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INTRODUCTION:
It is the branch of engineering which deals with the measurement, monitoring, display etc. of the several of
energy exchanges which take place during process operations. "In short Instrumentation is the study of
Instrument."
INSTRUMENT:
Instrument is a device which is used to measure, monitor, display etc. of a process variable.
SOME ABBREVIATIONS:
QCP Quality Control Plan
ITP Inspection Test Plan
TQ Technical Query
SAEP Saudi Aramco Engineering Procedure
SAES Saudi Aramco Engineering Standard
SAIC Saudi Aramco Inspection Checklist
SATIP Saudi Aramco Typical Inspection Plan
SATR Saudi Aramco Test Report
SASD Saudi Aramco Standard Drawing
Merajul Haque Siddique | QA/QC Notes 1
SAIP Saudi Aramco Inspection Personal
SAMSS Saudi Aramco Materials System Specification
SASO Saudi Arabian Standards Organization
NEC National Electrical Code
NACE National American Corrosion Engineers
SCADA Supervisory Control and Data Equation
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
ASME American Society of Mechanical Engineers
BS British Standards
IEEE Institute of Electrical and Electronic Engineers
ICEA Insulated Cable Engineers Associations
IEC International Electro Technical Commission
NEMA National Electrical Manufactures Associations
NFPA National Fire Protection Association
FM Factory Mutual
IP Ingress Protection
UL Underwriters Laboratories
ITC Instrument Tray Cable
PLTC Power Limited Tray Cable
PVC Polyvinyl Chloride
XLPE Cross Linked Polyethylene
XLPO Cross Linked Polyolefin
HDP Sigh Density Polyethylene
RTD Resistance Temperature Detector
SWA Still Wire Armored
MICC Mineral Insulation Copper Conductor
PILC Paper Insulation Copper Conductor
FOC Fiber Optical Cable
OTDR Optical Time Domain Refrectoneter
Group 5: Thermocouple Extension wire conductor – solid thermocouple extension wire as per ANSI MC 96.1
Conductor Size: 16AWG for singal pair, 18 AWG for multipair.
Color Code: ANSI MC 96.1(Temperature Measurement Thermocouple), (Yellow and Red) Negative shall be
Red color and magnetic
Lugs: Drawing / Color Codes / Ferruling will be done for easy identification with use of lugs. Lugs are two
types. One is crimping type and the other one is soldering type.
Type of Lugs: (1) Shanap Type (2) Pin Type (3) Ring Type (4) U Type
Gland Size: ½” ¾” 1”1½” 2”
Thread Type: ET (Equal Thread), BSP (British Standard Pitch), NPT (National Pipe Pitch).
COLOR CODE:
AC Supply: Phase Black
Neutral White
Ground Green or Green with yellow tracer
TYPE OF THERMOCOUPLE:
o
T Type Thermocouple Copper + Constant -185 ~ 371 C Blue - Red
J Type Thermocouple Iron + Constant -190 ~ 750 oC White - Red
K Type Thermocouple Cromel + Alumel -190 ~ 1250 oC Yellow - Red
E Type Thermocouple Chromel + Constantan -196 ~ 982 oC Purple - Red
S Type Thermocouple Platinum/Rhodium-Platinum -18.0 ~ 1760 oC Black - Red
R Type Thermocouple Pt87/Rh13 + Platinum -17.7 ~ 1704 oC Black - Red
Design and installation of power and wiring system for instrument shall be in accordance with NFPA 70
and NEC.
Fireproofing of cable in fire hazardous area shall be in accordance with SAES-B-006.
Shielded cables shall be used as required to reduce Electrostatic noise. The shield shall be grounded at
one point only.
Cable Shield: Prevent Electromagnetic Electrostatic Interference from being endued into the inner wire
conductor.
Field Bus Cable shall Comply with IEC 61158-2 (Type A)
Pulling tension of FOC = 600 Pounds.
Merajul Haque Siddique | QA/QC Notes 3
Fir Resisting: (CI: Circuit Integrity), Flame Retardant.
For transmission of analog or digital signal to instrument and control systems.
Insulation: Silicon Rubber
Armor: Zinc Coated round steel.
RE: Instrument Cable
2G: Insulation of Silicon
SI: Collective Screen
H: Inner Jacket of LSZH
SWA: Round Steel wire armor
I/W: Outer Jacket of heat resistant PVC
FL: Reduced flame propagation
CI: Circuit Integrity
FB: Field Bus Cable
Y: Outer sheath of PVC
2X: Insulation of XLPE
PIMF: Pair Screen
Cable Bending Radius = 10 x Cable ϕ
HVAC: Heating Ventilation & Air Conditioning.
ISDN: Integrated Service Digital Network
LASER: Light Amplification by stimulated.
Primary cable installation 350mm we can keep it open with instrument side otherwise have to provide
conduit or tray.
Cable Insulation thickness .38 mm PLTC/ITC
TC Cable thickness = 0.64mm
Light blue color coding shall be used to identify intrinsically safe wiring the preferred practice is to specify
intrinsically safe interconnecting cable with blue outer jacket. Alternative blue sleeves slipped over the
jacket.
At all the points of termination may used to identify I.S. wiring.
If used for connections of equipment to ground rods or ground grid be min 25 mm2 (#4AWG)
Intrinsically safe system shall only be used in zone 0 hazardous area.
SIZING OF CABLE:
1mm2 18 AWG 1 mm2
1.5 mm2 16 AWG 1.5 mm2
2.5 mm2 14 AWG 25 mm2
4 mm2 12 AWG 35 mm2
6 mm2 10 AWG 50 mm2
10 mm2 8 AWG 70 mm2
16 mm2 5 AWG 120 mm2
Merajul Haque Siddique | QA/QC Notes 4
GROUNDING SYSTEM:
Ground rods 2.4M minimum length.
Cathode protection material is used galvanized steel.
Individual Ground rod maximum resistance should be 2.5 Ohm.
For copper or copper jacketed steel rods is a min of 16mm in diameter or 19mm in diameters.
Earth Tester is used for measuring of earthling system.
Underground wire to wire connections shall be Caldwell or thermoweld. Compression connector shall
not be used.
Shields and amour of power cables shall be grounded at both ends.
If used for connections of equipment to ground rods or ground grid be min 25 mm2 (#4AWG)
Metallic cable trays shall be bonded at both end points and a min of every 25m to the local ground
grid.
If buried and used for grids and or interconnections of ground rods be min 70mm2 (2/0AWG)
Be copper or copper jacketed steel or galvanized steel copper jacketed steel shall meet the
requirements of UL 476 (Underwriters Laboratories).
Power Applications: Metal cable trays must be grounded and eclectically continuous systems per
NEC article 318.
Non-Power Applications: Cable tray systems containing conductors outside the scope of NEC
Article 250 (such as communications, data, signal cables, etc.)
TRAY INSTALLATION:
Tray to Tray:
Level 1 to Level 2 gap should be 150mm
Level 2 to Level 3 gaps should be 500mm
Level 1 to Level 3 gaps should be 650mm
Tray to Conduits:
Level 1 to Level 2 gap should be 100mm
Level 2 to Level 3 gap should be 350mm
Level 1 to level 3 gaps should be 450mm
Conduit to Conduit:
Level 1 to Level 2 gap should be 75mm
Level 2 to Level 3 gap should be 225mm
Level 1 to level 3 gap should be 300mm
DUCT BANKS:
Consist of either hot dip galvanized rigid steel or PVC conduit, incase in concrete.
75 mm of concrete from the outside surface of the duck bank to any conduit or reinforcing steel.
Fabricated spacers shall be used at intewals not exceeding 2.4m.
The spacers shall provide a min conduit separation of 50 mm for 2 inch conduit.
For equipment, devices, or appropriates certified as intrinsically safe, only those that are certified are
category EEX or AEX “ia” shall be used.
All metal cable trays, enclosures used for intrinsically safe wiring shall be grounded to the plant
grounding system with a min of # 4AWG copper wire with green insulation.
CONDUIT INSTALLATION:
Conduit fittings and accessories include conduits and pull boxes:
Conduit cover and gaskets
Conduit Seal
Conduit Unions and Couplings
Factory Elbows
Drain
Breathers
Plugs
Conduit Connectors reducers
Expansion fittings
Straps and Clamps
Bushing
Cable and duct seal, etc.
Seals are provided in conduit & cable system to minimize the passage of gases and vapors and
prevent the passage of flame from one portion the electrical installation the conduit.
Bushings: where a conduit enters a box, fittings or other enclosure a bushing shall be provided to
protect the wire from abrasion.
BENDS:
Number in one run: There shall not be more than the equivalent of four quarter bends (360 degree total)
between pull point to point.
Mandrel Testing: Testing of underground duct bank and bend radius of conduit is 90 deg.
When union cannot be avoided in underground conduit installation, unions shall be protected with heat
shrinkable sleeves.
Conduit and cable sealing shall be installed in accordance with NEC-5050.10.
Conduit seals shall be installed within 450mm (18 inches) from the enclosure.
PB: Pull Box
RGS: Rigid Galvanized Steel.
Split Conduits: Split conduit Installation shall be used to repair existing conduits which contains existing
cable these conduits shall be installed in accordance with the manufacturer’s recommendations or NEMA
TCB2 User manual for the installation of order ground plastic conduits.
We can use maximum bend in one conduit (Point to Point) 360 degree, but we have to avoid 90
degree bend or sharp bends.
Merajul Haque Siddique | QA/QC Notes 7
If there is sharp bend so we can perform Mineral Test.
Direct buried conduits (Underground) shall be threaded, rigid steel per accordance ANSI C80.1 and
addition it shall be hot dip galvanized and PVC coated as per NEMA RN1 (min thickness of PVC 40
mils) or PVC conduit type DB-120 (Minimum elasticity 500-000 PSI) as per NEMA TC6 & TC8 type.
Concrete incase conduit shall be threaded, rigid steel as per ANSI C80.1 and in addition it shall be
hot dip galvanized.
Conduit Installed exposed (not embedded in walls) above grounding in outdoor industrial facilities
shall be threaded rigid steel per ANSI C80.1 and in addition it shall be sot dip galvanized.
Conduit above ground in severe corrosive environments shall be as threaded, rigid steel as per ANSI
C80.1, in addition shall be factory PVC Coated (min thickness of 40 PVC mils) as per NEMA RN-1.
Electrical Metallic Tubing (EMT) is acceptable only in non-hazardous indoor locations. EMT shall
comply with the requirement of ANSI C80.3
Intermediate metal conduit (IMC) is prohibited.
The Min conduit size shall be ¾ inch, except for instrumentation wiring inside building.
Conduit and threaded conduit fitting shall have tapered (NPT) threads in accordance with
ANSI/ASME B1.20.1
System Voltage Direct Buried Cable Direct Buried Duct Bank & Direct Buried Rigid Steel
600V & Below 610 460 460
600V to 35 KV 920 610 460
Over 35 KV 1070 760 460
ENCLOSURES:
Indoors and Outdoors Plant Area:
Indoors: With in the Perimeter of the Process Unit (NEMA 250 / NEMA ICS6)
Outdoor: Out side the Perimeter of Process Area (IP54)
Severe Corrosive Environment (Industrial Area) NEMA Type 4X or IP66.
Non Industrial Area IP34.
Name Plate Shall is attached to the cabinets using stainless screws.
INSTRUMENTATION QUESTION AND ANSWER
1. What is QA/QC?
Ans: QA/QC means, “Quality Assurance / Quality Control” The purpose of this (QA/QC) is to
establish the sequence of requirement for the quality of material, quality of works, its inspection, and
records.
5. What is non-conformity?
Ans: Non-conformity “Non-fulfillment of requirement”. (Complete failure of a system, or controls,
which result in completely unsatisfactory goods or services being provided).
Class II: Location in which the presence of combustible dust are in the air in sufficient quantity to
ignite or explode.
Class II conductive/non conductive dust is divided into three below.
Group E: Presence of metal dusts (aluminum, magnesium and chemical dust etc)
Group F: Presence of black carbon, charcoal, coal or coke dust etc.
Group G: presence of non-conductive dust (foam, starch, combustible plastics etc.)
Class III: Location in which easily ignitable fiber / flying are present but are not likely to be in
suspension in air in quantities sufficient to produce ignitable mixture.
Division – 1: The hazards are present continuously or periodically under normal operation condition.
Division – 2: The Hazards are only presents during accidental or abnormal condition.
26. What is Microprocessor control system? Give a brief of PLC, DCS and SCADA?
Ans: Computer based control process system is called microprocessor control system. The brief of
PLC, DCS and SCADA are as following:
Merajul Haque Siddique | QA/QC Notes 11
PLC: Programmable Logic Control System.
PLC’s are used in practice with the aim of achieving a higher degree of availability or fault tolerance.
The types are as follow.
Fault Tolerant: 1 out of 2 system objective: reduce the probability of losses of production by
switching to a standby system.
Fail Safe: 2 out of 2 system objective: protect life, the environment and investment by safely
disconnecting to a secure “off” position.
DCS: Distribute Control System.
SCADA: Supervisory Control and Data Acquisition.
28. What are inspection points for field instruments with impulse tubing?
Ans: Materials inspection as per approved spec material, type and size, Installation as per Hook-up,
check line route to avoid any obstruction, check tube bending, and check tube support, compression
fitting or ferrules, and then pressure test (hydrostatic test) shall be done.
30. What are inspection points for Junction Box and Marshalling cabinets?
Ans: Material Inspection, type, size as per approved specification, installation hook up for frame,
bracket or stands, fixed properly means shaking free, Name Plate, and tag no.
31. What are standards methods or ferrules addressing to and from a Junction Box?
Ans: For to side only terminal’s address required which shall be close to terminal either side and
complete information shall be of from side after or before as per left and right side.
46. What are the requirements for carrying out installation inspection of any instruments and receiving
inspection of the said equipment?
Ans: Following are the requirements at the time of execution of an inspection.
a. Instrument data sheet.
b. Test Instrument Certificate.
c. Vendor instruction manual.
d. Test Instrument instruction manual.
49. What is Schedule ‘Q’and how many appendices are there in schedule ‘Q’?
Ans: Schedule ‘Q’ is the guidelines for the method application related to quality including the
distribution of manpower (quality field oriented) and the quality process execution including quality
control and quality assurance.
It has got six appendices covering all the process implementations related to execution of project
performance with the focus towards maintainability of quality control and quality assurance.
50. What are the linked documentations carried out related to QC activity for oil & gas construction
project?
Ans: a. Application for inspection from construction department after completion of every activity.
b. Production of drawing based on the planning.
c. Method application priority wise.
d. Procurement of item and equipments required for the execution of the project.
54. What do you know about NEC, NEMA VE 1, NEMA VE 2, NEMA RN?
55. What are the articles refereed during carrying out the following activities?
(1) Grounding. (2) Installation of cable Tray. (3) Fire alarm System Installation. (4) Installation
Instrument Cable Tray etc,
Ans: (1) Grounding Article 250 (Chapter IX for instrumentation), (2) Installation of cable tray Article
392, (3) Fire Alarm System Art 760, Installation of instrument cable tray art 727.
57. What would be the thickness of the top layer of a Duct Bank and color?
Ans: 5mm and Red Dye.
59. What are types of conduits used in electrical and instrumentation wiring circuits?
Ans: Rigid Metallic Conduit (RMC), Intermediate Metallic Conduit (IMC), Rigid Nonmetallic Conduit
(RNC).
60. What are the differences between a JB (Junction Box) and Terminal Box?
Ans: The purpose of JB (Junction Box) is used as a linkage between one or more inlet and one or
more outlet. Whether terminal box has inlet on or more but out let may be one for earthen or it may
not be. JB can be used in between the routing for providing support and extra opening but TB is used
as Termination means at the end of the routing.
67. How are the hazardous and non hazardous areas classified?
Ans: Hazardous and non hazardous areas are classified according to the classifications and zones.
68. What is the Expansion joint? What should be the standard gap maintained in expansion joint?
Ans: It I the breathing space provided to accommodate the expansion of horizontal cable tray to suit
with different climatic condition by maintaining a standard length wise distribution.
According to NEMA VE 2 it is after every 20 M with a spacing (expansion joint) of 25mm to be
maintained. It sometimes differs, but should not be more for the horizontal length of the cable try.
73. What is the minimum thickness of concrete from outside surface of the duct bank to any conduit or
reinforcing steel?
Ans: 75mm
74. What is mean by Guwat and Guwa, where it is applicable for use?
Ans: You can use in conduit installation for lighting purpose.
Guwat: With terminal block.
Guwa: Withought Terminal block.
75. How the Metallic and PVC conduit entering from below of any equipment like switchgear control
cabinets and similar enclosures sitting?
Ans: The metallic conduit shall be cut and threaded 50mm above finished grade level and a threaded
insulated grounding bushing shall installed, also PVC conduit shall be cut flush with finished grade
level and shall have its inner edge filed to a smooth radius.
76. What type of sealing is used for all ducts inside all manholes and hands holes where permitted inside
hydrocarbon handling plants?
Ans: All ducts shall be sealed with 3M scotch cast brand 4416 cable duct sealing kits or other
methods approved by the electrical standards committee chairman.
78. What should be done, when union cannot be avoided in underground conduit installation?
81. What is the minimum conduit size excepted for instrumentation wiring inside building?
Ans: ¾ Inch.
82. What is the minimum conduit size excepted for prefabricated skids and in-industrial area?
Ans: ½ Inch.
84. What are the conduit fittings for outdoor rigid steel conduit and liquid tight flexible metal (LFMC)?
Ans: Shall be cast or forged steel, cast iron or malleable iron either hot-dip galvanized (preferably)
electroplated.
90. What shall be minimum acceptable insulation resistance of instrument cable during megger test?
Ans: 100 Mega ohms
92. What shall be the maximum acceptable attention value of fiber during OTDR test?
Ans: 0.5Db/Km or less for wave length of 1310 nm and 0.3Db/Km or less .for wave length of
1550nm.
93. What shall be the maximum pulling tension of FOC?
Ans: 600 Pounds.
94. What is the meaning AWG?
Ans: American Wire Gage