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Engineering Procedure

SAEP-744 22 July 2013


Preventive Maintenance and Condition
Assessment for Communication Towers
Document Responsibility: Communications Standards Committee

Saudi Aramco DeskTop Standards


Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 Applicable Documents.................................... 2
4 Definitions …………………………….……….. 2
5 Instructions..................................................... 3
6 Responsibilities.............................................. 7

Appendix A – Proposed PM Forms...................... 9

Previous Issue: 18 July 2012 Next Planned Update: 22 July 2018


Revised paragraphs are indicated in the right margin Page 1 of 12
Primary contact: Abdullatif, Abduladhim Habib on +966-3-8801356

Copyright©Saudi Aramco 2013. All rights reserved.


Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

1 Scope

This procedure provides minimum mandatory requirements to addresses the


maintenance and condition assessment of the communications tower structures.

2 Conflicts and Deviations

2.1 Any conflicts between this Procedure and other applicable Saudi Aramco
Engineering Standards (SAES's), Materials System Specifications (SAMSS's)
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing to the Manager, Process & Control Systems Department of
Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate any mandatory security requirement from this
procedure in writing to the Manager, Process & Control Systems Department of
Saudi Aramco, Dhahran who shall follow internal company procedure SAEP-302.

3 Applicable Documents

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures


SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
SAEP-340 Air Dispersion Modeling and Emission Inventory

Saudi Aramco Engineering Standard


SAES-T-744 Design Criteria/Installation of Communication Towers

3.2 Industry Codes and Standards

Telecommunications Industry Association


TIA-222-G Structural Standards for Antenna Supporting
Structures and Antennas

4 Definitions

Preventive Maintenance: The maintenance that is performed before a problem exists.


Preventive maintenance consists of cleaning, inspecting, lubricating, adjusting and
servicing the infrastructure components of communications towers, antenna/(s) and its
mounting brackets or equipment.

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

Routine or scheduled Maintenance: The maintenance that is performed in intervals


normally based on time, mileage or hours. Scheduled maintenance is designed to keep
the infrastructure components of communications towers, antenna/(s) and its mounting
brackets or equipment in top operating condition and prevent untimely breakdowns and
repairs. Scheduled maintenance that is required by the manufacturer and not performed
can void the warranty.

Class I Structures: Structures used for services where a delay in returning the service
would be acceptable and the structure represents a low hazard to human life and/or
property. Example services would be: residential wireless and conventional 2-way
radio communications; television, radio, and scanner reception; wireless cable; amateur
and CB radio communications. Structures of this classification are exempt from ice and
earthquake loading and wind loads are reduced 13% compared to Class II structures.

Class II Structures: Structures used for services that may be provided by other
means or structures that represent a significant hazard to human life and/or property.
Example services would be commercial wireless communications; television and radio
broadcasting; cellular, PCS, CATV, and microwave communications.

Class III Structures: Structures specifically designed for essential communications


or structures that represent a substantial hazard to human life and/or property.
Examples of essential communications would be: civil or national defense; emergency,
rescue, or disaster operations; military and navigation facilities. Loadings are increased
for structures of this classification compared to Class II structures (15% for wind, 25%
for ice and 50% for earthquake).

5 Instructions

5.1 Maximum Intervals

Maintenance and condition assessment shall be performed as follows:


a) Three-year intervals for guyed masts and five-year intervals for self-
supporting structures.
b) Immediately after severe wind, ice storms, seismic events or other extreme
conditions.
Note: Refer to SAEP-340 for severe and extreme wind conditions definition.

c) Immediately after a man-made or natural disaster.


d) Shorter [less than 3 years] inspection intervals may be required for
Class III structures and structures in coastal regions, in corrosive
environments, and in areas subject to frequent vandalism.

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

This procedure provides checklists for:


a) Maintenance and condition assessment.
b) Field mapping of structures and appurtenances.
Note: This procedure does not provide means and methods for RF protection.

5.2 Maintenance and Condition Assessment

5.2.1 Structure Condition, the following components shall be inspected:


1) Damaged members (legs and bracing).
2) Loose members.
3) Missing members.
4) Climbing facilities, ladders, platforms, catwalks, gratings – all secure.
5) Loose and/or missing bolts and/or nut locking devices.
6) Visible cracks in welded connections.
7) Record temperature, wind speed and direction, and other
environmental conditions.
8) Waveguide bridge/ladder and supports (rust, loose or missing
hardware).

5.2.2 Finish, the following components shall be inspected:


1) Paint and/or galvanizing condition.
2) Rust and/or corrosion condition including mounts and accessories.
3) FAA or ICAO color coding conditions.
4) Water collection in members (to be remedied, e.g., unplug drain
holes, etc.).

5.2.3 Lighting

The following components shall be inspected:


1) Conduit, junction boxes, and fasteners (weather tight and secure).
2) Drain and vent openings (unobstructed).
3) Wiring condition.

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

4) Light lenses.
5) Bulbs Conditions.
6) Controllers (functioning).
a) Safety lights and flashers.
b) Photo control.
c) Alarms.

5.2.4 Grounding

The following components shall be inspected:


1) Connections (Broken, Loose or missing wires).
2) Corrosion.
3) Lightning protection (secured to structure).

5.2.5 Antennas and Lines

The following components shall be inspected:


1) Antenna condition.
2) Mount and/or ice shield condition (bent, loose, and/or missing
members).
3) Feed line condition (flanges, seals, dents, jacket damage,
grounding, etc.).
4) Hanger condition (snap-ins, bolt on, kellum grips, etc.).
5) Secured to structure.

5.2.6 Other Appurtenances (walkways, platforms, sensors, floodlights, etc.)


1) Condition
2) Secured to structure

5.2.7 Insulator Condition


1) Cracking and chipping
2) Cleanliness of insulators
3) Spark gaps set properly

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

4) Isolation transformer condition


5) Bolts and connection secure

5.2.8 Guys
1) Strand condition (corrosion, breaks, nicks, kinks, etc.)
2) Guy Hardware Conditions
a) Turnbuckles or equivalent (secure and safety properly
applied)
b) Cable thimbles properly in place (if required)
c) Service sleeves properly in place (if required)
d) Cable connectors (end fittings)
(i) Cable clamps applied properly and bolts tight
(ii) Wire serving properly applied
(iii) No signs of slippage or damaged strands
(iv) Preformed wraps – properly applied, fully wrapped, and
sleeve in place
(v) Poured sockets secure and showing no separation
(vi) Shackles, bolts, pins and cotter pins secure and in good
condition
3) Guy Tensions
4) Measure guy tensions (refer to Annex K of TIA-222G)
5) Record temperature, wind speed and wind direction and other and
other environmental conditions.

5.2.9 Concrete Foundations


1) Ground condition
a) Settlement, movement or earth cracks
b) Erosion
c) Site condition (standing water, drainage, trees, etc.)

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

2) Anchorage condition
a) Nuts and/or nut locking device (tightened)
b) Grout condition
c) Anchorages and/or anchor rod condition
3) Concrete condition
a) Cracking, spalling, or splitting
b) Chipped or broken concrete
c) Honeycombing
d) Low spots to collect moisture

5.2.10 Guyed Mast Anchors

The following components shall be inspected:


1) Settlement, movement or earth cracks.
2) Backfill heaped over concrete for water shedding.
3) Anchor rod condition below earth (Maintain required structural
capacity of anchor during exploration. Attachment to temporary
anchorage may be required).
4) Corrosion control measures (galvanizing, coating, concrete
encasement, cathodic protection systems, etc.).
5) Anchor heads clear of earth.

5.2.11 Tower Alignment

The following component shall be inspected:

Tower Plumb and Twist (see Figures J-1 and J-2 of Annex J, TIA-222-G).

6 Responsibilities

6.1 It is the proponent responsibility to ensure that communication towers


preventive maintenance is conducted regularly, address (or correct) any
unsatisfactory tower condition, and maintain historical inspection records, as
specified in paragraph 5.1.

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

6.2 All personnel who are expected to climb towers shall have completed OSHA-
recognized certification courses or equivalent.

6.3 Communications Tower Riggers are the only personnel and technicians
recognized and allowed to work and climb on Saudi Aramco communications
towers. Tower riggers should possess a valid Certification issued by the
Employer that guarantees the high-skilled qualifications, experience and
competence of the Rigger. The Company issuing Rigger’s Certificate/(s) should
be an accredited Saudi Aramco communications tower Contractor, Vendor
and/or Erector.

Revision Summary
22 July 2013 Revised the “Next Planned Update.” Reaffirmed the content of the document, and reissue with
minor revisions as follows:
1. The document was revised to be in line with the latest TIA-222.
2. New section Definitions was added to clarify some of the terminology.
3. Preventive Maintenance (PM) forms were added..

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

Appendix A – Proposed PM Forms

TOWER INSPECTION - SELF SUPPORTING


PM INSPECTION
PREVENTIVE MAINTENANCE CHECK LIST
TYPE: _______________________________________
SITE: ________________________________________ DATE:_________________________

PLEASE PERFORM THE FOLLOWING PREVENTIVE MAINTENANCE ITEMS INDICATED ON


THIS CHECK LIST.

EQUIPMENT/JOB DESCRIPTION OK
A. FOUNDATIONS
1. Movement, cracking, or deterioration of concrete or grout.
2. Full bearing on baseplates.
3. Adequate backfill and drainage

B. TOWER MEMBERS AND CONNECTION


1. Bent, fractured, corroded or missing members
2. Loose, missing, short or corroded bolts and cracks in welds

C. LADDERS, GRATINGS & HANDRAILS


1. Loose or missing supports. Fractured members. Cracks in welds and corrosion
2. Adequate safety climbing devices

D. GROUNDING
1. Loose, missing or corroded connections on lightning rod and ground wiring
2. No sharp bends in lightning rod ground wire

E. WAVEGUIDE BRIDGE
1. Bent, fractured, corroded or missing members

F. ANTENNAS AND MEMBERS


1. Bent. Fractured. Corroded or missing member

G. TRANSMISSION LINES
1. Loose, missing, short or corroded bolts and cracks in welds
2. Dented or damaged lines
3. Lines chafing on structure
4. Missing protective sleeves
5. Looses or missing line supports
6. Line pressurization operation
7. Line port into building sealed

H. LIGHTING SYSTEMS
1. Bent, corroded, loose or missing conduit hardware
2. Loose, broken or corroded lamp fixtures
3. Broken globes and burned out bulbs on obstruction and external lights

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

EQUIPMENT/JOB DESCRIPTION OK

I. PAINTING
1. All tower surfaces painted
2. No peeling, blistering, flaking, etc.

J. TOWER SITE
1. Excessive sand buildup on site
2. Condition of security fence
3. Danger and warning signs in place

K. VERTICAL ALIGNMENT AND TWIST


1. Vertical alignment and twist within tolerance

Please note minor maintenance and/or major maintenance necessary later.

REMARKS: FOLLOW-UP:

Refer to appropriate technical manual for the equipment test procedure, test set up and parameters

TIME STARTED:_________________ TIME COMPLETED:______________


TRAVEL/MISC. TIME:____________ TOTAL PM HOURS:______________
TOTAL HOURS:__________________ DATE COMPLETED:______________

CRAFTSMAN NAME: ___________________ BADGE NO:_________________


___________________ BADGE NO:_________________
___________________ BADGE NO:_________________

SUPV/FRMN NAME: ___________________ BADGE NO:_________________

NOTE: Kindly return this work order to your PM Maintenance Unit Coordinator for completion.

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

TOWER INSPECTION - GUYED


PM INSPECTION
PREVENTIVE MAINTENANCE CHECK LIST
TYPE: _______________________________________
SITE: ________________________________________ DATE:_________________________

PLEASE PERFORM THE FOLLOWING PREVENTIVE MAINTENANCE ITEMS INDICATED ON


THIS CHECK LIST.

EQUIPMENT/JOB DESCRIPTION OK
A. FOUNDATIONS
4. Movement, cracking, or deterioration of concrete or grout.
5. Full bearing on baseplates.
6. Bent, fractured, corroded or gut anchor plates anchor sharrs and anchor bolts.
7. Adequate backfill and drainage.

B. GUYS AND HARDWARE


3. Broken guy strands.
4. Slipped guy grips or clips
5. Loose or broken ties on guy ends
6. Loose. Worn. Cracked. Bent. Missing or corroded hardware.
7. Rotations. Articulation and proper take-up on turnbuckles
8. Guy barrier condition

C. TOWER MEMBERS AND CONNECTION


1. Bent, fractured, corroded or missing members
2. Loose, missing, short or corroded bolts and cracks in welds

D. LADDERS, GRATINGS AND HANDRAILS


3. Loose or missing supports, fractured members, cracks in welds and corrosion
4. Adequate safety climbing devices

E. GROUNDING
3. Loose, missing or corroded connections on lightning rod and ground wiring
4. No sharp bends in lightning rod ground wire

F. WAVEGUIDE BRIDGE
2. Bent, fractured, corroded or missing members

G. ANTENNAS AND MEMBERS


2. Bent, fractured, corroded or missing members

H. TRANSMISSION LINES
8. Loose, missing, short or corroded bolts and cracks in welds
9. Dented or damaged lines
10. Lines chafing on structure
11. Missing protective sleeves
12. Looses or missing line supports
13. Line pressurization operation
14. Line port into building sealed

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Document Responsibility: Communications Standards Committee SAEP-744
Issue Date: 22 July 2013 Preventive Maintenance and Condition
Next Planned Update: 22 July 2018 Assessment for Communication Towers

EQUIPMENT/JOB DESCRIPTION OK

I. LIGHTING SYSTEMS
4. Bent, corroded, loose or missing conduit hardware
5. Loose, broken or corroded lamp fixtures
6. Broken globes and burned out bulbs on obstruction and external lights

J. INSULATORS
3. Cracked. Chipped or leaking guy and tower base insulators.

K. PAINTING
4. All tower surfaces painted
5. No peeling, blistering, flaking, etc.

L. TOWER SITE
2. Excessive sand buildup on site.
3. Condition of security fence.
4. Danger & warning signs in place.

M. VERTICAL ALIGNMENT AND TWIST


1. Vertical alignment and twist within tolerance

Please note minor maintenance and/or major maintenance necessary later.

REMARKS: FOLLOW-UP:

Refer to appropriate technical manual for the equipment test procedure, test set up and parameters

TIME STARTED:_________________ TIME COMPLETED:______________


TRAVEL/MISC. TIME:____________ TOTAL PM HOURS:______________
TOTAL HOURS:__________________ DATE COMPLETED:______________

CRAFTSMAN NAME: ___________________ BADGE NO:_________________


___________________ BADGE NO:_________________
___________________ BADGE NO:_________________

SUPV/FRMN NAME: ___________________ BADGE NO:_________________

NOTE: Kindly return this work order to your PM Maintenance Unit Coordinator for completion.

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