OUTDOOR LIGHTING & OUTLET INSTALLATION AND TESTING

PURPOSE
SCOPE
APPLICABLE DOCUMENTS
RESPONSIBILITY
MANPOWER
TOOLS & EQUIPMENT
METHODS/PROCEDURES
QUALITY CONTROL
SAFETY PRECAUTION
ATTACHMENTS

1.0 PURPOSE

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 Saudi Aramco Job Specifications. This procedure is intended to provide general application guidance and establish controls during preparation and installation.

2.0 SCOPE

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

3.0 APPLICABLE DOCUMENTS

3.1 Project Specification and Standards

3.1.1 D-000-1383-701 To 706 Typical Installation Lighting Works.
3.2 Saudi 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-P-100 Basic Power System Design Criteria.
3.2.3 SAES-P-104 Wiring Methods and Materials.
3.2.4 SAES-P-123 Lighting.
3.2.5 SAES-P-111 Grounding.
3.2.6 NFPA 70 National Electrical Code.
3.2.7 AD-03687 4-001 Installation Direct Buried Electric Cable and Conduit.
3.2.8 AB-036326-001 Standard Sign Underground Electric Cable.
3.2.9 AB-036273-001 Surface Marker Underground Electric Cable.
3.2.10 Schedule Q Saudi Aramco Project Quality Requirements .
3.2.11 Schedule G Material, Tools, and Equipments.
3.2.12 Schedule D Safety, Health and Environmental Requirements.

3.3 Inspection and Test Plan

3.3.1 Saudi Aramco Typical Inspection Plan (SATIP)

3.3.1.1 SATI P-P-123-01 Light Fixtures and Lighting Systems
SATIP-P-104-12 Receptacles and Cord Connected Equipment
3.3.2 Saudi Aramco Inspection Checklist (SAIC)
3.3.2.1 SAIC-P-3616 Lighting Accessories – Material Receiving
3.3.2.2 SAIC-P-3623 Lighting Control System – Installation and Pre Commissioning
SAIC-P-3601 Receptacles & Cords – Pin and Sleeve Receptacle/ Plug — Material Receiving
SAIC-P-3602 Receptacles & Cords — NEMA Receptacle / Plug Material Receiving
SAIC-P-3603 Receptacles & Cords – Flexible Cord – Material Receiving

SAIC-P-3604 Receptacles & Cords – Cable Reels — Material Receiving
SAIC-P-3605 Receptacles & Cords – Festoon Systems – Material Receiving

3.3.3 Saudi Aramco Test Report (SATR)

SATR-P-3603 Receptacles and Cords-Pin-and-Sleeve Receptacle / plug – Installation, Functional and Polarity Testing.
SATR-P-3604 – Receptacles and Cords – NEMA Receptacle / Plug – Installation, Functional and Polarity Test.
SATR-P-3605 – Receptacles and Cords – Cable Reels Installation, Functional and Polarity Testing.

SATR-P-3610 Area & Street Lighting (point to point) – Illumination Level Testing.
SATR-P-3606 – Receptacles and Cords – Festoon Systems Installation, Functional and Polarity Testing.

3.4 Latest Revision of the following Documents shall be used

3.4.1 Saudi Aramco Standard Drawing
3.4.1.1 AB-036398 Street Lighting Details
3.4.2 Latest Approved Drawing
3.4.2.1 D-120-1383-101_0F1 Lighting Plan Layout/Detail

3.5 Saudi Aramco Safety, Health and Environmental Standard

3.5.1 Construction safety manual
3.5.1.1 Electrical Equipment
3.5.2 General Instructions (G.l’s) at the work site
3.5.2.1 GI 2.100 Work Permit System
3.5.2.2 GI 2. 717 Procedure & Guideline for Handling.

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. He shall study all aspects of work procedure as per Saudi Aramco Standards.

4.1 Electrical Superintendent shall study and review all necessary documents for the installation and testing of lighting works in his area to include the technical scope of work, specifications, bill of quantities, planned milestone dates and construction procedure in support to his Electrical Supervisor. He shall coordinate with the other discipline to visualize possible conflicts in the drawings as well as in the schedules, and to provide other options in preventing unnecessary delays and obstruction.

4.2 Electrical Supervisor-in-charge shall be responsible in the implementation and control of all activities ensuring that all works are performed in accordance with this method of statement, project specification, approved for construction drawings and Saudi Aramco Standard/Procedures. He shall study and review all necessary documents for the lighting 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 Saudi Aramco Standards and latest approved IFC drawings.
4.4 QC Inspector shall be responsible to verify and inspect the work and ensures that the work is performed and properly documented in accordance with Saudi Aramco Standards and Procedures.
4.5 Safety Engineer shall be responsible in monitoring safety aspects and ensuring that the work is done in accordance with Saudi Aramco Construction Safety Manual (CSM). 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 Boom truck operator
5.1.5 Plate Welder
5.1.6 Riggers
5.1.7 Man lift Operators
5.1.8 Crane Operator
5.1.9 Helper
5.1.10 Scaffolders
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:

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.

6.2 All tools utilized in a classified area should be intrinsically safe and suitable for hazardous areas.

7.0 OUTDOOR LIGHTING & OUTLET INSTALLATION AND TESTING METHODS / PROCEDURES

7.1 GENERAL PREPARATORY WORKS

7.1.1 All permanent and consumable materials shall be prepared prior to installation.
7.1.2 Manpower, equipment, tools and other logistics shall be prepared and ready for installation.
7.1.3 Special tools and testing tools shall bear valid calibration certificates traceable to a national standard indicating calibration validity and periodically (at least 6 months) checked by a third party laboratory testing facility.
7.1.4 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.

7.1.5 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.

7.1.6 Subcontractor shall verify confirmation list of latest construction drawing received from Company to be used as basis for the work activity.
7.1.7 Safety aspects shall be discussed on a daily basis to include associated installation care needed as well as installed equipments that may exist in the plant. Refer also to Section 9 “Safety Precautions” and Section 10.0 Attachment 01 “Job Hazard and Risk Assessment” (JHRA).

7.2 WORK EXECUTION PROCEDURES

7.2.1 INSTALLATION OF LIGHTINGS, DEVICES AND RELATED FIELD DEVICES

7.2.1.1 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 (QCF-015). Where physical damage or non-compliance with the technical scope of work and Saudi Aramco Standards had been found, ARCC shall record using Non Conformance Report (QCF-026) or Observation Report and report immediately for disposition.

7.2.1.2 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 if non compliance be found against the materials. Lightings, devices and controls shall comply with SAES-P-123.
7.2.1.3 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.
7.2.1.4 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.
7.2.1.5 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 DEC/JGC latest approved construction drawing and details, as well as with area classification requirements.
7.2.1.6 Check that mounting heights are in accordance with the elevations shown on the plan and detail drawings as per Technical Scope and Saudi Aramco Standards.
7.2.1. 7 Where manufacturer’s instructions are furnished with the lighting fittings and devices, installation detail shall conform to the requirements.
7.2.1.8 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 representative by issuing “Site Query” and rectify the installation as instructed by the “Site Query” response, which is to be incorporated in the “As Built Drawing” later.
7.2.1.9 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.
7.2.1.10 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.
7.2.1.11 Fix all supports including fabricated steel supports in which welded or cut portion of the supports shall be treated with applicable paint system.
7.2.1.12 Lighting fittings including lamps, covers, guards and diffusers shall be handled with care to avoid breakage or damage to the fragile parts.
7.2.1.13 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.
7.2.1.14 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 interferences.
7.2.1.15 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.
7.2.1.16 Lighting unit orientation shall be verified ensuring illumination in the area is sufficient and not obstructed by pipes or structures.
7.2.1.17 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.
7.2.1.18 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.
7.2.1.19 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.

7.2.1.20 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.
7.2.1.21 Double check all wiring and circuit connections for the lightings/ devices with respect to circuit diagram to avoid possible short circuiting and damage.

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

7.2.2.1 Expedite materials for lighting and equipment supports from lay down yard to job site utilizing boom truck for loading and unloading.
7.2.2.2 QC visual inspection and acceptance for lighting equipment including material supports.
7.2.2.3 Erect scaffoldings outside railings and underneath grating platform.
7.2.2.4 Fabrication of lighting pole 2″ painted HDG steel pipe sched 40.

7.2.2.5 Fabrication and installation of supports for lighting pole at handrail and base using angular/unistrut channel.
7.2.2.6 Primer, finishing and touch up paint for every cutting, grinding and drilling edge of trays and conduits.
7.2.2.7 QC inspection and acceptance for lighting pole and supports prior to installation.
7.2.2.8 Lighting pole wiring and lighting fixtures assembly and installation.

7.2.2.9 Lighting pole wiring termination, splicing with proper terminal lugs, heat resistance insulation sleeve and name plate installation.
7.2.2.10 QC inspection and acceptance for 3.0 meters long pole.

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

7.2.3.1 Check PVC conduit stub up, anchor bolt and embedded steel bars of concrete foundation. They shall be in accordance to detailed drawings and project specifications.

7.2.3.2 Excavation works for branch trench is at least 460 mm below finishing grade from trench to post. Refer to D-000-1382-712.
7.2.3.3 Thermal sand bedding/filling, clearing and compaction shall be in accordance to detail and Approved for Construction drawing.
7.2.3.4 QC shall do inspection, testing and acceptance for compacted sand bedding and trench utilizing the applicable Saudi Aramco Inspection Checklist (SAIC) forms.
7.2.3.5 Expedite cable drums from lay down yard to plant site using boom truck prior to cable drum and cable stand setting.
7.2.3.6 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.
7.2.3.7 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.
7.2.3.8 QC shall conduct inspection, testing, acceptance for sand and gravel back filling, trench compaction and protection tiles installation.
7.2.3.9 Warning tape shall be installed from main trench to branch trenches of lighting post foundation to next post.
7.2.3.10 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. After complete installation of lighting post QC will prepare all necessary documents for final inspection of lighting post together with the Contractor QC.
7.2.3.11 For underground cable installations refer to section 7.2.9 of 1770- MS-ELEC-007 – Control, Low & Medium Voltage Electrical Cable Installation.

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

7.2.4.1 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.
7.2.4.2 Secure approved drawing for electrical, structural and piping for reference during layout. It should be approved for construction.
7.2.4.3 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.
7.2.4.4 Expedite cable stand cable pulling tools from tool room to site area utilizing boom truck to load and unload.
7.2.4.5 QC inspection and acceptance for materials and equipment.

7.2.4.6 Mass fabrication of typical support for lighting fixtures, conduits, convenience outlets etc. with primer, finish and touch up paint.
7.2.4.7 Layout, measuring, markings and installation of supports for lighting fixture, convenience outlet, conduits and branch perforated tray support.
7.2.4.8 Installation of conduits fittings based on the approved for construction drawings.
7.2.4.9 Primer finishing and touch up paint for every edging, cutting, grinding and drilling of channel and structural unit.
7.2.4.10 Installation of lighting assembly or convenience outlet assembly, JB assembly, etc. based on the approved drawing.
7.2.4.11 Grounding bonding for lighting, junction boxes and convenience outlets connected to grounding bar.
7.2.4.12 QC inspection and acceptance for the installed lighting fixtures, convenience outlets, and PVC coated conduits.
7.2.4.13 Cable drum and cable stand setting ready for pulling.
7.2.4.14 Cable pulling for lighting fixtures or convenience outlets.
7.2.4.15 QC inspection and acceptance for cable pulling above ground level passing main tray towards lighting panel board.

7.2.4.16 Cable visual inspection, testing (continuity/insulation test). QC shall witness and record the result.
7.2.4.17 Glanding termination, splicing, cable tags, core marker and name plate installation as per requirements.
7.2.4.18 Internal inspection/review by QC and operation on a possible overlook of material requirements as per drawing and rectify right away prior to RFIT submittal within 24 hours.

7.2.4.19 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.

Lighting Installation and Testing in Plants

7.2.5 TESTING OF LIGHTINGS, DEVICES AND RELATED FIELD DEVICES

7.2.5.1 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.
7.2.5.2 Visual inspection shall include dimensional check for junction box, support inspection and location verification which shall be recorded to the approved forms.
7.2.5.3 Conduct preliminary testing prior to final inspection ensuring that all connections and functions are appropriate with respect to wiring diagrams and other requirements.
7.2.5.4 Final illumination and functional test shall be conducted and all results shall be recorded as per SAIC and SATR forms.
7.2.5.5 All inspections and testing activities shall be referred to SATIP-P-123 complying with all the requirements. QC Inspector shall witness and record the result and shall be submitted.
7.2.5.6 Documentation of the whole system after completion shall be completed as required, which shall be submitted to EPC COMPANY then for review and approval of documents.

7.2.6 STORAGE AND HANDLING

7.2.6.1 Upon delivery of materials, QC Inspector will conduct receiving inspection as per Schedule G for Handling and Preservation to verify conformance to vendor drawings. Any deviation shall be documented through a QCIR.
7.2.6.2 Fixtures, Post and other devises should be stored indoor in a clean dry area.
7.2.6.3 Keep sufficient gap between stored materials and equipment for easy access, lifting and moving.
7.2.6.4 Fixtures and other devises should be covered with plastic sheets and sealed tight. All parts must be kept in the unopened original shipping case and plugs intact and shall be covered with plastic sheets.
7.2.6.5 Regular visual inspection shall be conducted by Subcontractor QC to check any dust accumlation and damaged on the fixture and other devises.

8.0 QUALITY CONTROL

All testing and inspection shall be coordinated with Inspector.
QC Inspector shall be assigned to ensure the quality control and assurance requirement of the project.
QC Inspector shall be responsible to conduct all required inspection/ documentation and ensures that all applicable requirements, codes, and standards are complied with.
QC Inspector has to utilize the applicable inspection and test forms reflected on approved SATIP.

9.0 SAFETY PRECAUTION

Secure the approved work permit from the concerned Representative before starting any work.
Fire Watcher with Fire Extinguisher shall be assigned at work area whenever there is hot work.
Hazardous area and its precautionary measure requirements shall be properly discussed to the working crew following all safety requirements.
Continuous monitoring and checking shall be conducted by concerned supervisor/foreman to detect and correct unsafe practices while performing the work activities.
Provide warning sign and sufficient barricade on working areas to avoid unauthorized entry. Only assigned personnel shall be allowed in the area.
Safety harness with double lanyards shall be used when working at elevated temporary platforms (1.8 meters and above).
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 being supplied and used and shall comply with Contractor and Company applicable general instruction and standards.
Toolbox meeting shall be conducted by Electrical Supervisor daily so that work activities will be properly coordinated to all concerned and all safety measures will be carried out on the entire work duration.
Housekeeping shall be maintained and working area shall be kept clean and tidy in accordance with Site Housekeeping Procedure.
Job Hazard and Risk Assessment of this procedure shall be disseminated and explained to workers for safety awareness.

TYPICAL INSTALLATION LIGHTING WORK

Following points are important for lighting installation work in plants and refineries.

INSTALLATIONS AND MATERIALS SHALL BE PER SAES-P-123 &. SAES-P-101 WHERE APPLICABLE.
ALL THREADS SHALL BE LIGHTLY LUBRICATED WITH RUST PREVENTIVE GREASE BEFORE ASSEMBLY.
ALL DIAMENTIONS ARE IN MILLIMETERS AND ELEVATIONS ARE IN METER UNLESS OTHERWISE SPECIFIED.
ALL THREADED FITTINGS INCLUDED CABLE GLANDS SHALL BE TAPERED THREADS (NPT) IN ACCORDANCE WITH ANSI BL.20.1.
ALL FIELD CUI CONDUITS SHALL BE REAMED TO REMOVE ALL ROUGH EDGES BEFORE INSTALLATION.
ALL FIELD FABRICATED STEEL SUPPORTS WHICH ARE WELDED SHALL BE FILLET WELD ALL AROUND THE TOUCHING FACE.
SECTIONS OF EXPOSED CABLE LONGER THAN 2 METERS SHALL HAVE CONTINUOUS SUPPORT BY RGS CONDUIT OR CABLE TRAY.
COATING SYSTEM APCS 26 SHALL BE APPLIED FOR GALVANIZED STEEL SURFACE AND APCS-1A SHALL BE APPLIED FOR NON-GALVANIZED SURFACE AS PER SAES-H001 PARA. 7.1.
COLOUR SHALL BE RAL 7042, UNLESS OTHERWISE SPECIFIED.
NUMBER OF CINDUCTORS IN CONDUIT PIPE SHALL NOT EXCEED FOLLOWING PERCENTAGE FILL.