Conduit Types, Specifications, and Applications According to Aramco and NEC Standards

The document outlines conduit types, material specifications, support and fastener requirements, and applications as
per Aramco standards and the National Electrical Code (NEC). It also incorporates details regarding conduit sizes,
dimensions, naming conventions, and installation guidelines.

Conduit Types and Specifications

1. Rigid Metal Conduit (RMC)

• Material: Galvanized steel or stainless steel.

• Sizes:
o Common sizes NEC: ½ inch, ¾ inch, 1 inch, 1.5 inches, 2 inches, up to 6 inches.
o Aramco: ¾ to 6 inches.
• Length: 3m
• Threads: Minimum 5 threads
• Traceability: Must
• Applications:
o Hazardous areas (oil and gas facilities, refineries).
o Areas subject to high mechanical damage.
o Outdoor and underground installations (with corrosion protection).

2. Intermediate Metal Conduit (IMC)

• Material: Galvanized steel.

• Sizes:
o Common sizes: ½ inch, ¾ inch, 1 inch, 1.5 inches, 2 inches, up to 4 inches.
• Applications:
o Indoor and outdoor installations requiring moderate mechanical protection.
o Used where RMC is too heavy or costly, but stronger than EMT.

3. Electrical Metallic Tubing (EMT)

• Material: Coated steel or aluminum, light weight. No threads

• Sizes:
o Common sizes: ½ inch, ¾ inch, 1 inch, 1.5 inches, 4 inches.
o ARAMCO: 1/2 to 4 inches.
• Length: 1.8m could be used at Aramco site.
• Support/Fastner: 300mm to 3m
• Marking: Every 3m
• Applications:
o Dry, indoor locations.
o Light-duty commercial, industrial, or residential installations.

4. Rigid PVC Conduit

• Material: Polyvinyl chloride (PVC).

 • Sizes:
o Common sizes: ½ inch, ¾ inch, 1 inch, 1.5 inches, 2 inches, up to 6 inches.
o ARAMCO: 1/2 to 6 inches.
• Applications:
o Corrosive environments such as chemical plants.
o Underground installations, wet, or damp locations.

5. Flexible Metal Conduit (FMC)

• Material: Spiral-wound metal strips.

• Sizes:
o Common sizes: ½ inch, ¾ inch, 1 inch, 1.5 inches, 2 inches.
• Applications:
o Installations requiring flexibility, such as motor connections or vibrating equipment.
o Tight spaces where rigid conduit bending is challenging.

6. Liquid-Tight Flexible Metal Conduit (LFMC)

• Material: Spiral-wound metal with a liquid-tight coating.

• Sizes:
o Common sizes NEC: ½ inches to 4 inches.
o ARAMCO: 3/8 to 4 inches.
• Length: 1.8m could be used at Aramco site.
• Support/Fastner: 300mm to 1.4m
• Applications:
o Instrument Cable, Outdoor equipment or wet environments requiring both flexibility and water
resistance.

Support and Fasteners - Types and Specifications

1. Strut Channel Systems

• Material: Galvanized or stainless steel.

• Applications:
o Used to support and organize conduits in industrial settings.
o Adjustable and flexible for various conduit layouts.

2. Conduit Hangers

• Material: Galvanized steel or stainless steel.

• Applications:
o Used to suspend conduits from ceilings or walls.
o Available in various sizes to match conduit dimensions (½ inch to 6 inches).

3. U-Bolts and Beam Clamps

• Material: Stainless steel or galvanized steel.

 • Applications:
o Used for securing conduits to beams or other structures.
o Suitable for areas with high vibrations or requiring additional rigidity.

4. Conduit Straps (One-hole and Two-hole)

• Material: Galvanized steel.

• Applications:
o Secure conduits to flat surfaces such as walls or floors.
o Available in both one-hole and two-hole designs for different applications.

Conduit Types, Sizes, Materials, Applications, and References

Conduit Type Sizes Material Applications Standards/References
Rigid Metal ½ inch to 6 Galvanized Hazardous areas, high-impact zones, outdoor NEC: Article 344,
Conduit (RMC) inches steel and underground installations. Aramco: SAES-P-114,
Intermediate ½ inch to 4 Galvanized General-purpose indoor/outdoor use, NEC: Article 342,
Metal Conduit inches steel moderate mechanical protection. Aramco: SAES-P-114,
(IMC)
Electrical Metallic ½ inch to 2 Coated Dry, indoor locations, light-duty commercial NEC: Article 358,
Tubing (EMT) inches steel/aluminum and industrial installations. Aramco: SAES-P-114,
UL 797
Rigid PVC Conduit ½ inch to 6 Polyvinyl Corrosive environments, underground NEC: Article 352,
inches chloride (PVC) installations, wet or damp locations. Aramco: SAES-P-114,
UL 651, IEC 61386
Flexible Metal ½ inch to 2 Spiral-wound Areas with vibration or movement, tight NEC: Article 350,
Conduit (FMC) inches metal spaces. Aramco: SAES-P-114
Liquid-Tight ½ inch to 4 Spiral-wound Wet or damp locations, outdoor equipment NEC: Article 350,
Flexible Metal inches.. metal with requiring liquid resistance. Aramco: SAES-P-114
Conduit (LFMC) A: 3/8 inch waterproof
to 4 inches coating

Key Standards and References for Conduit Installation

1. National Electrical Code (NEC):

o NFPA 70: National Electrical Code (NEC) provides detailed requirements for conduit types, installation,
grounding, bonding, and usage in different environments.
▪ Article 342: Intermediate Metal Conduit (IMC)
▪ Article 344: Rigid Metal Conduit (RMC)
▪ Article 358: Electrical Metallic Tubing (EMT)
▪ Article 350: Flexible Metal Conduit (FMC) and Liquid-Tight Flexible Metal Conduit (LFMC)
▪ Article 352: Rigid PVC Conduit
2. Aramco Standards:
o SAES-P-114: Saudi Aramco Engineering Standard for Electrical Conduits and Fittings. This standard
specifies the types of conduits, materials, sizes, installation procedures, and usage in industrial and
hazardous environments.
o SAES-P-100: General electrical engineering guidelines that also cover conduit installation and material
selection in Saudi Aramco projects.
3. ASTM Standards:
o ASTM A53: Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded, and Seamless,
which applies to RMC and IMC conduits.
 o ASTM A1057: Specification for Steel Conduit, Zinc-Coated, which is used for RMC applications.
4. UL Standards:
o UL 797: Standard for Electrical Metallic Tubing (EMT), which provides safety guidelines and quality
requirements.
o UL 651: Standard for Schedule 40 and 80 Rigid PVC Conduit and Fittings.
5. IEC Standards:
o IEC 61386: Conduit systems for cable management, particularly for rigid PVC and other non-metallic
conduits used in industrial environments.

Aramco Standards and Key Documents

1. SAES-P-114: Electrical Conduits and Fittings.

2. SAES-P-100: General Electrical Engineering Guidelines.
3. SATIP-A-104: Inspection and Testing Procedures for Electrical Installations.
4. NEC (NFPA 70): National Electrical Code for Conduit Installations.
5. API RP 500: Recommended Practice for Classification of Locations for Electrical Installations.

Application Guidelines Based on Conduit Types:

• RMC (Rigid Metal Conduit):

o Use: Ideal for hazardous areas (e.g., oil and gas facilities), high-impact zones, and
outdoor/underground installations where mechanical protection is critical.
o Reference: NEC Article 344, SAES-P-114.
• IMC (Intermediate Metal Conduit):
o Use: Suitable for general-purpose indoor and outdoor installations with moderate mechanical
protection requirements.
o Reference: NEC Article 342, SAES-P-114.
• EMT (Electrical Metallic Tubing):
o Use: Best for dry, indoor locations and light-duty commercial and industrial installations.
o Reference: NEC Article 358, SAES-P-114.
• Rigid PVC Conduit:
o Use: Optimal for corrosive environments, underground installations, and wet or damp locations.
o Reference: NEC Article 352, SAES-P-114.
• FMC (Flexible Metal Conduit):
o Use: Ideal for areas with vibration or movement (e.g., motor connections), or in tight spaces where
rigid conduits are difficult to install.
o Reference: NEC Article 350, SAES-P-114.
• LFMC (Liquid-Tight Flexible Metal Conduit):
o Use: Best for wet or damp locations, outdoor equipment, or environments that require both flexibility
and liquid resistance.
o Reference: NEC Article 350, SAES-P-11

Conduit Size Classification for Aramco and Industrial/Non-Industrial Uses

Conduit Size Industrial Use Non-Industrial Use

½ inch (12.7 mm) Instrumentation wiring. Small electrical circuits in homes or offices.
Light-duty power circuits in control rooms. Residential lighting and receptacles.
Indoor installations for low-current signals.
¾ inch (19.05 mm) Motor control wiring in hazardous areas. Commercial office lighting and receptacles.
 Control systems for oil and gas facilities. Small HVAC system wiring in residential
areas.
Industrial lighting circuits (non-explosive
zones).
1 inch (25.4 mm) Power circuits for motors, pumps, and Small commercial building circuits.
compressors.
General-purpose industrial control circuits. Air conditioning unit wiring in homes.
1.5 inches (38.1 mm) High-power motor circuits and power Larger HVAC systems for non-industrial
distribution. buildings.
Large industrial lighting systems.
2 inches (50.8 mm) Power circuits in hazardous/explosion-prone Main electrical feed for small commercial
areas. buildings.
Wiring for medium-voltage equipment in
refineries.
2.5 inches (63.5 mm) Heavy-duty industrial installations (motors, Rarely used in non-industrial applications.
MCCs).
Underground power distribution for
substations.
3 inches (76.2 mm) Main feeders for heavy industrial equipment. Large commercial electrical feeds (e.g.,
shopping malls).
3.5 inches (88.9 mm) High-power feeders and distribution for critical Rare in non-industrial settings.
facilities.
4 inches (101.6 mm) Large conduits for multiple power or control Main electrical service in commercial
circuits. complexes.
5 inches (127 mm) Very high-power circuits for substations and Non-industrial use is uncommon.
power plants.
6 inches (152.4 mm) Used in refineries for main feeders, large MCCs, Not applicable in non-industrial use cases.
and substations.

Aramco-Specific Applications for Conduit Sizes

1. Conduit Sizes ½ inch to 1 inch:

o Aramco Industrial Use: Instrumentation circuits, fire alarm systems, process control systems, and small
power circuits.
o Non-Industrial Use: Typically for light-duty electrical systems in offices or small residential complexes.
2. Conduit Sizes 1.5 inches to 2.5 inches:
o Aramco Industrial Use: Power circuits for heavy-duty equipment like motors, large compressors, control
panels, and process equipment in refineries and petrochemical plants.
o Non-Industrial Use: Main feeders for commercial office buildings, small shops, or service panels in
moderate-size buildings.
3. Conduit Sizes 3 inches to 4 inches:
o Aramco Industrial Use: High-power feeders for critical equipment in hazardous areas, main distribution
feeders, large motor control centers (MCCs), and substation cabling.
o Non-Industrial Use: Electrical service for large commercial properties, malls, and shopping centers.
4. Conduit Sizes 5 inches to 6 inches:
o Aramco Industrial Use: Specialized applications such as refineries, gas plants, and large substation
installations for main power distribution or highly critical electrical systems.
o Non-Industrial Use: Rarely applicable, except for very large commercial or institutional facilities.
Stub-up:
A stub-up refers to the vertical section of a conduit that extends from a horizontal run (typically embedded in a slab or
underground) to an electrical box, panel, or device. It is commonly used in electrical installations across commercial,
industrial, and residential settings.

Installation Process for Stub-Ups

1. Planning and Layout

• Determine the precise location of the stub-up based on the electrical system layout and equipment placement.
• Ensure proper alignment between the stub-up, horizontal conduit run, and electrical box or panel.

2. Cutting and Bending Conduit

• Cut the conduit to the required length for the vertical run.
• Use a conduit bender to create a 90-degree bend at the base of the stub-up if needed.
• Ensure the bend radius complies with NEC Article 344 for Rigid Metal Conduit (RMC) or NEC Article 358 for
Electrical Metallic Tubing (EMT).

3. Securing the Stub-Up

• Secure the stub-up with conduit straps or clamps to the structure (walls, floors, or slabs).
• When working with concrete slabs, use sleeves or embedment fittings to protect the conduit during the pouring
process.

4. Connecting to the Horizontal Run

• Use appropriate conduit fittings (e.g., couplings or connectors) to join the stub-up to the horizontal conduit run.
• Ensure the joints are tight and watertight if the installation is outdoors or in wet locations.

5. Installing the Electrical Box or Panel

• Connect the stub-up to the electrical box or panel using a conduit connector.

6. Pulling Wires

• using tools such as fish tape or a pull string to guide the wires without damaging them.

Best Practices for Stub-Ups

1. Bending Radius:
▪ RMC/IMC: Minimum radius = 6 times the conduit diameter.
▪ EMT: Minimum radius = 5 times the conduit diameter.
▪ PVC: Minimum radius = 6 times the conduit diameter.
o Avoid sharp bends that could damage the conduit or the wires inside.
2. Support and Spacing:
▪ RMC/IMC: Maximum spacing of 10 feet for horizontal runs and 5 feet for vertical runs.
▪ EMT: Maximum spacing of 5 feet for horizontal runs and 3 feet for vertical runs.
 3. Grounding:
o Metallic conduits must be properly grounded and bonded as required by NEC Article 250.
4. Sealing:
o Use sealing fittings or compound to prevent moisture ingress in outdoor, underground, or hazardous
locations.
5. Labeling:
o Label the stub-ups for easy identification during maintenance or future upgrades.

Applications of Stub-Ups

1. Slab-on-Grade Construction:
o Stub-ups provide vertical conduit connections from underground conduit systems to electrical boxes or
panels above the slab.
2. Wall-Mounted Equipment:
o Stub-ups allow for conduit transitions from horizontal runs to wall-mounted panels or devices.
3. Outdoor Installations:
o Stub-ups are used for outdoor lighting, equipment, and electrical devices.
4. Industrial Facilities:
o Commonly used in oil refineries, process plants, and other industrial settings for connecting electrical
equipment to the main conduit system.

Conduit Types for Stub-Ups

Conduit Type Sizes Material Applications

Rigid Metal Conduit (RMC) ½ inch to 6 Galvanized steel Hazardous areas, outdoor, underground,
inches high-impact zones.
Intermediate Metal Conduit ½ inch to 4 Galvanized steel General-purpose indoor/outdoor use.
(IMC) inches
Electrical Metallic Tubing ½ inch to 2 Coated steel/aluminum Dry indoor locations, light commercial
(EMT) inches applications.
Rigid PVC Conduit ½ inch to 6 Polyvinyl chloride (PVC) Underground, corrosive environments.
inches
Flexible Metal Conduit (FMC) ½ inch to 2 Spiral-wound metal Vibration-prone areas, flexible
inches installations.
Liquid-Tight Flexible Metal ½ inch to 2 Metal with waterproof Wet or damp locations, equipment prone
Conduit (LFMC) inches coating to movement.

Summary of Stub-Up Installation Process

Step Details
Planning Determine alignment with horizontal conduit run and location of equipment.
Cutting and Bending Cut conduit to the required length, bend as needed.
Securing Secure stub-up using straps or clamps.
Connecting Connect the stub-up to the horizontal run using appropriate fittings.
Installing Box/Panel Attach stub-up to the electrical box or panel.
Pulling Wires Pull wires or cables through the conduit system.

Aramco and NEC Conduit Installation Requirements

1. Sizing and Fill Capacity

• NEC Fill Capacity:

o 1 conductor: 53% of conduit cross-sectional area.
o 2 conductors: 31% of conduit cross-sectional area.
o 3 or more conductors: 40% of conduit cross-sectional area.

2. Bending Radius

• NEC:
o Minimum bending radius for conduits:
▪ RMC/IMC: 6 times the conduit diameter.
▪ EMT: 5 times the conduit diameter.
▪ PVC: 6 times the conduit diameter.

3. Grounding and Bonding

• NEC:
o Metallic conduits must be properly grounded and bonded to prevent electrical hazards.
o Complies with NEC Article 250 on grounding and bonding.

4. Conduit Supports and Fasteners

• NEC:
o Maximum support spacing:
▪ RMC/IMC: 3 meters (10 feet) for horizontal runs, 1.5 meters (5 feet) for vertical runs.
▪ EMT: 1.5 meters (5 feet) for horizontal runs, 1 meter (3 feet) for vertical runs.

Duct Bank:

A duct bank is a group of conduits used to protect and route electrical cables, communication lines, or utilities
underground or within concrete structures. Duct banks are used in industrial, commercial, and utility installations to
provide a safe and organized pathway for cables while safeguarding them from mechanical damage, moisture, and
environmental hazards.

Purpose of Duct Banks

1. Cable Protection: Protects cables from physical damage, moisture, and environmental threats.
2. Organization: Provides a systematic and organized pathway for multiple cables.
3. Future Expansion: Enables easy addition or replacement of cables over time.
4. Heat Dissipation: Assists in managing heat, especially in high-load applications.

Types of Duct Banks

1. Concrete-Encased Duct Bank

• Description: Conduits encased in concrete for added strength and protection.

• Applications: Heavy-duty industrial setups, areas with significant mechanical stress, and corrosive
environments.
2. Non-Concrete Duct Bank

• Description: Conduits buried in trenches without concrete encasement.

• Applications: Light-duty installations or in low-stress areas.

3. Prefabricated Duct Bank

• Description: Pre-assembled duct banks made of materials like PVC or HDPE.

• Applications: Quick and cost-effective installations for utilities and communication lines.

Design Considerations for Duct Banks

1. Conduit Material

• PVC Conduits: Non-metallic, corrosion-resistant applications.

• HDPE Conduits: Flexible and durable for underground installations.
• RMC/IMC Conduits: Heavy-duty or hazardous environments.

2. Conduit Size and Number

• Determined by:
o Number of cables.
o Cable diameter and fill capacity (per NEC Article 310).
o Future expansion needs.

3. Spacing and Arrangement

• Proper spacing is critical for heat dissipation and mechanical strength.

• Use spacers to maintain consistent conduit separation.
o Spacer Size: Typically, spacers are designed to provide 1.5 inches to 3 inches of separation between
conduits, depending on the duct bank size and voltage level. For high-voltage cables, larger spacers are
used to ensure adequate space for heat dissipation.
• Common conduit arrangements include:
o Single Layer: Conduits placed side by side.
o Multiple Layers: Stacked conduits for higher capacity installations.

4. Grounding and Bonding

• For metallic conduits, grounding and bonding must comply with NEC Article 250. Grounding rods and
connections are required .

5. Marking and Identification

• As per NEC 300.5(D), use warning tape (buried 12 inches above the duct bank) to indicate the presence of
buried electrical lines.
• Alternatively, in certain cases, red dye can be added to the concrete encasement for high-voltage duct banks as
an additional visual marker for underground cables (a common practice in Aramco installations).
Installation Process for Duct Banks

1. Trench Excavation

• Dig to the required trench depth, ensuring the bottom is smooth and level.

2. Conduit Placement

• Lay conduits in the desired configuration (single or multiple layers).

• Use spacers to maintain correct spacing between conduits for heat dissipation and to accommodate concrete
encasement.

3. Concrete Encasement (if applicable)

• Pour concrete around the conduits to form the duct bank. Ensure complete coverage and adequate strength for
mechanical protection.

4. Backfilling/ Compact backfill

5. Grounding and Bonding

6. Marking and Documentation

Aramco Standards for Duct Banks

Aramco adheres to SAES-P-114 (Electrical Conduits and Fittings) Key standards include:

• Use of corrosion-resistant materials like PVC or HDPE in corrosive or harsh environments.

• Concrete encasement is mandatory in high-traffic or heavy-load areas.
• Compliance with NEC and IEC standards for conduit sizing, spacing, grounding, and bonding.
• Implementation of conduit spacing using approved spacer sizes to ensure proper heat dissipation and
mechanical protection.
• Use of warning tape or red-dyed concrete for high-voltage installations to prevent accidental damage during
future excavations.

Applications of Duct Banks

Application Details
Industrial Facilities Protects power and control cables in plants and refineries.
Commercial Buildings Routes electrical and communication lines underground.
Utility Installations Provides pathways for power distribution and communication cables.
Oil and Gas Facilities Ensures safe and reliable cable routing in hazardous environments.
Data Centers Organizes and protects high-capacity power and data cables.

Summary of Duct Bank Design and Installation

Aspect Details
Conduit Material PVC, HDPE, RMC, or IMC based on application.
Conduit Size and Number Determined by cable size, fill capacity, and future expansion.
Spacing and Arrangement Maintain proper spacing for heat dissipation and concrete encasement.
Depth and Trench Dimensions Follow NEC and local code requirements for burial depth.
Grounding and Bonding Ensure proper grounding for metallic conduits.
Marking and Identification Use warning tape or red dye, and label conduits for easy identification.