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Training & Development Workshop

for
ELECTRICAL QA/QC

KCS ELECTRICAL
TRAINING TOPICS

About Quality Assurance (QA) and Quality


Control (QC)
Duties and Responsibilities of an Electrical

QC Inspector
Inspection Levels (Procurement Phase)
Inspection Levels (Construction Phase)
Documents Required for Inspection
Attachments

KCS ELECTRICAL DEPARTMENT


ABOUT QUALITY ASSURANCE (QA) and QUALITY CONTROL (QC)

1. Quality Policy - Overall intension and direction of an


organization with regard to quality.
2. Quality Planning - Activities that establish the objectives and
requirements for quality and for the application of quality
system.
3. Quality System - Organizational structure, procedures,
processes and resources needed to implement quality
management.
4. Quality Assurance - Plans and systematic activities
implemented within the quality system that provide
confidence that an entity will fulfill requirements for quality.
5. Quality Control - Operational techniques and activities that
are used to fulfill requirements.
6. Conformity - Fulfillment of specified requirement.
7. Non-conformity - Non-fulfillment of specified requirement.

KCS ELECTRICAL DEPARTMENT


ABOUT QUALITY ASSURANCE (QA) and QUALITY CONTROL (QC)

8. Project Specification - A document stating requirements


which include drawings or other relevant records to
indicate the means and the criteria whereby conformity
can be checked.
9. Project Standard - A document stating requirement and
guideline to perform the task required by the project
specification.

KCS ELECTRICAL DEPARTMENT


DUTIES & RESPONSIBILITIES of an ELECTRICAL QC INSPECTOR

The responsibilities of the Electrical QCI are as follows:

1. To carry out off site inspections for materials during


manufacturing, before delivery to site, if required by the client
and the Project Quality Plan (PQP).
2. Upon delivery of ordered materials, to check full conformance
of all electrical materials and related accessories to both the
specifications and the purchase order and resolve any non-
conformance of the received goods by taking the appropriate
corrective action .
3. Assemble all Manufacturer’s Instructions received inside the
packaging of the materials, to be retained for the Client.
4. To check, if any, materials supplied by the Client for fitness and
suitability to the work required.
5. To perform routine inspection on completed works and inform
the Client’s Representative by the official RFI form as and when
their presence is required to carry out the inspection.
KCS ELECTRICAL DEPARTMENT
DUTIES & RESPONSIBILITIES of an ELECTRICAL QC INSPECTOR

6. To accompany the client’s representative to carry out routine


inspections and release Hold Points.
7. To maintain and keep records of daily Electrical QA/QC reports
for reference.
8. To co-ordinate with Third Party Independent Testing Agencies
and Sub-contractors, if applicable; to ensure their full
compliance with KCS Quality Procedures (CQPs).
9. Filing, compiling and reviewing all relevant documentation
and Test Reports and to prepare all Dossiers to be handed over
and to clear out all Non-conformances.
10. Review comments of audit assessment findings and propose to
his management the recommended Corrective Action; to
rectify the situation.
11. Assist in the preparation of additional work procedures dealing
with the installation of electrical installations; if no such
procedure exists.

KCS ELECTRICAL DEPARTMENT


DUTIES & RESPONSIBILITIES of an ELECTRICAL QC INSPECTOR

12. Shall check and verify if all the testing and monitoring
equipment has been calibrated and certified by an approved
Third Party and that the Calibration Certificate is still valid.
13. After completion of the work; to assist the Technical Office
Engineer (TOE) in the preparation and submittal of Operation
& Maintenance Manuals.
14. To assist the Electrical Site Discipline Engineer (SDE) in the
preparation of As-built Drawings after the work completion.

KCS ELECTRICAL DEPARTMENT


INSPECTION LEVELS (Procurement Phase)
1. LEVEL 0 - No inspection is required.

2. LEVEL 1 - Only final inspection is required before shipping.

3. LEVEL 2 - Includes as a minimum inspection meetings, one


or more un-specified "in progress" surveillance
visit (s) to consider all witness and hold points,
final inspection and release shipment.

4. LEVEL 3 - Includes as a minimum inspection meetings, "in


progress“ surveillance inspection shall be on
regular basis (daily, weekly, monthly etc.) as
specified by key factors.

5. LEVEL 4 - Resident inspector continuously monitoring the


work.

KCS ELECTRICAL DEPARTMENT


INSPECTION LEVELS (Construction Phase)
1. Record review “R” - where the inspection/test records are
considered enough for client satisfaction.

2. Surveillance inspection "S“ - here the monitoring of works is


considered enough for client satisfaction.

3. Witness inspection "W" - where the client is invited to witness


the inspection test, however, his presence is not mandatory
and in case the client representative does not show up, the
work will proceed.

4. Hold point inspection "H" - where the works cannot proceed


unless inspection/test is witnessed and approved by the client
representative.

KCS ELECTRICAL DEPARTMENT


DOCUMENTS REQUIRED FOR INSPECTION

1. ITP – Inspection and Test Plan

2. CL’s – Checklists

3. CMS – Construction Method Statement

4. RFI – Request for Inspection

Note: Item nos. 1, 2 and 3: Approval by the client is necessary


before starting the construction activities.

KCS ELECTRICAL DEPARTMENT


INSPECTION AND TEST PLAN (ITP)
ITP is consists of the following sections:

1. Document Review
2. Receiving Inspection
3. Installation
4. Pre-Commissioning
On every section of the ITP, enumerate the specific activity and
indicate the applicable Quality documents per Project
Specifications.

Note: Attached is a copy of Saudi Aramco ITP as reference

KCS ELECTRICAL DEPARTMENT


CHECKLIST (CL)
Checklist is consists of the following sections (Acceptance
Criteria):

1. Document Review
2. General Requirement
3. Material Inspection
On each section of the Checklist, enumerate
the required activity and specify the
applicable standard per Project
Specifications.

Note: Attached is a copy of Saudi Aramco


Checklist as reference.

KCS ELECTRICAL DEPARTMENT


CONSTRUCTION METHOD STATEMENT (CMS)
A Construction Method Statement consists of the following pages
paragraph and/or sections:
1. Covering Page – Indicate the specific work to be done
2. Revision History Sheet – Enumerate revision, work and/ or
activity description that was done.
3. Table of Contents – List of issues to be discuss.
4. Introduction – Brief description of the work to be done.
5. Purpose – The intension or objective of the Method Statement
6. Scope of Work – Describe or classify the work to be done.
7. Location – Identify the specific work area.
8. Definitions - Brief precise statement of what a word or
expression means.
9. References – List of applicable standards per Project
Specifications.
10. Materials, Tools and Equipment – List of required items to
perform the work.

KCS ELECTRICAL DEPARTMENT


CONSTRUCTION METHOD STATEMENT (CMS)
11. Responsibilities – Classify the role of the involved personnel, i.e.
Construction Manager, QA/QC Manager, HSE Manager
QC Inspector and Site Engineer.
12. Work Procedure – Established or correct method to perform
the work.
13. Inspection and Test – Documents such as Inspection and Test
Plan (ITP), Checklists and Test Forms required to perform
QA/QC.
14. HSE Requirements – Explain and emphasize the importance of
safety during the execution of work.
15. Attachments – Relevant documents related to the work to be
done such as IFC Drawings, Response to Technical Queries
and Job Hazard Analysis (JHA).
Note: Attached is a copy of Method Statement for Installation of
Raceway and Control Cables for the HVAC Control System
(Project # 78: Cryogenic, FST & STF PI Bldgs.) as reference.

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco ITP, page 1 of 7
SATIP No . APPROVED DATE DISCIPLINE:
SAUDI ARAMCO TYPICAL INSPECTION PLAN
Metallic Instrumentation and Control Cable SATIP-J-902-01 1-Oct-06 Instrumentation
PROJ ECT TITLE: WBS/ BI/J O/ NO. CONTRACTOR/ SUBCONTRACTOR

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAMCO

1.0 DOCUMENT REVIEW

Cable and Conduit Seal To be review ed and approved prior to electrical and
1.1
Installation Procedure
SAIC-P-3004 SAIC-P-3004 RH1 R1 instrumentation w ork at the jobsite.
RECEIVING
2.0
INSPECTION
Cable Storage, Handling,
2.1 and Preservation SAIC-P-3201 SAIC-P-3201 W2 S Weekly Inspection by Contractor QC
Visual Inspection
For intrinsically safe cable accessories,
see SATIP-J-903-01.

For FOUNDATION™ Fieldbus Systems,


see SATIP-J-904-01.

I&C Copper Cable -Unshielded Single Cable accessories include cable pulling lubricant;
Tw isted Pair / Triad, Multipair / triad, cable gland connector fittings, hot and cold shrink
2.2 Group 1 & 3 (Cable Reel) SAIC-J-6601 H1 W1 insulation tubing; electrical tape; cable straps and
Material Receiving ties; crimp w ire connectors; cable termination kits;
Visual Inspection bulk terminal blocks and points; bulk electrical nuts,
bolts and w ashers; crimping tools & dies; w eather-
proof cable and duct seal, hazardous location
damming fiber and cement.

Notify SA PID by RFI on initial receipt of each listed


accessory (by type and/or manufacturer).

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco ITP, page 2 of 7
SATIP No . APPR OVED DATE DISCIPLINE:
SAUDI ARAMCO TYPICAL INSPECTION PLAN
Metallic Instrumentation and Control Cable SATIP-J-902-01 1-Oct-06 Instrumentation
PROJ EC T TITLE: WB S/BI/J O/NO. CONTRACTOR/SUB CONTR ACTOR

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
C NTRC TR
ARAM C O

For intrinsically safe cable accessories,


see SATIP-J-903-01.
For FOUNDATION™ Fieldbus Systems,
see SATIP-J-904-01.
Cable accessories include cable pulling lubricant;
I&C Copper Cable -Shielded Single
cable gland connector fittings, hot and cold shrink
Tw isted Pair / Triad, Multipair / triad,
insulation tubing; electrical tape; cable straps and
2.3 Group 2 & 4 SAIC-J-6602 SAIC-J-6602 H1 W1
ties; crimp w ire connectors; cable termination kits;
Material Receiving (cable Reel)
bulk terminal blocks and points; bulk electrical nuts,
Visual Inspection
bolts and w ashers; crimping tools & dies; w eather-
proof cable and duct seal, hazardous location
damming fiber and cement.
Notify SA PID by RFI on initial receipt of each listed
accessory (by type and/or manufacturer).
For intrinsically safe cable accessories,
see SATIP-J-903-01.
For FOUNDATION™ Fieldbus Systems,
see SATIP-J-904-01.
Cable accessories include cable pulling lubricant;
I &C Copper Cable -Thermo-Couple cable gland connector fittings, hot and cold shrink
Extension Cable - Material Receiving insulation tubing; electrical tape; cable straps and
2.4 SAIC-J-6603 SAIC-J-6603 H1 W1
Material Receiving (cable Reel) ties; crimp w ire connectors; cable termination kits;
Visual Inspection bulk terminal blocks and points; bulk electrical nuts,
bolts and w ashers; crimping tools & dies; w eather-
proof cable and duct seal, hazardous location
damming fiber and cement.
Notify SA PID by RFI on initial receipt of each listed
accessory (by type and/or manufacturer).

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco ITP, page 3 of 7
SATIP No . APPROVED DATE DISCIPLINE:
SAUDI ARAMCO TYPICAL INSPECTION PLAN
Metallic Instrumentation and Control Cable SATIP-J-902-01 1-Oct-06 Instrumentation
PROJ ECT TITLE: WBS/ BI/ J O/ NO. CONTRACTOR/SUBCONTRACTOR

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAMCO

For intrinsically safe cable accessories,


see SATIP-J-903-01.
For FOUNDATION™ Fieldbus Systems,
see SATIP-J-904-01.
Cable accessories include cable pulling lubricant;
Instrument Cable - Coaxial and Tw in cable gland connector fittings, hot and cold shrink
axial Data Cable insulation tubing; electrical tape; cable straps and
2.5 SAIC-J-6604 SAIC-J-6604 H1 W1
Material Receiving (cable Reel) ties; crimp w ire connectors; cable termination kits;
Visual Inspection bulk terminal blocks and points; bulk electrical nuts,
bolts and w ashers; crimping tools & dies; w eather-
proof cable and duct seal, hazardous location
damming fiber and cement.
Notify SA PID by RFI on initial receipt of each listed
accessory (by type and/or manufacturer).

For intrinsically safe cable accessories,


see SATIP-J-903-01.
For FOUNDATION™ Fieldbus Systems,
see SATIP-J-904-01.
Cable accessories include cable pulling lubricant;
Instrument Cable - Accessories - cable gland connector fittings, hot and cold shrink
Material Receiving insulation tubing; electrical tape; cable straps and
2.6 SAIC-J-6605 SAIC-J-6605 H1 W1
Material Receiving (cable Reel) ties; crimp w ire connectors; cable termination kits;
Visual Inspection bulk terminal blocks and points; bulk electrical nuts,
bolts and w ashers; crimping tools & dies; w eather-
proof cable and duct seal, hazardous location
damming fiber and cement.
Notify SA PID by RFI on initial receipt of each listed
accessory (by type and/or manufacturer).

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco ITP, page 4 of 7
SATIP No . APPROVED DATE DISCIPLINE:
SAUDI ARAMCO TYPICAL INSPECTION PLAN
Metallic Instrumentation and Control Cable SATIP-J-902-01 1-Oct-06 Instrumentation
PROJ ECT TITLE: WBS/ BI/J O/ NO. CONTRACTOR/SUBCONTRACTOR

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAM CO

3.0 INSTALLATION

Cable Pulling See See SA PID shall be notified on start of this activity f or
3.1 H1 W2
Visual Inspection Remarks Remarks each process system, and plant area.
See SATIP-Q-001-02 for additional test and
Direct Buried
inspection activities for road crossings.
Cable Trench See See
3.2 H1 W1 See SATIP-A-114-01 for additional direct buried
Visual Inspection Remarks Remarks
earthw ork QA/QC activities, requirements, and
(Before Cable Laying)
coordination.
Below Grade Cable Laying and
See See Hold points for all direct buried cables prior to
3.3 Warning Marker Installation H1 W1
Remarks Remarks backfilling of cable and safety w arning markers.
Visual Inspection
Cable dressing and termination w ork (inside cabinet)
shall not proceed until all cable glands, cable route
and cable dressing in tray has been inspected by
Cable Gland Installation, Cable
See See Contractor QC.
3.4 Dressing, Cable Identification and
Remarks Remarks
H1 W2
SA PID shall be notified on termination of first ten
Termination Visual Inspection
circuits of each signal service level.
SA PID shall be notified on start of this activity f or
each process system and plant area.

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco ITP, page 5 of 7
SATIP No . APPROVED DATE DISCIPLINE:
SAUDI ARAMCO TYPICAL INSPECTION PLAN
Metallic Instrumentation and Control Cable SATIP-J-902-01 1-Oct-06 Instrumentation
PROJ ECT TITLE: WBS/ BI/J O/ NO. CONTRACTOR/SUBCONTRACTOR

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAM CO

For intrinsically safe cable accessories,


see SATIP-J-903-01.
For FOUNDATION™ Fieldbus Systems,
see SATIP-J-904-01.
Cable accessories include cable pulling lubricant;
Instrument Cable - Installation,
cable gland connector fittings, hot and cold shrink
termination, identification, and Pre-
insulation tubing; electrical tape; cable straps and
3.5 Commissioning SAIC-J-6606 SAIC-J-6606 H1 W1
ties; crimp w ire connectors; cable termination kits;
Material Receiving (cable Reel)
bulk terminal blocks and points; bulk electrical nuts,
Visual Inspection
bolts and w ashers; crimping tools & dies; w eather-
proof cable and duct seal, hazardous location
damming fiber and cement.
Notify SA PID by RFI on initial receipt of each listed
accessory (by type and/or manufacturer).

4.0 PRE-COMMISSIONING

SAIC - J - 6606 Reserved


Instrument Cable - Continuity and
SAIC - J - 6607 Reserved
Insulation Resistance Testing (On
SA PID shall be notified on testing of first ten circuits
Reel)
4.1 SATR-J-6601 SATR-J-6601 H1 W2 of each signal service level.
Cable Continuity (Volt-Ohm Meter)
and Insulation (Megger) Testing
SA PID shall be notified on start of this activity for
(Installed Cable)
each process system and plant area.

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco ITP, page 6 of 7
SATIP No . APPROVED DATE DISCIPLINE:
SAUDI ARAMCO TYPICAL INSPECTION PLAN
Metallic Instrumentation and Control Cable SATIP-J-902-01 1-Oct-06 Instrumentation
PROJ ECT TITLE: WBS/ BI/J O/ NO. CONTRACTOR/SUBCONTRACTOR

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAM CO

Instrument Cable - Continuity, SAIC - J - 6606 Reserved


Insulation Resistance (Installed), and SAIC - J - 6607 Reserved
Termination Torque Testing SA PID shall be notified on testing of first ten circuits
4.2
Cable Continuity (Volt-Ohm Meter)
SATR-J-6602 SATR-J-6602 H1 W2 of each signal service level.
and Insulation (Megger) Testing SA PID shall be notified on start of this activity for
(Installed Cable) each process system and plant area.

Instrument Cable - Installation, SA PID shall be notified on testing of first ten circuits
Termination, Identification, and Pre- of each signal service level.
4.3 SAIC-J-6606 SAIC-J-6606 H1 W2
CommissioningCable Termination Crimp SA PID shall be notified on start of this activity for
(w ire pull-out) andTorque Testing each process system and plant area.
Cable / Conduit See See
4.4
Hazardous Location Sealing Remarks Remarks
H1 H1 Hold point for cement pouring

For instrument loop checking requirements see


Cable / Loop See See
4.5 RH1 RH1 SATIP-J-902-02.
Quality Record Review Remarks Remarks
Hold point for pre-commissioning of each signal loop.
For instrument loop checking requirements see
Cable / Loop See See
4.6 H1 H1 SATIP-J-902-02.
Final Visual Inspection Remarks Remarks
Hold point for pre-commissioning of each signal loop.

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco ITP, page 7 of 7
SATIP No . APPROVED DATE DISCIPLINE:
SAUDI ARAMCO TYPICAL INSPECTION PLAN
Metallic Instrumentation and Control Cable SATIP-J-902-01 1-Oct-06 Instrumentation
PROJ ECT TITLE: WBS/ BI/ J O/NO. CONTRACTOR/ SUBCONTRAC TOR

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAM CO

GENERAL NOTES

The first three incidents of each Inspection or testing activity listed require 100 % participation by Saudi Aramco Site Inspection Personnel. After this period, Saudi Aramco Inspection may
1
adjust the levels of Saudi Aramco participation based upon the Contractor’s performance.
2 Surveillance: QA/QC organization to monitor w ork in progress w ithout notice from Construction Organization
Witness: QA/QC organization shall be notified of the timing of Inspection or test in advance. How ever, the inspection or test shall be performed as scheduled if the QA/QC organization
3
representative is not present.
Hold: QA/QC organization shall be notified of the timing of inspection or test in advance. Inspection or test shall not be carried out w ithout the QA/QC organization representative
4
in attendance.
5 If the Main Contractor delegates the assigned responsibility to the Subcontractor, then the Main Contractor w ill have the same degree of responsibility as assigned to Saudi Aramco.

LEGEND
W1 100% Witness Inspection/Test H2 Sample Hold Point for QC Inspection or Test RH1 100% Review and Approval of Documents
W2 Sample Witness Inspection/Test R1 100% Review of Documents RH2 Sample Review and Approval of Documents
H1 100% Hold Point for QC Inspection or Test R2 Sample Review of Documents S Surveillance

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted ITP (per Project Specs) page 1 of 5

SADARA TANK FARM INSPECTION TEST PLAN SATIP No. REV. No. APPROVAL DATE DISCIPLINE:

Metallic Instrumentation and Control Cable STFITP-J-902-01 REV.1 Instrumentation


WBS/BI/JO/NO. CONTRACTOR/SUBCONTRACTOR
PROJECT TITLE: SADARA TANK FARM PROJECT
DAEWOO E & C / KETTANEH CONSTRUCTION

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD
SUBCON DEC SADARA

1.0 DOCUMENT REVIEW

Cable and Conduit Seal To be review ed and approved prior to electrical


1.1
Installation Procedure
STFIC-P-3004 STFIC-P-3004 R RH R and instrumentation w ork at the jobsite.
RECEIVING
2.0
INSPECTION
Cable Storage, Handling,
2.1 and Preservation STFIC-P-3201 STFIC-P-3201 W W S Weekly Inspection by Contractor QC
Visual Inspection

Cable accessories include cable pulling


lubricant; cable gland connector fittings, hot and
cold shrink insulation tubing; electrical tape;
cable straps and ties; crimp w ire connectors;
I&C Copper Cable -Shielded Single cable termination kits; bulk terminal blocks and
Tw isted Pair / Triad, Multipair / triad, points; bulk electrical nuts, bolts and w ashers;
2.2 Group 2 & 4 STFIC-J-6602 STFIC-J-6602 H H W crimping tools & dies; w eather-proof cable and
Material Receiving (cable Reel) duct seal, hazardous location damming fiber and
Visual Inspection cement.

Notify SADARA PID by RFI on initial receipt of


each listed accessory (by type and/or
manufacturer).

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted ITP (per Project Specs) page 2 of 5

SATIP No. REV. No. APPROVAL DATE DISCIPLINE:


SADARA TANK FARM INSPECTION TEST PLAN
Metallic Instrumentation and Control Cable STFITP-J-902-01 REV.1 Instrumentation
PROJECT TITLE: SADARA TANK FARM PROJECT WBS/BI/JO/NO. CONTRACTOR/SUBCONTRACTOR

DAEWOO E & C / KETTANEH CONSTRUCTION

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD
SUBCON DEC SADARA

3.0 INSTALLATION
SADARA PID shall be notified on start of this
Cable Pulling See See
3.1 H H W activity for each process system, and plant
Visual Inspection Remarks Remarks
area.
See STFITP-Q-001-02 for additional test and
Direct Buried
inspection activities for road crossings.
Cable Trench See See
3.2 H H W See STFITP-A-114-01 for additional direct buried
Visual Inspection Remarks Remarks
earthw ork QA/QC activities, requirements, and
(Before Cable Laying)
coordination.
Below Grade Cable Laying
See See Hold points for all direct buried cables prior to
3.3 and Warning Marker Installation H H W
Remarks Remarks backfilling of cable and safety w arning markers.
Visual Inspection

Cable dressing and termination w ork (inside


cabinet) shall not proceed until all cable glands,
cable route and cable dressing in tray has been
inspected by Contractor QC.
Cable Gland Installation, Cable
See See
3.4 Dressing, Cable Identification and
Remarks Remarks
H H W SADARA PID shall be notified on termination of
Termination Visual Inspection
first ten circuits of each signal service level.

SADARA PID shall be notified on start of this


activity for each process system and plant area.

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted ITP (per Project Specs) page 3 of 5

SADARA TANK FARM INSPECTION TEST PLAN SATIP No. REV. No. APPROVAL DATE DISCIPLINE:

Metallic Instrumentation and Control Cable STFITP-J-902-01 REV.1 Instrumentation


WBS/BI/JO/NO. CONTRACTOR/SUBCONTRACTOR
PROJECT TITLE: SADARA TANK FARM PROJECT
DAEWOO E & C / KETTANEH CONSTRUCTION

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD
SUBCON DEC SADARA

For intrinsically safe cable accessories,


see STFITP-J-903-01.

For FOUNDATION™ Fieldbus Systems,


see STFITP-J-904-01.

Cable accessories include cable pulling


Instrument Cable - Installation, lubricant; cable gland connector fittings, hot and
termination, identification, and Pre- cold shrink insulation tubing; electrical tape;
3.5 Commissioning SAIC-J-6606 SAIC-J-6606 H H W cable straps and ties; crimp w ire connectors;
Material Receiving (cable Reel) cable termination kits; bulk terminal blocks and
Visual Inspection points; bulk electrical nuts, bolts and w ashers;
crimping tools & dies; w eather-proof cable and
duct seal, hazardous location damming fiber and
cement.

Notify SADARA PID by RFI on initial receipt of


each listed accessory (by type and/or
manufacturer).

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted ITP (per Project Specs) page 4 of 5

SATIP No. REV. No. APPROVAL DATE DISCIPLINE:


SADARA TANK FARM INSPECTION TEST PLAN
Metallic Instrumentation and Control Cable STFITP-J-902-01 REV.1 Instrumentation
PROJECT TITLE: SADARA TANK FARM PROJECT WBS/BI/JO/NO. CONTRACTOR/SUBCONTRACTOR

DAEWOO E & C / KETTANEH CONSTRUCTION

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD
SUBCON DEC SADARA

4.0 PRE-COMMISSIONING

STFIC - J - 6606 Reserved


Instrument Cable - Continuity and
STFIC - J - 6607 Reserved
Insulation Resistance Testing (On
SADARA PID shall be notified on testing of first
Reel)
4.1 SATR-J-6601 SATR-J-6601 H H W ten circuits of each signal service level.
Cable Continuity (Volt-Ohm Meter)
and Insulation (Megger) Testing
SADARA PID shall be notified on start of this
(Installed Cable)
activity for each process system and plant area.

Instrument Cable - Installation,


Termination, Identification, SADARA PID shall be notified on testing of first
and Pre-Commissioning ten circuits of each signal service level.
4.2
Cable Termination
SAIC-J-6606 SAIC-J-6606 H H W SADARA PID shall be notified on start of this
Crimp (w ire pull-out) and activity for each process system and plant area.
Torque Testing
Cable / Conduit See See
4.3
Hazardous Location Sealing Remarks Remarks
H H H Hold point for cement pouring

For instrument loop checking requirements see


Cable / Loop See See STFIC-J-902-02.
4.4
Quality Record Review Remarks Remarks
R RH RH
Hold point for pre-commissioning of each signal
loop.

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted ITP (per Project Specs) page 5 of 5

SATIP No. REV. No. APPROVAL DATE DISCIPLINE:


SADARA TANK FARM INSPECTION TEST PLAN
Metallic Instrumentation and Control Cable STFITP-J-902-01 REV.1 Instrumentation
PROJECT TITLE: SADARA TANK FARM PROJECT WBS/BI/JO/NO. CONTRACTOR/SUBCONTRACTOR

DAEWOO E & C / KETTANEH CONSTRUCTION

INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD
SUBCON DEC SADARA

For instrument loop checking requirements see


Cable / Loop See See STFIC-J-902-02.
4.5
Final Visual Inspection Remarks Remarks
H H H
Hold point for pre-commissioning of each signal
loop.

GENERAL NOTES

The first three incidents of each Inspection or testing activity listed require 100 % participation by SADARA Site Inspection Personnel. After this period, SADARA Inspection may adjust the
1
levels of SADARA participation based upon the Contractor’s perf ormance.
2 Surveillance: QA/QC organization to monitor w ork in progress w ithout notice from Construction Organization
Witness: QA/QC organization shall be notified of the timing of Inspection or test in advance. How ever, the inspection or test shall be performed as scheduled if the QA/QC
3
organization representative is not present.
Hold: QA/QC organization shall be notified of the timing of inspection or test in advance. Inspection or test shall not be carried out w ithout the QA/QC organization representative
4
in attendance.
5 If the Main Contractor delegates the assigned responsibility to the Subcontractor, then the Main Contractor w ill have the same degree of responsibility as assigned to SADARA.

LEGEND
W 100% Witness Inspection/Test RH 100% Review and Approval of Documents
H 100% Hold Point for QC Inspection or Test R 100% Review of Documents S Surveillance

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 1 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

EQUIPMENT ID NUMBER(S) EQUIPMENT DESCRIPTION EQPT CODE SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUMBER REV. NO. PURCHASE ORDER NUMBER EC / PMCC / MCC NO.

SCHEDULED INSPECTION DATE & TIME ACTUAL INSPECTION DATE & TIME QUANTITY INSP. MH's SPENT TRAVEL TIME

SAUDI ARAMCO USE ONLY


SAUDI ARAMCO TIP NUMBER SAUDI ARAMCO ACTIVITY NUMBER WORK PERMIT REQUIRED?

SAUDI ARAMCO INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

A. Document Review and Third-Party Listing


Schedule Q,
A1 Review Quality Documentation for Material Receiving.
Att, IV, Sec. 3.1.

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 2 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Identification - Instrumentation materials shall be identified by using Schedule "Q"


A2 tags, stamps, color coding, stencils or labels. The location and method Attachment lV
of identification shall not affect the function or quality of the materials. Sec. 3.2
Schedule "G"
A3 New and Unused - Instrumentation materials shall be new and unused.
Sec. 4.1
As Designed - Instrumentation materials shall be in accordance with
Schedule "G"
A4 the Saudi Aramco-approved project-specific design drawings,
Sec. 4.1
diagrams,schedules, lists, databases, and associated documents.
Free of Damage - Instrumentation materials shall be free of damage.
Schedule "Q"
All Incoming material shall be visually inspected for damage and
A5 Attachment lV
conformance to all applicable inspection releases with Material Test
Sec 7.1
Report (MTR).
QC Before Installation - Instrumentation materials shall conform to all Schedule "Q"
A6 applicable requirements, standards, and specifications prior to release Attachment lV
to be used as part of the work. Sec 7.1

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 3 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Traceability - Instrumentation materials shall be traceable from the Schedule "Q"


A7 manufacturer and supplier through delivery, storage, fabrication, Attachment lV
erection, installation, repair, modification and use. Sec. 3.3
Verify that the contractor or it's Saudi Aramco approved third party
inspector performed the quality activities at the supplier and sub- Schedule Q
A8 supplier locations as required by the inspection level assigned for the Attachment llI Sec
materials and equipment identified in SAER-1972 Inspection 1.2
Requirements.
Cable materials supplied shall be third-party listed as meeting the
requirements of ULstandards (UL 13, 1277, 1709, 2250, NEC Article 34-SAMSS-913
A9
727, and NEC Article 725 as applicable, or approved equal Sec. 3.2
standards). (NFPA 70 NEC)
Inspection Items manufactured to this Specification (34-SAMSS-913)
34-SAMSS-913
A10 are subject to the minimum inspection requirements as specified in
Sec. 9.1
Saudi Aramco Inspection Requirements Form 175-347600. 9.2

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 4 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Nonmaterial Requirements The supplier shall provide nonmaterial 34-SAMSS-913


A11
items as shown on Form NMR-7930. Sec. 9.2
B. General Requirements Common to Group 2 Single Twisted Pair / Triad , shielded and Group 4
Multipair / triad, Overall Shields
Conductor: Stranded, circular copper, per ASTM B3, 7 strands
minimum; tinned, per ASTM B33, if primary insulation may corrode 34-SAMSS-913,
B1
unprotected copper (e.g., unstabilized XLPO/XLPE) or if otherwise Sec. 6.3.1 & 6.5.1
specified
Primary Insulation Material: Flame retardant PVC or thermoset cross 34-SAMSS-913,
B2
linked polyolefin (XLPO or XLPE), minimum temperature rating 90°C. Sec. 6.3.3 & 6.5.3
Primary Insulation Voltage Rating: 300 V for Type PLTC and Type ITC 34-SAMSS-913,
B3
Cable 600 V for Type TC Cable Sec. 6.3.4 & 6.5.4
Primary Insulation Thickness: 0.38 mm (15 mils) minimum average
34-SAMSS-913,
B4 thickness for Types PLTC and ITC Cables .64 mm (25 mils) minimum
Sec. 6.3.5 & 6.5.5
average for Type TC Cable

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 5 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Assembly: Two insulated conductors uniformly twisted into a pair or 34-SAMSS-913,


B5
three insulated conductors uniformly twisted into a triad Sec. 6.3.6 & 6.5.6
34-SAMSS-913,
B6 Lay of Twist: 40 to 60 mm Sec. 6.3.7 &.
6.5.7
Color Code: One black wire, one white wire for pairs; one black wire,
34-SAMSS-913,
B7 one white wire, one red wire for triads; or as specified on Form 8020-
Sec. 6.3.8 & 6.5.8
913-ENG, Line Item 14
34-SAMSS-913,
Jacket Material :Flame retardant PVC, minimum temperature rating
B8 Sec. 6.3.15 &
90°C dry, 75°C wet
6.5.25
Jacket Thickness:
34-SAMSS-913,
Minimum thickness per UL 13, paragraph 13.1 for Type PLTC
B9 Sec. 6.3.16 &
Minimum thickness per UL 1277, paragraph 11.3 for Type TC
6.5.26
Minimum thickness per UL 2250, paragraph 16.3 for Type ITC

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 6 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

34-SAMSS-913,
B10 Jacket Application: Extruded over assembly Sec. 6.3.17.&
6.5.27
Jacket Color: 34-SAMSS-913,
B11 Non-intrinsically safe applications: Manufacturer's standard other than Sec. 6.3.18 &
blue; Intrinsically safe applications: Blue; FF applications: Orange 6.5.28

Outer Jacket Marking


The following information shall be clearly marked on the outer jacket of
the cable, in no specific order: a) Manufacturer's name, trade name,
catalog or type number b) Number of pairs/triads c) Conductor size in
mm² or AWG d) Voltage rating (300 or 600 V) e) Type of cable (PLTC,
TC or equivalent) f) Approval mark of listing authority (UL, IEC, BS, 34-SAMSS-913,
B12
DIN, or equivalent) g) "Sunlight resistant" designation, in Sec. 7.1
Manufacturer's standard nomenclature, for Type TC cable (Optional for
Type PLTC cable) h) "Direct burial" designation, if applicable per UL
13 or UL 1277, in Manufacturer's standard nomenclature I) "Oil
resistant" designation, in manufacturer's standard nomenclature, for
Type TC Cable (preferred for Types ITC and PLTC Cable)

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 7 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Cable Reel Marking


Each reel shall have a weatherproof (metal or plastic) tag, securely
attached to a flange of the reel and plainly stating:
a) Manufacturer's trade name
b) Date of manufacture
c) Conductor size
34-SAMSS-913,
B13 d) Cable rating
Sec.7.2
e) Type of cable
f) Temperature designation
g) Minimum bend radius
h) Maximum pulling tension
i) Shipping length and diameter of cable
j) Saudi Aramco Purchase Order number
Cables installed in Zone 1 (Class -1, Div.-1) shall be listed as suitable SAESJ--902,
B14
for that classified area. I Note 1
Cables used in other classified areas shall meet the requirements SAESJ--902,
B15
outlined in NFPA 70 (NEC), articles 501-505. 2. Note 1

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 8 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

A larger wire size shall be considered to overcome potential voltage SAESJ--902,


B16
drops. The maximum voltage drop shall not exceed 5%. Note 2
Type ITC cable shall not be installed on either non-power limited
SAESJ--902,
B17 circuits or powered limited circuits operating at more than 150 volts or
Note 3
more than 5 amperes.
Differences in the manufacturer recommended cable and these SAESJ--902,
B18
requirements shall be resolved with Instrumentation Unit/PID/P&CSD. Note 4
C. Group 2 Single Twisted Pair / Triad , Shielded
Conductor Size: 16 AWG or as specified on Form 8020-913-ENG, 34-SAMSS-913,
C1
Line Item 13 or project specification. Sec. 6.3.2
Aluminum foil bonded to non-hygroscopic polyester (Mylar) tape, either 34-SAMSS-913,
C2
foil free edge or equal-width foil and tape, per Manufacturer's standard. Sec. 6.3.9
34-SAMSS-913,
C3 Shield Thickness: 0.022 mm (0.85 mil) minimum
Sec. 6.3.10

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 9 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Shield Application: Helical, minimum 25% overlap, to provide 100% 34-SAMSS-913,


C4
coverage and electrical isolation from conductors Sec. 6.3.11
Shield Drain Wire Conductor: Stranded, circular tinned copper, per 34-SAMSS-913,
C5
ASTM B33, 7 strands minimum Sec. 6.3.12
Shield Drain Wire Size: Manufacturer's standard, with minimum size 34-SAMSS-913,
C6
one even gauge size smaller than conductor size Sec. 6.3.13
34-SAMSS-913,
C7 Shield Drain Wire Application: In continuous contact with shield foil
Sec. 6.3.14
D. Group 4 Multipair / Triad , Individual and Overall Shields
Conductor Size: 18 AWG or as specified on Form 8020-913-ENG, 34-SAMSS-913,
D1
Line Item 13 or project specification. Sec. 6.5.2
Number of Pairs or Triads: Refer to Form 8020-913-ENG, line item 12.
34-SAMSS-913,
D2 Manufacturer's standard products, meeting or exceeding this number is
Sec. 6.5.9
acceptable upon approval of Buyer
Pair/triad Identification: Number designation continuously stamped on 34-SAMSS-913,
D3
white conductor Sec. 6.5.10

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 10 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Cable Assembly: Single grouped assembly, per Manufacturer's 34-SAMSS-913,


D4
standard Sec. 6.5.11

Communication Wire: Not required. If provided, shall be Manufacturer's 34-SAMSS-913,


D5
standard size; insulation same as primary insulation; orange color Sec. 6.5.12

Individual Shield Material: Aluminum foil bonded to non-hygroscopic


34-SAMSS-913,
D6 polyester (Mylar) tape, either: foil free-edge or equal-width foil and
Sec. 6.5.13
tape, per Manufacturer's standard
34-SAMSS-913,
D7 Individual Shield Thickness: 0.022 mm (0.85 mil) minimum
Sec. 6.5.14
Individual Shield Application : Helical, minimum 25% overlap, to
34-SAMSS-913,
D8 provide 100% coverage and electrical isolation from other shields and
Sec. 6.5.15
conductors
Individual Shield Drain Wire Conductor: Stranded, circular tinned 34-SAMSS-913,
D9
copper, per ASTM B33, 7 strands minimum Sec. 6.5.16

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 11 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Individual Shield Drain Wire Size: Manufacturer's standard, with 34-SAMSS-913,


D10
minimum size one even gauge size smaller than conductor size Sec. 6.5.17
Individual Shield Drain Wire Application: In continuous contact with 34-SAMSS-913,
D11
shield foil Sec. 6.5.18
Overall Shield Material: Aluminum foil bonded to non-hygroscopic
34-SAMSS-913,
D12 polyester (Mylar) tape, either: foil free-edge or equal-width foil and
Sec. 6.5.19
tape, per Manufacturer's standard.
34-SAMSS-913,
D13 Overall Shield Thickness: 0.022 mm (0.85 mil) minimum
Sec. 6.5.20
Overall Shield Application: Helical, minimum 25% overlap, to provide
34-SAMSS-913,
D14 100% coverage and electrical isolation from conductors and other
Sec. 6.5.21
shields
Overall Shield Drain Wire Conductor: Stranded, circular tinned copper, 34-SAMSS-913,
D15
per ASTM B33, 7 strands minimum Sec. 6.5.22
Overall Shield Drain Wire Size: Manufacturer's standard, with minimum 34-SAMSS-913,
D16
size one even gauge size smaller than conductor size Sec. 6.5.23

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 12 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

Overall Shield Drain Wire Application: In continuous contact with shield 34-SAMSS-913,
D17
foil Sec. 6.5.24
REMARKS:

REFERENCE DOCUMENTS:
1. Schedule G -- Material, Tools and Equipment (Pro Forma MP-IK-LS Contract), July 1993
2. Schedule Q -- Quality Requirements (Pro Forma Contract), November 2003
3. SAES-J-902, Electrical Systems for Instrumentation, 31 May 2005
4 34-SAMSS-913, Instrumentation and Thermocouple Cable, 31 July 2005
5.NFPA 70 - 2005- National Electric Code 2005 Edition

ATTACHMENTS:
1. Attachment 1 -- Wire and Cable Minimum Requirements for Instrument Circuits

KCS ELECTRICAL DEPARTMENT


Attachment: Original Saudi Aramco Checklist, page 13 of 13
SAUDI ARAMCO INSPECTION CHECKLIST SAIC NUMBER DATE APPROVED QR NUMBER
I & C Copper Cable- Shielded, Single Twisted Pair
SAIC-J-6602 1-Oct-06 INST
/ Triad, Multipair / triad , Group 2 & 4-MR
PROJECT TITLE WBS / BI / JO NUMBER CONTRACTOR / SUBCONTRACTOR

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

NOTES:
1. Approved - Acceptable to the authority having jurisdiction (i.e., Saudi Aramco ID).
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).
3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned with evaluation of products
or services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and whose
listing
thatstates
the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a
specified
4. Labeled purpose.
- Equipment or materials to which has been attached a label, symbol, or other identifying mark of an approved qualified
organization concerned
with product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by whose labeling the
manufacturer
indicates compliance with appropriate standards or performance in a specified manner.
5. Notes: This check list is for Instrument Cable-Shielded, Single Twisted Pair / Triad, Unshielded, Group 2 & 4 Multipair / triad ,
Shielded oror
Shielded without overall
without Overallshield-Material Receiving
Shields-Material (For(For
Receiving signaling andand
signaling Control purpose
Control only)
purpose only)
Contractor / Third-Party Saudi Aramco
Construction Representative* PMT Representative
Work is Complete and Ready for Inspection: T&I Witnessed QC Record Review ed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Inspector PID Representative


Perf ormed Inspection Work / Rew ork May Proceed T&I Witnessed QC Record Review ed Work Verified
Name, Initials and Date: Name, Initials and Date:

QC Supervisor Proponent and Others


Quality Record Approved: Name, Organization, T&I Witnessed QC Record Review ed Work Verified
Name, Initials and Date:
Initials and Date:

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted Checklist (per Project Specs), page 1 of 5

SADARA TANK FARM INSPECTION CHECKLIST STFIC NUM BER DATE APPROVED QR NUM BER

I & C Copper Cable- Shielded, Single Twisted Pair / Triad, Multipair / Triad , Group 2 & 4-
STFIC-J-6602 INSTRUMENTATION
Material Receiving
PROJ ECT TITLE WBS / BI / J O NUM BER CONTRACTOR / SUBCONTRACTOR

SADARA TANK FARMS PROJECT DAEWOO / KETTANEH


EQUIPM ENT ID NUM BER(S) EQUIPM ENT DESCR IPTION EQPT CODE SYSTEM ID. PLANT NO.

LAYOUT DRAWING NUM BER REV. NO. PUR CHASE ORDER NUM BER EC / PM CC / MC C NO.

SCHEDULED INSPECTION DATE & TIM E ACTUAL INSPECTION DATE & TIM E QUANTITY INSP. MH's SPENT TRAVEL TIM E
SADARA USE ONLY
STFTIP NUM BER R EV . N O . STFITP ACTIVITY NUM BER WORK PERM IT REQUIRED?
STFTIP-J-902-01 0
COM PANY INSPECTION LEVEL CONTRACTOR INSPECTION LEVEL
W H

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
A Document Review and Third-Party Listing
Schedule Q, Att,
A1 Review Quality Documentation for Material Receiving.
IV, Sec. 3.1.
Identification - Instrumentation materials shall be identified by using tags, stamps, color coding, stencils or labels. Schedule Q
A2
The location and method of identification shall not affect the function or quality of the materials. Att. lV Sec. 4.2
Schedule "Q" Sec.
A3 New and Unused - Instrumentation materials shall be new and unused.
3.2
As Designed - Instrumentation materials shall be in accordance w ith the SADARA-approved project-specific Schedule "G"
A4
design draw ings, diagrams, schedules, lists, databases, and associated documents. Sec. 4.1
Schedule "Q"
Free of Damage - Instrumentation materials shall be free of damage. All Incoming material shall be visually
A5 Attachment lV
inspected for damage and conformance to all applicable inspection releases w ith Material Test Report (MTR).
Sec 3.2
Schedule "Q"
QC Before Installation - Instrumentation materials shall conform to all applicable requirements, standards, and
A6 Attachment lV
specifications prior to release to be used as part of the w ork.
Sec 3.2
Schedule "Q"
Traceability - Instrumentation materials shall be traceable from the manufacturer and supplier through delivery,
A7 Attachment lV
storage, fabrication, erection, installation, repair, modification and use.
Sec. 4.4

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted Checklist (per Project Specs), page 2 of 5

SADARA TANK FARM INSPECTION CHECKLIST STFIC NUMBER DATE APPROVED QR NUMBER

I & C Copper Cable- Shielded, Single Twisted Pair / Triad, Multipair / Triad , Group 2 & 4-
STFIC-J-6602 INSTRUMENTATION
Material Receiving
PROJ ECT TITLE WBS / BI / J O NUM BER CONTRACTOR / SUBCONTRACTOR

SADARA TANK FARMS PROJECT DAEWOO / KETTANEH

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Verify that the contractor or it's SADARA approved third party inspector performed the quality activities at the Schedule Q
A8
supplier and sub-supplier locations as required by the inspection level assigned for the materials and equipment. Attachment llI Sec 3.2
G7D-0408-00
Cable materials supplied shall be third-party listed as meeting the requirements of UL standards (UL 13, 1277, General
A9
1709, 2250, NEC Article 727, and NEC Article 725 as applicable, or approved equal standards). (NFPA 70 NEC). Requirements for
Insrument Wire and
General Requirements Common to Group 2 Single Twisted Pair / Triad , Shielded and Group 4
B
Multipair / Triad, Overall Shields
G7D-0408-00
Single Conductor, Class B, 7 strand concentric, annealed copper w ire in accordance w ith ASTM B - 3 and B - 8. General
B1
Conductor shall be in continuous length w ithout splices. Requirements for

Insrument Wire and

Primary insulation shall be thermoplastic or Polyvinyl Chloride (PVC) w ith a temperature rating of 105 C for 300 V
B2 G7D-0408-00
PLTC and Type ITC Cable and temperature rating of 90 C for 600 V Type TC Cable.
G7D-0408-00
Primary Insulation Voltage Rating:
General
B3 300 V for Type PLTC and Type ITC Cable
Requirements for
600 V for Type TC Cable
Insrument Wire and
Primary Insulation Thickness: 0.38 mm (15 mils) minimum average thickness for Types PLTC and ITC Cables .64 mm
B4 G7D-0408-00
(25 mils) minimum average for Type TC Cable.
Assembly: Tw o insulated conductors uniformly tw isted into a pair or three insulated conductors uniformly tw isted
B5 G7D-0408-00
into a triad .
Jacket Thickness:
Minimum thickness per UL 13, paragraph 13.1 for Type PLTC
B6 G7D-0408-00
Minimum thickness per UL 1277, paragraph 11.3 for Type TC
Minimum thickness per UL 2250, paragraph 16.3 for Type ITC

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted Checklist (per Project Specs), page 3 of 5

SADARA TANK FARM INSPECTION CHECKLIST STFIC NUM BER DATE APPROVED QR NUM BER

I & C Copper Cable- Shielded, Single Twisted Pair / Triad, Multipair / Triad , Group 2 & 4-
STFIC-J-6602 INSTRUMENTATION
Material Receiving
PROJ ECT TITLE WBS / BI / J O NUM BER CONTRACTOR / SUBCONTRACTOR

SADARA TANK FARMS PROJECT DAEWOO / KETTANEH

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
Overall Polyvinyl Chloride (PVC) jacket (conventional), 90° C, flame retardant and sunlight resistant Polyvinyl
B7 Chloride (PVC) jacket shall be applied over the core assembly w ith nylon rip cord directly under jacket to facilitate G7D-0408-00
removal.
Outer Jacket Marking
The follow ing information shall be clearly marked on the outer jacket of the cable, in no specific order: a)
G7D-0408-00
Manufacturer's name, trade name, catalog or type number b) Number of pairs/triads c) Conductor size in mm² or
General
AWG d) Voltage rating (300 or 600 V) e) Type of cable (PLTC, TC or equivalent) f) Approval mark of listing
B8 Requirements for
authority (UL, IEC, BS, DIN, or equivalent) g) "Sunlight resistant" designation, in Manufacturer's standard
Insrument Wire and
nomenclature, for Type TC cable (Optional for Type PLTC cable) h) "Direct burial" designation, if applicable per UL
Cable
13 or UL 1277, in Manufacturer's standard nomenclature I) "Oil resistant" designation, in manufacturer's standard
nomenclature, for Type TC Cable (preferred for Types ITC and PLTC Cable)
Reel Type - The cable shall be furnished on non-returnable reels w hich shall have substantial strength to G7D-0408-00
w ithstand handling shipment at the construction site. Cable ends shall be sealed using heat shrinkable, self sealing General
B9 end caps to prevent the entrance of moisture into the cable prior to installation. Cable ends shall be secured to reel Requirements for
in such a w ay that no damage to cable is incurred. Reel lengths shall be furnised as specified in continuous Insrument Wire and
lengths w ithout splices. Reel length shall be minus 0.0% - plus 5.o%. Cable
C Group 2 Single Twisted Pair / Triad , Shielded
C1 Conductor Size: 18 AWG or as specified on project specification. G7D-0408-00
Aluminum foil bonded to non-hygroscopic polyester (Mylar) tape, either foil free edge or equal-w idth foil and tape,
C2 G7D-0408-00
per Manufacturer's standard.
Shield Application :Overall shield to provide 100% coverage and electrical isolation from other shields and
C3 G7D-0408-00
conductors
C4 Shield Drain Wire Conductor: Stranded, circular tinned copper, per ASTM B33, 7 strands minimum G7D-0408-00
Shield Drain Wire Size: Manuf acturer's standard, w ith minimum size one even gauge size smaller than conductor
C5 G7D-0408-00
size
C6 Shield Drain Wire Application: In continuous contact w ith shield foil G7D-0408-00

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted Checklist (per Project Specs), page 4 of 5

SADARA TANK FARM INSPECTION CHECKLIST STFIC NUM BER DATE APPROVED QR NUM BER

I & C Copper Cable- Shielded, Single Twisted Pair / Triad, Multipair / Triad , Group 2 & 4-
STFIC-J-6602 INSTRUMENTATION
Material Receiving
PROJ ECT TITLE WBS / BI / J O NUM BER CONTRACTOR / SUBCONTRACTOR

SADARA TANK FARMS PROJECT DAEWOO / KETTANEH

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
D Group 4 Multipair / Triad , Individual and Overall Shields
D1 Conductor Size: 18 AWG or as specified on project specification. G7D-0408-00
Length of pair of triad lay shall be UL 13 (PLTC), UL2250 (ITC), and UL 1277 (TC) as required by the individual
D2 G7D-0408-00
cable specification. Use of reverse lay cabling is permitted.
D3 Pair/triad Identif ication: Number designation continuously stamped on w hite conductor G7D-0408-00

D4 Cable Assembly: Single grouped assembly, per Manufacturer's standard G7D-0408-00


Individual Shield Material: Aluminum foil bonded to non-hygroscopic polyester (Mylar) tape, either: foil free-edge or
D5 G7D-0408-00
equal-w idth foil and tape, per Manufacturer's standard
Shield Application :Overall shield to provide 100% coverage and electrical isolation from other shields and
D6 G7D-0408-00
conductors
D7 Individual Shield Drain Wire Conductor: Stranded, circular tinned copper, per ASTM B33, 7 strands minimum G7D-0408-00
Individual Shield Drain Wire Size: Manufacturer's standard, w ith minimum size one even gauge size smaller than
D8 G7D-0408-00
conductor size
D9 Individual Shield Drain Wire Application: In continuous contact w ith shield foil G7D-0408-00
Overall Shield Material: Aluminum foil bonded to non-hygroscopic polyester (Mylar) tape, either: foil free-edge or
D10 G7D-0408-00
equal-w idth foil and tape, per Manufacturer's standard.
REMARKS:

KCS ELECTRICAL DEPARTMENT


Attachment: Submitted Checklist (per Project Specs), page 5 of 5

SADARA TANK FARM INSPECTION CHECKLIST STFIC NUM BER DATE APPROVED QR NUM BER

I & C Copper Cable- Shielded, Single Twisted Pair / Triad, Multipair / Triad , Group 2 & 4-
STFIC-J-6602 INSTRUMENTATION
Material Receiving
PROJ ECT TITLE WBS / BI / J O NUM BER CONTRACTOR / SUBCONTRACTOR

SADARA TANK FARMS PROJECT DAEWOO / KETTANEH

ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.

ATTACHMENTS:
1. Attachment 1 -- Wire and Cable Minimum Requirements for Instrument Circuits

NOTES:
1. Approved - Acceptable to the authority having jurisdiction (i.e., SADARA ID).
2. Identified - Recognizable as suitable for the specific application by a qualified testing laboratory (i.e., listing and/or labeling).
3. Listed - Equipment and materials included in a list published by an approved qualified organization concerned w ith evaluation of products
or services, that maintains periodic inspection of production of listed equipment or materials or periodic evaluation of services, and w hose listing states
that the equipment, material, or services either meets appropriate designated standards or has been tested and found suitable for a specif ied purpose.
4. Labeled - Equipment or materials to w hich has been attached a label, symbol, or other identifying mark of an approved qualified organization concerned
w ith product evaluation, that maintains periodic inspection of production of labeled equipment or materials, and by w hose labeling the manufacturer
indicates compliance w ith appropriate standards or performance in a specified manner.
5. Notes: This check list is for Instrum ent Cable-Shielded, Single Tw isted Pair / Triad, Group 2 & 4 Multipair / triad , Shielded or w ithout ove rall shield-Material Receiving
Shielded or w ithout Overall Shields-Material Receiving (For signaling and Control purpose only)
Contractor / Third-Party COMPANY
Construction Representative* PMT Repres entative
Name, Initials and Work is Complete and Ready for Inspection: Name, Initials and T&I Witnessed QC Record Work Verif ied
Date: Date:
QC Inspector PID Represe ntative
Name, Initials and Performed Inspection Work / Rew ork May Proceed Name, Initials and T&I Witnessed QC Record Work Verif ied
Date: Date:
QC Supervisor Proponent and Others
Name, Initials and Quality Record Approved: Name, Initials and T&I Witnessed QC Record Work Verif ied
Date: Date:
*Pers o n R es p o ns ib le fo r Co mp let io n o f Quality Wo rk / Tes t Y = YES N = NO F = FAILED

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 1 of 17
02 03 Nov 2013 For Construction
01 01 July 2013 For Approval
00 13 May 2013 For Approval
Reviewed by Reviewed by Reviewed & Reviewed & Approved
Rev. Date Description
Construction HSE Checked by QC by SADARA PMT

OWNER:

SADARA TANK FARM


SUBCONTRACT NO.: OPAC1-L-A-001
MAIN CONTRACTOR:

SUBCONTRACTOR:

Document Title: NAME SIGNATURE DATE

METHOD STATEMENT: Prepared by V. Almonidovar 3 Nov 2013


Checked by D. Jansalin 3 Nov 2013
INSTALLATION of RACEWAY and Checked &
Praveen G. 3 Nov 2013
CONTROL CABLES for the HVAC Approved by
CONTROL SYSTEM (CRYOGENIC, FST Checked &
J. Ando 3 Nov 2013
Approved by
and STF PI BUILDINGS
Approved by A. Khlat 3 Nov 2013
Document No.:
STF/KCS/MS/B/0008 Revision Number 02
Document Status □ FOR INFORMATION □ FOR APPROVAL □ FOR REVIEW
■ FOR CONSTRUCTION □ AS BUILT
Document N o. Revision N o. Date Page N o.
STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 1 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 2 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

Summary of Document Revisions


Revision Section
Revision No. Revision Description
Date Revised
00 09 May 2013 New Issued for Review and Approval
01 22 Jun 2013 Page 4/12 Added “vendor’s installation procedures”.
Revised Specs. # from G7D-0322-A to G7D-0322-A-DAS1
Page 5/12, Item 6.2
Revised Specs. # from RT7D-0462-01 to G7D-0462-01
Page 6/12, Item 7.1 Revised RFC # from A554-RFC-002, Rev.00 dated 12 Mar 13 to A554-RFC-822-002, Rev.00 dated 12 Mar 13
Page 7/12, Item 7.2 Revised RFC # from A554-RFC-002, Rev.00 dated 12 Mar 13 to A554-RFC-822-002, Rev.00 dated 12 Mar 13
Page 8/12 Item 9.1C - Rev RFC # from A554-RFC-002, R 00 dated 12 Mar 13 to A554-RFC-822-002, R 00 dated 12 Mar 13
Added “ The cable tray specification shall be based on PLA”
Add Document no. A554-O-PRG-IC-GEN-BOD-003, Rev. 4 (Inst. Basis of Design for EPC), Para. 7.4, Sec.7.4.3
Page 9/12 Added “Loading Requirement per NEMA 20C”.
Added “Installation of cable tray supports as per NEMA Standards”.
Revised statement regarding number of 90⁰ conduit bends.
Deleted minimum size of conduit, etc.
Item 9.2, Sec. c – Reference Std.: SAES-J902, Sec. 10.1.1
Item 9.2, Sec. d – Reference Std.: SAES-J902, Sec. 10.1.2
Note: a) Use steel box for non-hazardous area per G7C -0311-01, Para. 4.4, Sec. 4.4.1.1.
b) Conduit size for Fire/Gas Actuator is 1-1/2” Ф per IFC drawings.
c) Cable Gland mentioned in SAES-J-902 is for armored cable.
Item 9.2, Sec. e – Reference Std.: SAES-J902, Sec. 15.1.2
Item 9.3 Sec c. – Cable specified in this Method Statement is non-armored type per A554-RFC-822-002, Rev.00
dated 12 Mar 13. Also, attached is catalogue cut of field devices fitted with PVC cable gland Type PG. Please
take note that Damper Actuator is supplied with fly leads.
Item 9.3, Sec. j - Added “The cable interface between Fire Alarm Panel and HVAC Panel shall be rated as fire
alarm cable”.
02 03 Nov 2013 Issued for Construction
Document N o. Revision N o. Date Page N o.
STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 2 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 3 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

CONTENT
1. Introduction
2. Purpose
3. Scope of Work
4. Location
5. Definitions
6. References
7. Materials and Testing Equipment
8. Responsibility / Supervision
9. Work Procedure
10. Inspection and Test
11. HSE Requirements
12. Attachments

Document N o. Revision N o. Date Page N o.


STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 3 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 4 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

 INTRODUCTION

This document specifies the method statement for the installation HVAC Control System to be used in the construction of:

SADARA TANK FARM PROJECT


Contract No. OPAC1-L-A-001

 PURPOSE
The purpose of this Method Statement is to provide a procedure to be performed throughout the project to ensure conformity with the project specification
and approved drawings.

 SCOPE OF WORK
Electrical works related to HVAC, such as supply and installation of raceway (cable tray, conduits, fittings and supports), supply and installation of
control cables to the HVAC Control Panel and related field devices, shall be installed and hooked-up in accordance with the project specifications,
approved drawings and vendor’s installation procedures.
The following works are not included in this Method Statement and shall be described by other concerned parties:
 HVAC control interface to the Fire Alarm System
 HVAC control interface to the Building Management System

4.0 LOCATION
The specified HVAC Control System stated in the Scope of Work shall be used in the following Buildings:

Document N o. Revision N o. Date Page N o.


STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 4 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 5 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

 A0501 MCC/PIB ( Unit 822 - Feedstock Tank Farm)


 A1101 MCC/PIB (Unit 822 – Cryogenic Tank Farm) and
 L3503 MCC/PIB (Unit 820 – Site Tank Farm)

5.0 DEFINITIONS
In the context of this document, the following abbreviations, words, or phrases shall be taken to have the meaning assigned to them:

COMPANY : Saudi Aramco and DOW Chemical Company (SADARA)


PROJECT : SADARA TANK FARM
MAIN CONTRACTOR : DAEWOO E & C (DEC)
SUB CONTRACTOR : KETTANEH CONST’N. S.A. LTD.
HVAC : Heating Ventilating and Air Conditioning
HCP : HVAC Control Panel
PLTC : Power Limited Tray cable
QA/QC : Quality Assurance / Quality Control

6.0 REFERENCES
This document is based on the requirements of the following documents:
6.1 International Codes:
NEMA Standard VE 1 : Cable Tray

Document N o. Revision N o. Date Page N o.


STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 5 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 6 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

ANSI C80.1 : Rigid Steel Conduit


ASTM A123 or A125 : Rigid Steel Conduit Hot Dip Galvanized
NFPA 70 : National Electrical Code 2008 Edition
ASTM B3 : Standard Specification for Soft or Annealed Copper
Wire
ASTM B8 : Standard Specification for Concentric Lay Stranded
Copper Conductors (Hard, Medium Hard or Soft)
IEC 60227 & BS 6004 : 450/750V CU/PVC Stranded Grounding Conductor

6.2 SADARA Project Documents:


SCHEDULE Q : Quality Requirements
A554-RFC-822-002, Rev.00 : Request for Clarification dated 12-Mar-13
A554-G-A0501-DWG-A05-021, Rev.1 : Unit 822F – Feedstock Tank Farm, HVAC Control Equipment Schedule and I/O Point
A0501 MCC/PIB Building
A554-G-A0501-DWG-A05-022, Rev.1 : Unit 822F – Feedstock Tank Farm, HVAC Control Schematic Diagram
A0501 MCC/PIB Building
A554-G-A0501-DWG-A05-023, Rev.1 : Unit 822F – Feedstock Tank Farm, HVAC Control Wiring Plan for Ground Floor
A0501 MCC/PIB Building

A554-G-A0501-DWG-A05-024, Rev.1 : Unit 822F – Feedstock Tank Farm, Enlarged Control Wiring Plan for HVAC Room
A0501 MCC/PIB Building

Document N o. Revision N o. Date Page N o.


STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 6 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 7 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

A554-G-A1101-DWG-A05-021, Rev.2 : HVAC Control Equipment Schedule and I/O Point


A1101 MCC/PI Building (Cryogenic Tank Farm)
A554-G-A1101-DWG-A05-022, Rev.2 : HVAC Control Schematic Diagram
A1101 MCC/PI Building (Cryogenic Tank Farm
A554-G-A1101-DWG-A05-023, Rev.2 : HVAC Control Wiring Plan for Ground Floor
A1101 MCC/PI Building (Cryogenic Tank Farm)
A554-G-A1101-DWG-A05-024, Rev.2 : Enlarged HVAC Control Wiring Plan for HVAC Room
A1101 MCC/PI Building (Cryogenic Tank Farm)
A554-G-L3503-DWG-A05-021, Rev.1 : Unit 820 – Site Tank Farm, HVAC Control Equipment Schedule and I/O Point
AL3503 MCC/PIB Building
A554-G-L3503-DWG-A05-022, Rev.1 : Unit 820 – Site Tank Farm, HVAC Control Schematic Diagram
L3503 MCC/PIB Building
A554-G-L3503-DWG-A05-023, Rev.1 : Unit 820 – Site Tank Farm, HVAC Control Wiring Plan for Ground Floor
L3503 MCC/PIB Building
A554-G-A0501-DWG-A05-024, Rev.1 : Unit 820 – Feedstock Tank Farm, Enlarged Control Wiring Plan for HVAC Room
L3503 MCC/PIB Building
A554-O-PRG-IC-GEN-BOD-003, Rev. 4: Instrument Basis of Design for EPC
RT7D – 0461- 01 : Instrument Wire and Cable Type ITC-ER, Shielded Pair or Triad Shielded, RTIP Code “E1-ER”
G7D – 0462- 01 : Instrument Wire and Cable, Multi Pairs or Triads - # 20 AWG, Individual Shields and Overall Shield
PVC Jacket – 300 Volts, DOW Code “EM1”
G7C – 0104- 00 : Grounding Design Aid
Document N o. Revision N o. Date Page N o.
STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 7 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 8 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

G7D – 0321 - 00 : Cable Tray Systems for North America


G7D – 0322 - 00 : Aluminum Cable Tray
G7D – 0322 – A-DAS1 : Aluminum Cable Tray Buyer’s Part A
G7D – 0311 - 01 : Material Specification for Galvanized Rigid Steel Conduit (Elbows, Nipples, Coupling)
For DOW North America
G7C – 0311 - 01 : Installation of Rigid Steel Conduit System for DOW North America
G7C – 0311 - 05 : Flexible Conduit Systems Metallic Liquid Tight (Metallic and Non- Metallic) for DOW North America

7.0 MATERIALS AND TESTING EQUIPMENTS


1) Aluminum type perforated cable tray (indoor / outdoor without cover) per Request for Clarification no. A554-RFC-822-002, Rev.00, dated 12-Mar-13,
Document no. A554-O-PRG-IC-GEN-BOD-003, Rev. 4 (Instrument Basis of Design for EPC), Para. 7, Sec. 7.4.3 and the following IFC Drawings:

a. A554-G-A0501-DWG-A05-023, Rev.1 : Unit 822F – Feedstock Tank Farm, HVAC Control Wiring Plan for Ground Floor (A0501 MCC/PIB
Building)
b. A554-G-A0501-DWG-A05-024, Rev.1 : Unit 822F – Feedstock Tank Farm, Enlarged Control Wiring Plan for HVAC Room (A0501 MCC/PIB
Building)
c. A554-G-A1101-DWG-A05-023, Rev.2 : Unit 822 – Cryogenic tank Farm, HVAC Control Wiring Plan for Ground Floor (A1101 MCC/PIB
Building)
d. A554-G-A1101-DWG-A05-024, Rev.2 : Unit 822 – Cryogenic Tank Farm, Enlarged Control Wiring Plan for HVAC Room (A1101 MCC/PIB
Building)
e. A554-G-L3503-DWG-A05-023, Rev.1 : Unit 820 – Site Tank Farm, HVAC Control Wiring Plan for Ground Floor (L3503 MCC/PIB Building)

Document N o. Revision N o. Date Page N o.


STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 8 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 9 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

a. A554-G-L3503-DWG-A05-024, Rev.1 : Unit 820 – Site Tank Farm, Enlarged Control Wiring Plan for HVAC Room (L3503 MCC/PIB
Building)

1) Instrument Wire and Cable per Request for Clarification no. A554-RFC-822-002, Rev.00, dated 12-Mar-13 and Material Specs. RT7D - 0461- 01 and
RT7D – 0462-01.
2) Galvanized Rigid Steel Conduit and Fittings ANSI C80.1 (hot dip galvanized per ASTM A123 or A125) in accordance with Material Specs. G7D-
0311-01.
3) Liquid Tight Flexible Conduit and Fittings in accordance with Material Specs. G7C-0311-05.
4) Electrical boxes in non-hazardous area in accordance with Material Specs. G7D-0311-01, Para. 4.4, Sec. 4.4.1.1
5) Cable tray and conduit supports.
6) Insulation Resistance Tester
7) Multi Tester
8) Pipe Threading Machine, 120V, 1Ø, 60 Hz equipped with Pipe Cutter and Reamer.
9) Manual Pipe Threader
10) Electric Grinder, 120V, 1Ø, 60 Hz
11) Portable Electric Drill, 120V, 1Ø, 60 Hz
12) Hydraulic Crimping Tool
13) Manual Crimping Tool

Document N o. Revision N o. Date Page N o.


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KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 10 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

1) Hydraulic Pipe Bender


2) Manual Pipe Bender
3) Hacksaw
4) Tri Pod

8.0 RESPONSIBILITIES / SUPERVISION


8.1 Construction Manager:
1) Preparation of the method statement for this work.
2) Document control for installation of cable tray, conduits and control cables
3) Training for site engineer and staff.
4) Supervision of work
5) Training for site engineer and staff.

8.2 Site Engineer:


1) Control of workers on site.
2) Holding tool box meeting prior to starting daily work for safe working condition.
3) Monitoring of HSE condition during working hours.
4) Supervision of work.
5) Authorization for stopping work that is unsafe.

Document N o. Revision N o. Date Page N o.


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KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 11 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

8.3 QA/QC Manager:


1) Preparation of inspection and Test Plan for this work.
2) Review of the method statement for this work.
3) Inspection and testing.
4) Preparation of maintenance of inspection and test record.
5) Notification to Client for inspection and testing.

8.4 HSE:
1) Oversee and carry-out site inspections to ensure the safety requirements are strictly followed.
2) Ensure that appropriate PPE’s are provided on personnel involved in the activity.
3) Review of the method statement for this work.
4) Inspection and testing.
5) Preparation of maintenance of inspection and test record.
6) Notification to Client for inspection and testing.
7) Supervision and monitoring of safety aspect around working area.
8) Instruction of worker for potential risks.
9) Authorization for stopping work for unsafe condition during installation of cable tray, conduit and control cable.

8.0 WORK PROCEDURE


8.1 Cable Trays, Conduits and Fittings
a. Prior to commencing the installation, QC inspector shall check the materials relevant to the installation of its conformance to the standard
specifications and free from defects.

Document N o. Revision N o. Date Page N o.


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KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 12 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

a. Installation of HVAC control system shall be done by qualified personnel in handling and usage of applicable tools and equipment.
b. Cable tray shall be made from aluminum perforated type, aluminum per Request for Clarification no. A554-RFC-822-002, Rev.00, dated 12-
Mar-13, Document no. A554-O-PRG-IC-GEN-BOD-003, Rev. 4 (Instrument Basis of Design for EPC), Para. 7.4, Sec.7.4.3
c. The tray specification shall be based on PLA.
d. Cable tray shall be installed in accordance with G7C-0321-01.
e. The cable tray system shall be installed with the manufacturer’s standard fittings, splice plates and blind ends.
f. All fasteners (i.e., nuts, bolts, washers, etc.) used to connect and assemble the cable tray system shall be 304 SS per Document no. A554-O-
PRG-IC-GEN-BOD-003, Rev. 4 (Instrument Basis of Design for EPC), Para. 7.4, Sec.7.4.3
g. Cable tray system shall be free from burrs or other sharp projections that could cause damage to the cable jacket during installation.
h. Cable tray fills shall not exceed Loading Requirement per NEMA 20C.
i. Installation of cable tray supports shall be as per NEMA Standards. Suitable supports shall be used such as:
 Cantilever brackets
 Trapeze support or
 Individual rod suspension brackets
j. Install necessary interconnecting conduits and cable tray between the HVAC Control Panel and associated field devices.
k. Route exposed conduit parallel and perpendicular to walls.
l. The maximum number of 90⁰ bends, or equivalent between pulling points in any conduit run shall be three.
m. The QC inspector will inspect the installation to ensure that materials, supports and fittings adhere with project specifications and standard
installation details.

Document N o. Revision N o. Date Page N o.


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KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 13 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

9.2 Connections at Field Instruments and Electrical Boxes


a) All associated field devices of the HVAC system will be supplied by DEC and installed by the KCS HVAC Dept.
b) Installation of electrical boxes shall be in accordance with G7C -0311-01, Para. 4.4, Sec. 4.4.1.1, NEC and installation drawings
c) All connections at the field instrument shall be made on screw type terminal blocks. Wire nuts and spring type terminals shall not be used. Field
Instruments with integral terminal blocks shall be connected directly to the field cable. (Ref. SAES-J-902, Sec. 10.1.1)
d) If the Field Instrument is fitted with factory sealed fly leads (in case of Fire/Gas Damper Actuators), then it shall be connected to a screw type
terminal block installed in a 4” x 4” x 4” square steel box. (Ref. SAES-J902, Sec.10.1.2).
e) When screw type terminals are provided on field instruments or other electrical devices, solder less crimp/compression connectors shall be used
for connecting stranded copper conductors. (Ref. SAES-J-902, Sec.15.1.2)
9.3 Control Wiring
a) Control cables shall be stranded copper, pair/multi-pair/triad, shielded and non-armored type per Request for Clarification no. A554-RFC-822-
002, Rev.00, dated 12-Mar-13, Document no. A554-O-PRG-IC-GEN-BOD-003, Rev. 4 (Instrument Basis of Design for EPC), RT7D-0461-01
and G7D-0462-01.
a) Splices are not permitted in wiring. When wiring must be extended, connections shall be made via terminal blocks in an electrical box installed
aboveground.
b) Control cable shall be terminated using appropriate PVC cable glands.
c) The outer jacket of shielded twisted single pair/triad cables shall be left intact up to the point of termination (approximately three to four inches
from terminal blocks).
d) Twisted, multi-pair/triad cables shall be cut to appropriate length to minimize looping and flexing of the cable within the electrical box.
e) Control cable shall be megger tested prior to termination.

Document N o. Revision N o. Date Page N o.


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KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, 14 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

a) Control cable shall be megger tested prior to termination.


b) All wiring shall be tagged at each end. Each wire tag shall have two labels. The first label (closest to the end of the wires) shall identify the
terminal number to which the wire is physically connected. The other label shall be the terminal number of the connection of the opposite end of
the wire.
c) Homerun cables shall be tagged with the assigned “IC” cable number
d) Homerun cables shall be tagged with the assigned “IC” cable number.
e) The cable tagging philosophy for cables routed from junction boxes to field instruments shall be defined by the Main Contractor (DEC).
f) The cable interface between Fire Alarm Panel and HVAC Panel shall be rated as fire alarm cable.
9.2 Automatic Control Equipment
a) HVAC Control Panel will be supplied by DEC.
b) Power supply and equipment ground to the HVAC Control Panel will be supplied and installed by DEC.
c) HVAC Control Panel shall only be installed in an indoor and air conditioned environment
d) All control cable connections and tagging shall be in accordance with the project requirement
e) Certified factory test conducted on the HVAC Control Panel is acceptable.

9.3 Grounding
a) Electrical system must be connected to ground for the protection of personnel and equipment from fault current and to minimize electrical
interference in signal transmission circuits.

Document N o. Revision N o. Date Page N o.


STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 14 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 15 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

a) Grounding system recommendations and requirements provided by the manufacturers of instrumentation and control systems shall also be taken
into consideration.
b) Shielded cables shall be used to reduce electrostatic noise. The shield shall be grounded at one point only, typically at the HVAC Control Panel.
c) #2/0 AWG (70 mm2) CU/PVC green colored ground wire - to be installed in or on the tray (as ground bus) running the entire length of the tray
per Specs G7C-0104-00, Para. 6.6.2, Sec. 6.6.2.1 and G7C-0321-01, Para.11, Sec. 11.3
d) # 2 AWG (35 mm2) CU/PVC green colored ground wire – to be installed on splice joint to ensure grounding continuity per Specs G7C-0321-01,
Para.11, Sec. 11.2
e) # 4 AWG (16 mm2) CU/PVC green colored ground wire – to be installed on cable tray and conduit transition per Engineering detail G7C-0326-
02
f) # 10 AWG (6 mm2) CU/PVC green colored ground wires - for instrument not grounded through process connection, routed back through open
cable tray or conduit and connect to the cable tray ground bus (#2 AWG CU/PVC green color).

10.0 INSPECTION AND TEST


10.1 General
a) The Inspection and Test Plan (ITP) for this work shall be approved by the client.
b) The following ITP and corresponding Checklist shall be provided by the Main Contractor (DEC). The supply and installation of the raceway
(cable tray and conduits) and control cables for HVAC Control System is an integral part of the required ITP’s.
 Electronic Control System
 Metallic Instrumentation and Control Cables
 Instrumentation Racks and Panel (Open); Terminal Boxes and Instrument Cabinets (Enclosed)
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KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 16 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

 Cable Tray, Fittings and Accessories


 Above Ground Conduit, Fittings and Accessories
 Grounding and Bonding
 Instrumentation / control cable test form
a) The inspection shall be performed by qualified inspector.
11.0 HSE REQUIREMENTS
11.1 General
a) Work shall be executed safely in accordance with HSE requirements.
b) Job Safety Analysis (JSA) for potential risks shall be prepared by HSE Manager and shall be communicated to all workers.
c) All supervisors / workers shall be alerted by HSE Manager for the potential risks prior to execution of this work.
d) All supervisors shall have tool box meeting for discussing the risk and environmental aspect prior to starting the daily work.
e) Copy of JSA in language understood by workforce shall be available at job site.
11.2 Health

a) Each worker shall be provided with drinking water during working hours.
b) All work forces shall wear personnel protective equipment (safety helmet, goggles, safety shoes, dust mask, etc.) and gloves & ear protector, if
needed.

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KCS ELECTRICAL DEPARTMENT


Attachment: METHOD STATEMENT, page 17 of 17
SADARA TANK FARM

METHOD STATEMENT: HVAC CONTROL FOR BUILDINGS


STF/KCS/MS/B/0008

a) Safety patrol shall be utilized during working time in case of emergency or accident that may occur to inform the nearest first aid team by wireless
radio, cellular phone, or other devices for assistance, and contact the Medical Section and HSE Manager.

11.2 Safety
a) Equipment and hand tools shall be in good working condition and checked before using. Electric powered equipment shall have all connections
and cords properly insulated are suitably earthed to avoid electrocution hazards.

b) Material hauling, handling, to and from heights, Personnel shall be kept at a safe distance from the load, and the load lowered slowly. Tag lines
will be fitted to guide the load into position.

c) All working areas shall be clean of all debris, waste and put in designated garbage bins provided by the Safety Department.
d) 10 minutes tool box meeting shall be performed daily before staring to work.
e) Back up alarm is installed on all mobile equipment to serve as warning signal prior to backing out of the equipment.
f) The fire extinguisher shall be kept on standby with equipment & generators in case of fire.

12.0 ATTACHMENTS
12.1 IFC Drawings

12.2 Job Hazard Analysis

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STF/ KCS/ MS/ B/ 0008 02 03-N ov-13 17 of 17

KCS ELECTRICAL DEPARTMENT


Attachment: JOB HAZARD ANALYSIS (JHA), page 1 of 2

SADARA Tank Farm

JOB HAZARD ANALYSIS

Document No. Revision Status Date Page No.

0 0 09 May 2013 Page 1 of 2

COMPANY: Kettaneh Construction S.A. Ltd. Date: JHA NO: ______________


(SUB-CON)
WORK: Installation of HVAC Control System in MCC/PI Buildings EQUIPMENT/TOOLS USED: Pipe cutter, Pipe
threader, Electric grinder, Electric drill, Conduit
bender, Electrical tester and Pick-up
NAME POSITION SIGNATURE
PREPARED BY: DEPARTMENT

REVIEWED BY: HSE Dept.

APPROVED BY

Risk
Activity Order Potential Hazards Hazard Control Proactive Measures
Rating
List the steps required to perform the Against each step list the potential 1 = V/LOW For each hazard identified, list the control measures
5 = V/HIGH
task in the sequence they are carried hazards that could cause injury when required to eliminate or minimize the risk of injury
out the task is performed, name tools
and equipment

KCS ELECTRICAL DEPARTMENT


Attachment: JOB HAZARD ANALYSIS (JHA), page 2 of 2

SADARA Tank Farm

JOB HAZARD ANALYSIS

Document No. Revision Status Date Page No.

0 0 09 May 2013 Page 2 of 2

1. Cutting and threading of  Hand injury 3  Wear proper PPE’s (suitable gloves, safety
conduits using pipe cutter and  Back injury goggles, and safety hat and safety shoes).
threader  Slip & trip  Equipments shall be inspected by a competent
 Eye injury person prior to usage.
 Electrocution  Equipment should be operated and checked by
a competent person prior to use.
 Work area shall be free from slip and tripping
hazards.
2. Transporting conduits and cable  Equipment malfunction 2  Equipment shall be inspected by a competent
trays from warehouse to work  Load fall person on a regular basis prior to operation.
area (Pick-up)  Struck against  Conduits and cable trays shall be secured
properly.
 A competent signal man shall be present to
assist the driver during transport.
3. Transporting conduits and cable  Hand injury 2  Wear proper PPE’s (suitable gloves, safety
trays from fabrication shop to  Back injury goggles, and safety hat and safety shoes).
work area (manual handling  Slip & trip  Work area shall be free from slip and tripping
 Eye injury hazards (rebars and electrical cables).

4. Flush grinding of rough edges  Hand injury 2  Wear proper PPE’s (suitable gloves, safety
using electric grinder  Eye injury goggles, and safety hat and safety shoes).
 Electrocution  Equipment should be operated and checked by
a competent person prior to use.
5. Installation of conduit, cable  Back strain 3  Personnel have the work breaks to prevent
tray and control cables  Hand injury back strains.
 Eye injury  Wear proper PPE’s (suitable gloves, safety
 During emergency evacuation goggles, and safety hat and safety shoes).
(while installing of conduits,  An access and egress ladder shall be in place in
cable trays and control cables. case of emergency evacuation.

KCS ELECTRICAL DEPARTMENT


THANK YOU…

KCS ELECTRICAL DEPARTMENT

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