Inspection Procedure

15-SAIP-51 Inspection Procedure for PVC Coated Rigid Steel Conduit Document Responsibility: Inspection Department 31 August, 2004

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 Scope........................................................... Purpose........................................................ Abbreviations................................................ References................................................... Inspection Procedure.................................... Inspection's Reporting Methods................... 2 2 2 2 3 5

Previous Issue: 31 December, 2000 Next Planned Update: 1 September, 2008 Revised paragraphs are indicated in the right margin Primary contact: Nasser M. Balhareth on 874-6604

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Document Responsibility: Inspection Department Issue Date: 31 August, 2004 Next Planned Update: 1 September, 2008

15-SAIP-51 Inspection Procedure for PVC Coated Rigid Steel Conduit

Scope 1.1 1.2 This procedure defines the inspection requirements prior to and during installation of PVC coated rigid steel conduits. This SAIP is intended to establish a standardized methodology by Saudi Aramco inspection personnel in the implementation of inspection programs within Saudi Aramco facilities. The SAIP shall not be included in purchase order or contract documents issued to outside agencies.

Purpose The purpose of this procedure is to provide a standard inspection guideline for identifying PVC coated rigid steel conduit, which conforms to Saudi Aramco Standards, and to assure that proper procedures and tools are utilized during installation.

Abbreviations SAEP SAIP SAES NEC ANSI PVC NEMA EMT IMC Saudi Aramco Engineering Procedure Saudi Aramco Inspection Procedure Saudi Aramco Engineering Standard National Electrical Code American National Standards Institute Polyvinyl Chloride National Electrical Manufacturing Association Electrical Metallic Tubing Intermediate Metal Conduit

References 4.1 Saudi Aramco References Saudi Aramco Engineering Standard SAES-P-104 Wiring Methods and Materials

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Document Responsibility: Inspection Department Issue Date: 31 August, 2004 Next Planned Update: 1 September, 2008 Saudi Aramco Engineering Procedure SAEP-1150 4.2 Industry Code and Standards National Electrical Code (NEC) Article 346

15-SAIP-51 Inspection Procedure for PVC Coated Rigid Steel Conduit

Inspection Coverage on Projects

National Electrical Manufacturing Association Standard NEMA RN-1 Polyvinyl-Chloride (PVC) Externally Coated Galvanized Rigid Steel Conduit and Intermediate Metal Conduit (IMC)

American National Standards Institute ANSI C80.1 ANSI C80.3

Commentary Notes: SAES-P-104 prohibits the installation of IMC in Saudi Aramco facilities. Electrical metallic tubing (EMT) is acceptable only in non-hazardous indoor locations. EMT shall comply with the requirements of ANSI C80.3.

Rigid Steel Conduit-Zinc Coated Electrical Metallic Tubing-Zinc Coated

Inspection Procedure Inspection of PVC coated rigid steel conduit shall include but not necessarily be limited to the following: 5.1 Bonding of PVC Coating to Galvanized Conduit 5.1.1 Bonding can be determined by attempting to pry the coating material from the conduit. If it is properly bonded, the coating material will be damaged but the bond will remain. The following extract from NEMA RN-1 may be used for guidance in inspection of bonding: "The adhesion of the PVC coating shall be determined by making two circumferential cuts, about inch apart, through the plastic to the substrate. A third cut shall be made perpendicular to and crossing the circumferential cuts. The edge of the plastic shall be carefully lifted with a knife to form a plastic tab. This tab shall be pulled perpendicular to the conduit with a pair of pliers. The plastic tab shall tear rather than any additional coating film separating from the substrate."

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Document Responsibility: Inspection Department Issue Date: 31 August, 2004 Next Planned Update: 1 September, 2008 5.1.2

15-SAIP-51 Inspection Procedure for PVC Coated Rigid Steel Conduit

Partial bonding of the PVC coating is characterized by good and bad bonding spots on each conduit. The coating cannot be completely removed without it being damaged. Unbonded PVC coating is the condition where the coating can be completely removed without damage to the coating except where it is cut. It does not adhere to the conduit at any point. Partially bonded and unbonded PVC coating should be rejected.

5.1.3

5.1.4 5.2

Coating Thickness The minimum PVC coating thickness to be utilized on Saudi Aramco facilities is 40 mil. The thickness can in some cases be obtained by consulting current literature from the manufacturer. Otherwise, it should be measured by a paint thickness gage and any thickness under 40 mils nominal is to be rejected.

5.3

Rigid Steel Conduit Preparation After the threads have been cut rigid steel conduit must be hot-dip galvanized, prior to having the PVC coating applied. Hot-dip galvanizing is superior to a metalized zinc coating and/or elector- galvanizing. It protects the interior of the conduit and the threads where the other methods only protect the exterior. It also provides a zinc coating approximately ten times as thick as the other methods.

5.4

Uniformity of Use Conduits with different thickness of PVC coating must not be used on the same conduit system, i.e., 20 mil must not be used with 40 mil, etc. This is necessary because the seal at fittings and couplings etc. is ineffective if mixed coating thicknesses are used. This problem is eliminated by ensuring that all conduits have a 40 mil thick PVC coating.

5.5

Installation Inspection 5.5.1 Tools Confirm that the installer is using proper tools for handling PVC coated conduit such as vice adapters, strap type wrenches, oversized bending forms to allow for the coating thickness and oversized guides on the threading machines. Oversized bending forms will prevent coating damage when bending the conduits. The use of oversized guides on the threading machines will prevent the operator stripping the PVC coating off to allow a normal sized guide to go over the conduit. Page 4 of 5

Document Responsibility: Inspection Department Issue Date: 31 August, 2004 Next Planned Update: 1 September, 2008 5.5.2 Integrity of the PVC Coating 5.5.2.1

15-SAIP-51 Inspection Procedure for PVC Coated Rigid Steel Conduit

There should be no metal left exposed at joints and fittings and plastic sleeves must not be cut off couplings and fittings. Coating thickness must be uniform throughout the conduit system. All coating damage must be repaired or the section of conduit replaced. Small areas of damaged coating on above and below grade conduit can be repaired using PVC patching compound. However, where larger areas of damaged coating are below grade and cannot be maintained the use of wrap-around heat shrink sleeves should be considered. Where the conduit will be exposed to a severe corrosive environment or standing water, joints should be solvent welded by applying PVC patching compound to the inside of the sleeve immediately prior to making up the joint.

5.5.2.2

5.5.2.3

5.6

Storage and Handling Another cause of damage to the PVC coating on conduit is improper storage and handling. A review of storage and handling procedures and equipment should be conducted as part of on-site inspections. The conduit should be stored and handled in a manner that prevents injury to the PVC coating by stones and any other material.

Inspection's Reporting Methods Any deficiencies in the above mentioned methods or procedure should be reported by one of the methods outlined in SAEP-1150, Inspection Coverage on Projects, or through the worksheet system in operating plants.
Revision Summary Revised the "Next Planned Update". Revised paragraph 5.4.

31 August, 2004

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