Lighting Installation and Testing in Plants

To ensure that Lightings and Convenience Outlet Installation including its supports and Testing are performed safely, efficiently and in accordance with good working practice, as per International law and Saudi Aramco Specifications. This procedure is intended to provide general application guidance and establish controls during preparation and installation. Main keywords for this article are Lighting Installation and Testing in Plants, Method Statement Lighting Installation, Lighting in Plant.

This method statement will cover the minimum requirements for installation, storage, handling, preparation, safety and testing of lighting fixtures (Connection / Function Check and Illumination Test), including Convenience Outlet in accordance with the scope of work, approved for construction drawings, project specification and applicable Procedures.

Lighting Installation and Testing in Plants, Refineries and Buildings

TOOLS AND EQUIPMENT

Tools and equipment needed should be in good condition and must be checked by Supervisor / Safety Engineer prior to use in the construction area.  These includes but not limited to:

• Man lift
• Boom Truck
• Crane
• Welding Machine
• Multi-meter
• Ladders
• Insulation Tester
• Electric Power Tools (i.e. drill with bits, grinder)
• Termination Tools
• Lux Meter
• Knock out Punch Machine (Hydraulic)
• Hydraulic Pipe Bender
• Cut off wheels (speed cutter)
• Tripod vise
• Threading machine
• Torque Wrench
• Drill Press Machine (Magnetic Mounted)
• Claw bar
• Measuring Tape

Method Statement Lighting Installation and Testing

Ensure that working areas are ready for installation with respect to other disciplines for the use of scaffolding materials (if necessary), affected   equipment and other existing facilities.

Identify area classification and verify hazardous areas to be considered during installation activities considering precautionary measures in using tools,   equipment and materials to be installed, making sure that all these items are   suitable and appropriate as per the area requirements.

INSTALLATION OF LIGHTINGS, DEVICES AND RELATED FIELD DEVICES

• Lighting fixtures, devices, junction boxes and its support shall be inspected for possible factory or handling damage and recorded using Quality Control Material Receiving Inspection Report form. Where physical damage or non-compliance with the technical scope of work and International Standards had been found, Subcontractor / Contractor shall record using Non Conformance Report or Observation Report and report immediately.
• Verify the material specification to its conformance with the classification area requirements especially to hazardous areas. This    shall be included in material receiving inspection procedure and to   be recorded in Quality Control Material Receiving Inspection Report form, which is to be reported immediately to company if non-compliance be found against the materials. Lightings, devices and controls shall comply with SAES-P-123.
• Explosion proof identification to the specific material shall be  verified with stipulating certifications (if any) as per requirements depending on the intensive usage of the material according to the drawing, as well as area classification.
• Survey the location of equipments/devices and/or lightings with reference to layout drawings and details as well as in the given Technical Scope of Work. Identify area classifications to include hazardous areas in accordance with the latest Approved for Construction drawing.
• Categorize and select lighting fittings, devices, junction boxes and related materials to include wattage, types of    fixtures/devices/junction boxes, and type of mounting in accordance to the latest approved construction drawing and details, as well as with area classification requirements.
• Check that mounting heights are in accordance with the elevations  shown on the plan and detail drawings as per company Technical Scope and Saudi Aramco Standards.
• Where manufacturer’s instructions are furnished with the lighting fittings and devices, installation detail shall conform to the requirements.
• Installation of fixtures, devices and junction boxes should consider possible clashing against nearby plant equipment, instruments, valves, pipes and flanges to be added. If obstruction occurs during  installation, field supervisor shall inform immediately the company  representative by issuing “Site Query” and rectify the installation as instructed by the “Site Query’’ response, which is to be incorporated the “As Built Drawing” later.
• Install necessary supports and poles as per detail drawings given, and to the installation standards in accordance with the Technical Scope of Works. Ensure that the support is suitable to the lightings/devices materials in consideration to the various  environmental classifications stated in layout drawings.
• Supports shall be assembled with proper fittings mounted plumb, level and rigidly secured to structure. No welding works shall be       executed in any process plant equipment such as vessel.
• Fix all supports including fabricated steel supports in which welded or cut portion of the supports shall be treated with applicable paint
• Lighting fittings including lamps, covers, guards and diffusers shall be handled with care to avoid breakage or damage to the fragile
• Check the proper position when bringing the fixture to its location and verify also that overhead clearance, working radius and path  are clear from any protruded materials or obstruction.
• Mount the lighting fixture and devices in the position, elevation and location as shown on project Approved for Construction drawings. Location may be varied slightly to avoid piping or structural
• The elevation, level and vertical alignment of the lighting fixtures and devices shall be checked ensuring that it is securely and rigidly fixed in place.
• Lighting unit orientation shall be verified ensuring illumination in the area is sufficient and not obstructed by pipes or structures.
• The final angular displacement and aiming points shall be determined in the field, adjusting each lighting fixture in order to    provide the optimum light coverage.
• Ensure that the conduit to which lighting fittings, devices, and       junction boxes were attached are fixed by substantial screws so that       the weight of the installed lighting fittings, devices and junction         boxes will not be carried by the conduit.
• After installation following the complete drawing and details, clean the lamps, reflectors, diffusers and housing body. Dust and dirt shall  be removed by using appropriate rags.
• Terminate all wiring or cable connections according to the termination schedule, installing all termination requirements including identifications required, in which non-corroding material with cable reference numbers, as noted in the cable schedule, are clearly visible. Cabling and wiring works shall be done as   per SAES-P-104.
• Double check all wiring and circuit connections for the lightings/  devices with respect to circuit diagram to avoid possible short- circuiting and damage.

LIGHTING IN PLANT/LIGHTING POLE 3 MTR LONG WITH CABLING WORKS (Lighting Pole at Platforms and Railings)

• Expedite materials for lighting and equipment supports from lay down yard to job site utilizing boom truck for loading and  unloading.
• QC visual inspection and acceptance for lighting equipment  including material supports.
• Erect scaffoldings outside railings and underneath grating platform.
• Fabrication of lighting pole 2”Ø painted HDG steel pipe sched 40.
• Fabrication and installation of supports for lighting pole at handrail and base using angular/unistrut channel.
• Primer, finishing and touch up paint for every cutting, grinding and  drilling edge of trays and conduits.
• QC inspection and acceptance for lighting pole and supports prior to installation.
• Lighting pole wiring and lighting fixtures assembly and installation.
•   Lighting pole wiring termination, splicing with proper terminal lugs, heat resistance insulation sleeve and name plate installation.
• QC inspection and acceptance for 3.0 meters long pole.

LIGHTING IN PLANT/ AREA LIGHTING POST (8-15m) HEIGHT/ CABLING

• Check PVC conduit stub up, anchor bolt and embedded steel bars of concrete foundation. They shall be in accordance to detailed drawings and as per project specifications.
• Excavation works for branch trench is at least 460 mm below finishing grade from trench to post. (General Practice).
• Thermal sand bedding/filling, clearing and compaction shall be in accordance to detail and Approved for Construction drawing.
• QC shall do inspection, testing and acceptance for compacted sand bedding and trench utilizing the applicable  Inspection Checklist (IC) forms.
• Expedite cable drums from lay down yard to plant site using boom truck prior to cable drum and cable stand setting.
• Cable pulling, arrangement along the branch trench, cable tags installation and protection tiles installation must conform to SAES-P-104. Mark the cable route in accordance with for construction standard drawing.
• Prior to thermal sand filling, clearing, de-watering and compaction,  QC Inspector shall conduct visual inspection and acceptance  for cable laying at trench and cable testing (continuity and insulation test) end to end of foundation and post. It shall be recorded on applicable SAIC/SATR forms.
• QC shall conduct inspection, testing, acceptance for sand and gravel back filling, trench compaction and protection tiles installation.
• Warning tape shall be installed from main trench to branch trenches of   lighting post foundation to next post.
• Complete inspection of post foundation prior for installation of lighting post. Install lighting post using crane. For lighting post detail (lighting fixture, terminal blocks assembly including its accessories), lighting post wiring, termination, splicing with proper terminal lugs, heat resistance insulation sleeve for fixture and name plate installation, refer to Approve for Construction drawings.
• For underground cable installations refer to Underground Installation Requirements , GROUNDING INSTALLATION AND TESTING.

LIGHTING IN PLANT/LIGHTING FIXTURE WITH CABLING WORKS AND CONVENIENCE OUTLET WITH CABLING WORKS

• Check the readiness of steel and concrete structure of the area. They shall be positioned, leveled and located in accordance to detailed drawings and Project Specifications.
• Secure approved drawing for electrical, structural and piping for reference during layout. It should be approved for construction.
• Expedite steel materials (various channel), lighting fixtures,  convenience outlet, equipment and cable drum from lay down to site area utilizing boom truck to load and unload.
• Expedite cable stand cable pulling tools from tool room to site area utilizing boom truck to load and unload.
•   QC inspection and acceptance for materials and equipment.
• Mass fabrication of typical support for lighting fixtures, conduits, convenience outlets etc. with primer, finish and touch up paint.
• Layout, measuring, markings and installation of supports for lighting fixture, convenience outlet, conduits and branch perforated tray support.
• Installation of conduits fittings based on the approved for construction drawings.
• Primer finishing and touch up paint for every edging, cutting, grinding and drilling of channel and structural unit.
• Installation of lighting assembly or convenience outlet assembly, JB assembly, etc. based on the approved drawing.
• Grounding bonding for lighting, junction boxes and convenience outlets connected to grounding bar.
• QC inspection and acceptance for the installed lighting fixtures, convenience outlets, and PVC coated conduits.
• Cable drum and cable stand setting ready for pulling.
• Cable pulling for lighting fixtures or convenience outlets.
• QC inspection and acceptance for cable pulling above ground level passing main tray towards lighting panel board.
• Cable visual inspection, testing (continuity/insulation test). QC shall witness and record the result.
• Glanding termination, splicing, cable tags, core marker and name plate installation as per requirements.
• Protection (cover) for the inspected equipment shall be installed using preferably fire blanket to avoid being hit by welding flux and potential fire. Also, fire blankets shall be always placed underneath the welding locations to avoid falling welding flux and potential fire onto people and equipment.

TESTING OF LIGHTINGS, DEVICES AND RELATED FIELD DEVICES

• QC inspection for completed lightings, devices, and steel supports shall be requested, and inspection/test results shall be filed and recorded on appropriate approved forms.
• Visual inspection shall include dimensional check for junction box, support inspection and location verification which shall be recorded to the approved forms.
• Conduct preliminary testing prior to final inspection ensuring that all connections and functions are appropriate with respect to wiring  diagrams and other requirements.
• Final illumination and functional test shall be conducted and all  results shall be recorded.