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SADARA

MIXED FEED CRACKER PROJECT

METHOD STATEMENT FOR JUNCTION BOX AND SUPPORT


INSTALLATION
(FOR INSTRUMENTATION WORKS)

Document No. A554-E-103-IC-GEN-DOC-004

Revision: 0 1 2 3

Prepared by: J.U. Saguagan

Reviewed by: J.H Lee

Checked by
K. K. Akhter
QA/QC:

Approved by: S.H Joo

Owner
Approved by:

Revision Date: 19 FEB 13

Issue Purpose: IFA

This document contains technical information that may be subject to the export control regulations
of the United States and/or other jurisdictions. It may not be exported or re-exported except as
authorized under applicable U.S. or other export control regulations.

Contains Confidential Information of SADARA


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SADARA Mixed Feed Cracker Document No: A554-E-103-IC-GEN-DOC-
004
Revision: 0
Document Title: Method Statement For Junction Box & Support Installation Issue
Purpose: IFA

SUMMARY OF DOCUMENT REVISIONS


Rev. Date Section
No. Revised Revised Revision Description
0 19 FEB 13 Initial Issue

Contains Confidential Information of SADARA


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SADARA Mixed Feed Cracker Document No: A554-E-103-IC-GEN-DOC-
004
Revision: 0
Document Title: Method Statement For Junction Box & Support Installation Issue
Purpose: IFA

Table of Contents

Section Topic

1.0 Purpose . 4

2.0 Scope . 4

3.0 Responsibilities . 4

4.0 References .. 5

5.0 Definitions .. 5

6.0 Method of Preparation .... 6

7.0 Safety Requirements .. 6

8.0 QA / QC Requirements .... 7

9.0 Procedure .... 7

Contains Confidential Information of SADARA


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SADARA Mixed Feed Cracker Document No: A554-E-103-IC-GEN-DOC-
004
Revision: 0
Document Title: Method Statement For Junction Box & Support Installation Issue
Purpose: IFA

1.0 PURPOSE:

The purpose of this procedure is to ensure that all works regarding


Junction Box and Support (Indoor and Outdoor) Installation for
Instrumentation Works shall be done in accordance with the SADARA
standards and all other applicable international codes and standards.

2.0 SCOPE:

The scope covers the steps to be followed for the Junction Box and
Support (Indoor and Outdoor) Installation for Instrumentations intended for
permanent installation in the plant.

DAELIM and AIC shall ensure that the construction method of procedures is
adhered to the SADARA Standards with reference to SADARA specifications.

2.0 RESPONSIBILITIES:

The DAELIM Instrumentation Construction Manager is responsible to plan and


schedule activities for the installation execution in co-ordination with client
personnel.

It is the responsibility of the materials personnel; to receive & visually inspect


Junction Box, delivered on site before handing them over to SADARA
Instrument Dept. and shall be responsible for the safekeeping and its
reservation that received.

It is the responsibility of the Instrument QC inspector to carry out inspection.


Check the physical condition of the JB boxes before installation. Any damages
found must be reported immediately.

3.0 REFERENCES:

A554-O-PRG-IC-GEN-BOD-003 : SADARA Instrument Basis of Design

G6A-0002-00 : DOW Global Instrument Administrative Guideline

G6A-0041-00 : DOW Global Instrument Job Specification Master Dictionary

G7C-0326-XX to G7C-0327-XX :DOW Global FJB/MCJB & Support Installation Details

RT6D-0301-XX to RT6D-0303-XX : DOW Global Field Junction Box Specs.

SADARA Approved IFC Drawing.

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SADARA Mixed Feed Cracker Document No: A554-E-103-IC-GEN-DOC-
004
Revision: 0
Document Title: Method Statement For Junction Box & Support Installation Issue
Purpose: IFA

4.0 DEFINITIONS:

Field Junction Box (FJB) a metallic/nonmetallic equipment use for


connection of wires and cable which is installed in a designated area or
outdoor.

Motor Control Junction Box (MCJB) junction box in which cables and wire
for motor controls is being connected with.

5.0 METHOD OF PREPARATION:

5.1) The Instruments Construction Manager /or Superintendent shall plan


and schedule activities for the installation of the instrument junction box
in co-ordination with Mechanical Construction group.

5.2) Instrument Junction boxes are subject to inspection and witness by the
client.

5.3) Forms, procedures and sign off sheets for activity shall be prepared and
submitted for review and approval of the client prior to beginning of any
activity.

5.4) Availability of equipments like welding machines, to be able to weld to


the steel post column, and drill machine to make a hole to mount JB
boxes on its location where it is supposed to place. The assigned
supervisor or foreman will be in supervision to do in the mode of JB
handling to avoid scratches or dented. Ensure that the area is
barricaded for safety purposes.

5.5) All instrument JB supports shall be in accordance to standard details of


IFC drawings.

5.6) Necessary clearances shall be taken from other group, (like piping and
structural group) before proceeding with the works to avoid any
overlapping/interference of work executions.

5.7) The Safety Work Permit shall be prepared based on the schedule of field
erection activities, or in a daily base activities.

5.8) JB systems shall be electrically continuous, or safety grounded to earth


as shown on the approved drawing.

Contains Confidential Information of SADARA


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SADARA Mixed Feed Cracker Document No: A554-E-103-IC-GEN-DOC-
004
Revision: 0
Document Title: Method Statement For Junction Box & Support Installation Issue
Purpose: IFA

5.10) Work shall be done according to the approved IFC. Technical query shall
be submitted officially for any amendment from the approved IFC
drawing, prior to start any work.

6.0 SAFETY REQUIREMENTS:

6.1) Safe work permit requirement is mandatory. All personnel involved in


the activities shall wear complete personal protective equipments (PPE)
in accordance with the safe work requirements.

6.2) Conduct job safety tool box before starting the work, and issue daily
JSA. And the safety officer shall verify that all the necessary and
applicable documents, related to the safest operation are in possession
before commencing the job.

6.3) Place barricade and warning sign boards in applicable locations. Restrict
Personnel/equipments entering the work area.

6.4) Check adequacy and availability of all tools, before commencement of


installation activity.

6.5) If the weather conditions turns bad, (like sand storms, wind storms
raining or hailstorms) shall immediately coordinate to safety officer and
all works shall be stopped.

6.6) Safety procedures shall be followed at all times.

7.0 QA/QC REQUIREMENTS:

7.1) The Quality Control Program shall be as per DAELIM Project Procedure,
SADARA MIXED FEED CRACKERS Project Procedure in conjunction with
the SADARA Engineering Standard. The detailed inspection stages and
methods shall be as per the Approved Inspection and Test Plan.

7.2) Prior to commencing the installation work, the Instrument JB shall be


inspected visually for any damages during the transportation.

7.3) All installed instrument JB shall be inspected for elevation as per the IFC
drawings.

7.4) Inspection and test plan must be submitted ahead of time for PMT &
Daelim approval.

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SADARA Mixed Feed Cracker Document No: A554-E-103-IC-GEN-DOC-
004
Revision: 0
Document Title: Method Statement For Junction Box & Support Installation Issue
Purpose: IFA

7.5) All RFIs shall be submitted 24 hours ahead of scheduled date of


inspection.

7.6) All relevant attachments including IFC Drawing must be attached on all
submitted RFIs.

7.7) Work execution, material approval and testing shall be monitored


witnessed and recorded on documents in accordance to the inspection
list, QC form given by applicable ITP JB installation and support
installation.

7.8) Instrument inspector shall carefully check against IFC drawing for the
following items:

a.) Check for correct elevation as per IFC drawing.


b.) Check the correct size and materials.
c.) Check for proper grounding as per IFC drawing.
d.) Check area Classification.
e.) Check for maintenance accessibility.

8.0 PROCEDURES:

8.1 Handling

Every Item delivered shall be inspected to ensure compliance to specification,


Data sheet & free from damages. Offloading shall be in responsible & Safe
Manner.

8.2 Issue of Document and Drawings and pre-installation check:

Ensure receipt of all related documents and IFC drawings from the client
before proceeding with transportation & installation.

8.3 Installation of Instrumentation junction box:

8.3.1) Instrument JB installations shall meet the requirements of G7C-


0326-XX to G7C-0327-XX DOW Global FJB/MCJB Installation
Details and Manufacturers recommendation.

8.3.2) Supports (Hot dipped galvanized, Unistrut channels, steel C-


channels, steel angle bars, flat bars) shall be welded to
structural steel columns and not limited to anchoring to
concrete column if necessary otherwise specify. Approved
galvanized coating will be done for damaged galvanized
surfaces. Before touch-up coat, the metal surface must be
cleaned, brushed to ensure effective coatings.

Contains Confidential Information of SADARA


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SADARA Mixed Feed Cracker Document No: A554-E-103-IC-GEN-DOC-
004
Revision: 0
Document Title: Method Statement For Junction Box & Support Installation Issue
Purpose: IFA

8.3.3) Junction boxes and instrument cases shall be positioned so


doors may be fully opened, covers are fully removable, vent
holes are not blocked, and adjustment screws, valves, wiring
and piping connections are accessible.

8.3.4) The height installation shall be 56 (1675 mm) top of the


junction box to grade level. Both on paved and unpaved area or
directly mounted on beams. Or also 44 (1321 mm) centerline
of the enclosure to grade level.

8.3.5) All instrumentation JB systems shall be connected to the plant


grounding system as per approved IFC drawing.

8.3.6) All material of JB components and accessories shall be inspected


and approved by company before installation.

8.3.7) All grounding cable jumper for JB must be as indicated in IFC


Drawing.

8.3.8) All JB support must be fabricated and installed in a skillful


manner considering proportionality and alignment.

8.3.9) All support installed shall be level and plumb.

8.3.10) Conduit or cable shall not enter through the top of field junction
boxes. All conduits are to enter from the bottom of the junction
boxes unless there are more conduits required that can fit. All
conduits coming from locations above the junction box shall
have a low point drain adjacent to the junction box.

8.3.11) Adequate spare conduit or cable entry hubs fitted with threaded
plugs shall be provided in the junction boxes.

8.3.12) Junction boxes shall be independently mounted and shall not


rely on the mechanical support of the attached conduit for
support.

8.3.13) All fastening hardware like bolt, nut etc. should be stainless
steel.

8.3.14) Final alignment shall be done after installing the JB. Ensure all
elevation shall be as per approved IFC drawing.

8.3.15) Tighten the JB bolts after alignment.

8.4 Receipt and Inspection

Contains Confidential Information of SADARA


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SADARA Mixed Feed Cracker Document No: A554-E-103-IC-GEN-DOC-
004
Revision: 0
Document Title: Method Statement For Junction Box & Support Installation Issue
Purpose: IFA

8.4.1) When the unit is received shall be examined, inspected to


ensure that it is free from any physical defects or damages and
conduct visual inspection as required to established the
condition of the materials.

8.4.2) Receipt of each package items shall be documented with details


such as received date, type of parts or fittings, quantity, and
avoid loss of parts during storage.

Contains Confidential Information of SADARA


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