Professional Documents
Culture Documents
for
ELECTRICAL QA/QC
KCS ELECTRICAL
TRAINING TOPICS
QC Inspector
Inspection Levels (Procurement Phase)
Inspection Levels (Construction Phase)
Documents Required for Inspection
Attachments
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.
2. CL’s – Checklists
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.
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.
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAMCO
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.
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.
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
C NTRC TR
ARAM C O
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAMCO
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.
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAM CO
4.0 PRE-COMMISSIONING
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD SAUDI
CNTRCTR
ARAM CO
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
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
SADARA TANK FARM INSPECTION TEST PLAN SATIP No. REV. No. APPROVAL DATE DISCIPLINE:
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD
SUBCON DEC SADARA
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
SADARA TANK FARM INSPECTION TEST PLAN SATIP No. REV. No. APPROVAL DATE DISCIPLINE:
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD
SUBCON DEC SADARA
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD
SUBCON DEC SADARA
4.0 PRE-COMMISSIONING
INSPECTION RESPONSIBILITY
ITEM PROJECT PHASE QUALITY QUALITY ASSIGNMENTS
TASK / ACTIVITY REMARKS
NO. & ACTIVITY CODE PROCEDURE RECORD
SUBCON DEC SADARA
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
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
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
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
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
ITEM
ACCEPTANCE CRITERIA REFERENCE PASS FAIL N/A RE-INSP DATE
No.
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
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:
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
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
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
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
⁰
Insrument Wire and
⁰
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
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
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
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
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
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
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
OWNER:
SUBCONTRACTOR:
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
INTRODUCTION
This document specifies the method statement for the installation HVAC Control System to be used in the construction of:
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:
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:
6.0 REFERENCES
This document is based on the requirements of the following documents:
6.1 International Codes:
NEMA Standard VE 1 : Cable Tray
A554-G-A0501-DWG-A05-024, Rev.1 : Unit 822F – Feedstock Tank Farm, Enlarged Control Wiring Plan for HVAC Room
A0501 MCC/PIB Building
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)
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
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.
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.
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.
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).
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.
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
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
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.