QUALITY CONTROL PROCEDURE FOR LIGHTING FIXTURE AND LIGHTING SYSTEM INSTALLATION
Table of Contents
2. PURPOSE
3. DEFINITIONS
4 . REFERENCES
5. RESPONSIBILITY
6. SAFETY REQUIREMEN
7. QA/QC REQUIREMENTS
8. MATERIAL RECEIVING
9. TOOLS AND EQUIPTMENT1
10. METHOD OF PREPARAT
11. INSTALLATION PROCEDURE
12. DOCUMENTATION
1. SCOPE:
This Quality Control Procedure covers the new installation of small power and lighting system for only installed building and Substations in ______________________________ Project.
2. PURPOSE:
The purpose of this procedure is to provide a systematic method of performing lighting fixture and lighting system works.
To ensure that all required inspection and tests have been performed during construction and the work complies with all project specification and drawing requirements.
3. DEFINITIONS:
COMPANY : SAUDI ARAMCO
CONTRACTOR :
SUB CONTRACTOR :
PROJECT :
SAPMT : SAUDI ARAMCO PROJECT
MANAGEMENT TEAM SAPID : SAUDI ARAMCO PROJECT INSPECTION
DIVISION SAPOD : SAUDI ARAMCO POWER OPERATION
DISTRIBUTION :
4. REFERENCES:
1. Construction specification
2. IFC Drawings
3. SAES-P-111 - Grounding
4. SAES-P-104 - Wiring Methods and Materials
5. SAES-P-123 - Lighting
6. SAES-M-100 –Saudi Aramco Building Code
7. Schedule “Q”
8. SAES-P-119 - Substation
9. SAES-B-014 – Safety Requirements for Plant &Operation Support Bldgs.
10. SAES-P-100 - Basic Power System Design Criteria
11. National Electrical Manufacturer Association (NEMA)
12. National Electrical Code (NEC)Article No. 318/392
13. National Fire Protection Association (NEFA )
14. Approved Inspections and Testing Plan
15. Site Quality Plan
16. Approvals material and Accessories
17. Test Reports for required materials
18. Manufacturer’s instructions and procedures
19. Material Safety Data Sheets
5. RESPONSIBILITIES:
5.1 Project Manager:
An authorized GAC representative towards Contractor, Sub-Contractor and other relevant agencies and authorities to manage this project, it is overall responsibility of the PM to organize resources to perform construction activities as per project specification, in compliance with quality, schedule, safety and standard requirements.
5.2 QA/QC Manager:
Shall be responsible to manage overall QA/QC activities and interacting with related to all QA/QC activities of the project. He shall be responsible for Nonconformance Management and Quality Audit.
5.3 QC Supervisor (Electrical):
Shall be responsible for the supervision of all QC electrical Inspectors activities such as Testing and Inspection to be submitted in appropriate time with correct documentation to Contractor electrical Inspector
5.4 Safety Manager:
Shall be responsible for all the safety requirements are fulfilled prior to start of the job and during the works, Job safety analysis/safety task assignments will be strictly implemented and make sure that all the activities are fulfilled as per project safety requirements.
5.5 Construction Manager:
Shall be responsible for construction activities are executed according to the relevant project specifications, in compliance as per required quality of work. Take all preventive and precautionary measures during execution of work. He should also ensure that all necessary safety protective equipment is provided to each and every individual involved in the work.
5.6 Electrical Supervisor:
Responsible for construction work supervision. Ensure that all the work being executed is meeting conformity with IFC drawings, project specifications Engineering standards, and HSE requirements. He is the responsible for allotment and supervision of every individual group. Conduct Tool Box Talk, Guide, Monitor the work force and report to the construction manager in regular basis. Also ensure that necessary permits have been taken for all the work involved and maintains the records on regular basis.
5.7 QC Inspector:
Electrical inspectors shall be responsible for carrying out of all stage wise inspections and preparation of inspection report and offering inspection for QC Inspector CONTRACTOR/COMPANY ensure and expedite the release certificate from other discipline for the availability of the work area. All drawings, construction materials and tools shall be approved and available to ensure the completion of installation and periodical quality inspection and test. Acceptance.
5.8 HSE Officer:
Overall responsible for the safety related aspects of work at site. Ensure that all activities are undertaken and installed in a safe manner as per the HSE Plan.
6. SAFETY REQUIREMENTS:
6.1. A specific site Job Safety Analysis (JSA) will be required prior to start the work in order to assess the specific risk that could arise in work location, which will include all HSE requirements and the specific safety measures to perform the work safely.
6.2. Conduct job safety talk every day before starting the work. Necessary safe work permit shall be obtained. All person involved in these activities shall wear complete appropriate Personal Protective Equipment (PPE) in accordance with safety work requirements.
6.3. All electrically driven power tools and equipment shall be properly grounded.
6.4. When working in height refer for approval of JSA for scaffold working platforms requirement and attain 100% tie-off safety policy.
6.5. Barricades and signboards shall be installed around the working area to restrict others that are not involved in these activities.
7. QA/QC REQUIREMENTS:
7.1. All inspection shall be conducted by QC electrical inspector after work has been verified by the construction electrical supervisor / superintendent.
7.2. QC electrical Inspector shall verify the installed materials. Components shall be in accordance with same materials approved during material receiving inspection.
7.3. QC electrical Inspector shall carefully check the work execution against all relevant IFC drawings and applicable standards.
7.4. The quality control program shall be as per (SAES) Saudi Aramco Engineering Standards.
7.5. The detailed inspection stages and methods shall be as per Saudi Aramco typical inspection plan (SATIP) and Saudi Aramco Inspection check list (SAIC).
7.6. All installation shall be inspected for correct elevation and routine in accordance with relevant approved IFC drawings.
7.7. Inspection and test plan must be submitted in appropriate time to Contractor electrical Inspector.
8. MATERIAL RECEIVING AND PRESERVATION:
8.1. The material received from shall be stored in the designated area of the warehouse and storage, and preservation of materials shall be in accordance with manufacturer’s recommendations and Saudi Aramco standards.
8.2. The Lighting fixture, sockets and receptacle shall be segregated as per location and hazardous classification
8.3. Arrangement shall be made, and maintained, to ensure protection against the effects of local weather and condition environment.
8.4. During shifting of the material special care shall be taken to protect from any damage.
8.5. Proper lifting and transporting equipment shall be used as required. Properly mark and segregate incoming materials for traceability and identification of the quantities that are already inspected and not yet inspected.
8.6. All material shall be segregated accordingly to facilitate location of the items
8.7. All the materials to be kept away from inflammable/combustible materials, and keep the location clean
9. TOOLS AND EQUIPTMENT:
9.1. Fork Lift
9.2. Boom Truck
9.3. Safety cones
9.4. Hand grinder
9.5. Electric saw
9.6. Hydraulic punching machine
9.7. Set of socket wrench
9.8. Torque Wrench
9.9. Spanners different sizes
9.10. Set of Ratchet
9.11. Plug, outlet
9.12. Paint brush
9.13. Wire brush
9.14. Set of Screw driver
9.15. Measuring Tape
9.16. Electric drill
9.17. Pipe wrench
9.18. Cutting disks
9.19. Welding machine
9.20. Hammer
9.21. Hacksaw Blade Cutter
9.22. Face shield
9.23. Safety Helmet
9.24. Safety Shoes
9.25. Hand Gloves
9.26. Safety Glasses
9.27. Safety Harness (If required)
9.28. Dust mask
10. METHOD OF PREPARATION:
10.1. Review and ensure that lighting fixtures and accessories to be used conform to the applicable standard and requirements.
10.2. Prior to the start the related work shall initiate a kick-off meeting with all concern parties to ensure full understanding on the execution, requirements control of the activity.
10.3. Shall be ensuring the approved MRI for Lighting system and small power devices prior to start Installation works.
10.4. Installation of Lighting fixture and the small power devices shall be according to manufacturer’s Technical Data Manual.
10.5. Installer should be competent and qualified persons to perform the work also familiar with standard in electrical construction practices and safety of electrical wiring systems.
10.6. Remove any materials that can cause slipping, tripping and falling from the floor and mobile work platforms.
10.7. The lighting fixtures and junction box to be segregated and keep in the safe condition.
10.8. Use only portable drill, jigsaw, speed cutting machine and electric hand tools that have been inspected and are safe to use.
10.9. Use only hand tools that have been inspected and are safe to use.
10.10. Use only good electrical connections and cables.
10.11. Supervisors shall conduct safety inductions and daily tool box talks to workers before the activity.
10.12. Inspect tools, equipment and PPE’s before each use. Do not use defective items. Keep records.
10.13. Follow the applicable standards for all electrical cables and equipment.
10.14. Conduct daily inspections and remove damage or worn electrical items to prevent electrical fires and electrical shocks.
10.15. Site supervisors shall implement daily housekeeping activities,
10.16. Report to the supervisor any near miss incidents so that corrective actions can be done immediately.
11. INSTALLATION PROCEDURE:
11.1. The lighting fixtures to be segregated as normal lightings, emergency lighting, emergency lighting, security, exit lighting and hazardous classified lighting.
11.2. Ensure the materials to install shall be as per approved updated Issued for Construction drawings complete with control copy stamp by the Contractor. Ratings and specification as per approved schedules.
11.3. Verify there is no damage or missing parts also at accessories in lighting fixtures and small power devices prior to installation.
11.4. For explosion proof enclosures, ensure that all flange joints are clean and free from damaged and verify the proper IP rating. Luminaries for Hazardous areas shall meet the certification requirement of SAES-P-100.
11.5. Install / erect proper scaffolds / ladders wherever required for safe installation practices. Safety Department before use must inspect and approves scaffolds erected.
11.6. Ensure that wiring and cables to lighting fixture and small power devices shall be properly identified, dressed and tight firmly. Luminaries and control switches shall be tagged with circuit number and panel board number.
11.7. The position of luminaires shown on the drawings shall be used as a guide only actual location shall take into account adjacent pipe work and equipment and the luminaries positioned to provide the maximum use of light output and access for maintenance. Any deviation from the drawings shall be agreed with the Client and all changes recorded on the As Built drawings. The location of luminaire outdoor shall favor platforms, landings or stairways, ladder, gauge and indicating instruments. In addition, luminaries shall be suitable for the environment where they are installed.
11.8. Lighting fixture shall be fixed as per IFC drawings such as hanging type, direct fixed at wall or roof with lighting support beam.
11.9. Distribution board circuit charts shall be completed neatly and permanently with the protective device rating and circuit description.
11.10. Provide proper platform and assess (e.g. scaffolding) for installation of lighting fixture.
11.11. A work permit system shall be established prior to testing /checking energizing of electrical equipment to avoid any incident.
11.12. It will be preferable that inspection/ testing of electrical/instrument should be carried out through checklist.
11.13. Lighting junction box, support & raceway installation shall be as per project standard and specification.
11.14. Hazard warning signs should be placed on all live electrical panels.
11.15. "DO NOT TOUCH" tags should be placed on all switches in order to avoid persons touching/pressing etc.
12. DOCUMENTATION:
12.1. All inspection reports shall be filed at QA/QC department including test reports in accordance with Saudi Aramco typical inspection plan. SATIP-P-123-01 Light Fixtures and Lighting Systems and SATIP-P-104-12 Receptacles and Cord Connected Equipment.
12.2. Lighting test shall be carried out for all lighting circuits and facilities, and shall be confirmed that the following item are satisfactory.
12.3. Verify the emergency lightings routes are separated from normal light routings. Minimum duration of emergency in the event of normal power failure shall be one and one half hours (1-1/2 hrs.).
12.4. Valid up to date Calibration Certificate for Multi-meter tester, IR Tester and Lux illumination tester with testing equipment prior to use.
12.5. For lighting circuit continuity, insulation resistance test shall be done for each circuit as per the following:
a) L to GRND, N to GRND, L to N and L to L.
b) Lighting circuit by circuit continuity and IR Testing.
c) Lighting on-off - switch functional testing.
12.6. Illumination testing. For Illumination levels for emergency, task and egress lighting, refer to SAES-P-123 Para. 5.6.3, 5.6.4 and 5.6.7.
12.7. Ensure the panels; receptacles are installed as per the layout location, elevation, type, rating classification, etc. with the client ITP checklist.
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