1.0 PURPOSE
2.0 SCOPE
3.0 APPLICABLE DOCUMENTS
4.0 RESPONSIBILITY
5.0 MANPOWER
6.0 TOOLS & EQUIPMENT
7.0 METHODS/PROCEDURES
8.0 QUALITY CONTROL
9.0 SAFETY PRECAUTION
10.0 ATTACHMENTS
1.0 PURPOSE
1.0 This method statement will serve as a minimum guideline to carry out the Cable Tray Installation activities for commercial buildings, plants and refineries in accordance with Project Drawings and Specifications.
2.0 SCOPE
2.0 This method statement will cover the minimum requirements for installation of cable trays and other related electrical works to be applied at the site for commercial buildings, plants and refineries.
3.0 APPLICABLE DOCUMENTS
3.1 Project Specification and Standards
3.2 ARAMCO Specification and Standards
3.2.1 SAEP-302 Instruction for Obtaining a Waiver of a Mandatory Saudi ARAMCO Engineering Requirements
3.2.2 SAES-H-101 Approved Protective Coating Systems
3.2.3 SAES-P-100 Basic Power System Design Criteria
3.2.4 SAES-P-104 Wiring Methods and Materials
3.2.5 SAES-P-111 Grounding
3.2.6 SAES-J-902 Electrical System for Instrumentation
3.2.7 SAES-8-068 Electrical Area Classification
3.2.8 Schedule Q Saudi Aramco Project Quality Requirements
3.2.9 Schedule G Material, Tools, and Equipments
3.2.10 Schedule D Safety, Health and Environmental Requirements
3.2.11 Related Vendors Installation and maintenance manuals and /or specifications
3.3 International Standard
3.3.1 NFPA 70 National Electrical Code (NEC)
3.3.2 NEMA VE2 Cable Tray Installation Guidelines
3.3.3 NEMA VE1 Metal Cable Tray Systems
3.3.4 IEC 60840 International Standard
3.4 Inspection and Test Plan/ Method Statement
3.4.1 SATIP-P-104-03 Cable Tray Fittings and Accessories
3.5 Latest Revision of the following Documents shall be used
3.5.1 Vendor Drawing
3.5.2 Latest Approved Drawing
3.6 Saudi ARAMCO Safety, Health and Environmental Standard
3.6.1 Construction safety manual
3.6.2 General Instructions (G.l’s) at the work site
4.0 RESPONSIBILITY
4.1 Construction Manager is responsible for implementation of all HSE requirements; he shall study, analyze and schedule all construction activities with his department to include manpower and equipment line up as well as other possible resources required for the successful implementation of the construction work activities. Study all aspects of work procedure as per Technical Scope of Work.
4.1 Electrical Superintendent shall study and review all necessary documents for the installation works in his area to include the technical scope of work, specification, bill of quantities, planned milestone dates and construction procedure in support to his Electrical Supervisor.
4.2 Electrical Supervisor-in-charge shall study and review all necessary documents for the Power Works in his area to include, specifications, bill of quantities and construction procedures. He shall monitor the availability of materials in accordance with the schedules and construction analysis.
4.3 The Electrical Foreman shall be directly responsible for the work supervision at site installation following all schedules and specific work activities ensuring that the works are performed in accordance with Technical Scope of Work and latest approved IFC drawings.
4.4 QC Inspector shall be responsible in monitoring and inspection of the work and ensures that the work is performed and properly documented in accordance with Technical Scope of Work and Standards.
4.5 Safety Supervisor shall be responsible in monitoring safety aspects and ensuring that the work is done in accordance with Safety Standard Procedure. He shall discuss to the workers the characteristics of related materials and status of work area
giving reminders as an additional point to injury and incident free environment.
5.0 MANPOWER
5.1 The Electrical Supervisor shall control the overall activities at site and he will be directly reporting to the Site Superintendent. The basic manpower under him shall consist but not limited to the following:
5.1.1 Electrical Foreman.
5.1.2 Electrical Leadman.
5.1.3 Industrial Electrician.
5.1.4 Plate Welder.
5.1.5 Helper.
5.1.6 Scaffolders.
5.1. 7 Manlift Operator.
5.2 QC Inspector.
5.3 Safety Engineer.
6.0 TOOLS AND EQUIPMENT
6.1 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:
6.1.1 Metal Cutting Saw
6.1.2 Touch-up Material
6.1.3 Torque wrenches
6.1.4 Screwdriver
6.1.5 Electric Power tools (Drill with Bits)
6.1.6 Welding machine
6.1.7 File
6.1.8 Open end Wrench.
6.1.9 Nylon Cord.
6.1.10 Leveling Device.
6.1.11 Tape Measure.
6.1.12 Square.
6.1.13 C-clamp.
6.1.14 Ratchet Wrench.
6.1.15 Cutter.
6.1.16 Hydraulic Crimper.
6.1.17 Manual Cable Cutter.
6.1.18 Set of Nylon Ropes.
6.1.19 Receptacles (Welding Conventional Outlet).
6.1.20 Manlift.
7.0 METHODS / PROCEDURES
7.1 CABLE TRAY INSTALLATION
7.1.2 Review all references such as the latest issued approved for construction drawings, layout and technical scope of work. Also refer to project specification for additional references.
7.1.3 Coordinate with Contractor / Company for withdrawal of cable tray materials. Visual inspection shall be conducted for possible factory or handling damage and record it in approved DEC/JGC Material Receiving Inspection Report Form.
7.1.4 Survey the cable tray position or location for possible obstruction and rerouting. In case of discrepancy of cable tray layout against site conditions, shall be informed for final disposition.
7.1.5 Install cable tray as per latest issued Approved for Construction drawing. Bevel the sharp edges and burrs from cut/machined parts to prevent damage to cable insulation during cable pulling activity. Cable tray shall be cut along side of a line of plain metal and not through any perforations. After cutting, all sharp edges shall be beveled using file. Welded or cut portions shall be treated with zinc rich paint. Holes through tray shall be similarly treated.
7.1.6 Cable trays shall be installed as a complete system. Cable tray systems shall not have mechanically discontinuous segments of cable tray runs. Refer to SAES-P-104 sec. 9 para. 9.7.
7.1.7 Install necessary fabricated supports for cable tray as per installation detail. All permanent materials (including fabricated supports), consumables, construction area and resources shall be prepared and checked prior to installation works and shall be approved by client representative.
7 .1.8 Supports for cable tray shall provide strength and work load capabilities
sufficient to meet the load requirements of the cable tray wiring system and future cable wiring system and future cable addition.
7.1.9 Self standing support for cable tray shall be made of I-beam channel vertically installed and supported with concrete foundation, anchor bolt grouting, etc.
7 .1.10 Cable tray shall not be supported from process piping. Refer to SAES-P-104 sec.9 para. 9.9. The fabricated support shall be intended only for cable tray.
7.1.11 Minimum Distance between process pipe surface and cable tray in parallel run shall be 300mm.
7.1.12 Cable tray system shall not be used where subject to severe physical damage. (NEC 392.4). Refer to SAES-P sec.104 para. 4.1. It shall be recorded and reported.
7.1.13 Cable tray shall never be used as a walkway (NEMA VE2 sec. 5 para. 5.3).
7.1.14 Minimum clearance between instrument line/conduit surface and cable tray in parallel run shall follow as per SAES-J-902 para 4.2.
7.1.15 Furnish the tray expansion in cable tray run if the tray runs between independent structures, and though the run is smaller than 20meters.
7.1.16 Splice plates (joints) shall not be located over support, and shall be located between supports and quarter points.
7 .1.17 No more than one splice shall be located between two adjacent supports. Refer to SAES-P-104 sec. 9 para. 9.5.
7.1.18 The maximum spacing between expansion joints shall be based on a temperature differential of 55C (100F) and expansion gap setting shall be in accordance with NEMA VE2, fig 4.13B, based on a minimum temperature of 0C and a maximum temperature of 55C. Refer to SAES-P-104 sec. 9 para. 9.6. End of cable tray shall be installed with end cup/plate.
7.1.19 Support shall be located within 2ft (600mm max.) of each side of expansion splice plates. (NEMA VE2-4.3.3).
7.1.20 The cable tray shall be anchored at the support nearest to its midpoint between the expansion joint and secured by expansion guides at all other supports location. The cable tray shall be permitted longitudinal movement in both directions from fixed point. NEMA VE2 sec. 4.3.2 fig. 4.13A.
7.1.21 Cable tray run is Substation or PIB all cable trays shall have a minimum of 200mm clear space above the tray.
7.1.22 The elevation of the bottom of the lowest cable tray shall be minimum of 2.67M above the substation floor.
7.1.23 Minimum clearance in horizontal angle between tray and building wall shall be 300mm.
7.1.24 All cable trays installed inside buildings shall be fixed with hold down clip.
7.1.25 Bonding jumpers shall be provided to ensure the continuity of electricity at the connecting points of trays and ducts. Provide grounding bonding from cable tray to conduit, stanchion and other support and shall be connected to grounding bus bar.
7.1.26 Bonding jumpers shall be installed on tray at expansion connections plates and hinged fittings at both sides as per NEMA VE2.
7.1.27 Cable tray shall be bonded to the grounding electrode at each end.
7.1.28 For touch up painting for every steel surface, edging caused by cutting, drilling, welding and grinding.
8.0 QUALITY CONTROL
8.1 All Testing and Inspection shall be coordinated by Inspector.
8.2 QC Inspector shall be assigned to ensure the quality control and assurance requirement of the project.
8.3 QC Inspector shall be responsible to conduct all required inspection / documentation and to ensure that all applicable requirements, codes, and standards are complied with.
8.4 Contractor has to utilize the applicable inspection and test form reflected on approved SATIP.
9.0 SAFETY PRECAUTION
9.1 Obtain necessary work permits from the concerned Representative intended for the job before starting any work.
9.2 Conduct proper preparation to include required safety equipment and tools for the commencement of the work.
9.3 Activities shall be executed in accordance with this procedure and related standards and specifications.
9.4 Provide warning sign and sufficient barricade on working area. Only assigned personnel will be allowed in the area to maintain a safe work environment.
9.5 Conduct safety briefing to all working crew to remind them of all the basic safety requirements on the job to ensure safe work flow.
9.6 Continuous monitoring and inspection shall be implemented by the site supervisor/foreman together with the assigned safety supervisor in the area. Any unsafe practices while performing the work activities shall be corrected immediately to avoid stoppage of the work.
9. 7 Good housekeeping shall be maintained throughout the work activity. The work site shall be kept clean and safe. Do not keep any standby materials on the scaffolding.
9.8 Safety Supervisor shall monitor the work activities to help and protect all assigned workers against exposure to safety hazards. He shall ensure that Personal Protective Equipments (PPE’s) are supplied and worn at all times.