3.

4 ELECTRICAL
WORKS
 DETAILED ENGINEERING
ELECTRICAL CONSUMERS / LOAD

¾ MOTORS FOR PUMPS, COMPRESSORS, FANS ETC.

¾ ELECTRICAL HEATERS, TRACE HEATERS
¾ ELECTROSTATIC EQUIPMENT
¾ AIR-CONDITIONING SYSTEMS
¾ LIGHTING
¾ CONTROL SYSTEMS PANELS
¾ TELECOM EQUIPMENT
¾ POWER SOCKETS

2
 DETAILED ENGINEERING
POWER SUPPLY TYPES & RELIABILITY

¾ MAIN SOURCE (GRID or GTG)

¾ EMERGENCY DIESEL GENERATORS

¾ UNINTERRUPTED POWER SUPPLY (UPS)

¾ SOLAR POWER SOURCE

3
 DETAILED ENGINEERING
LOAD POWER RATING & VOLTAGES

¾ MOTORS < 180 W, 230 Volts, 1-PH

¾ MOTORS < 160kW, 400 Volts, 3-PH

¾ MOTORS > 160kW, 3.3kV or 6.6kV

4
 DETAILED ENGINEERING
MAJOR ELECTRICAL EQUIPMENT

Generators Soft starters

Motors Variable Speed Drives
HV Switchgear AC UPS+ Batteries
LV Switchgear DC UPS+ Batteries
Distribution Boards Remote Control Units
Transformers Elect Heat Tracing
Cables CP material
Busducts Lighting / Earthing

5
 DETAILED ENGINEERING
DESIGN DOCUMENTS

6 ELECTRICAL EQUIPMENT LAYOUTS

6 CABLE LAYOUTS

6 LIGHTING LAYOUTS

6 EARTHING LAYOUTS

6 CABLE LISTS / SCHEDULES

6 BOQ / MTO
6
 Inputs from Electrical to other Disciplines
mainly Civil

6 Sub-station building dimensions, Floor cut outs

6 Transformer dimensions and weight for foundations and walls

around transformers

6 Cable trench type, routing and dimensions

6 Overhead cable tray layout and loading

6 Outdoor lighting layout for pole foundations

6 Any other outdoor electrical equipment foundations or

excavations, where required.
Deliverables & Activities of Electrical Department
(Contd…)
¾ Specifications / Datasheets / Requisitions
¾ Indoor substation layout drawing
¾ Outdoor switch yard layout drawing (if required)
¾ Cable Layouts
¾ Lighting & Earthing Layouts
¾ Cable & Interconnection schedules
¾ Electric Heat Tracing Drawings
¾ Vendor Drawing Reviews
¾ Inspection at Vendors works
¾ Field Co-ordination
2.4 Electrical Installation Works
Electrical Installation work in any project is classified under
following categories.
¾ Preparation for Electrical Construction Works

¾ Installation of cable trays & Cable laying

¾ Installation of Transformers, Switchgear, MCC and DB

¾ Installation of Generator Set

¾ Installation of Earthing & lightning protection

¾ Installation of Lighting System

I- Preparation for Electrical Construction works:
Preparations and execution planning is very important aspect and
comprises of the following.

¾ Review and Study of drawings and specifications

First step for reviewing the drawing is to go through the Technical document
register and filter for electrical drawings. This gives the detailed list of the drawing
for electrical works. The most frequently used drawing for electrical constructions
are:
ƒ Single Line diagram
ƒ Cable schedule
ƒ Drum schedule
ƒ Lighting fixture schedule
ƒ JB schedule
ƒ Electrical cable routing and layout drawings
ƒ Earthing layout drawing
ƒ Lighting layout drawing
ƒ Interconnection schedule
ƒ Installation drawings
Besides the above we need to study the following drawing
of the other discipline for proper understanding of the
project and properly coordinate the work

• Equipment list
• PI&D
• Control Narrative & philosophy

After the familiarization a careful study is to be made to ensure that

there is no discrepancy between the various drawings. If any
discrepancy is found it has to be informed to the field engineering /
engineering team, through Construction Manager on site
¾If protection against dust ingression is needed, suitable
coverage shall be provided to the equipment.

¾Check adequacy of availability of all vendor /documents and test

certificates issued by company. Shortfalls and discrepancies in
vendor documents shall be notified and further documentation will
be requested.

¾Check if all materials required for proper installation and

assembly of the equipment are received in good conditions. Any
discrepancy shall be reported, recorded and followed up properly to
make good of the deficiency.

¾Ensure that Operation, Installation and Maintenance Manual of

the equipment is available.
¾Check availability of all required base frames / mounting frames
are supplied by the vendor.

¾Due care shell be taken, while unpacking & identification of all

materials, relays, loosely packed items and other delicate materials.

¾ The batteries shall be stored properly as per the instruction

manual to avoid short circuit of battery terminals.
2. Method statement

Detailed method statement shall be prepared for various activities of

the electrical work and company approval shall be obtained

3. Review of ITP

ITP shall be reviewed the various hold and witness point shall be
noted and taken care accordingly.

4. Electrical bulk items review

Coordinate with sub contractor and estimate the quantity of various

bulk items required and check if the required quantity has been
ordered or not. If there are shortages appropriate action shall be
initiated.
II- Installation of cable trays & Cable laying
Ensure the required cable trays and cable drums are received at site.
Coordinate with the subcontractor and identify the sequence in
which cable drums are required and check at the site if safe
withdrawal in that sequence is possible or else coordinate with
material controller for possible rearrangement.
1.Installation of cable trays, Racks and Conduit
¾ The routes of the cable tray installed is checked with the drawing
and confirmed that the routes are as per the drawing.
¾ Supports for site routed cable trays or racks shall be provided in
accordance with the contract documents or the manufacturer’s
recommended loading and span distances.
¾ Every effort shall be made to keep all cable runs in accessible
positions. The minimum height of cable supports crossings walkways
or other minor access ways shall be 2.2m.
¾ Cable trays/racks shall be bolted to supports. Welding of
trays/racks to supports or structural steel shall
not be permitted.

¾ Electrical continuity shall be maintained at joints between sections

of metallic cable tray/rack and all continuous runs shall be bonded
to the main structure at one end as a minimum or as detailed on the
contract drawings.

¾ Cable tray/racks shall only be cut along a line of un perforated

material. After cutting, all sharp edges shall be made smooth and the
finish made good as detailed in the Supplier’s instructions.

¾ Supports for horizontal cable tray/racks shall be spaced in

accordance with the contract drawings. The maximum spacing shall
not exceed 3 meters.

¾ Support brackets for cable tray/racks shall be fabricated and

painted in accordance with the standard installations drawings.
¾ Cable tray and rack sections shall be labeled in accordance
with the contract drawings.

¾ The cables are installed in trays or ladder in smooth parallel

formation and twist, crossing and inter winding of cables are
avoided.

¾ The cables are installed with different voltages or services are run
in separate trays or ladder or separated by metallic barriers when
installed in the same tray.

¾ The cables are strapped / cleated / clipped / tied by non-corrosive

material at regular intervals and also tied at each bend or change in
direction.

¾ Cables 40 mm diameter and above shall be cleated individually

but the smaller diameter cables may be clamped together.
2. Pre-Installation Test for cable

¾Cables shall be tested on cable drums prior to removal to the work

site.

¾Low voltage cables rated up to and including 1KV shall be tested

for insulation resistance using 500 Volt insulation resistance testers.
The insulation resistance between cores, and between individual
cores armoring as applicable shall be checked.

¾The continuity of each core of the cable shall be checked.

¾The test readings are recorded in the format with proper details of
the cable drums and size

¾After completion of the tests the ends of the cable shall be sealed to
prevent ingress of moisture.
3. Cable Pulling
¾Prior to laying cables in trenches, the dimensions of the trenches
shall be checked against the drawings.
¾Cable drums shall be lifted by fork lift or such other lifting
equipment to the yard near the main LV switch board skid and
placed in convenient location to cut and lay the cable from the
switchboard
¾The entire process of the cable installation is done manually or by
winch.
¾All the cable routes shall be accurately measured prior to cutting
any cable and the routes shown in the layout drawing are to be
strictly adhered.
¾All the cabling arrangement either on racks or under ground is to
be strictly as per the layout drawings.
¾Each cable is run as continuous length from the origin to
destination without joint, except as specified in the drawings
¾Cable shall run straight out of the gland for a minimum of 150 mm
before being bent to terminate.
¾Where the cable ends are pending termination the cable is to be
coiled individually and strapped together firmly using adhesive tape
or twins and armoring wire is not be used for this purpose. The coils
are to be arranged in sequence for ease of accessibility for
installation.
¾All the installed cable ends, which are pending termination, are to
be sealed to prevent ingress of moisture.
¾The cable shall be pulled manually and if pulled by winches it is to
be ensured that the maximum pulling force is less than the
manufacturer’s permissible pulling tension values.
¾Individual cable lengths shall be taken from its designated drum.
The record shall be maintained as already reckoned to indicate the
balance in the drum after cutting each length.
4. Cable Installation Under Ground

¾Where the cables are laid direct in the ground the bottom of the
trench is to be cleared of all the rocks, stones and sharp object and
covered with a 75/100 mm lightly compacted layer of sifted soil or
clean sand. After laying the cables is to be covered with a further
layer of lightly compacted sifted soil or sand to a depth of 75 mm.
The cable protection tiles are then placed above the sand and back
filled.

¾The depth of the cables nearest the surface shall be 600 mm for
low voltage cables.

¾Where the cables surface they are to be provided with mechanical

protection by suitably installed sleeves, which is to be extended
150mm above the ground level. These ducts are to be sealed around
the cable with suitable sealant.
¾The cable shall be provided with cable marker along the full length
of the trench at suitable intervals.

¾The cables are taken in single, multi layer as indicated in the

drawing and the single core cables are laid in trefoil arrangement.

¾The cable are laid in the routes as in the layout drawing

5. Cable and Core Identification

¾ Each cable is to be individually and uniquely identified as

designated in the cable schedule by identification markers along the
full length of the cable and at the point of origin and termination.

¾ Cable not listed in the cable schedule is marked using the sub
circuit reference.

¾ Multi core cables are not provided with phase identification as

they are already colour-coded.

¾ The single core cables are to be provided with phase identification

by appropriate colour tape.
6. Cable Termination

¾Cables are terminated with cable glands which are suitable for
receiving all the cores of the cable and are to be securely clamped to
the cable in a permanent manner. The glands for armored cable are
inner and outer seals and armour clamps.

¾Wherever the cable enters into an enclosure, which is untapped for

fixing gland then it has to be fixed to the enclosure by a heavy duty
plated brass nut with a sealing washer. A plated earth tag to be fitted
if there is no electrical continuity between the enclosure and gland.
In such case the earth tag is to be bonded to an earth terminal
located with in the enclosure.
III- Installation of Transformers, Switchgear,
MCC and DB
The drawing indicating the location of equipment shall be identified
and checked with respect to site orientation. Discrepancies found if
any shall be notified to company and suitable corrective action shall
be taken.

1. Site Preparation
¾ Verify site access and check area / building where the panels /
distribution boards will be installed, in pre-construction survey.

¾ Obtain work permit as required.

¾ The suitability of cut outs for cable entry as per drawing shall be
checked.
¾The suitable size of screw anchor for grouting of LV switchboards,
MCC’s and distribution boards shall be checked.

¾Ensure that proper materials such as shipping section bolt and

nuts, panel bus bar and fix plates, for the same are available and are
suitable for use.

¾Marking of the four-corner of the complete panels shall be done to

avoid any interference with beams / structure.

¾The water level of foundation of switchboards and distribution

boards shall be checked and the area shall be cleaned.
2. Installation and Alignment

¾The QA/QC Civil Inspector shall check the readiness of

building, foundation / cut outs, and structural work before handing
over and QA/QC Electrical shall check with respect to the above
mentioned drawings mentioned in bullet no 3(four) of site
preparation.
¾The base frames of the panel shall be leveled / fixed by means of
anchoring.
¾The switchboards shall be shifted from store yard to site by Crane
/ Forklift and trailer as per the lifting plan.
¾The crane to be used for lifting and shifting of switchboards /
distribution boards, etc., shall have project certification.
¾Panel shall be lifted by using lifting hooks / eye bolts provided at
the four corners of the shipping section.
¾The panels shall be carefully shifted by putting pipe rollers
and due care shall be taken while shifting to avoid damages
to enclosure and other accessories inside the panels.
¾Placing of the shipping sections or panel at the right locations as
per Equipment layout / vendor drawing.
¾The first section of the panel as mentioned in the GA drawing shall
be placed to the left.
¾The second section is to be placed to the first and shipping sections
shall be bolted using the hardware supplied by the vendor. The same
procedure is to be followed for the other sections also.
¾The main bus bars, distribution bus bars and the neutral bus bars
are to be coupled after the alignment of the panel.
¾After placing all shipping sections assembling of the panels
shall be carried out to avoid mechanical stress on bus bars.
¾Proper thickness of shims shall be provided between the panel to
proper coupling of panel sections if required.
¾Correct size of fasteners shall be used for coupling of shipping
sections of panels and also proper care shall be taken to avoid
damage to gaskets, while jointing the sections.
¾Bus bars of correct sizes shall be used for phase and neutral and
earth.
¾Holes on fishplate for coupling bus bar, if required shall be
marked and drilled as per actual measurement taken from the
panels erected.
¾All the loose components like relays, meters etc. supplied along
with panels shall be placed at the appropriate cut outs.
¾Inter-panel wiring shall be done as per the scheme
drawings provided by the vendor.

¾All mechanical checks like rack in / rack out of breakers, fixing

earthing trucks and interchangeable of same rating of
breakers/feeders shall be carried out after installation is completed.

¾Insulation mats, danger boards, of suitable voltage grade shall be

provided.

¾Panels shall be thoroughly cleaned by vacuum cleaner and box up.

¾The continuity test and IR value test of main feeder cable shall be
tested as per the testing procedure of cables in full compliances with
Inspection Test Plan.

¾The Marshalling box panel shall be installed. The connections in

marshalling box shall be carried out as per the connection diagram
for interface between electrical and instrumentation system.
IV- Installation of Generator sets
The vendor GA drawing for Generator is to be studied and
checked with respect to site orientation Discrepancies found if any
shall be notified to construction manager and suitable corrective
action shall be taken. The site readiness for shifting the generator
shall be checked for the following.
¾Proper access for the crane is to be checked

¾The area to be back filled and leveled for crane movement.

¾The QA/QC Civil Inspector shall check the foundation of the generator with
reference to the drawing

¾The water level of the foundation shall be checked.

¾The centre line of the foundation shall be marked and to be matched with that of
the generator set.

¾The Generator shall be unloaded on to the foundation

1. Installation and alignment
¾The base rail of Generator Set should be leveled using shims
before grouting with foundation bolts. Care should be taken so that
the shims are placed on both sides of foundation bolts.

¾A detailed lifting plan will be made before installation of the

generator set.

¾Fuel tank installation and inter connecting piping work shall be

carried out by mechanical department as per vendor drawings and
there will be no welding work on piping and all connections are
made by flange couplings.

¾All support work required for fixing exhaust silencer shall be

carried out as per drawings, specifications and methodology for
structural steel.
¾Air inlet, outlet, duct and exhaust silencer shall be installed
on the container.

¾After installation of table cooler besides the container the cooling

pipes between the container and the table cooler.

¾The cooling tank is to be filled with antifreeze liquid.

¾The silencer shall be placed on the supports and opening provided

for the same will be suitably packed with insulating materials, if
required.

¾Battery & battery charger shall be installed at the designated place

and all connections made as per approved drawings.
¾The interconnecting cabling and terminations between
alternator and engine control panel shall be done in
compliance with vendor drawing

¾The generator shall be earthed at two distinct points through a

conductor as per earthing drawings and specifications.

¾After completion of all Generator Set related works, the area shall
be cleaned

¾The installation and alignment of DG set shall be carried out with

reference to the layout plan
V- Installation of Earthing & lightning protection

The areas where Earthing Cables, Lightning conductor and earthing

electrodes are to be laid /buried shall be identified by the Electrical
engineer / Site Supervisor. The Site Supervisor shall identify the
earth electrodes, earthing cables, and lightning conductors as per the
overall earthing and lightning layout plan. After the identification,
the excavation work shall be carried out by Civil as per the Method
Statement The area where cables are to be laid shall be properly
graded, leveled and cleaned The QA/QC Civil Inspector will check
the excavated area as per the specification before handing over to
Electrical Department and the QA/QC Electrical Inspector will
check the same as per the acceptance criteria indicated in the ITP.
The earthing work inside the building can be started only after
obtaining the clearance from civil department.
1.Cable / Conductor Laying and Termination

¾The earthing system shall comprise of PVC Insulated cable as

main grid, to be laid underground /cable trench and earth electrodes
shall be buried as per specifications and drawings.

¾Lightning protection shall comprise of bare copper conductor

fixed to the buildings/structures and earth electrodes shall be buried
as per specifications and drawings.

¾The material of construction and number of earth electrodes shall

be in compliance with specifications & AFC Drawings.
¾Ensure that all necessary tools & certified tackles are made
available for lifting of the cable / conductor drum while transporting
the drum from the cable drum yard. Lifting and transporting the
cable drum either by forklift or by crane and transporting by trailer
can avoid damage to cable.

Cables are inspected by the QA/QC Inspector immediately on

receipt at site. If any damage is found during the site inspection,
action for total or partial replacement, as the case shall be initiated.
The damaged cable is quarantined in a lay down area allocated for
rejected and returned material.
¾Ensure that the necessary cable / conductor drums of
required length have reached site and proper arrangement
for storing of the same. The Site Supervisor shall prepare the drum-
cutting schedule for each and every cable drum as per the required
length indicated in the drawing before installation of cable. It is the
responsibility of Site Foreman to ensure that these cutting schedule
lengths are verified with actual measurement and are cut and
installed. In case of discrepancy is found between site measurement
and cutting schedule it will be informed to the supervisor who in
turn takes up with Field Engineering Department for solution.

¾Check the earthing cable routing and make sure that all the duct,
tray and conduit routing shall not present a trip hazard and shall
provide adequate headroom clearance over roads and access ways.
¾Ensure that proper clearances are available on building / structure
to fix the Lightning conductor. The roof conductors shall be clamped
to the cladding at maximum 1500mm interval and the down
conductor shall be clamped at 750mm interval.

¾The Site Supervisor decides cable / conductor drum cutting

schedule for optimum utilization and record.

¾Make arrangements for the proper tools such as cable jacks, shaft
for releasing the cable/conductor from the drum.

¾Location of earth electrodes shall be as per approved drawing and

as per actual site condition.
¾Electrodes shall be located avoiding interference with road,
building, foundations, columns, pipelines, etc. In case of any clash of
the earthing with pipelines, roads etc. It shall be notified to the
Supervisor and shifted to a suitable location in consultation with
Field Engineering personnel.

¾The depth of earth conductor laid shall be as per drawings &

specifications.

¾Civil works associated with earth electrode will comply with

specifications and drawings.

¾Termination of PVC insulated copper conductor / bare copper

conductor with earth electrode shall be done by proper lugging and
bolting.
¾All branches off earth connections from main earth grid
conductor shall be connected by means of Cad Welding,
as per specifications and drawings.
CAD welding shall be carried out as detailed below. Clean the
conductor with coarse file and position them in a clean and dry
mould. Lock the mould with handle clamp. Insert the steel disc into
the mould crucible; ensuring it is centre over the tap hole.
Pour the welding powder in to the crucible and spread the starting
powder on the top of welding powder evenly and also place small
amount of starting powder on the top edge of the mould for easy
ignition. Close the cover and ignite the starting powder with the flint
gun wait for few seconds and check the weld.
Gloves, safety goggles boots and helmet are the normal protection
required for this. Fire bucket or fire extinguisher is also to be
provided.
The exothermic welding material for CAD welding is to be stored in
a dry and secure place.
¾All metallic non-current carrying parts of all electrical
equipments, steel structures, storage tanks, vessels, columns
and other process equipments, cable shields and armor shall be
earthed.
¾The earth resistance of individual electrode shall be up to 6 ohm
and the grid earth resistance shall be less than 1 ohm. QA/QC
Engineer shall perform the testing of the earth resistance and
recorded as indicated in the ITP
¾Lightning protection shall be provided for equipments, structures
and buildings as per applicable codes and standards.

¾Ensure that the cables/conductor are properly cleated / clamped in

cable trays and angle droppers as per specifications & good
engineering practice.
¾Earthing Cables shall be properly glanded using suitable sizes of
cable glands at equipments as per drawings.
¾Appropriate sizes of lugs will be used for termination.

¾Earthing of all equipments, structures & junction boxes

shall be done properly.

¾Ensure that after laying of cable, the cable trenches are back filled
and trench covers are laid.

¾If any earthing cable is not terminated due to non-readiness of

equipment the ends of the cables will be sealed by means of cable
end caps to avoid entry of moisture. The Site Foreman shall be
responsible to verify this activity.

¾The sleeves provided for the cable/conductor entry to the building

shall be sealed with silicon sealing compound to avoid entry of
moisture. To perform this activity no special PPE is required. MSDS
will be submitted later.
VI- Installation of Lighting System

The areas and buildings where the lighting system is to be installed

will be identified in pre-construction survey. Identification of
Lighting Layout Drawing for External Areas, Internal Building and
Street Lights has to be carried out in pre construction survey. The
layout drawing indicating the external & internal areas to be
illuminated shall be identified and checked with respect to site
orientation. Discrepancies found if any shall be notified to Company
and suitable corrective action shall be taken.
1. Site Preparation
¾Verify site access and check area / building where the light fittings
will be installed.

¾Obtain work permit as required.

¾Ensure that proper materials such as profile channel, profile

mounted clamps, conduits, conduit fixing clamps, junction boxes;
junction box clamps are available and suitable for use as per
approved drawings.

¾The anchor bolt & templates shall be fixed as per the drawing

¾The lighting poles shall be installed as per the lighting layout

¾The PVC duct of 50mm diameter shall be installed for cable entry.
¾The Civil QA/QC Inspector shall check the readiness
of building in full compliance with the drawing and as per
the ITP for Structural Steel Erection before handing over.

¾Marking on wall for Profile channel shall be carried out as per the
lay out drawing.

¾Marking on ceiling for indoor lighting shall be carried out as per

the layout drawing.

¾The type of fittings to be installed shall be checked as per the area

classification.

¾The elevation of light fittings shall be checked as per the drawing.

2. Installation and Alignment

6The clamps / supports shall be fixed and leveled by means of

welding, anchoring, grouting.

6The light fittings are to be installed at the required elevation by

using scaffolding / manlift.

6The workman involved working at height shall use proper safety

harness.

6The lamps shall be fitted and operation shall be checked before

installation.

6Batteries of emergency fittings shall be checked before installation.

6The light fittings shall be fitted to the poles at the time of pole
installation.

6Correct size of fasteners shall be used for installation of light

fittings.

6Internal wiring shall be done as per the scheme drawing.

6All the fittings shall be thoroughly cleaned and boxed up.

3. Outdoor Lighting
¾Ensure that the excavation for ground poles is carried out
for the right depth.
¾Poles shall be located at the correct location as per coordinates and
drawing.
¾The distance between pole-to-pole shall be as per layout drawing.
¾Ensure that necessary tools and certified tackles are made
available for lifting of poles from the yard and a lifting plan is made
and shall be adhered.
¾The poles shall be lifted by crane and loaded to a trailer and
shifted to locations.
¾The elevation of foundation for the lighting poles shall be checked
by Civil QA/QC Inspector and installation can be performed in the
excavated /paved area / platforms as applicable.
¾Proper provision shall be made in the pole and Junction
Box for entry of cables.
¾Check the line and level of poles by using pendulum weight and
spirit level and ensure provision of pipe sleeves for loop in loop out
of cables before pouring concrete of correct ratio.
¾For platform / fence light poles, install the poles as per locations
mentioned in the drawings. Check the line and level of the poles by
using pendulum weight and spirit level and clamping of the poles
with U-bolts or welding of the poles as applicable as per drawing.
¾Fixing of all junction boxes, installation of light fixtures and laying
of flexible cable from JB to light fixture.
¾Laying of main cables from respective Distribution Boards to poles
and looping cables from pole to pole as per drawing.
¾Ensure proper earthing of poles and light fixtures as per drawing.
4. Indoor Lighting

6Care should be taken while transporting to avoid any damage to

the light fixtures, conduits and associated accessories.

6Profile hanger clamp adjustable type, perforated steel profile shall

be installed as per the drawing.

6The light fittings shall be installed at the required elevation by

using scaffolding or man lift.

6Ensure all conducting and wiring is completed as per drawing.

6Check model number and type of lighting fixture to be installed as
per layout and area classification drawings.

6Check installation level and alignment as per drawing.

6Ensure proper earthing of all lighting fixtures as per drawing.

6For details of cable laying, please refer to Method Statement for

Cable Pulling
INSTRUMENTATION
 Introduction

Instrumentation in process industries is essentially required for the

following purpose:
6 to monitor the process parameters and process equipment
operation;
6 to operate the plant; Man Machine Interface or operator stations
provide the platform to see and operate the plant from a central
location;
6 to automatically control the process parameters like pressure,
temperature, flow, level, quality etc. within the desired limits
required by the process design of the plant as defined in the
P&IDs and process data sheets;
6 to provide safety system that executes automatic and safe shut
down of the plant and raises alarm in case of process abnormality
or hazards like fire or gas break out; this protects equipment,
persons and environment;

6 to maintain a track or log of the plant operation history, predict

maintenance requirement, to provide data for management
information; this is asset management function;

6 to provide a platform for plant process /product/efficiency

enhancement by the way of simulation.
Scope of Instrumentation in Oil and Gas projects.
6 Oil and Gas plants may cover entire range of process control
instrumentation involving field devices like transmitters, gauges,
shutdown and control valves, pressure relieving devices,
analyzers, fire and gas detectors and devices, machine monitoring
system, plant control system for process (DCS), system for safety
shutdown(IPS or ESD system), safety system for fire and gas
events (F&G systems).
6 Due to remote oil fields, sometimes RTUs (Remote Terminal
Units) are used to gather data from the transmitters of the oil or
gas fields including the wells (well data). These RTUs process the
data and transmit them as (wireless) radio signals (telemetering)
or as optical signals through optical fibre cables as the oil or gas
fields are scattered far away from the main plant or the facility.
The data by the RTUs are finally received by a plant DCS or by a
SCADA. Usually the term SCADA (Supervision Control and
Data Acquisition) is used to explicitly define a system that is
meant principally for data acquisition for supervision purposes
and logging.
6 Data transmission by radio signals or telemetering requires the
involvement of telecommunication group. They do the survey and
path study of radio propagation to establish an interruption free
communication.

6 The oil and gas filed instrumentation usually includes a bit of

complicated devices as the oil and gas comes out of the well in
mixed condition along with water and at high pressure and
temperature. Multiphase flow-meters, high integrity shutdown
valves, high pressure reducing choke valves, hydraulic actuators,
well head control panels supplying high pressure hydraulic oils to
actuators, Surface and Subsurface safety valves in the wells are
some of the special items not frequently used in other process
plants.

6 Sometimes, extremely corrosive and toxic gases and corrosive oils

are available in the reservoirs. This requires elaborate safety
systems including toxic gas detectors and specially metallurgy to
be compatible with the corrosive process.
6 Usually the well head instrumentation is designed to work over a
time that sees the depletion of the wells. This means provisions
are made in the valve sizing, flow-meter design etc. so that with
no or minimum change it is possible to use the instruments which
initially see a healthy well with certain gas and oil ratio and then
sees the depleting wells with more gas and water and less oil.
Some times the IPF and Choke valves with other instruments are
deliberately assembled in skids so that they can be shifted from
an exhausted well to a producing well.

6 Instrumentation in gathering stations where oil and gas are

received typically consists of instrumentation of continuous
process plants. Such plant will have export or custody transfer
terminals which will have storage tank instrumentation and flow
metering systems.
Instrument Installation work in any project is
classified under following categories.

6 Preparation for Instrument Construction Works i.e. planning the

work, ensuring availability of resources and work front. This is
further explained later.
6 Off plot work, i.e. fabrication work (making instrument
stanchions, supports etc.) and calibration of instruments, testing
of valves etc.
6 Uncrating of instruments received at site, inspection of
instruments, materials received at site.
6 Installation of Junction boxes, cable trays.
6 Cable laying in trenches and trays.
6 Installation work inside Control room and other rooms

having Instrument cabinets, Operator consoles, servers etc.

6 Installation of other field instruments like transmitters, branch

cable laying to transmitters.

6 Installation of Fire and Gas detectors and devices (sounders,

beacons) etc. and the associated junction boxes, cables.

6 Installation of Shelters, cabinets in the field, like analyzer

shelters.

6 Co-ordination with piping group for the installation of inline

instruments like Control valves, Orifice plate assembly etc.,
installation of instrument air manifolds.
6 Installation of mechanical instruments like relief valves,

gauges, thermo-wells and corresponding coordination with

piping.

6 Installation of Instrument packages like flow-metering skids and

corresponding coordination with piping.

6 Instrument tubing work, impulse and pneumatic tubing.

6 Instrument tie in documents (for tie in to existing installations).

6 Modifications to be carried out at site for instrument installation

and system configuration.

6 Pressure testing, loop checking, participation in site acceptance

tests, pre-commissioning and commissioning.
Preparation for instrument construction work

Preparation and execution planning is a very important aspect and

essentially consists of the review of resource and review of work front

availability.
availability Resource means drawings, documents, manpower,
materials to be installed, construction equipment, tools, tackles.

Work front availability means readiness of a construction site where

the construction work has been planned to begin.

Review and study of drawings and specifications.

The construction specifications include the scope of work, approval

process, statutory rules, construction measurement process etc.
which are the basic guide lines.

The technical documents like method statements, drawings,

manuals, schedules specify the detail of the work to be carried out
for every type of work.

A list of such documents which one frequently comes across in a

construction work is listed below.

To begin the construction work a stock of drawing and document

availability to be checked and the documents/drawings which are
required at the beginning to start the work must be identified.
First step for reviewing the drawing is to go through the
Technical document register (TDR) for instrument drawings and
documents and Vendor document register (VDR) for specific
documents from the vendors. This gives the detailed list of the
drawings and documents for instrument work. The most frequently
used drawings and documents for instrument construction work
are:

¾ Specification for instrument construction

¾ Responsibility matrix showing how the scope of work is divided
among the subcontractors and the main contractor (Petrofac).
¾ Instrument index
¾ Instrument location and layout drawings
¾ Instrument Cable routing, Cable trench/tray layout drawings

¾ Cable schedule

¾ Cable Drum schedule

¾ Junction Box schedule

¾ Instrument earthing drawings, typical schemes.

¾ Typical installation and fabrication drawings (providing details

of supports, civil foundation etc. for instruments, Fire and Gas
items, trays, Junction boxes etc.).

¾ Control Room equipment layout drawings.

¾ Instrument hook up drawings (Impulse tubes and other hook

ups)
¾ Instrument wiring and termination details.
¾ Analyzer interface drawings, shelter drawings.
¾ Instrument loop wiring diagrams.
¾ Alarm and trip schedule.
¾ Instrument data sheets.
¾ Instrument bill of materials.
¾ Level sketches.
¾ General arrangement , terminal plans and wiring drawings of
cabinets, power distribution drawings by instrument vendor
¾ General arrangement drawings of inline instruments, valves.
¾ Instruction and Operation manuals of instrument vendors.

¾ Instrument drawings and documents of package plant suppliers.

¾ Site Acceptance Test (SAT) procedures.

¾ System architecture drawings (required for overview of the

Control and Safety systems).

¾ Control narratives, (Functional Logic Diagrams) FLDs, Cause

and Effect diagrams.

¾ Plant commissioning and operation manual

Besides the above we need to study the following drawings and

documents produced by other disciplines for proper understanding

of the project and properly coordinating the work.

¾ Safety rules and regulations.

¾ Equipment list

¾ P&IDs

¾ UPS and non UPS power distribution diagrams

¾ Earthing layouts in control rooms and field

¾ Package plant drawings and documents.
¾ Instrument package vendor drawings and documents
¾ Civil foundation drawings for Instrument Package items, Air
Volume tanks, Analyzer shelters etc.
¾ Piping isometrics for all inline instruments, thermo-wells.
¾ Electrical control circuit diagrams
¾ GA drawings of equipment indicating instrument mounting
nozzles.
After the familiarization a careful study is to be made to ensure that
there is no discrepancy between the various drawings. If any
discrepancy is found it has to be informed to the field engineering /
engineering team, through Construction Manager on site.
Besides the above the availability of test, calibration certificates,
results, FAT reports from the vendors to be checked. These
documents are required as a part of construction QA/QC and also
helps to trouble -shoot any problems during testing and calibration
at site.
Review of other resources.

¾ Ensure the availability of the manpower for a given work.

¾ Availability of calibration equipment if calibration to be carried

out. Calibration equipment must have valid certificates traceable
to calibration report of certifying authorities.

¾ Availability of utilities like power supply, air supply required for

calibration or for construction.

¾ Availability of materials to be installed. Check that instruments,

cabinets, hardware, construction spares are all received in good
conditions.
¾ Availability of materials required for construction like
consumables (welding rods, sealing compounds, Teflon tapes
etc.).
¾ Availability of construction equipment like a grinder, welding
machine, lifting equipment etc. and also personal safety
equipment.
¾ Availability of special tools, kits, software tools, dongles, backup
CDs etc.
¾ Any discrepancy shall be reported, recorded and followed up
properly to make good of the deficiency.
Site Survey, work front availability
The site where a construction job has been planned must be
surveyed before the work starts to ensure that the work can be
carried out and also that there is no safety issue.
It is necessary to see who are the other construction contractor
already working in the same area or going to work and that any
clash while working can be avoided by proper sequence of work.
Access to the construction site to be evaluated in term of the
installation material to be carried into and also construction
equipment to be brought in.
Arrangement for scaffolding if required, availability of construction
power etc. to be surveyed.
The area to be surveyed with layout drawings to identify if any
difference is observed from the drawing. Implication of any such
change to be reviewed before the start of work.
Work permits are required from the authority under certain
circumstances.
Work independent of site readiness.

While planning the work it must be considered that the calibration

and testing of instruments including valves can take place

irrespective of site readiness provided testing and calibration setup

is ready and instruments are available.

Materials received at site and storage.

¾ Due care shall be taken, while unpacking & identification of all

instruments, cabinets, loosely packed items and other delicate
materials.
¾ Check that all items are identified with correct tag plates,
markings, packing lists.
¾ Check that all the licenses, software back ups, dongles, as listed in
documents are received and securely stored with proper records.
¾ Some parts of instrument skids, big valves , Annubars, flow-
meters, cable glands etc. may be sent in semi knocked down
conditions. All knocked down parts should have identification
labels provided by supplier and shall be correctly identified at
site.
¾ Supports to be provided to the personnel responsible for

storing to avoid any mix up and to ensure correct and speedy

issue of items from the store. The ambient conditions of safe

storing is provided by the vendors in storage specifications and

same to be followed for storing under shade or in open yards.

Electronic items may require controlled environment storage.

¾ Some items like calibration gases have shelf life, i.e. such things

will not be fit for use if stored long. Shelf life of all such items to

be checked when received at site and to be reviewed with the

planned date of use of such items.

Method statement
Detailed method statement shall be prepared for various activities
of the instrumentation work and company approval shall be
obtained. These statements describe in detail how a specific work to
be carried out and the acceptance criteria of the work carried out.
Usually the method statements shall be available at site as
construction documents.

Review of ITP
ITP shall be reviewed the various hold and witness point shall be
noted and taken care accordingly.
There will be project approved forms available to enter the
inspection, test, calibration results and remarks.
Instrument bulk items and consumable review

Coordinate with sub contractor and estimate the quantity of various

bulk items required and check if the required quantity has been

ordered or not. If there are shortages appropriate action shall be

initiated.

Ensure that the installation contractor has arranged all the

consumable in his scope as per the approved make and specifications

and in accordance with the supply responsibility matrix.

Installation of cable trays, racks & Cable laying
Ensure the required cable trays and cable drums are received at
site. Coordinate with the subcontractor and identify the sequence in
which cable drums are required and check at the site if safe
withdrawal in that sequence is possible or else coordinate with
material controller for possible rearrangement.
6 The routes of the cable tray installed is checked with the drawing
and confirmed that the routes are as per the drawing. Also verify
that the destinations or the two end points of the cable at the site
are matching with the construction drawings.
6 Supports for site routed cable trays or racks shall be provided in
accordance with the contract documents or the manufacturer’s
recommended loading and span distances.
6 Ensure that the instruction manual of the cable vendor indicating
the installation and cable handling methods have been followed,
recommended bending radii are adhered. Also ensure that the
ambient temperature during cable laying is not beyond the limits
stipulated by the manufacturer.
6 Keep updated with the plan dates of closing cable trenches and
ensure that all cables are laid well in advance.
6 Cable trays/racks shall be bolted to supports. Welding of
trays/racks to supports or structural steel shall not be permitted.
6 Electrical continuity shall be maintained at joints between
sections of metallic cable tray/rack and all continuous runs shall
be bonded to the main structure at one end as a minimum or as
detailed on the contract drawings.
6 Cable tray/racks shall only be cut along a line of un perforated

material. After cutting, all sharp edges shall be made smooth and

the finish made good as detailed in the Supplier’s instructions.

6 Supports for horizontal cable tray/racks shall be spaced in

accordance with the contract drawings. The maximum spacing

shall not exceed 3 meters.

6 Support brackets for cable tray/racks shall be fabricated and

painted in accordance with the standard installations drawings.

Pre-Installation Test for cable
¾ Cables shall be tested on cable drums prior to removal to the
work site.
¾ Continuity and insulation testing of the cables shall be done as
per the approved method statements. Special care is required for
low voltage cables.
¾ Optical fibre cables are tested by specialists before and after
installation (after cable joint, after termination.
¾ The test readings are recorded in the format with proper details
of the cable drums and size.
¾ After completion of the tests the ends of the cable shall be sealed
to prevent ingress of moisture.
Cable Pulling

6 Cables shall be tested on cable drums prior to removal to the

work site.

6 Prior to laying cables in trenches, the dimensions of the trenches

shall be checked against the drawings.

6 Ensure that the ambient temperature variation does not go beyond

the limits specified by the cable vendor during the planned time
of laying.

6 Cable drums shall be lifted by fork lift or such other lifting

equipment to the installation location to cut and lay the cable.
The entire process of the cable installation is done manually or
by winch.

¾ All the cable routes shall be accurately measured prior to cutting

any cable and the routes shown in the layout drawing are to be
strictly adhered.
¾ All the cabling arrangement either on racks or under ground is to
be strictly as per the layout drawings.
¾ For site routed cables due care to be taken so that they are not
routed through fire prone areas or through high temperature
zones.
¾ Ensure that segregation of cables have been correctly maintained
with respect to physical distance and grouping.
¾ Ensure that tagging of all cables is done, all cable markers are in
place, dressing and clamping are as per the installation
standards.
Cable Installation Under Ground

¾ Where the cables are laid direct in the ground the bottom of the
trench is to be cleared of all the rocks, stones and sharp object
and covered with a 75/100 mm lightly compacted layer of sifted
soil or clean sand. After laying the cables is to be covered with a
further layer of lightly compacted sifted soil or sand to a depth of
75 mm. The trench filling shall be as per the approved
construction drawings. The cable protection tiles are then placed
above the sand and back filled.
¾ The depth of the cables and the number of layers shall be as per
the approved construction drawings.
¾ The cable shall be provided with cable marker along the full
length of the trench at intervals as indicated in the construction
drawings.
Cable Termination

6 Cables are terminated with cable glands which are suitable for
receiving all the conductors of the cable and are to be securely
clamped to the cable in a permanent manner. The glands for
armoured cable are inner and outer seals and armour clamps.

6 Wherever the cable enters into an enclosure, which is untapped

for fixing gland then it has to be fixed to the enclosure by a heavy
duty plated brass nut with a sealing washer. A plated earth tag to
be fitted if there is no electrical continuity between the enclosure
and gland. In such case the earth tag is to be bonded to an earth
terminal located with in the enclosure.

6 The conductors shall be provided with marking ferrules,

crimping lugs as required by the installation drawings and
method statements.
6 Crimping lugs shall be used only with stranded conductors.

6 Cable screens shall be terminated on the assigned terminals or

screen bar as indicated in the termination drawings. Screen shall
be provided with coloured insulating sleeves. Screen at the field
instrument shall not be terminated, they shall be insulated and
tied back.

6 System cables, data cables may require special end connectors

like Radikor boards or may require soldering.

6 Optical fibre cables require special tools for termination and

patch chords.
Installation of Instruments

¾ A thorough site survey should be done before starting any

installation work. If any work permit is required the same should
be arranged in advance. All safety rules must be adhered to. Co-
ordination with other contractors working in the same site to be
done to ensure the work front availability.

¾ All instruments shall be installed such that they are not subjected
to excessive vibration and are not exposed to atmospheric or
ambient conditions detrimental to the instrument. The contractor
shall fabricate or supply canopies for instruments as indicated in
the bill of material to provide protection from direct exposure to
sunlight/rain.

¾ Location of instruments, junction boxes shall be reviewed with

the construction drawing and as per the actual site conditions.
Any change from the approved drawings if required shall be
done trough the specified approval process. Any instrument shall
be sufficiently away from the surrounding process vents, drains,
and exhaust points.
¾ Installation of transmitters, DP gauges, switches, field
mounted switches and converters shall include the
fabrication of the stanchions, installation of stanchions and
painting, installation of the manifolds. Stanchions shall be
fabricated such that the final elevation of the centre line of the
instrument is approximately at 1.35 metres from grade level. Co-
ordination work is required with civil contractor for the
provision of local foundations wherever applicable.

¾ Due care to be taken while installing instruments with capillary.

Capillaries shall be routed /supported on covered trays or angles
wherever required.

¾ All cables at the termination points shall have coils looped.

Similarly any excess capillary lengths shall be looped neatly.

¾ Location of F&G detectors are sometimes specified by co-

ordinates (determined from mapping study) and thus they should
be accurately installed. The orientation of some type of detectors
9like flame detectors) are very important and must be followed as
specified on the F&G layout drawings.
Inline instruments.

¾ Inline instruments like control valves, shutdown valves, orifice

plate assembly etc. are installed by the piping installation group.
Installation of such items are done in close co-ordination between
the instrument and piping group.
¾ Most of the items are either installed after the hydro-test or
pressure test, or if they are installed before they are dismantled
during such tests and re-installed later.
¾ Location of the inline instruments shall be as per the P&ID and
the piping isometric.
¾ Orientation of the instruments along the flow direction, upstream
& down stream straight lengths, orientations of the actuators are
some of the important aspects to be followed as indicated in the
piping drawings and also in instrument documents.
Installation in buildings, control rooms
¾ Verify site access and check area / building where the cabinets,
marshalling and control panels, consoles, distribution boards will
be installed, in pre-construction survey.
¾ Obtain work permit as required.
¾ The suitability of cut outs for cable entry as per drawing shall be
checked.
¾ The availability of the structural base for fixing the cabinet base
frames shall be checked.
¾ The suitable size of anchor bolts for grouting of cabinets and
panels shall be checked.
¾ Ensure that proper materials such as shipping section bolt and
nuts, panel bus bar, each bar, fix plates, for the same are
available and are suitable for use.
¾ Marking of the four-corner of the complete panels shall be done
to avoid any interference with beams / structure.
¾ The water level of foundation of cabinets, panels etc. shall be
checked and the area shall be cleaned.
Installation and Alignment
6 The QA/QC Civil Inspector shall check the readiness of building,
foundation / cut outs, and structural work before handing over.

6 Cleanliness inside the control room and underneath the false

floor is of utmost importance when the cabinets and panels are
shifted inside the rooms. HVAC should be running.

6 The base frames of the panel shall be levelled / fixed by means of

anchoring.

6 The items shall be shifted from store yard to site by Crane /

Forklift and trailer as per the lifting plan.

6 The crane to be used for lifting and shifting of shall have project
certification.

6 Panel and cabinets shall be lifted by using lifting hooks / eye bolts
provided at the four corners of the shipping section.
¾ The panels shall be carefully shifted by putting pipe rollers
and due care shall be taken while shifting to avoid damages to
enclosures and other accessories inside the panels.
¾ Placing of the shipping sections or panel at the right locations as
per Control room equipment layout / vendor drawing.
¾ The panel sections shall be installed in sequence as identified in
the layout drawing.
¾ Proper thickness of shims shall be provided between the panel to
proper coupling of panel sections if required.
¾ Correct size of fasteners shall be used for coupling of shipping
sections of panels and also proper care shall be taken to avoid
damage to gaskets, while jointing the sections.
¾ All the loose components like relays, meters, etc. supplied
¾ along with panels shall be placed at the appropriate locations
indicated in the vendor drawing.
¾ Inter-panel wiring shall be done as per the scheme drawings
provided by the vendor.
¾ All mechanical checks like door closure, swing frame operation
shall be carried out after installation is completed.
¾ Insulation mats, danger boards, labels, shall be provided in
addition to permanent ones if required for safety.
¾ Panels shall be thoroughly cleaned by vacuum cleaner and box
up after all cable termination work is over.
The interposing relay cabinets will be normally installed inside
electrical switch gear rooms and due co-ordination is required with
electrical group before installation.
Installation of Building F&G system and detectors.

¾ Usually the building F&G panels are wall mounted or small in

size.
¾ Ensure that they are installed along with the required battery
back up as per the specifications.
¾ The smoke, heat, gas detectors, bells, beacons, manual call points
shall be installed as per the drawings which show he locations as
per the international standards and applicable local regulations.
¾ Co-ordination with the building HVAC contractor, Safety and
electrical groups are required during this work.
¾ For the High Sensitivity Smoke Detection and Alarm system the
aspirating tubes to be installed as per the tube/sampling layout
drawing covering all the sample points.
Installation of Analyzers.

¾ Ensure that the civil foundation is ready for all analyzer shelters.
¾ Shelter may be supplied with a number of loose instruments and
items like tubes, fittings, solenoid valves, sampling handling
frames etc. which need to be installed inside the shelter after the
installation of the shelter.
¾ Shelters may be provided with local HVAC requiring electrical
power. Ensure that all such utilities like UPS, non -UPS power,
instrument air etc. are available for connection.
¾ There will be some vent and drain points which might require to
be connected to the piping headers. Ensure the readiness of such
piping tie points.
¾ The analyzer shelter may have a bank of gas cylinders. Ensure
safe handling during installation.
¾ Analyzer sampling tubes to be routed to ensure that the tube
length does not exceed the limits set for sample transport lag. The
tubes may be in the form of pre-heat trace tube bundle. Such a
tube will be provided with heat tracing power and may have
temperature sensor and temperature control circuit.
Instrument and sample tubing.

¾ The impulse tube details are provided in impulse tube or

instrument process hook up drawings.
¾ It may not be always possible to install the tube as per the hook
up drawing due to change of elevation of transmitter or the
tapping point from the engineering drawing. All such cases to be
reviewed and drawing change to be implemented as per the
approved process of change.
¾ Usually the length of impulse tube should be short but sometimes
it may be necessary to provide longer lengths so that a very cold
or hot process fluid gets sufficiently warmed or cooled
respectively before reaching the instrument when the instrument
is hooked up to the live process.
¾ Impulse tubes often require slopes. Slopes to be maintained as
indicated in the Hook-up drawing or method statements.
¾ Longer impulse tubes to be supported. Sometimes project
specification requires insulating sleeves between the tube and
support member to prevent galvanic corrosion.
¾ Impulse tubing may need heat tracing. Heat tracing requirement
to be identified before installation. Heat tracing and thermal
insulation is done by others as per the relevant heat tracing
drawings (by Electrical group). If heat traced tube bundles are
used, instrument hook-up drawings provide the details.
¾ Analyzer sample tubing to be laid as not to exceed the maximum
stipulated length. The tubes may require heat tracing. Analyzers
normally require smaller size tubes (typically 1/4", 1/8"). Some
analyzer (gas chromatograph) require interruption less (without
fittings, bends) tubing immediately upstream of the analyzer.
¾ Pneumatic tubing shall be as per the pneumatic hook up
drawings. The tube size may vary based on the size of the valves.
Such sizes will be indicated in the pneumatic hook up drawings.
It is necessary to review the pneumatic hook up drawings with
the corresponding drawings provided by the valve vendors.
¾ The impulse and pneumatic tubes are subjected to pressure test
as per the method statements.
 Installation of Earthing conductors

¾ Earthing conductors will be installed by the electrical group as

per the typical Instrument Earthing drawings and Eathing
Layout drawings by electrical group. Such drawings will
incorporate the vendor recommendation if any, say for control
cabinets or for magnetic flow-meters.

¾ Electrical group will construct instrument earth pit following the

minimum earthing resistance limits indicated in the typical
instrument earth drawing and also in Electrical earthing
specifications.

¾ Separate earth pit requirements are governed by the earthing

specifications and may difference from one project to the other.
Calibration of instruments and testing.

¾Instruments are always calibrated at factory before delivering to

site. Site calibration is required to establish that no drift has
occurred from the calibration at factory. Any minor drifts are
eliminated by site calibration.
¾Calibration and testing of instruments before installation allows
one to identify any faulty instrument and take necessary mitigation
actions well in advance of installation.
¾Sometimes instruments are required to be re-calibrated to match
the site conditions. For example a level transmitter may need to be
re-calibrated due its change of elevation from the value determined
during engineering stage or due to the change of the density of
process liquid when the plant is actually commissioned.
¾Calibration set up for electronic instruments, transmitters,
analyzers etc. at site is normally arranged in rooms or shelters with
controlled environment (with air conditioning).
¾ Equipment, calibrating instruments which are used to do
calibration must have the performance factors (like accuracy,
repeatability) better than those which are to be calibrated.
Calibrating instruments must have valid calibration certificates
which are traceable to laboratories which certify calibrating
instruments/equipment.
¾ Mechanical devices like safety relief valves are tested for the cold
set point. Special arrangements, called test benches consisting of
pressurization equipment, test pressure gauges, fixing jigs etc. are
parts of such test benches.
¾ Calibration of control valves, testing of pneumatic shutdown
valves require instrument air and pneumatic test bench.
¾ FF (Foundation filed bus) instruments require special power
supply kit and calibrators which can receive or generate filed bus
signals.
¾ Calibration and testing are witnessed by the client and also
inspectors from QA/QC group. The results are recorded in
project specific formats. Acceptance criteria are as per the
acceptance criteria stated in the manufacturer’s approved test
and calibration certificates sent along with the items. The site test
results are signed off by all concerned and preserved. These are
all part of handover documents.
¾ Items like Gas detectors for F&G systems require calibration
gases in bottles. These detectors are usually checked with a single
calibrating gas or two calibrating gases of different compositions.
¾ Process gas analyzers are usually checked for calibration during
the analyzer commissioning. Calibration gas cylinders are
normally supplied along with the analyzers.
¾ Fiscal flow-meters are factory calibrated and they are retested/
proved at site when they are commissioned.
Some of the common calibration instruments,
tools, equipment

¾ Dead weight testers

¾ Manometers

¾ Digital multi-meters

¾ Hand held calibrators, FF calibrators

¾ Test pressure gauges

¾ Resistance box

¾ Milivolt generators and signal generators

¾ Portable pneumatic calibrator

¾ Portable air compressor

¾ Rheostat

¾ Variac

¾ Temperature bath

¾ Precision thermometers

¾ Special screw drivers

¾ Buffer solution, Calibration gases

¾ Wobblers

¾ Bench vice, clamps, jigs, fittings, tubes etc.

¾ Soldering iron, solder flux.

SAT (Site acceptance Test) and Loop checking.

¾ After the installation of a system, say DCS, is mechanically over,

it is then arranged for powering up. SAT is done after the system
is powered up before the loop checking. The purpose of SAT is to
ensure that the DCS/ESD/F&G systems delivered intact to the
site. The tests done during FAT (factory acceptance test) are
again done during SAT. Loop checking are carried out usually by
simulating signals from the field or actually providing physical
input to the field device.

¾ SAT is conducted for all such systems under the supervision of

vendor's engineers.

¾ Loop check some times can overlap with the trial run of the
package plants or instrument packages.
¾ SAT and loop checks lead to the hand over of the plant
instrumentation from the construction to the commissioning
group.

¾ High degree of coordination activities and interactions happen

among the instrument vendors, package vendors and
Instrumentation site engineers.
 Measurement of construction and material and
work reconciliation

6 Measurement of construction work is one of the most important

tasks that continues to happen throughout the construction
phase. Measurement is taken and recorded with all the concerned
parties as per the method statements.

6 Reconciliation of materials and work depends upon the correct

measurement and record.
Responsibility Matrix
Instrument Location Layout
Instrument Cable and Piping
Installation Details
Instrument Level
Sketches
 Instrument
Impulse Lines
Instrument Signal Diagram
GA Terminal Plans Wiring
Power distribution drawings
of cabinets