Hawiyah Unayzah

Gas Reservoir Storage Project

C SAMSUNG GEC,
500 Sangil-dong, Gangdong-Gu, Seoul, Korea 05288

6600046420 (OOK),
ContractNo. : SECL Job No. :SG6427
O 6600045884 (IK)
COMPANY : SAUDI ARAMCO Document No. :SG6427-SY-CK0P-MTD-736-004

N .

T
METHOD STATEMENT
S OF
INSTRUMENT JUNCTION BOX INSTALLATION

B 26 Dec 2020 Issued for Review S.S.Byun Gi. Han Y.J.Choi S.H.Choi

A 05 Dec 2020 Issued for Review S.S.Byun Gi. Han Y.J.Choi S.H.Choi

Rev. Date Status Written by Checked by App’d by PM

 METHOD STATEMENT SG6427-SY-CK0P-MTD-736-004

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Hawiyah Unayzah Gas REV.NO B
Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 2 of 12

1. PURPOSE 3

2. TERMS AND DEFINITIONS 3

3. SCOPE.......................................................................................................3

4. REFERENCES 3

5. RESPONSIBILITIES 4

6. TOOLS AND EQUIPMENT 6

7. METHODS/PROCEDURES 6~10

8. ORGANIZATIONAL CHART 10

9. QUAITY CONTROL 10

10. SAFETY PRECAUTIONS................................................ .......................11

ATTACHMENT: Job Safety Analysis(JSA) for

Instrument JB installation ..........
12
 METHOD STATEMENT SG6427-SY-CK0P-MTD-736-004

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Hawiyah Unayzah Gas REV.NO B
Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 3 of 12

1. PURPOSE

This method statement will serve as a minimum guidelines to carry out the Instrument
Junction Box Installation for Hawiyah Unayzah Gas Reservoir Storage Project to
ensure that the work is carried out in accordance with Project Drawings and
Specifications.

2. TERMS AND DEFINITIONS

The following constitutes a list of terms, which have been used in this plan:
Client / Company : Saudi Aramco
Main Contractor : Samsung Engineering CO., LTD.(Hereafter, SECL)
Subcontractor : SAMYOUNG SAUDI ARABIA CO., LTD.(Hereafter, SY)
Project : Hawiyah Unayzah Gas Reservoir Storage Project

3. SCOPE

This method statement will cover the procedure to be followed in receiving of

materials, preparation, handling, installation, inspection and preservation of
Instrument Junction Box for Hawiya Unayzah Gas Reservoir project, in accordance
with the scope of work, Approved Construction Drawing, SECL/SY project
specifications, applicable Saudi Aramco Standards, National and International
Engineering Standards and specifications.

4. REFERENCES

4.1 Saudi Aramco Engineering Standard

SAEP-302 Instruction for Obtaining a Waiver of Mandatory

Saudi Aramco Engineering Requirement
SAES-J-902 Electrical System for Instrumentation
SAES-J-904 Foundation Field-bus (FF) Systems
Schedule D Safety, Health and Environmental Requirements
Schedule G Material, Tools, and Equipment
Schedule Q Saudi Aramco Project Quality Requirements
NFPA 70 National Electrical Code
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Hawiyah Unayzah Gas REV.NO B
Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 4 of 12

4.2 Inspection and Test Plan:

SAIC/SATR : Saudi Aramco Inspection Check list/Saudi Aramco Test Report

Latest Revision of the following Documents shall be used:
Saudi Aramco Standard Drawing
Latest Approved Drawing
Saudi Aramco Safety, Health and Environmental Standard
Construction Safety Manual
General Instructions (G.I’s) at the work site

5. RESPONSIBILITIES

5.1 Site Manager:

Site Manager is responsible for supporting and encouraging the related staffs and
workers, so as for them to participate actively as worksite. Site Manager is
responsible for implementation of HSE requirements.

5.2 Construction Manager:

Construction Manager is responsible for compliance with this Method Statement and
shall ensure to review contract documents and provide all resources necessary to
effectively implement throughout the construction period. Construction Manager shall
monitor the quality and progress of the work and ensure that job target is achieved.
Construction Manager is responsible for complying with HSE requirements.

5.3 QA/QC Manager:

Responsible for the overall discipline of QA/QC Inspection, verification of the project
specification, documentation and QC records for final acceptance. Prepare and
submit procedure for SECL and Saudi Aramco review and approval. Provide
technical support to site operation group. Provide latest revision of IFC drawings,
procedures, material specifications, standards and technical specifications.

5.4 HSE Manager:

HSE Manager shall monitor related works under carrying out, and advise
supervisors for corrective measures, if required. He shall ensure holding of pre task
HSE meeting / daily tool box talks covering details of specific tasks and specific job
risks involved to the work force involved. He shall also ensure appropriate mode of
communication in case of emergency

5.5 Instrument Supervisor:

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Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 5 of 12
Ensure relevant permits are raised and received prior to commencement of work,
with full compliance by associated Foreman and Instrument calibrator to the
requirements of this method statement, Quality Control Procedures, reference
drawings, and Customer’s Specifications.

5.7 Quality Control Supervisor:

Monitor daily, instrument activities and verify compliance to Customer’s
Specifications. Perform activities in accordance with the Project QA Manual and
Quality Control Inspection Plan. Prepare daily QC records and final acceptance
documentation. Maintain a close working relationship with the Company’s
Representative.

5.8 Quality Control Inspector:

Monitor daily, electrical activities and verify compliance to Customer’s
Specifications. Perform activities in accordance with the Saudi Aramco
Engineering Standard and Quality Control Inspection & Test Plan. Prepare daily
QC records and final acceptance documentation. Maintain a close working
relationship with the Contractor/ Company’s Representative.

5.9 Safety Supervisor:

Check the work areas for any unsafe conditions. Ensure that all safety
requirements have been adequately addressed and the work is carried out in
accordance with Saudi Aramco Project safety procedures.

5.10 Instrument Foreman/Crew:

Ensure relevant permits are raised and received prior to commencement of work,
with full compliance by all associated technician to the requirements of this
method statement. Responsible for the execution of the work, manpower
assignments and hourly monitor the work done and preparing the work activities
for the technician.

6.0 TOOLS AND EQUIPMENT

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Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 6 of 12
Tools and equipment should be in good condition and must be checked by
Instrument Supervisor prior to use in the construction area. These includes but not
limited to:

6.1.1 Set of Instrument Hand Tools

6.1.2 Cutting Machine

6.1.3 Welding machine

6.1.4 Common Hand Tools

6.1.5 Electric Power Tools (i.e. electric drill, etc.)

6.1.6 Portable 120VAC, 60 Hz Gasoline Powered Generator

7.0 METHODS / PROCEDURES

7.1 General preparatory works

7.1.1 All permanent materials, consumables and junction box for installation shall be
prepared and checked in accordance with S-000-1378-204 Sec. 3.

7.1.2 Ensure that working areas are ready for installation to include availability of
scaffolding (if needed), supports and access to avoid delays of the activities.

7.1.3 Study and prepare Junction box installation requirements and related references
such as IFC drawings and Technical Scope of Work, work permit requirements, and
work procedures.

7.2 Work Execution Procedures

7.2.1 Survey the location of junction box to be installed comparing the installation details
and layout. Ensuring free access for maintenance and no obstruction. If there are
obstruction or discrepancies found between actual site condition and IFC drawings,
site query shall be raised to SECL/SY for further site instruction, refer to S-000-
1630-006 for Site Query Procedure.

7.2.2 Prior to installation, Junction boxes shall be visually inspected for possible factory or
handling damage. Where physical damage or non-compliance with the specification
has been found, it shall be recorded using QC Material Receiving Inspection Report
(SAIC-P-3007) General Boxes, Enclosures, and Accessories Material Receiving:
7.3 General Material Requirements:
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Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 7 of 12
7.3.1 Boxes and Enclosure Certification: In outdoor plant areas, boxes and enclosures
shall be certified by the third party.

7.3.2 Before installing in position, junction box sections shall be opened up and inspected
for cleanliness and to ensure no foreign bodies are present.

7.3.3 Junction boxes shall be identified by means of an engraved laminated plastic label.
Generally black text with white background color. All field junction box, in a Class I,
Zone 2 location and in non-hazardous areas, shall be a single door NEMA Type 4X
or IEC 60529 Type IP 66 box, as per SAES-J-902, Para: 7.2. Junction boxes having
an internal volume exceeding 2,000 cm³ shall be provided with Type 300 Series
stainless steel breather and drain fittings, or a combination breather and drain
fitting, as per SAES-J-902, Para: 7.4.

7.3.4 Check junction box locations and provide markings. The elevations, mounting
height and orientations shall conform with the latest IFC drawings.

7.3.5 Install necessary fabricated supports and brackets for junction box as per SECL/SY
latest IFC drawings. Welding of supports shall be done wherever necessary.

7.3.6 Install necessary miscellaneous foundation if required.

7.3.7 Junction Box support shall be inspected as per SAIC-J-6031

7.3.8 Particular attention shall be paid to the fixing points for correct sizing and clearance.

7.3.9 All rough edges of the support or brackets shall have been removed; the assembly
primed and painted in accordance with the Project Specification.

7.3.10 The installed support shall be inspected to ensure it is level, vertical and the whole
assembly is rigid.

7.3.11 Provide 12AWG bonding wire (Green and Yellow) inside JB between door and
body, and between back-pan panel and body.

7.3.12 The required minimum working clearance shall be maintained, the door of junction
boxes shall be free to be opened at a minimum of 90°. All field junction boxes shall
be mounted vertically i.e.; the door shall be open from right-to-left.

7.3.13 Cable gland being used shall be selected as per the "Cable Gland Selection Table"
(document No.: D-000-1378-001)

7.3.14 Cable entries for the junction boxes shall be sequentially arrange and identified by
cable number.

7.3.15 All cable entries to field junction boxes shall be through the bottom. Conduit and
cable sealing shall be as per SAES-J-902, Para: 6.
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Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 8 of 12
7.3.16 Conduit entries shall be through gasket hubs (Myers hub) provided by vendor.
Gasket material shall be oil resistant. Conduit connection shall be NPT thread.
Refer to specification no. S-000-1378-204 sec.

7.3.17 Power supply shall be checked as per connection wiring schedule.

7.3.18 All junction boxes shall be grounded.

7.3.19 Where install miscellaneous foundation, finishing mortar for concrete foundation
with sunlight resistant coating as per project specification.

7.3.20 Protection cover against damage during construction shall be provided.

7.4 ESD Junction Box and Local Control Panel requirement

7.4.1 Local control panel (LCP) for ZV shall be as per 34-SAMSS-634.

7.4.2 Environmental Conditions of the LCP & it's components shall be as per 34-SAMSS-
634, Para: 4.

7.4.3 Emergency shutdown system (ESD) wiring shall have dedicated junction box.

7.4.4 Junction boxes in shutdown service the text shall be white with red background
color. Refer to specification no. S-000-1378-204 sec. 3.1.4.

7.4.5 Field junction box shall follow the requirement of SAES-J-902, Para: 7.

7.4.6 Junction box requirement in fire hazardous zone installation of junction boxes in the
fire hazardous zones shall be avoided wherever possible, otherwise shall meet the
requirement of SAES-B-006, Para: 6.4.4

7.5 Terminal Block (SAES-J-902 Para. 15 Sec. 15.2)

7.5.1 Terminal blocks shall be channel (rail) mounted, strip type, with tubular box clamp
connector and compression bar or yoke for wire termination. As a minimum, the
thickness of the terminals shall be 5 mm or higher. Multi-deck and spring type
terminal blocks are not acceptable.

7.5.2 Terminals and terminal block accessories (e.g., DIN rail mounting brackets for
electrical insulation, bus bar support blocks, end brackets, etc.) shall be made of fire
retardant, halogen free, high strength material such as polyamide or equivalent in
accordance with UL 94, V0. Brittle materials such as melamine shall not be used.

7.5.3 Fused terminals shall be equipped with blown fuse visual indication. The disconnect
levers for fused terminals and knife- switch terminals shall be hinged.
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Hawiyah Unayzah Gas REV.NO B
Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 9 of 12
7.5.4 Wires terminated on these terminal blocks shall not have the bare ends coated with
or dipped in solder (“tinned”). However, termination of wiring that has individual
strands of the copper conductor tinned during manufacture (typical of shield drain
wires or for corrosion protection) is acceptable. Direct termination of the bare wire
end is acceptable. No more than two bare wire ends shall be connected to each
side of a single terminal block.

7.5.5 The use of crimp-on ferrules for this type of termination shall follow manufacturer's
guidelines. Ferrules shall be provided with plastic insulating collars. Two-wire
ferrules are acceptable. However, the use of ferrules to daisy chain is not
acceptable. Only one ferrule shall be connected to each side of a single terminal
block.

7.6 Terminal Strip Assemblies (SAES-J-902 Para. 15 Sec. 15.3)

7.6.1 Terminal strip spacing shall allow ample room for plastic wire ducts and permit
training and lacing of cables, and fanning of individual wires to termination points.
Each terminal strip shall be labelled above or below with the terminal strip number,
as shown on wiring diagrams.

7.6.2 Terminals for similar (AC or DC) current service shall be grouped together and
physically separated from terminals for different service by means of dividers,
separate mounting rails or separate enclosures.

7.6.3 Terminals for 120 VDC and 120 VAC power for field contacts shall be segregated
from other systems.

7.6.4 Terminal strips for ESD wiring shall be completely separate from all other wiring
including power, control and instrumentation.
7.7 Foundation fieldbus (FF) Junction Boxes requirements

7.7.1 FF Junction box shall be as per SAES-J-904, Para: 6.5.

7.7.2 All trunk and spur connections in the field junction boxes, including pass through
trunk pairs without spurs, shall be terminated on wiring-blocks specifically made for
FOUNDATION™ fieldbus networks.

7.7.3 The wiring-blocks shall be mounted vertically in the field junction box.

7.7.4 Junction Boxes shall contain only FF signal wiring.

7.7.5 A warning label must be prominently affixed on the FF junction box door (inside)
stating the following: (red lettering with white background) (SAES-J-904 Para. 6.5
Sec. 6.5.4)

“WARNING: Explosion Hazard – Do not connect or disconnect the 'trunk connections'

on the wiring-block unless power has been switched off or the area is known to be
non-hazardous.”
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Hawiyah Unayzah Gas REV.NO B
Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 10 of 12
7.7.6 An information label must be prominently affixed on the junction box door (inside)
stating the following: (black lettering with white background) "The spur connections
may be connected or disconnected while the circuit is live, i.e., you may connect or
disconnect the spur on the wiring-block or at the device without sniffing the area for
combustible gasses." as per SAES-J-904, Para: 6.5.5

8.0 ORGANIZATIONAL CHART:

Permit
Receiver

9.0 QUALITY CONTROL

All Installation Inspection shall be coordinated with SECL by SY
Inspector.

9.1 SY QC Inspector shall be assigned to ensure the quality control and assurance
requirement of the project.

9.2 SY QC Inspector shall be responsible to conduct all required inspection /

documentation and to ensure that all applicable requirements, codes, and standards
are complied.

9.3 Contractor has to utilize the applicable inspection and test form reflected on
approved SATIP.

9.4 SY QC Inspector, who conducts surveillance and inspection, shall coordinate to

SECL and Saudi Aramco Representative.

10.0 SAFETY PRECAUTION

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Hawiyah Unayzah Gas REV.NO B
Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 11 of 12
10.1 Obtain necessary work permits from the concerned SECL Representative intended
for the job before starting any work.

10.2 Conduct proper preparation to include required safety equipment and tools for the
commencement of the work. Activities shall be executed in accordance with this
procedure and related standards and specifications.

10.3 Provide warning sign and sufficient barricade on working area. Only assigned
personnel will be allowed in the area to maintain a safe work environment.

10.4 Conduct safety briefing to all working crew to remind them of all the basic safety
requirements on the job to ensure safe work flow.

10.5 All necessary personal protective equipment (PPE) shall be provided and to be worn
at all times in accordance with site Safety Procedure.

10.6 Safety harness with double lanyards shall be used all the time when working at
elevated temporary platforms 1.8 meters high and above.

10.7 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.

10.8 Good housekeeping shall be maintained throughout the work activity. The work site
shall be kept clean and safe.

10.9 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
Equipment’s (PPE’s) are supplied and worn at all times.

10.10 Proper tools to be used for the activities should have been checked by safety officer,
conformed to the designated electrical maintenance and tagged with monthly color
code tape.
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Hawiyah Unayzah Gas REV.NO B
Reservoir Storage Project INSTRUMENT JUNCTION BOX
INSTALLATION PAGE 12 of 12

ATTACHMENT:
Job Safety Analysis (JSA) for
Instrument Junction Box Installation