procedure, all
quality inspection and test records for that portion will be
assembled and reviewed for completeness by Manar
Arabian Corp. (MACO) Quality Inspectors and Quality
Assurance Manager. Assembled documents will then be
turned over to Manar Arabian Corp. (MACO)Document
Control.
Accompany Company representatives, as required, to

carry out routine inspections of release hold points by
signing and obtaining representatives approval
signatures per the various Royal Commission for Jubail
& Yanbu Test and Inspection Plans (SATIP) as recorded
proof of project work conforming to specifications.
The Discipline QC Engineers will be responsible for:
Ensure that the work conducted in assigned discipline is

in accordance with quality and engineering standards and
that the QC procedures and SATIP is followed.
Prepare and submit for the QA Managers review the

necessary discipline quality documentation.
Implement quality control activities on site in line with

the established quality control program. Supervise the
QC
Inspectors in performing inspections and testing,
compiling records and reports.

The Discipline QC Inspectors will be responsible for:
Perform or witness the inspections and test required by

the respective Royal Commission for Jubail & Yanbu
Test and Inspection Plan (SATIP). To this end they
coordinate with the construction personnel who have the
responsibility for issuing the necessary notifications to
QC.
Report the inspection and testing results on the inspection

and test form and check sheets.
Issue through the QC Engineer all request for inspection

to the contractor and Royal Commission for Jubail &
Yanbu. Coordinates timing and procedure.
Report to the Discipline QC Engineer any non-

conformance identified during inspections.
Safeguard inspection documentation until submission to

the Document Control Clerk for proper filing after all
inspection pertaining to an MCC segment is complete.
The Technical Clerk will be responsible for:
Keeping daily log of all Inspection Forms Requests by

Site/Section Engineers. If a technical clerk is not
available, the log and inspection records will be kept by
the originating quality inspection organization.
Filing and compiling all inspection records and handing

over documents under the supervision and instructions of
the Quality Assurance Manager.
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 sub-
contractor 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

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.

6 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.

f) Verify that personnel protective equipment is available and stored

in a cabinet, and that required signs have been posted and battery
information has been conveniently placed on the wall (SAES-P-
103).
g) Verify that the shower is at least 3 meters away from the nearest
battery cell (SAES-B-069) or that a protective screen has been
provided. If eyewash only (no shower) the separation shall be
minimum of 1.5 meters.
Rectifiers and Power Boards. The following inspections apply for

the installation of the rectifiers/power boards:
a) Ensure that the rectifiers are insulated from the cable trays and
from the power distribution board.
b) Ensure that the equipment racks are securely fastened to the floor
and are also fastened at the top to the nearest overhead structure.
Verify that the equipment racks are bonded to the overhead cable
trays and grounded to the master ground bus (MGB).
c) Ensure that a plexiglass cover is provided in the back of the power

board.
MCC/Partial MCC
Upon completion of the Final Company inspections, a partial

Mechanical Completion Certificate (MCC) (Form A-7213) can be
issued and signed. The partial MCC shall not be signed if the Work
is not completed as required by the project requirements. However,
as determined by the designated MCC Committee Chairman, the
MCC can be signed with an Exception Item List (EIL) attached if
these exceptions do not prevent energizing the equipment and do not
affect the safety and integrity of the project.
Partial MCCS can be generated and signed/approved for each project

subsystem. Upon Completion of the project these partial MCCs can
be incorporated into the Final Project MCC. This method will
expedite the installation activities. It is to the benefit of both the
Contractor and the Company to utilize this method if possible for
MCC approval.

Review, Witness And Hold Points
The level of surveillance inspection for each activity is indicated in

the SATIP column marked Surveillance/Inspection Code.
The following codes are indicated:
A1 100% Actual Inspection / Test

W1 - 100% Witness Inspection / Test
W2 - Sample Witness Inspection / Test
H - Mandatory Hold Point
R1 - 100% Review Documents
R2 - Sample Review Documents
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

DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF JUNCTION BOXES AND
DEVICES
DOCUMENT NO.:
MACO-QECP-010
Index Page
1 Scope 2
2 References 2
3 Materials Control 2
4 Quality Control 2
5 Procedure 3
6 Documentation 3

DESCRIPTION
NO. DATE BY BY BY
Installation of Junction Boxes and Devices Page 1 of 3 MACO-QECP-010

INSTALLATION OF JUNCTION BOXES AND DEVICES
1 SCOPE
This procedure covers the inspection, method and criteria for

installation of junction boxes and devices.
SAES-P-100 - Basic Power System Design Criteria

SAES-P-104 - Wiring Methods and Materials
SAES-B-068 - Electrical Area Classification.
NEC - National Electric Code
NEMA - National Electrical Manufacturers Association
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.
4 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

f) Upon installation the supports will be checked to ensure rigidity and

junction box fitting points are available.
5 CONSTRUCTION PROCEDURES
a) Junction boxes shall be installed in accordance with the detailed drawings.

All accessories and conduit fittings are installed where applicable and are
of approved type materials.
b) The Civil Erection Group will install concrete foundation .Prior to
installing the supports, the fixing points and bases will be checked to
ensure their line and level is correct .Cable entries will be checked to
ensure they are clear of debris.
c) All junction boxes supports shall be applied with prime coating and
approved corrosive resistant epoxy paint finished prior to installation of
boxes.
d) All junction boxes and steel supports shall be provided with earthing wire
securely and effectively bonded to main grounding grid.\
e) Ensure that proper conduit fittings are installed with threads fully engaged
and the proper sealing compound is used .Sealing fittings and drains are
installed as per detailed drawings.
f) Plug or cap all unused threaded hubs opening with a metallic square head
plug.
6 DOCUMENTATION
None

DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF CABLE TRAYS
DOCUMENT NO.:
MACO-QECP-011
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Definitions 2
6 Procedure 3
7 Documentation 3

DESCRIPTION
NO. DATE BY BY BY
Installation of Cable Trays Page 1 of 3 MACO-QECP-011

INSTALLATION OF CABLE TRAYS
1 SCOPE
This procedure covers the inspection, method and criteria for installation of
cable trays, fittings and supports carried out by the Electrical Department.

d) NEC - National Electric Code
e) NEMA - National Electrical Manufacturers Association
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
CHECK FOR THE FOLLOWING

Conformance to specification and drawings.
All braces and supports are adequate to handle weight of cable trays and
cables in accordance with detailed drawings.
Hold down clips properly installed .Tray is included only on location shown
on drawings.
Expansion joints properly installed.
No sharp edges to cut cables.
No obstruction to pulling of cable.
All covers, fire stops and partitioned installed.
All earthing bonding jumpers are effectively grounded as per SAES-P-11.
Check correct use off fittings and accessories for change indirection splices
and drops.
Spacing and clearances from other cables/wires with different system voltage
levels.
Cable tray is mechanically connected to conduit or raceways they terminate to.

Check that installation of cable trays does not conflict to other services on
equipment.
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

DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF COMMUNICATION SYSTEMS
DOCUMENT NO.:
MACO-QECP-012
Index Page
1 Scope 2
2 References 2
3 Material Control 2
4 Quality Control 3
5 Testing 4
6 Documentation 4

DESCRIPTION
NO. DATE BY BY BY
Communication Systems Page 1 of 4 MACO-QECP-012

INSTALLATION OF COMMUNICATION SYSTEMS
1 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.
2 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) ANSI AMERICAN NATIONAL STANDARDS INSTITUTE

b) NFPA NATIONAL FIRE PROTECTION CODE
c) NEC National Electrical Code
d) API American Petroleum Code
e) NEMA National electrical manufacturing association
f) IEEE Institute of electrical & electronics engineer
g) NETA National electrical testing association
h) UL Underwriters laboratory
i) FM Factory mutual corporation
j) BICSI Building industry consulting services intl
k) SAES-T-243- Distribution &protection equipment
l) SAES-T-435 Communication station protection
m) SAES-T-481 Powered in-plant communication
n) SAES-T-622 Communication conduct & manhole
o) SAES-T-629 Telecom buried cable &wire
p) SAES-T-632 Communication cable splicing
q) SAES-T-633 Communication splice closure
r) SAES-T-903 Communication electrical protection
s) SAES-T-916 Communication building cable

3 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.

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 Paging system equipment such as amplifier, junction boxes, termination racks

and speakers will be installed as per Royal Commission for Jubail & Yanbu
standards.
2 The placement of handsets and speakers will be checked against the layout
drawings.
3 Loudspeaker system will be inspected to ensure correct type and location,
orientation and their fixing are secured properly.
4 Conduits, trays cables, and earthing system will be installed as in item (8)
through (10) inclusive.
5 TESTING
Communication system will normally be tested and commissioned by vendor

representatives.
a) Prior to energization, control panels will be merger tested to ensure it has

Leakage paths to earth.
b) Power and control circuits will be checked in accordance with

manufacturing instruction.
c) The test will b recorded.
6 DOCUMENTATION
Communication system test

Inspection and test report.

DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF CONDUITS & FITTINGS
DOCUMENT NO.:
MACO-QECP-013
Index Page
1 Scope 2
2 References 2
4 Quality Control 2
5 Documentation 3

DESCRIPTION
NO. DATE BY BY BY
Conduits and Fittings Page 1 of 3 MACO-QECP-013

CONDUITS AND FITTINGS
1 SCOPE
These procedures covers the inspection and field installation checklist

pertaining to the installation of above ground conduits and fittings carried out by the
Electrical Department.
2 REFERENCE STANDARDS & CODES

d) SAES-P-111 - Grounding System
f) NEMA - National Electrical Manufacturers Association
g) NFPA - National Fire Protection Association
h) UL - Underwriters Laboratories
i) SAMSS - Saudi Aramco Material Supply Standard
3 MATERIALS CONTROL
a) Ensure that materials are handled in accordance with Sec.III.5.1

(General Electric Procedure) and Sec.III.8.1 (Materials control System).
b) Check all the materials received are in conformance with Purchase
order and Specs. Requirements
c) Where conduits and miscellaneous fittings are supplied loose, these
shall be identified and checked against the equipment delivery.
d) Ensure that conduits and fittings are stored and protected against
atmospheric action, dust and dirt.
4 QUALITY CONTROL
4.1 CHECK FOR THE FOLLOWING
a) Conduits and fittings to conform to SAES-P-104 Para 4.3.

b) PVC coated 40 mils thick rigid steel conduit shall be used in damp
locations, exposed to weather, direct buried underground and as
conditions of installation, operations and on maintenance requiring
protection from liquids, vapors or solids.
c) 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 in above finished floor and accessible to authorized operating or

maintenance personnel only
d) Rigid Plastic conduit (PVC) shall be used below slabs on grade ,encased
in concrete ,unless otherwise indicated in approved drawings .Riser
elbows and extensions above grade or concrete shall terminate in rigid
steel conduit ,using appropriate PVC to steel adapter
e) Space conduit at least 6(150mm) from coverings of hot water pipes
,18(460mm) from covering on flues and breaching ,24 (600mm)from
radiant heaters.
f) Exposed conduits shall run parallel at or right angles with the lines of
the buildings .Route exposed conduit to preserve head room, access
space and work space.
g) All wiring and cables installed in conduits will not exceed 40%
conductor fill .Conductor fill of seal fittings shall not exceed 25%.
5 DOCUMENTATION
Field Inspection Checklist.

DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF DISCONNECT SWITCHES
DOCUMENT NO.:
MACO-QECP-014
Index Page
1 Scope 2
2 References 2
4 Quality Control 2
5 Procedure 3
6 Documentation 3

DESCRIPTION
NO. DATE BY BY BY
Disconnect Switches Page 1 of 3 MACO-QECP-014

INSTALLATION OF DISCONNECTING SWITCHES
1 SCOPE
installation of disconnecting switches.
b) This procedure shall be applied to the inspection, method and criteria for
a) SAES-P-116
b) 16-SAMNS-510
c) NFPA-70.
d) OSHA - Occupational Safety & Health Act.
f) NEMA - National Electrical Manufacturers Association
g) IEEE - Institute of Electrical & Electronics Engineers
h) SAMSS - Saudi Aramco Materials Systems Specification.
3 MATERIALS CONTROL
a) Ensure that materials are handled in accordance with Royal Commission for
Jubail & Yanbu Procedure and Materials control System.
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.
4 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

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
6 DOCUMENTATION
Disconnect Switch Inspection Checklist

DOCUMENT TITLE:
PROCEDURE FOR:
LOW VOLTAGE MOTOR CONTROL CENTER
DOCUMENT NO.:
MACO-QECP-015
Index Page
1 Purpose 2
2 Scope 2
3 References 2
4 Materials 2
5 Procedure 2
7 Documentation 7

DESCRIPTION
NO. DATE BY BY BY
Low Voltage Motor Control Center Page 1 of 8 MACO-QECP-015

LOW VOLTAGE MOTOR CONTROL CENTER
1 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.
2 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.
3 References:
NEC (National Electrical Code)

Royal Commission for Jubail & Yanbu Material Systems
specifications ( SMSS )
Royal Commission for Jubail & Yanbu Engineering Standards (SES)
SES - P 119-02 Basic Design Aspects

37 SMSS Circuit Breakers
32 SMSS Metal Clad Switch Gear
4 Material:
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 Suitable for continuous operation.

4.1.1.2 Ambient temperature shall be maximum of 40 deg c and
minimum of zero deg c.

4.1.1.3 Rated current shall be 600 Amps ( minimum ) for horizontal

bus & 300 Amps for vertical bus.
4.1.1.4 Short circuit interrupting rating (minimum) shall be 25 KA
rms.
4.1.1.5 Rated operational voltage 480 volts & rated max. 575 volts or
600 volts.
4.1.1.6 Rated short circuit with stand current shall be 25 KA RMS
for 3 cycles.
4.1.1.7 Die-electric test shall be 2.5 KV for one minute.
4.1.1.8 All components and switching devices requiring routine
maintenance shall be accessible.
4.1.1.9 Roof lifting attachment shall be provided for lifting the entire
shipping.
4.1.1.10 Motor control centers shall be provided with a minimum of
one spare and one space for every three vertical section.
Openings between the vertical wire ways and switching
assemblies shall be covered with removable non metallic
barriers.
4.1.1.11 The vertical section shall share a common main circuit
horizontal bus and a common ground bus.
4.1.1.12 All switching assemblies shall be with draw able type except
circuit breaker greater than 225 Mmps shall be fixed. The
switching assemble module can be removed without de
energizing the MCC main circuit or without accessing the
rear of the MCC.
4.1.1.13 Exterior compartments shall be hinged type. But it is accepted
that the horizontal wire way compartment shall not be hinged.
4.1.1.14 In an MCC, under the test condition is shall not be possible
for a flexible rod of 13 mm diameter with a rounded tip to
contact live parts or being inserted into any openings. Any
voltage greater than 24 volts is live parts& "opening" means
the opening between separate compartments.
4.1.1.15 All wire ways shall be accessible from the front of each
vertical section via compartment doors. Horizontal wire ways
shall have a minimum internal height of 150 mm.
4.1.1.16 Each vertical section shall have a vertical wire way. This wire
way shall inter connect the top and bottom horizontal wire
ways.
4.1.1.17 Power and control terminal blocks directly related to the
switching assemblies may be installed with in the vertical
wire ways adjacent to the switching assembly.
4.1.1.18 MCC supplied in back to back configuration shall have two
separate assemblies' utilizing independent main circuits.

4.1.1.19 The main circuit horizontal bus system and ground bus
system serving multiple vertical sections shall each have the
same ampere rating. The horizontal bus, vertical bus and
ground bus shall be rigid surface shall be silver or tin plated.
4.1.1.20 All main circuit switches and main circuit breakers installed
in MCC shall have the following characteristics.
4.1.1.21 The exterior door shall be manually operable only with the
door in the closed position.
4.1.1.22 Operating handle shall be directly mechanically connected to
the switch / breaker irrespective of the position in open
position.
4.1.1.23 The operating lock shall be pad lockable in the open position.
4.1.1.24 There shall be external indication to show the handle position
in open position.
4.1.1.25 When the breaker is in the open position, the only voltage
present in switching terminal shall be at the incoming
terminal.
4.1.1.26 MCC shall not have more than one disconnector. If a circuit
breaker is used for disconnerctor. It shall not be equipped
with instantaneous ground fault protection.
4.1.1.27 Circuit breaker within switching assemblies shall be molded
case construction. Circuit breaker within switching
assemblies shall have a short circuit rating not less than that
of the complete MCC.
4.1.1.28 The main circuit contactors shall have electrically operated
type, magnetically held & field replaceable coil. Mechanical
interlocks shall be provided to prevent the compartment door,
while the circuit breaker operating handle is in closed poison.
4.1.1.29 Switching assemblies, controlling motors shall be factory
wired to accommodate installation of a field start / stop
device. Only electromechanical switching devices are
permitted with in the hard wired circuit.
4.1.1.30 Fuses shall not be used in the main circuit of an MCC with
the following exceptions, if it is used to provide current
limiting function as part of circuit breaker.
4.1.1.31 Fuses shall be non renewable type. Fuse body shall not be of
glass and rated a minimum of 240 V.
4.1.1.32 If the switching assembly is feeding a motor, all motors shall
have overload and instantaneous over current. Combination of
thermal & magnetic breaker is acceptable.
4.1.1.33 An overload of any of the three phase conductors shall open
the main circuit to the motor.
4.1.1.34 Trip characteristics shall be automatically ambient
compensated. It shall be adjustable over a range of 90 to 110

percent with the switching assembly compartment door

closed.
4.1.1.35 The switching assemblies shall be provided with individual
control transformer will supply all control powers except
space heater supply.
4.1.1.36 At least one space heater shall be provided within each
vertical section and shall be designed to eliminate internal
condensation. Space heater shall be accessible, designed to
operate continuously and the power supply shall be fed from
an external source.
4.1.1.37 All name plates tag, catalog designation and warning name
plate shall be provided with the unit.
4.1.2 Feeder Circuit Breaker
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
Control relay shall be heavy duty industrial type and time

delay shall be adjustable with spare N.O & N.C contacts.
Push buttons shall be heavy duty and oil tight rated
minimum 10 amperes continuous.

4.2 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
5 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.

5.1.11 No devices (circuit breaker, terminal blocks, relays etc.)

shall be field installed within the wire ways of MCC.
5.1.12 Barriers shall be placed in all services-entrance of motor
control centers to isolate service bus bars and terminals from
the remainder of MCC.
5.1.13 The ampere rating or setting of all over current protective
devices shall not exceed the rating of the common power bus.
5.1.14 If the MCC is within the same electrical room as the switch
gear from which it is fed, no main disconnector shall be
installed with in the MCC.
5.1.15 If the MCC is not within the same electrical room as the
switch gear from which it is fed, and if local isolation is
required a switch shall be specified as the main disconnector
inside MCC.
5.1.16 No intermediate circuit breaker shall be installed between
the switch gear and the MCC.
5.2 Installations of Circuit Breaker/Starters Inside MCC
5.2.1 Set motor circuit protectors and circuit breaker based on the
connected load.
5.2.2 Check and provide thermal over load on each phase of a unit
to match overload to motor full load current.
5.2.3 Install conduits, wires/cables and grounding interconnections
as per NEC and other standards.
5.2.4 Verify the name plate and other identifications for accuracy
and compliance and requirements.
6 INSPECTION & TESTING
6.1 Inspections and testing shall be performed in accordance with the code
and client specifications.
7 Associated Documentation
7.1 Low Voltage Motor Control Centers Checklist (QECP-007-01-MC)

LOW VOLTAGE MOTOR CONTROL CENTER INSTALLATION CHECKLIST

QECP-007-01-MC

CABLE NO: _____________________ SYSTEM: _________________
SI. NO. INSPECTION POINTS ACCEPT REJECT N/A

1 Check MCC for any damage during shipping.
Open and Check all compartments to verify size& type
2 breakers provided as per requirements.
Starters, overload protection settings as per project's
3 requirements.
Physical check on power circuit wires, control wiring
4 connotations.
Race ways fitting given as per top feed or bottom
5 feed of MCC.
Check all indicating lights (start, stop and trip ) are
6 working.
Check the draw-out tray bus bar spacing, isolation
7 barrier and locking mechanism are as per standard.
Foundation and mounting, in such a way that no
8 water get into MCC.
Space between the wall, space between the other units
9 & back to back mounting space as per standard.
10 Grounding as per standard.
No instrument installed in vertical and horizontal wire
11 ways.
Out going wires terminations tight properly and
12 pulled through the vertical and horizontal wire ways.
13 Bushings are provided for all conduit entry.
Check the space heater in working condition and out
14 side power given
15 Labels, tags etc. are as per the requirement and as per
the specification.
Remarks: _______________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

Signature:
Name:
Date:

DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF DRY-TYPE TRANSFORMERS
DOCUMENT NO.:
MACO-QECP-016
Index Page
1 Scope 2
2 References 2
3 Materials 2
4 Quality Control 3
5 Construction
Procedures 3
6 Documentation 3

DESCRIPTION
NO. DATE BY BY BY
Dry-Type Transformers Page 1 of 3 MACO-QECP-016

INSTALLATION OF DRY-TYPE TRANSFORMERS
1 SCOPE
a) This procedure covers the inspection and test procedure pertaining to

the installation of dry type transformers
b) This procedure shall be applied to the inspection, method and criteria
for installation work carried out by the Electrical Department.
NEC National Electric Code

NEMA National Electrical Manufacturers Association
UL Underwriters Laboratories.
SAES-P-100 Basic Power System Design Criteria
SAES-P-114 System & Equipment Protection
SAES-P-121 Transformers.
SAES-P-111 Grounding System.
ANSI American National Standards Institute
3 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.

4 QUALITY CONTROL
CHECK FOR THE FOLLOWING:
a) The transformer nameplate data will be checked against technical

specification to ensure its conformity.
b) The transformer concrete foundation will be checked for cleanliness and
proper level.
c) Check the location and alignment of cable ducts to ensure sufficient
clearance for entry and glanding of cables.
d) The winding insulation resistance will be megger tested and recorded.
e) Check the feeder cable sizes and type in conformance with the design and
specification. Ensure continuity and megger tests have been done prior to
termination.
f) Check earthing connection is potentially bonded to main grounding grid.
5 CONSTRUCTION PROCEDURE
a) Construct concrete foundation and other structures in accordance with

approved design drawings and Proponent Standard.
b) Install transformer in position and ensure cable duct is in their correct
location and cables are properly oriented.
c) The transformer will be inspected for mechanical damage and shall be
securely fastened with bolts, nuts and washers.
d) Prior to connection of power and control cables, check will be carried out
on the transformer windings and protective devices.
e) The winding insulation resistance will be Megger tested in accordance with
Aramco Test procedure 7825 as follows:
1. 480V Transformer Megger at 1000 V
2. 4.16V Transformer- Megger at 5000V
3. 13.8V Transformer Megger at 5000V
The test will be conducted between primary and secondary windings to
earth and between the two windings.
All tests will be conducted by Site Electrical Supervisor witnessed and
recorded by the Site Electrical QC Inspector.
f) Connect all earthing connection and bond all metal structures to main
ground grid.
6 DOCUMENTATION
a) Form QECP-016-01-DT Dry Type Transformer Inspection record.

b) Form QECP-016-02-DT Test records.

DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF OIL-FILLED TYPE
DISTRIBUTION TRANSFORMERS
DOCUMENT NO.:
MACO-QECP-017
Index Page
1 Scope 2
2 References 2
3 Materials 2
4 Quality Control 3
5 Documentation 3

DESCRIPTION
NO. DATE BY BY BY
Oil-Filled Type Distribution Transformers Page 1 of 4 MACO-QECP-017

INSTALLATION OF OIL-FILLED TYPE DISTRIBUTION

TRANSFORMERS
1 SCOPE
installation of Power Transformer.
NECA National Electrical Contractors Association

Standard of Installation
NETA National Electrical Testing Association
SAES-Q-Series Concrete Construction
SAES-T-Series Communication
UL Underwriters Laboratories
SAES-P-100 Basic Design Criteria
SAES-P-104 Wiring Methods & Materials
SAES-P-119 Substation.
SAES-P-111 Grounding System.
ANSI American National Standards Institute
API American Petroleum Institute
IEEE Institute of Electrical & Electronics Engineers.
FM Factory Manual Corporation.
3 MATERIALS CONTROL
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 Materials Department
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.
g) Where oil immerses transformer is delivered oil-filled, the oil level will
be checked to ensure no leakage.
h) 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.
4 QUALITY CONTROL
INSTALLATION AND TEST
a) The mechanical erection group in accordance with their quality

control procedure will carry out the transformer installation.
b) Prior to installation ,the transformer foundations will be checked for
cleanliness and proper elevation as per approved design drawing
c) Check the location and alignment of cable ducts to ensure sufficient
clearance for entry and glanding of cables
d) The installation of the transformer will be witnessed by the Site
Electrical QC Inspector to ensure correct orientation and alignment
of bus duct and or cables.
e) The transformer will be inspected for mechanical damage and shall
be securely fastened with bolts, nuts and washers.
f) Connect all earthing connections and bond all metal structures to
main ground grid. Prior to connection of the power & control cables
or bus ducts checks will be carried out on the transformer windings
and protective devices.
g) The winding resistance will be megger tested in accordance with
Aramco Test Procedure 7825 as follows:
1. 480V Transformer -Megger 1000V
2. 4.16V Transformer -Megger 5000V
3. 13.8V Transformer -Megger 5000V
The test will be conducted between the primary and secondary
windings to earth and between the two windings.
All tests shall be conducted by the Site Electrical Supervisor
witnessed and recorded by the Site Electrical QC Inspector.
h) For transformer above 500KVA ,voltage ratio be checked by voltage
injection test and recorded

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)
5 DOCUMENTATION
a) Form QECP-017-01-OT Oil Filled Inspection Record.

b) Form QECP-017-02-0T Power Transformer Test Record.
c) Form QECP-017-03-OT Pre-commissioning Form-Test
Inspection Records

DOCUMENT TITLE:
PROCEDURE FOR:
INSTALLATION OF BATTERIES AND CHARGERS
DOCUMENT NO.:
MACO-QECP-018
Index Page
1 Scope 2
2 References 2
3 Materials 2
4 Quality Control 3
5 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Batteries and Chargers Page 1 of 5 MACO-QECP-018

INSTALLATION OF BATTERIES AND CHARGERS
1 SCOPE
a) This procedure covers the inspection and test procedure pertaining to

installation of batteries and battery charger and uninterrupted power
supply systems.
installation work carried out by the electrical department.
2 REFERENCE STANDARDS
SAES-0111 Power Supplies
SAES-P-100 Basic Design Criteria
SAES-P-103 Batteries and UPS System
ADP-P-176 Un-Interruptible Power Supply System
NEC National Electrical Code
ANSI American Electrical Manufactures Association
UL Underwriters Laboratories
3 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).

c) Particular attention will be paid to the condition of battery charging panels

which have panel fascia mounted instruments. Where these panels are sealed
to prevent the ingress of moisture of dust, they shall not be disturbed unless
damage is observed.
d) Batteries will be removed from their packing cases and inspected for damage.
Where batteries are received filled with electrolyte, the transport sealant will
be removed to allow air circulation prior to storage. Where batteries are
received dry, the sealant may be left in place.
e) Batteries will be returned to their packing cases and stored at a dry, clean and
preferably cool location according to manufacture instructions.
f) 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.
4 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.

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 Charger and Inverter Panel Installations
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 Inspection and Test
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.

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 Battery Installation Inspection/Charger Report.

DOCUMENT TITLE:
PROCEDURE FOR:
ELECTRICAL DUCT BANKS & MANHOLES
DOCUMENT NO.:
MACO-QECP-019
Index Page
1 Scope 2
2 References 2
3 Materials 2
4 Quality Control 2
5 Procedures 4
6 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Electrical Duct Banks and Manholes Page 1 of 4 MACO-QECP-019

INSTALLATION OF ELECTRICAL DUCT BANKS AND

MANHOLES
1 SCOPE
installation of underground utilities, duct bank, duct bank cables and
conduits.
b) This procedure shall be applied to the inspection ,method and criteria for
SAES-P-100 Basic Power System Design Criteria

SAES-P-104 Wiring Methods and Materials
SAES-B-068 Electrical Area Classification.
S.A.G.1.2.705 Splicing /Terminations.
SAES-P-111 Grounding Systems
3 MATERIALS CONTROL
a) Ensure that materials are handled in accordance with Proponent Procedure

and Materials control System.
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.
4 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

above finished level and accessible to authorized operating or maintenance

personnel.
c) Rigid plastic conduit (PVC) shall be used below slabs or grade, encased in
concrete, unless otherwise indicated on approved construction drawings.
Riser elbows and extensions above grade or concrete slabs shall terminate in
rigid steel conduit, using appropriate slabs PVC to steel adapter.
d) Plastic conduit (PVC) bends shall be factory made bends, or field bend using
approved heat box bender and conduit mandrels to assure full inside diameter
and prevent deforming or discolor conduit. All bends shall have a radius not
less than the required by NEC-346-10.
e) All underground work shall be in accordance with Section III.1.2
(Excavation and Backfill) Section III.1.4 (Trenching and Backfilling), SAES-
P-104 and Proponent Standard Drawings.
f) Check that an excavation permit has been obtained prior to commencement
of work on hazardous restrictive area.
1. Refer to SAES-T-928, Para 4.1.2.1 for information on processing and
co-ordination with Non Proponent agencies. Otherwise, work permits
shall be handled in accordance with G.I.No.2-100.
2. Extreme caution shall be exercised when excavating near the existing
gas, oil and other hydrocarbon pipelines and power cables or
conductors. No work shall start in the vicinity of these facilities until
the proper work permits have been obtained and countersigned by the
appropriate agencies including PDD (Power Distribution Department)
where power cables or conduits are involved.
g) Check that level, location, and depth of trenches are correct.
h) Check that installation of materials does not conflict with other services or
equipment.
i) Check the preparation of cable or conduit trenches prior to installation.
j) Check that the material is installed according to Manufacturers
recommendations.
k) The minimum depth of burial and restoration requirements for underground
installation shall be as specified in SAES-P-104 and comply with Proponent
Standard Drawings.
l) All underground cable or conduit routes shall be marked with appropriate
post cable markers at 30 m intervals, at every junction and at every change of
direction as per Proponent Standard Drawings.
m) Following installation of cables/conduits, prior to termination to electrical
equipment, the cables shall be subject to an insulation resistance test. Low
voltage (600V and below) cables, including cable splices and existing cables,
shall be 500V DC megger tested after installation (prior to backfilling in the
case of direct buried cables) and prior placing in service. Medium voltage
cables (5KV and above) shall be tested as per SAES-P-104,Para 9.2. Record
results for low voltage cables on approved forms and medium voltage cables
on approved Proponent Form.

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.
6 DOCUMENTATION
Form QECP-019-01-DB Duct Manhole

Form QECP-019-02-DB Field inspection Checklist /Electrical Manhole
Form QECP-019-03-DB Underground Cable Duct Bank Test
Form QECP-019-04-DB Under ground Electrical Conduit.

DOCUMENT TITLE:
PROCEDURE FOR:
INSIDE BUILDING PIPING AND FITTINGS
DOCUMENT NO.:
MACO-QMCP-001
Index Page
1 Purpose 2
2 Definitions 2
3 Safety 2
4 References 2
5 Quality Procedures 3
6 Documentation 5
001 04/09/09 MACO-QMCP-001 APT GJR NZ

DESCRIPTION
NO. DATE BY BY BY
Inside Building Piping and Fittings Page 1 of 5 MACO-QMCP-001

INSIDE BUILDING PIPING AND FITTINGS
This quality Procedure shall cover inspection works for Piping and Fitting works inside
buildings.
1.0 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
QMP Quality Management Procedure
3.0 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 General Requirements for Pressure Testing.
SAES L - 001 Piping Standards
SAES L 005 Piping Components
SAES L 008 Selection of Valves
SAES L 009 Metallic Flanges, Gaskets and Bolts for Low and
Intermediate Temperature Service.
SAES L - 032 Material Selection of Piping Systems
SAES L 042 Plant Utility Stations

SAES S 050 Sprinkler & Standpipe System Components in

Buildings.
SAES S 060 Saudi Aramco Plumbing Code
SAES S 070 Installation of Utility Piping System
04-SAMSS 001 Gate Valves
04-SAMSS 002 Globe Valves
04-SAMSS 005 Check Valves
04-SAMSS-035 General Requirements for Valves
ANSI B 31.9 Building Service Piping
ASTM D 3311 PVC Plastic Pipe Schedule 40
ASTM D 2729 PVC Sewer Pipes and Fittings
AWWA C 651 Disinfecting Water Mains
SAES B 067 Safety Identification and Color Coding
SAES B 069 Emergency Eye Washes and Showers
SAES B Series Safety and Fire Water
SAES H 200 Storage, Handling and Installation of Pipe

Externally Coated with FBE or Polyethylene
SAES H 204 General Specifications of applying Heat-Shrink

Sleeves to Coated Pipes.
SAES H 203 Hand Applied Tape Wrapping of Buried Pipes.
5.0 QUALITY PROCEDURES
5.1 Piping Works
5.1.1 Perform work in accordance with Proponent and referenced

International Codes and standards.

5.1.2 Conform to SAES Codes for installation of backflow preventive

devices.
5.1.3 Below grade utility and drinking water piping shall be Type K copper
tube hard drawn temper conforming to ASTM B-88 with wrought
copper solder joint fittings compliant to ANSI B-16.22 (Solder using s/s
tin antimony solder.
5.1.4 Above grade utility and drinking water piping shall be Type L copper
tube hard drawn temper.
5.1.5 Dielectric unions shall be provided between dissimilar materials.
5.1.6 All under slab sanitary sewer pipes from fixtures to the building main
and up to 1.5 m from the building shall be PVC pipe Schedule 40.
Fittings shall be PVC schedule 40. Solvent weld shall comply with
ASTM D 2564 solvent cement.
5.1.7 All overhead and furred in sanitary sewer pipes form fixtures up to the
crisp of riser shall be acid-resisting oakum (appropriate rubber gaskets
are also ok).
5.1.8 Above and below grade acid-resistant pipe shall be schedule 40
polypropylene and joints shall be heat fusion bonded. PVC schedule 40
now acceptable for battery rooms (no solvents or hydrocarbon waste
allowed).
5.1.9 All roof drain and vent shall be galvanized steel, class 125.
5.1.10 Downspout exterior to building shall be corrugated sheet metal or
galvanized steel, class 125.
5.1.11 All excavations shall be restored to its required level. The bottom of
trench shall be dry prior to installation (Sand bedding / surround to be
used).
5.1.12 After installation, all pipe ends shall be capped to prevent egress of
unsuitable materials.
5.1.13 The trench bottom shall be continuous, smooth, free of rocks and in
accordance to the line and grade shown in the drawing.
5.2 Installation
5.2.1 Remove foreign matter from inside of pipe before installation.
5.2.2 Adequately support vertical lines at their bases or by a suitable hanger

place in horizontal line near riser or by a base fitting set on pedestal.
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.

5.2.5 Provide flanges and unions throughout piping system to facilitate the
installation and removal of piping and equipment.
5.2.6 Provisions must be included for servicing and removal of equipment

without dismantling piping works.
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 Do not install underground piping when bedding is wet.
5.2.9 Cut pipe ends with pipe cutter only. Hacksaw cutting shall not be
allowed.
5.2.10 Provide adapter where C.I. pipes connects PVC pipes.
5.2.11 Pecking, caulking and doping of pipes shall not be allowed.
6.0 DOCUMENTATION.
Inspection and Test Plan
Inspection and Test Record

DOCUMENT TITLE:
PROCEDURE FOR:
PIPE SLEEVES
DOCUMENT NO.:
MACO-QMCP-002
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
6 Quality Procedure 3
7 Documentation 4

DESCRIPTION
NO. DATE BY BY BY
Pipe Sleeves Page 1 of 4 MACO-QMCP-002

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 This procedure shall be used in conjunction with applicable manufacturers

installation and maintenance instruction manuals.
2 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. To achieve acceptable installation requirements and workmanship.
3 DEFINITIONS
HVAC Heating, Ventilating and Air Conditioning.
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
SAES-K-001 Heating, Ventilating and Air-Conditioning.

SAES-K-100 Saudi Aramco Mechanical Code (HVAC)
SAES-M-100 Saudi Aramco Building Code
SAES-S-060 Saudi Aramco Plumbing Code
SAMSS Saudi Aramco Material System Specifications
6 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.

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.
7 DOCUMENTATION
7.1 QMCP-002-01-ITP - Inspection and Test Plan
7.2 QMCP-002-02-QR - Quality Record.

DOCUMENT TITLE:
PROCEDURE FOR:
ANCHORS, SUPPORTS AND THRUST BLOCKS
DOCUMENT NO.:
MACO-QMCP-003
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
7 Documentation 4

DESCRIPTION
NO. DATE BY BY BY
Anchors, Supports and Thrust Blocks Page 1 of 4 MACO-QMCP-003

ANCHORS, SUPPORTS AND THRUST BLOCKS
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 DEFINITIONS
HVAC Heating, Ventilating and Air-Conditioning
4.0 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 Heating, Ventilating and Air-Conditioning
SAES-K-100 Saudi Aramco Mechanical Code (HVAC)

SAES-S-070 Installation of Utility Piping System
SAES-S060 Saudi Aramco Plumbing Code
SAES-l-011 Flexibility, Support and Anchoring of Piping.
ASME-B-31.9 Building Services Piping.
UMC Uniform Mechanical Code
Company Proponent
6.1 General
6.1.1 All HVAC equipment to be supplied and installed shall have

prior approval from the Company. All equipment shall meet the project
specifications and suitable for installation as required and in compliance
with the manufacturers recommendations.
1
6.2 Quality Control
6.2.1 Deliver, store, protect and handle products as per manufacturers and
Proponents requirements.
6.2.2 Materials, design and manufacture of supports, anchors and thrust blocks
shall conform to SAES standards and Code.
6.2.3 Selection and application shall conform to SAES standards and codes.
6.3 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 Thermoplastic pipes shall be protected from contact with concrete by tape
wrapping. Concrete thrust blocks shall be placed after hydrostatic test for
non-restrained gasketed joint RTR piping and neoprene for RTR and
thermoplastic pipes.

6.3.4 Install in accordance with manufacturers instructions.
6.3.5 Install supports at every direction.
6.3.6 Provide trapeze hangers for several pipes in parallel and at the same
elevations.
6.3.7 Exposed steel hangers and supports shall be prime coated.
6.3.8 Space pipe hangers in accordance with design specifications.
6.3.9 All HVAC equipment, which is floor, mounted shall be set on solid
concrete base. Provide templates, anchor bolts and accessories for mounting
and anchoring equipment.
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
Quality Record

DOCUMENT TITLE:
PROCEDURE FOR:
VIBRATION ISOLATION
DOCUMENT NO.:
MACO-QMCP-004
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
7 Documentation 3

DESCRIPTION
NO. DATE BY BY BY
Vibration Isolation Page 1 of 4 MACO-QMCP-004

VIBRATION ISOLATION
1.0 SCOPE
1.1 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.
2.0 PURPOSE
2.1 To provide vibration isolators of the appropriate sizes and proper loading to meet
the specified deflection requirements in conformance with manufacturers
recommendations.
3.0 DEFINITIONS
3.1 HVAC Heating, Ventilating and Air-Conditioning
3.2 QCP Quality Control Procedure
3.3 ITP Inspection and Test Plan
4.0 SAFETY
4.1 To ensure that Work Permit is valid, if applicable and all works done in the safest
5.0 REFERENCES
5.1 SAES-K-001 Heating, Ventilating and Air-Conditioning
5.2 SAES-K-100 Saudi Aramco Mechanical Code (HVAC)
5.3 ASHRAE American society of Heating, Refrigeration and

Air- conditioning Engineers.
6.1 Installation.
6.1.1 Install in accordance with manufacturers instructions.

6.1.2 Install isolation for motor-driven equipment.
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 Prior to making piping connections to equipment with operating weights

substantially different from installed weights, block up equipment with
temporary shims to final height. When full load is applied, adjust isolators
to load to allow shim removal.
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 Provide resiliently mounted equipment, piping and ductwork with seismic
snubbers. Each inertia base shall have minimum of 4 seismic snubbers located
close to isolators. Snub equipment designated for post disaster use to 0.05 inch
(1.5 mm) maximum clearance. Other snubbers shall have clearance between 0.15
inch (4.0 mm) and 0.25 inch (7.0).
6.4 Support piping connections to isolated equipment resiliently for scheduled

distance to nearest flexible pipe connector as follows:
6.4.1 Up to 4.0 inch (100 mm) first 3 points of support.
6.4.2 5.0 to 8.0 inch (125 to 200 mm) first 4 points of support.
6.4.3 10.0 inch (250 mm) first 6 points of support.
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.

EQUIPMENT ISOLATION SCHEDULE
Minimum operating Isolation

Equipment Isolator Efficiency
Deflection
-
Air handling Unit Neoprene pads 0.2
Air Cooled Condensing Neoprene Pads 0.2 -
Packaged A/C Units

Not required for on
(Check manufacturers - -
grade installation
literature)
Packaged A/C units on On roof curb with
- -
roof Neoprene pads
Workshop Equipment As per manufacturers recommendations
7.0 DOCUMENTATION

DOCUMENT TITLE:
PROCEDURE FOR:
AIR HANDLING UNIT
DOCUMENT NO.:
MACO-QMCP-005
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
6 Equipment Units 3
7 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Air Handling Unit Page 1 of 5 MACO-QMCP-005

AIR HANDLING UNIT
1.0 SCOPE
1.1 This procedure covers for inspection to be followed during installation of Air
Handling units as per project specifications and accepted international codes and
standards.
1.2 This procedure shall be used in conjunction with applicable manufactures

installation and maintenance manual.
2.0 PURPOSE
2.1 To ensure that all items required by this contract shall conform to project
3.0 DEFINITIONS
3.1 HVAC - Heating, Ventilating and Air-Conditioning
3.2 QCP - Quality Control Procedure
3.3 ITP - Inspection of Test Plan
4.0 SAFETY
5.0 REFERENCE
5.1 17-SAMSS0503 NEMA Frame Motors
5.2 ARI American Refrigeration Institute
5.4 SAES-K-002 Air-Conditioning Systems for Essential Operating

Facilities

5.5 SAES-K-003 Air-Conditioning System for Communication Building
5.7 ASHRAE American Society of Heating, Refrigeration and Air-

Conditioning Engineers
5.8 NEPA-90A Air-Conditioning and Ventilation System
6.0 EQUIPMENT UNITS
6.1 General
6.1.1 Unit shall be central station modular air-handler and shall be delivered to
site in one (1) piece.
6.1.2 Unit shall be vertical or horizontal draw through as indicated on

equipment schedule drawings.
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 All units shall be supplied with a longitudinal 12-gage, galvanized steel
structural perimeter base rail that shall serve as a housekeeping rail when
unit is installed.
6.1.5 Unit shall be capable of shipping fully assembled up to 40 ft. in length.
6.1.6 Sections supplied as separate components shall have mating flanges for
bolted assembly. Bolts shall be 5/16 inch and be located no further than
6.0 inch in center.
6.1.7 Units shall have provision for installation of instrumentation site.
6.2 Fan Section
6.2.1 Fan shall be constructed of insulated galvanized steel and have formed
channel base for integral mounting of and assembly and casing panels.
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 vibration-
absorbent fan discharge seal.

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 Fans shall be double-width, double-inlet type with airfoil or forward curve
section blades.
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 roller-
type 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 All coil sections shall be constructed of insulated mill galvanized steel
panels.
6.3.2 All coils shall be factory tested at 400 psig air pressure while sub-
merged in water.
6.3.3 Coil performance shall be certified in accordance with ARI standard 410.
6.4 Filter Section
6.4.1 Each filter shall be designed and constructed to house the specific type of
filter shown on the equipment schedule. Filter efficiencies shall be in
accordance with ASHRAE STD 52.
6.4.2 Filter mixing box section shall accept 2.0 inch thick disposable type
fiberglass filter with 20 25% average efficiency as per ASHRAE test
methods.

6.5 Damper Sections
6.5.1 Mixing boxes and filter-mixing boxes shall have opposed blades,
interconnecting outside-air and return-air dampers for outdoor units only.
6.5.2 All mixing boxes and filter-mixing boxes shall have a double-walled
hinged access door as specified.
6.5.3 All damper blades shall be galvanized steel, housed in a galvanized steel
frame and mechanically fastened to a hex axle rotating in stainless steel
bearings.
6.5.4 All dampers shall be opposed blade type and rated for a maximum leakage
test per square foot of 7.0 cfm. Per ft. at 1.0 inch w.g.
6.6 Access and Plenum Sections
6.6.1 Access and plenum sections shall be installed where indicated on the
drawings and shall be as specified on the equipment schedule.
6.6.2 Access sections shall have a double walled hinged door and 16 gage
floors to protect insulation.
7.0 DOCUMENTATION
Inspection and Test Plan.
Inspection and Test Record.

DOCUMENT TITLE:
PROCEDURE FOR:
AIR COOLED CONDENSING UNIT
DOCUMENT NO.:
MACO-QMCP-006
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
6 Quality Procedures 3
7 Documentation 4

DESCRIPTION
NO. DATE BY BY BY
Air Cooled Condensing Unit Page 1 of 4 MACO-QMCP-006

AIR COOLED CONDENSING UNIT
1.0 SCOPE
1.1 This covers procedures for inspection to be followed during installation of air-
cooled, 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 This procedure shall be used in conjunction with the applicable manufacturers
installation and maintenance instruction manual.
2.0 PURPOSE
2.1 To ensure that all equipment required by this contract shall conform to project
2.2 This procedure shall ensure that the main inspection requirements are met and that
2.3 To achieve acceptable workmanship and installation procedures.
3.0 DEFINITIONS
3.1 HVAC - Heating, Ventilating and Air-Conditioning
3.2 QCP - Quality Control Procedure
3.3 ITP - Inspection and Test Plan
3.5 Company - Proponent
4.0 SAFETY
4.1 To ensure that work Permit is valid, if applicable and all works done in the safest
5.0 REFERENCE
5.1 17-SAMSS0503 NEMA Frame Motors

5.2 SAES-K-001 Heating, Ventilating and Air-Conditioning.
5.3 SAES-K100 Saudi Aramco mechanical Code (HVAC)
5.4 ASHRAE American Society of Heating, Refrigeration and Air-

Conditioning Engineers.
6.1 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 Do not select evaporator/condensing unit operating suction temperatures

at less than 36F.
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 Provide special attention to units where significant distances (Vertical and
/ or horizontal) exist between evaporator and condensing unit locations.
6.1.5 Check the approval of all evaporator and condensing unit showing
certified combined performance ratings, refrigerant suction temperature
and proposed refrigerant line sizes.
6.2 Equipment
6.2.1 Unit shall be a serviceable semi-hermetic type compressor equipped with

internal vibration isolation, positive lubrication, crank case heater with
relay, motor overload protection, suction and discharge shut-off, service
vales, filter dryer, sight glass and a suction and discharge pressure gauge for
each refrigerant circuit.
6.2.2 Compressor shall be mounted on spring vibration isolators with minimum

95% isolation efficiency.
6.2.3 Condenser casing to be fully be mounted on spring vibration isolators with

minimum 95% isolation efficiency.
6.2.4 Condenser casing to be fully weatherproof, constructed of galvanized steel,

zinc phosphatized and finished with enamel.

6.3 Installation
6.3.1 Install in compliance with manufacturers recommendations.
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.
7.0 DOCUMENTATION
7.1 Inspection and Test Plan
7.2 Quality Record

DOCUMENT TITLE:
PROCEDURE FOR:
PACKAGE AIR CONDITIONING UNIT
DOCUMENT NO.:
MACO-QMCP-007
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 3
7 Documentation 4

DESCRIPTION
NO. DATE BY BY BY
Package Air Conditioning Unit Page 1 of 4 MACO-QMCP-007

PACKAGE AIR CONDITIONING UNIT
1.0 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.
installation and maintenance.
2.0 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 To achieve acceptable workmanship and installation procedures.
3.0 DEFINITIONS
4.0 SAFETY
5.0 REFERENCES
5.1 SAES-K001 Heating, Ventilating and Air-Conditioning.

5.2 SAIS-K-100 Saudi Aramco Mechanical Code (HVAC)
5.3 ARI American Refrigeration Institute
5.4 17-SAMSS-503 NEMA Frame Motors
6.0 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 Provide necessary controls for operation of the compressor below the
normal temperature of the compressor cutout.
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.
6.1 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.
6.2 Balancing and Testing
6.2.1 Operate the unit and check for proper air quantity supply, noise and
correct operations.

6.2.2 Report the airflow, static pressure, voltage and current draw of each item,
refrigerant pressure readings etc. as required by specifications.
7.0 DOCUMENTATION
7.2 Quality Record

DOCUMENT TITLE:
PROCEDURE FOR:
DUCTWORKS
DOCUMENT NO.:
MACO-QMCP-008
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
7 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Ductworks Page 1 of 5 MACO-QMCP-008

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
2.2 This procedure shall insure that the main inspection requirements are met and
that the findings and corrective actions are followed.
3. DEFINITIONS
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
5.3 SAES-M-100 Saudi Aramco Building Code

5.4 NFPA 90A Installation of Air-Conditioning and Ventilating System.
5.5 NFPA 91 Installation of Blower and Exhaust System
5.6 AWS D-9.1 Welding of sheet Metal
5.7 SMACNA HVAC Air Duct Leakage Test Manual
5.8 SMACNA HVAC Metal and Flexible Duct Construction Standards.
5.9 UL 181 Factory made Air Ducts and Connectors
5.10 ASTM A-36 Structural Steel
5.11 ASTM A-526 Requirements for Steel Sheets, Zinc-coated by hot dip
Process
5.12 ASTM A-568 Steel Sheets, Carbon and High Strength, Low-alloy Hot-
rolled and Cold-rolled
5.13 SMACNA Fire Damper Installation Guide
6. QUALITY PROCEDURES
6.1 Fabrication and Installation.
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 Fabricate continuously welded round and rectangular duct fittings two
gages heavier than the duct gages. Joints shall be minimum 4 cemented
slip joint. Prime coat all welded joints.
6.1.4 Apply interior of duct coats compatible with fume exhausted.
6.1.5 Install all fabricated ducts in accordance with SMACNA HVAC Duct
Construction Standards Metal and Flexible.

6.1.6 Provide openings to accommodate thermometers, controllers and pilot

tube for testing of system complete with metal can with spring device or
screw to ensure against air leakage.
6.1.7 Ducts must be located in sufficient spaces around equipment to allow

normal operating and maintenance activities.
6.1.8 Connect diffuser to low-pressure ducts directly held in place by strap or

clamp.
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.

6.3 Testing
6.3.1 Duct testing shall be by light test method.
6.3.2 A flash of light shall be introduced inside the finished duct works to
check if any ray of light is escaping form the inside of duct to signify
openings, cracks or damages.
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
7.2 Quality Record

DOCUMENT TITLE:
PROCEDURE FOR:
DUCTWORKS ACCESSORIES
DOCUMENT NO.:
MACO-QMCP-009
Index Page
1 Scope 2
2 Purpose 2
3 References 2
4 Definitions 2
6 Procedure 3
7 Documentation 4

DESCRIPTION
NO. DATE BY BY BY
Ductworks Accessories Page 1 of 4 MACO-QMCP-009

DUCTWORKS ACCESSORIES
1.0 SCOPE
1.1 This covers procedures for inspection to be followed during installation of turning
vanes, duct access doors, fire dampers, combination fire / smoke damper, flexible
connectors, volume and control dampers.
1.2 This covers the inspection of all aspects of ductwork accessories.
2.0 PURPSOSE
2.2 This procedure shall insure that the main inspection requirements are met and that
3.0 DEFINATIONS
4.0 SAFETY
5.0 REFERENCES
5.3 SAES-M-100/UBC Saudi Aramco Building Code

5.4 NFPA 90A Inspection of Air-Conditioning and Ventilating System.
5.5 SMACNA Fire Damper Installation Guide
5.6 SMACNA HVAC Metal and Flexible Duct Construction Standards.
5.7 UL 33 Heat Responsive Links for Fire Protection Services.
5.8 ASHRAE American Society of Heating Refrigeration and Air-

Conditioning Engineers.
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 Install all accessories in accordance with manufacturers instructions.
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 Demonstrate re-setting of fire dampers to the company.
6.2.6 Provide flexible connections immediately adjacent to equipment in ducts

associated with fans and motorized equipment supported with vibration
isolators.

6.2.7 Provide balancing dampers at points on supply, return and exhaust system
where branches are taken from larger ducts for air balancing. Install
minimum 2 ducts width from duct take-off.
6.2.8 Provide balancing dampers on duct take-off to diffuser, gullies and registers
regardless of dampers are specified as part of the diffuser, gull or register
assembly.
7.0 ATTACHMENTS
7.2 Quality Record

DOCUMENT TITLE:
PROCEDURE FOR:
DUCTWORKS INSULATION
DOCUMENT NO.:
MACO-QMCP-010
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
7 Documentation 4

DESCRIPTION
NO. DATE BY BY BY
Ductworks Insulation Page 1 of 4 MACO-QMCP-010

DUCTWORKS INSULATION
1.0 SCOPE
1.1 This covers procedures for inspection to be followed during installation and
application of insulation, jackets and accessories for Ductwork Insulation.
1.2 This covers the inspection of all aspects of ductwork insulation works.
2.0 PURPOSES
2.1 To ensure that all ductworks required by this contract shall conform to the project
2.2 This procedure shall ensure that the main inspection requirements are met and
that the findings and corrective actions are followed.
2.3 To achieve acceptable workmanship and installation of equipments.
3.0 DEFINITIONS
4.0 SAFETY
5.0 REFERENCES

5.4 SMACNA Sheet Metal and Air-Conditioning Contractors National

Association.
5.5 NFPA National Fire Protection Association
5.6 ASTM-B-209 Aluminum and Aluminum-alloy Sheet and Plate
5.7 ASTM C-553 Mineral Fiber Blanket and Felt Insulation
5.8 ASTM C-612 Mineral Fiber Block and Board Thermal Insulation
5.9 ASTM E-84 Surface Burning Characteristics of Building Materials
5.10 ASTM-96 Water Vapor Transmissions of Materials
5.11 SMACNA HVAC Duct Construction standards Metal and Flexible
6.1 Install material in accordance with manufacturers instructions.
6.2 Insulated ductwork conveying air below ambient temperature.
6.2.1 Provide insulation with vapor barrier jackets.
6.2.2 Finish with tape bands and vapor barrier jacket or stickpins where
applicable for wide ducts.
6.2.3 Continue insulation through walls, sleeves, hangers and other duct
penetrations. Do not use combustible duct bands in return air plenum.
6.2.4 Insulate entire system including fittings, joints, flanges, flexible

connections and expansion joints.
6.3 Insulated ductwork conveying air above ambient temperature.
6.3.1 Provide with standard vapor barrier jacket.
6.3.2 Insulate fittings and joints. Where service access is required, bevel and
seal ends of insulation.

6.4 For ductwork exposed in mechanical equipment rooms or in finished spaces

below 10-ft. (3.0 M) above finished floor, finish with aluminum jacket.
6.5 For ductwork exposed to outside, finish with all-purpose weatherproof jacket.
When specified in section 5500 for cladding, finish with stainless steel 304
jackets.
7.0 DOCUMENTATION
Quality Record

DOCUMENT TITLE:
PROCEDURE FOR:
MECHANICAL IDENTIFICATION
DOCUMENT NO.:
MACO-QMCP-011
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
7 Documentation 5

DESCRIPTION
NO. DATE BY BY BY
Mechanical Identification Page 1 of 5 MACO-QMCP-011

MECHANICAL IDENTIFICATION
1.0 SCOPE
1.1 This covers procedures for inspection to be followed during the marking and
identification of materials to identify HVAC equipment.
1.2 This covers the inspection of all aspects of mechanical identification.
2.0 PURPOSE
2.2 This procedure shall insure that the main inspection requirements are met and that
3.0 DEFINITIONS
3.1 HVAC Heating, Ventilating and Air-Conditioning.
3.2 QCP Quality Control Procedure.
4.0 SAFETY
5.0 REFERENCES
5.2 SAES-B-067 Safety Identification and Color Codling
5.5 ASME A-13.1 Scheme for the Identification of Piping System

5.6 UMC Uniform Mechanical Code
6.0 QUALITIES PROCEDURES
6.1 Piping Identifications Install plastic nameplates with corrosive -resistant

mechanical fasteners or adhesives. Apply with sufficient adhesive to ensure
permanent adhesion and seal with clear lacquer.
6.2 Install tags with corrosion resistant chain.
6.3 Install plastic pipe markers completely around pipe in accordance with
manufactures instructions.
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 Identify thermostats relating to terminal boxes or valves with nameplates.
6.4.3 Identify valves and air-terminal units with numbered tags.
6.4.4 Tag automatic controls, instruments and relays to conform with control
schematic.
6.4.5 Identify piping, concealed or exposed with plastic pipe markers. Use tags
on piping (20 MM) and smaller.
6.4.6 Identify ductwork with plastic nameplates. Identify air-handling units with
identification number and area served.
6.5 Provide ceiling tacks to locate vales or dampers above T-bar type panel ceilings.
6.6 Attach to each valve an engraved, plastic identification tag indicating valve
manufacturer, style, size, normal position, contents of pipe and sequential ID
number. Tag identification to be as follows :
Service Abbreviation
Cold Drinking Water DW ( Cold )

Hot Drinking Water DW ( Hot )
Utility Water UW
Fire Water FW
Compressed Air CA
6.7 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
6.7.3 Part / Model Number
6.7.4 Serial Number
6.7.5 Date of manufacture
6.7.6 Mark / Tag Number
6.8 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.

7.0 DOCUMENTATION
7.2 Quality Record

DOCUMENT TITLE:
PROCEDURE FOR:
TESTING & BALANCING OF MECHANICAL
SYSTEMS
DOCUMENT NO.:
MACO-QMCP-012
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
7 Documentation 3

DESCRIPTION
NO. DATE BY BY BY
Testing & Balancing 0f Mechanical Systems Page 1 of 4 MACO-QMCP-012

TESTING & BALANCING OF MECHANICAL SYSTEMS
1.0 SCOPE
1.1 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.
2.0 PURPOSE
2.1 To conduct airside balancing of HVAC system in accordance with the project
specifications and accepted international codes and standards.
3.0 DEFINITIONS
4.0 SAFETY
5.0 REFERENCES
5.1 AABC Associated Air-Balance Council
5.2 ASHRAE American Society of Heating, Refrigeration and Air-Conditioning

Engineers
5.3 SAES-K001 Heating, Ventilating and Air-Conditioning.
5.4 SAES-K100 Saudi Aramco Mechanical Code (HVAC)
5.5 ARI American Refrigeration
5.6 NFPA 90 A Air-Conditioning and Ventilation System

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 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 Place HVAC systems and equipment in to operation and continue

operation during each working day of balancing and adjusting.
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 Measure discharge air temperature. Adjust leaving air temperature to

schedule setting at design.
6.1.5 After individual box balancing, set all boxes to full heat and measure zone
flows with flow measuring devices.
6.1.6 Test equipment vibration and vibration isolation system in accordance

with methods and procedures given in the testing, adjusting and balancing
chapter of ASHRAE Systems Handbook.
6.1.7 Provide testing on air-handling units located on roof and exhaust fans
located also on the roof.
6.2 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 Record system operating static pressures, suction and discharge. Adjust
system for design re-circulated air CFM. Adjust main and zone supply,
return and exhaust air ducts to proper design CFM.

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 Make changes in pulleys, belts and dampers or addition of dampers

required for correct air-balance as per AABC requirements.
6.2.5 After coil adjustments and VAV box setting, re-check settings as required.
6.3 Operation
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 Record sling psychometric readings of both dry and wet bulb
temperatures for outside air conditioning, air handling unit (air and out),
room conditions and thermostat settings and moisture transducer field
calibrations.
6.4 Acceptance
6.4.1 The following items are to be completed before requesting a final

inspection:
System Balancing
Control System Checkout
Operating Instructions
6.4.1 A representative of the balancing Agency is to be present to assist during

final inspections. Contractors technicians shall be available to operate the
system, make adjustments and assist in final inspections.
7.0 DOCUMENTATION

7.2 Quality Record

DOCUMENT TITLE:
PROCEDURE FOR:
WELDING OF STRUCTURAL AND PIPING
DOCUMENT NO.:
MACO-QMCP-013
Index Page
1 Scope 2
2 Purpose 2
3 Definitions 2
4 Safety 2
5 References 2
7 Documentation 3

DESCRIPTION
NO. DATE BY BY BY
Welding of Structural and Piping Page 1 of 3 MACO-QMCP-013

WELDING OF STRUCTURAL AND PIPING
1.0 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 : Quality Manual Procedures

3.2 QCP : Quality Control Procedures
3.3 ITP : Inspection and Test Plan
3.4 COMPANY : Proponent
4.0 REFERENCES
4.1 SAES-M-001 : Basic criteria for steel structures

4.2 12-SAMSS-007 : Miscellaneous Steel Structure
4.3 SAES-W-011 : Welding Requirements for on-plot piping
4.4 SAES-H-001 : Specification requirements for industrial coating
5.0 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 PROCEDURE & INSPECTION AND TEST PLAN
6.1 Procedures.
MACO works shall procure documented procedures and submit for

approval. These Procedures are to make reference to the applicable
specification standards.

( a ) Material
The Procedure shall cover material inspections and

documents.
( 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

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THIS QUALITY MANUAL IS THE ONLY

CONTROLLED AND VALID VERSION.

KINGDOM OF SAUDI ARABIA

P.O. BOX 10257, DAMMAM 31433

QA/QC MANUAL VOL. 2

P.O. BOX 10257, DAMMAM 31433

1 ISSUED FOR APPROVAL Prepared By: CHECKED BY APPROVED BY APPROVED BY

2 QA/QC Quality Manual APT YSB NMZ SMZ

Description Name Designation Signature Date

Prepared QA/QC Senior Engineer

Approved Assistant General

Quality Manual Vol. 2 MACO-QM-001

Revision No. Purpose of Revision Issue Date

0 Submitted for Approval. April 01, 2009

Quality Manual Vol. 2 MACO-QM-001

QUALITY CONSTRUCTION PROCEDURES

SL NO. PROCEDURE DESCRIPTION DOCUMENT NO.

2 SITE PREPARATION MACO-QCCP-002

4 ASPHALT CONCRETE PAVING & BASE COURSE MACO-QCCP-004

5 CONCRETE WORKS MACO-QCCP-005

6 GROUTING WORKS MACO-QCCP-006

7 PROTECTIVE COATING FOR BURIED CONCRETE MACO-QCCP-007

8 WATERPROOFING, CAULKING AND SEALING MACO-QCCP-008

9 PIPE INSTALLATION PROCEDURE MACO-QCCP-009

10 CONCRETE BATCH PLANT MACO-QCCP-010

11 MISCELLANEOUS METALS MACO-QCCP-011

12 SITE NON-ELECTRICAL PROCEDURE 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

QUALITY CONSTRUCTION PROCEDURES

SL NO. PROCEDURE DESCRIPTION DOCUMENT NO.

ELECTRICAL WORKS/INSTRUMENTATION WORKS

1 WIRES AND CABLES INSTALLATION PROCEDURE MACO-QECP-001

2 GROUNDING SYSTEMS PROCEDURES MACO-QECP-002

4 SWITCH BOARDS AND PANEL BOARDS PROCEDURE MACO-QECP-004

5 INSTRUMENT AND WIRING PROCEDURE MACO-QECP-005

6 INSTRUMENT CONTROL PANEL PROCEDURE MACO-QECP-006

7 FIRE ALARM SYSTEMS MACO-QECP-007

8 INSTALLATION OF LIGHTING SYSTEM MACO-QECP-008

9 POWER SYSTEMS MACO-QECP-009

10 INSTALLATION OF JUNCTION BOXES AND DEVICES MACO-QECP-010

11 INSTALLATION OF CABLE TRAYS MACO-QECP-011

12 INSTALLATION OF COMMUNICATION SYSTEMS MACO-QECP-012

13 INSTALLATION OF CONDUITS AND FITTINGS MACO-QECP-013

14 INSTALLATION OF DISCONNECT SWITCHES MACO-QECP-014

15 LOW VOLTAGE MOTOR CONTROL CENTER MACO-QECP-015

16 INSTALLATION OF DRY-TYPE TRANSFORMERS MACO-QECP-016

17 INSTALLATION OF OIL-FILLED TYPE TRANSFORMERS MACO-QECP-017

18 INSTALLATION OF BATTERIES AND CHARGERS MACO-QECP-018

QUALITY CONSTRUCTION PROCEDURES

SL NO. PROCEDURE DESCRIPTION DOCUMENT NO.

1 INSIDE BUILDING PIPING AND FITTINGS MACO-QMCP-001

2 PIPE SLEEVES MACO-QMCP-002

3 ANCHORS, SUPPORTS AND THRUST BLOCKS MACO-QMCP-003

4 VIBRATION ISOLATION MACO-QMCP-004

5 AIR HANDLING UNIT MACO-QMCP-005

6 AIR COLLED CONDENSING UNIT MACO-QMCP-006

7 PACKAGE AIR CONDENSING UNIT MACO-QMCP-007

9 DUCTWORKS ACCESSORIES MACO-QMCP-009

10 DUCTWORKS INSULATION MACO-QMCP-010

11 MECHANICAL IDENTIFICATION MACO-QMCP-011

Contract No.: ___ Reference: _

Location: ___ Project: _