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- Herausgeber: John Wiley & Sons
- Kategorie: Wissenschaft und neue Technologien
- Sprache: Englisch
HANDBOOK OF CONSTRUCTION MANAGEMENT FOR INSTRUMENTATION AND CONTROLS Learn to effectively install and commission complex, high-performance instrumentation and controls in modern process plants In Handbook of Construction Management for Instrumentation and Controls, a team of experienced engineers delivers an expert discussion of what is required to install and commission complex, high-performance instrumentation and controls. The authors explain why, despite the ubiquitous availability of diverse international standards and instrument manufacturer data, the effective delivery of such projects involves significantly more than simply fitting instruments on panels. The book covers material including site management, administration, operations, site safety, material management, workforce planning, instrument installation and cabling, instrument calibration, loop check and controller tuning, results recording, and participation in plant commissioning exercises. It also provides an extensive compendium of forms and checklists that can be used by professionals on a wide variety of installation and commissioning projects. Handbook of Construction Management for Instrumentation and Controls also offers: * A thorough introduction to site operations, including the principles of equipment installation and testing * Comprehensive explorations of quality assurance and quality control procedures from installation to pre-commissioning to site hand-over * Practical discussions of site administration and operations, including planning and scheduling, site safety, and contractor permits-to-work, change and delay management * Detailed discussion of the installation and commissioning of complex instrumentation and control equipment Perfect for specialty contractors and subcontractors, general contractors, consulting engineers, and construction managers, and as a reference book for institutes teaching courses on Industrial Instrumentation, Handbook of Construction Management for Instrumentation and Controls will also benefit students looking for a career in instrument installation.
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Veröffentlichungsjahr: 2023
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Handbook of Construction Management for Instrumentation and Controls
K. Srinivasan, T.V. Vasudevan, S. Kannan, and D. Ramesh Kumar
This edition first published 2024
© 2024 John Wiley & Sons Ltd
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The right of K. Srinivasan, T.V. Vasudevan, S. Kannan, and D. Ramesh Kumar to be identified as the authors of this work has been asserted in accordance with law.
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Library of Congress Cataloging-in-Publication Data
Names: Srinivasan, K., editor. | Vasudevan, T.V., editor. | Kannan, S., editor. | Ramesh Kumar, D., editor.
Title: Handbook of construction management for instrumentation and controls
/ edited by K. Srinivasan, T.V. Vasudevan, S. Kannan, and D. Ramesh Kumar.
Description: Hoboken, NJ, USA : John Wiley & Sons, Ltd., [2024] | Includes
bibliographical references and index.
Identifiers: LCCN 2023003580 (print) | LCCN 2023003581 (ebook) | ISBN
9781394195206 (hardback) | ISBN 9781394195213 (ebook) | ISBN
9781394195220 (epub) | ISBN 9781394195237
Subjects: LCSH: Petroleum refineries--Design and construction. | Gas
manufacture and works--Design and construction. | Chemical
engineering--Instruments. | Factory management.
Classification: LCC TH4571 .H36 2024 (print) | LCC TH4571 (ebook) | DDC
658.5--dc23/eng/20230701
LC record available at https://lccn.loc.gov/2023003580
LC ebook record available at https://lccn.loc.gov/2023003581
Cover image: © Siegfried Kaiser/Getty Images
Cover design by Wiley
Set in 9.5/12.5pt STIXTwoText by Integra Software Services Pvt. Ltd, Pondicherry, India
Contents
Cover
Title Page
Copyright Page
About the Authors
List of Figures
List of Tables
List of Forms
Preface
Abbreviations
1 Site Operations Manual – General
1.1 Introduction to the Handbook
1.2 Need for Handbook
1.3 Contract Types and Construction Management
1.4 Roadmap to Handbook
1.4.1 Oil and Gas Industry
1.4.2 Codes and Standards
1.4.3 Influence of Chemical Plant Nature on Construction
2 Construction Management – SITE Operations
2.1 SITE Management and Operations – Overview
2.2 Site Operations Manual
2.2.1 Site Construction Manager
2.2.2 Site Mobilisation
2.2.3 Site Organisation
2.2.3.1 Size
2.2.3.2 Organisation Structure and Manpower Resources
2.2.4 Engineering Administration
2.2.4.1 Engineering Standards On Site
2.2.4.2 Documents to be Available On Site
2.2.4.3 Material Management
2.2.4.4 Tools and Tackles On Site
2.2.4.5 Installation and Commissioning Schedule
2.2.4.6 Detailed Schedules for Installation and Shutdown
2.2.4.7 Clearance Certificates
2.2.4.8 Morning Meetings
2.2.4.9 QA Procedures
2.2.4.10 Safety Policy
2.2.4.11 Installation, Testing and Commissioning
2.2.5 Site Safety Practices and Rules
2.2.5.1 General Requirements
2.2.5.2 Administration
2.3 Site Administration and Cost Control
2.3.1 Plans and Schedules
2.3.2 Materials Management and Storage
2.3.2.1 Goods Receipt
2.3.2.2 Goods Issue
2.3.2.3 Spares
2.3.2.4 Software
2.3.2.5 Site Purchase
2.3.3 Staff Management
2.3.3.1 Site Organisation Structure
2.3.3.2 Site Working Hours
2.3.3.3 Charge Numbers For Site
2.3.3.4 Applying for Leave
2.3.3.5 Travel for Staff on Site
2.3.3.6 Discipline on Site
2.3.3.7 Performance Review for Staff On Site
2.3.3.8 Staff on Temporary Transfer to Site
2.3.4 Site Administration and Cost Control
2.3.4.1 Site Cost Monitoring
2.3.4.2 Site Cost Control
2.3.4.3 Revised Cost Estimates
2.3.4.4 Budget Updates
2.3.4.5 Corrective Action
2.3.4.6 Estimate at Completion (EAC)
2.3.4.7 Lessons Learned
2.3.5 Subcontractor Management
2.3.5.1 Subcontractor Check List
2.3.5.2 Obligations to the Subcontractor
2.3.5.3 Subcontractor Supervision
2.3.5.4 Quality in Work
2.3.5.5 Morning Meetings
2.3.5.6 Delays Caused by the Subcontractor
2.3.5.7 Breach of Contract by the Subcontractor
2.3.5.8 Subcontractor Safety
2.3.5.9 Claims by the Subcontractor
2.3.5.10 Progress Payment Claims
2.3.5.11 Delay Claims
2.3.5.12 Extension of Time Claims (EOT)
2.3.5.13 Dealing With the Client
2.3.6 Role of the Site Manager
2.3.7 Documents and Records On Site
2.3.7.1 Engineering Manuals
2.3.7.2 Engineering Drawings and Database
2.3.7.3 Registers / Files to be Maintained On Site
2.3.7.3.1 General
2.3.7.3.2 Contract Related
2.3.7.3.3 Subcontractor Related
2.3.8 Drawings / Documents / Manuals Issued to Subcontractor
2.3.8.1 System Related
2.3.8.2 Software on Site
2.3.8.3 Material Management Related
2.3.8.4 Safety Related
2.3.9 Overseas Construction Sites (Middle and Far East)
2.3.10 Communications and Reporting
2.3.10.1 Language Parlance
2.3.10.2 Types of Communication
2.3.10.3 Fortnightly Events Report
2.3.10.4 MPR and S-Curve
2.3.10.5 SIR and CWR
2.3.10.6 Safety Report
2.3.11 Project Completion and Closure
2.3.11.1 Check List for Project Closure
2.3.11.2 Formal Acceptance of Closure
2.3.12 PMC / Owner – Roles and Responsibilities
2.3.12.1 Data Sharing
2.3.12.2 Legal
2.4 Site Work Clearances and Permits
2.4.1 Introduction
2.4.2 Clearance Requirements
2.4.2.1 Clearance to Work Certificate
2.4.2.2 Types of Permits
2.4.2.3 Work Requiring a Clearance to Work
2.4.2.4 Requesting a Clearance to Work
2.4.2.5 Issuing a Clearance to Work
2.4.2.6 Changes to Scope of Work
2.4.2.7 Authorised Issuers
2.4.2.8 Documentation
2.5 Planning, Scheduling and Cost Control
2.5.1 General
2.5.2 Introduction to Planning
2.5.2.1 WBS
2.5.2.2 CPD and CPM
2.5.2.3 Network Planning
2.5.3 Introduction to Scheduling (and Use of S-Curve)
2.5.4 Introduction to Reporting (Gantt Chart)
2.5.5 Introduction to Construction Cost Estimation
2.5.5.1 Overview
2.6 Technical Spec Tender and Template
2.6.1 Introduction
2.6.2 Scope of Works and Supply
2.6.2.1 Calibration Works
2.6.2.2 Supply and Installation Works
2.6.2.3 Cabling, Laying and Wiring Works
2.6.2.4 Piping and Tubing Hook-Up Works
2.6.2.5 Earthing Works
2.6.2.6 Loop Check Works
2.6.2.7 Documentation
2.6.2.8 Pre-Commissioning and Commissioning
2.6.2.9 Information From Tenderer
2.6.2.10 Mobilisation and SITE Management
2.6.2.11 Labour Laws and Law Requirements
2.6.2.12 Insurance
2.6.2.13 Contract Unassignable
2.6.2.14 Contractor’s Warranty
2.6.2.15 Contractor’s Guarantee
2.6.2.16 Inspection and Tests
2.6.2.17 Confidentiality
2.6.2.18 Contractor’s General Indemnity
2.6.2.19 Arbitration
2.6.2.20 Jurisdiction of Courts
2.6.2.21 Force Majeure
2.6.2.22 Annexure 1 to Section 2.6
2.6.2.23 Annexure 3 to Section 2.6
2.6.2.24 Annexure 4 Tender Schedule of Rates Format
3 Site Operations Manual – I&C
3.1 General
3.1.1 Engineering Handover
3.1.2 Site Structure for I&C Works Contract
3.1.3 Introduction to “Smart Instrumentation” Software
3.1.4 Preliminaries and Sequence of Works – I&C
3.2 Site Estimations and Preparations – I&C
3.2.1 Information Compilation
3.2.2 Man-Hour Estimate
3.2.3 Typical Engineering Cost Estimate Master Sheet
3.2.4 Documentation to be Available at Site
3.2.5 Tools, Tackles, Test Instruments / Equipment Miscellany
3.3 Field Installation
3.3.1 General
3.3.1.1 Overview
3.3.1.2 Equipment and Manpower Requirements
3.3.1.3 Instrument Mounting Locations
3.3.1.4 Accessibility
3.3.2 Field Installation – Instrument Accessories
3.3.2.1 Instrument Stanchion Installation
3.3.2.2 Instrument Sunshade Installation
3.3.2.3 Instrument Tag Plate Installation
3.3.2.4 Field Boxes and Panels Installation
3.3.3 Instrumentation Cabling Installation
3.3.3.1 Importance of Specification in Cable Laying
3.3.3.2 Cable Glands Installation
3.3.3.3 Cable Routing, Supporting and Fastening Installations
3.3.3.3.1 General
3.3.3.3.2 Cable Signal Segregation
3.3.3.3.3 Cable Routing Methods
3.3.3.3.4 Cabling From Field Junction Box to Control Room Marshalling Cabinets
3.3.3.3.5 Aboveground Cable Supporting System
3.3.3.3.6 Cable Tray-Ladder and Support Systems
3.3.3.3.7 Conduit and Conduit Fittings and Supports Installation
3.3.3.3.8 Cable Fastening
3.3.3.3.9 Underground Cable Supporting System
3.3.3.3.10 Computer False Floor
3.3.3.3.11 Cables in Trenches and/or Ducts
3.3.3.3.12 Duct Bank System Installation
3.3.3.3.13 Cable Entry Sealing
3.3.3.3.14 Cable Termination
3.3.3.3.15 Noise and Signal Interference Reduction
3.3.3.3.16 Cable Glands Installation
3.3.3.3.17 Connections at Field Instruments
3.3.3.3.18 Connections at Field Junction Boxes
3.3.3.3.19 Termination
3.3.3.3.20 Identification
3.3.3.3.21 Cable Supporting – Installation Detail
3.3.3.3.22 Cable Entry Sealing and Multi-Cable Transits (MCT) Installation
3.3.3.3.23 Cable End-to-End Installation
3.3.3.3.24 FF Cabling and Wiring – Special Note
3.3.3.3.25 Fibre Optic Network Cabling – Special Note
3.3.4 Field Instrumentation Earthing Installation
3.3.4.1 Grounding and Earthing Plan
3.3.4.2 Safety Ground Installation
3.3.4.3 Instrument DC and Shield Ground
3.3.4.4 Safety Ground Conductor Connections
3.3.4.5 Ground Fault Detection
3.3.5 Field Instrument-to-Process Installation
3.3.5.1 Instrument Impulse Tubing Installation
3.3.5.2 Pipe Manifolds and Direct Mounted Instruments – Installation
3.3.6 Online Instruments Installation
3.3.6.1 Pressure Gauges and Pressure Switches
3.3.6.2 Pressure and Differential Pressure Transmitters
3.3.7 In-Line Instruments Installation – Flow Meters
3.3.7.1 General Guidelines for Flow Meters
3.3.7.2 Orifice Plate and Flanges and Restriction Orifices
3.3.7.3 Venturi Tubes
3.3.7.4 Flow Nozzle
3.3.7.5 Wedge Flow Meter
3.3.7.6 Vortex Flow Meter
3.3.7.7 Ultrasonic Flow Meter Head
3.3.7.8 Coriolis Flow Meter
3.3.7.9 Electromagnetic (EM) Flow Meters
3.3.7.10 Variable Area Flow Meter (Rotameter)
3.3.7.11 Turbine Flow Meter
3.3.7.12 Positive Displacement or PD Flow Meter
3.3.7.13 Averaging Pitot Tube
3.3.8 In-Line instrumentation – Level Instruments on Vessels / Equipment
3.3.8.1 Types
3.3.8.2 General Guidelines For Installation
3.3.8.2.1 Standpipes / Stilling Well Fabrication Basics
3.3.8.2.2 Installation Guidelines
3.3.8.3 Level Gauges
3.3.8.3.1 Tubular / Reflex / Transparent Level Gauge / Indicators Installation
3.3.8.3.2 Magnetic Level Gauge / Indicators Installation
3.3.8.4 Guided Wave Radar (GWR)
3.3.8.5 Non-Contact Radar Level Transmitter Installation
3.3.8.6 Differential Pressure Level Instruments
3.3.8.7 Displacer Level Instruments
3.3.8.7.1 LVDT Type Displacer Level Instruments
3.3.8.7.2 Torque Tube Type Displacer Level Instruments
3.3.8.7.3 Installation Guidelines
3.3.8.8 Float Type Liquid Level Switches
3.3.8.8.1 Switch Mechanisms
3.3.8.8.2 Installation Guidelines
3.3.8.9 Magnetostrictive Level Transmitters
3.3.8.10 Capacitance Probe
3.3.8.11 Vibrating Fork Level Detector
3.3.8.12 Rotating Paddle Level Detector
3.3.8.13 Radiometric Level Detector
3.3.8.14 Tank Gauging – Manual
3.3.8.15 Automatic Tank Gauging (ATG)
3.3.8.15.1 Float Gauge–Servo
3.3.8.15.2 Hybrid Tank Gauging for Redundancy
3.3.9 Inline instruments – Temperature Instruments on Lines / Vessels / Equipment
3.3.9.1 General Guidelines for Temperature Measurements
3.3.9.2 Thermowells
3.3.9.3 Bi-Metal Thermometer
3.3.10 Process Analysers Installation
3.3.10.1 Introduction
3.3.10.2 Analyser Fundamentals
3.3.10.3 Analyser Installation Basics
3.3.10.3.1 Introduction to Installation
3.3.10.3.2 Analyser Enclosures Installation
3.3.10.3.3 General Sampling System Installation
3.3.10.4 Installation Guidelines
3.3.10.4.1 pH Analyser
3.3.10.4.2 Conductivity Analyser
3.3.10.4.3 Composition Analysis – Chromatographs
3.3.10.4.4 Oxygen Analyser
3.3.10.4.5 Sulphur Analyser
3.3.10.4.6 H2S Analyser
3.3.10.4.7 H2S – Oxygen Analyser
3.3.10.4.8 Oxygen Combustibles
3.3.10.4.9 Distillation Analyser
3.3.10.4.10 TOC Analyser
3.3.10.4.11 Oil-in-Water Analyser
3.3.10.4.12 Hydrogen-in-Gas Analyser
3.3.10.4.13 In-Line Hydrogen Sensor
3.3.10.4.14 Viscosity Analyser
3.3.10.4.15 Densitometer – Liquid
3.3.10.4.16 Densitometers – Gas and Wobbe Index
3.3.10.4.17 Moisture and Dew Point Analyser
3.3.10.4.18 Flash Point Analyser
3.3.10.4.19 Freeze Point and Cloud Point Analyser
3.3.10.4.20 RVP Analyser
3.3.10.4.21 Cold Filter Plug Point (CFPP)
3.3.10.4.22 Safety Gas Detectors
3.3.10.4.23 Analyser – Flare Emissions – EPA
3.3.10.24 Analyser – Others – EPA – Water
3.3.10.4.25 Analyser – CEM Other Than Flare Monitoring
3.3.10.4.26 AMADAS
3.3.11 CV, MOV and PSV
3.3.11.1 Control Valves
3.3.11.2 Motor Operated Valves
3.3.11.3 Safety Valves
3.3.12 Instrument Air Piping and Pneumatic Transmission – Installation
3.3.13 Instrument Hydraulic Transmission Installation
3.3.14 Instrumentation Painting Requirements
3.4 Calibration
3.4.1 Introduction
3.4.1.1 Reference Accuracy vs. Bench Accuracy vs. Installed Accuracy
3.4.1.2 Accuracy in Terms of %FS (Full Scale) or % of Reading
3.4.2 Method or Procedure Statements
3.4.2.1 Method Statement
3.4.2.2 Guidelines
3.4.2.3 Calibration of HART and SMART Instruments
3.4.3 Calibration vs. Functional Test
3.4.4 Typical Hook-Ups and Calibration Steps
3.4.4.1 Typical Calibration Hook-Ups
3.4.4.2 Typical Instrument Calibration Steps
3.4.4.2.1 Pressure Instruments
3.4.4.2.2 Level Instruments
3.4.4.2.3 Temperature Instruments
3.4.4.2.4 Flow Instruments
3.4.4.2.5 Control Valves and Accessories
3.4.4.2.6 Safety – Relief Valves
3.4.4.2.7 Analysers – Calibration
3.5 Electrical Works For I&C
3.5.1 Scope of Works
3.5.2 Electrical and I&C Interface Activities
3.6 Control Room and Automation Works
3.6.1 Introduction to Control Room and Building
3.6.2 Introduction to System Architecture
3.6.3 Control Room (CR) Installation Works
3.6.3.1 Control Room I&C System – Installation Works
3.6.3.2 System Cabinet / Consoles / Workstations / Panel Installation
3.6.3.3 CR Conduit, Cable Tray / Ladder Installation
3.6.3.4 Power Cable, Signal Cable, Fibre Optic Cable Installation
3.6.3.5 Junction Box / FGS Panel Installation
3.6.3.6 FGS and Other Instruments Installation
3.6.4 Building Management and Access Control
3.6.4.1 Control Room HVAC
3.6.4.2 FGS for Control Room
3.6.4.3 Access Control
3.6.4.4 Rodent Control
3.6.4.5 Corrosion Monitoring – Control / SIH Rooms
3.6.4.6 Surge Protection Devices (SPD)
3.6.4.7 CCTV System
3.6.4.8 System Interfaces and Cyber Security – OT
3.6.4.8.1 System Interface Management
3.6.4.8.2 Cyber Security
3.6.4.8.3 Sys Interface – Contractor’s Role
3.6.4.8.4 MODBUS Inter System Links
3.7 Special Packs
3.7.1 Compressor I&C Packages
3.7.2 HVAC Systems – I&C
3.7.3 Satellite Instrument House (SIH)
3.7.4 Wireless I&C Preparations
3.7.5 Special Automation Packages
3.7.5.1 Tank Gauging Systems (TGS)
3.7.5.2 Tank Automation Systems (TAS)
3.7.5.3 Product Terminal Systems
3.7.5.4 Meter Prover Systems and Custody Transfers
3.7.5.5 Chemical and Catalyst Loading Systems
3.7.5.6 Variable Speed / Frequency Drive System
3.7.6 Emergency Isolation and Depressuring System
3.7.7 Special Third-Party Interfaces on Installations
3.7.7.1 IBR (India)
3.7.7.2 Nuclear Third-Party Inspections
3.7.7.3 Fire and Gas Third-Party Interfaces
3.8 QA/QC Plan – I&C
3.8.1 Introduction
3.8.2 Typical I&C QA/QC Plan
3.8.3 Information and Construction Check List
3.8.4 Loop Test
3.8.4.1 Loop Folder
3.8.4.2 Loop Test / Checks
3.8.4.2.1 Basics of Loop Checks
3.8.4.2.2 Loop Check Principles
3.8.4.2.3 Loop Check Methods for 4–20 mA or HART Transmitters
3.8.4.2.4 Detailed Loop Checks Procedure
3.8.5 Site Acceptance Test (SAT) Works
3.8.6 Site Integrated Test (SIT) Works
3.8.7 Pre-Commissioning Check Lists
3.8.7.1 Activity Log Register
3.8.7.2 Change Management
3.8.7.3 Pre-Commissioning Check List
3.9 Commissioning Works
3.9.1 Integrated Control System Commissioning
3.9.2 Plant Commissioning Preparation and Steps
3.9.3 Loop Tuning
3.9.3.1 Loop Tuning Basics
3.9.3.2 Loop Tuning – A Brief Introduction
3.9.3.2.1 Trial and Error Method
3.9.3.2.2 Open Loop Control Method
3.9.3.2.3 Closed Loop Control Method
3.9.4 Final Commissioned Plant Submissions
3.9.4.1 Final Activities
3.9.4.2 Dossier and Forms
3.10 Sign-Offs and Handover
3.10.1 Final Site Cleaning
3.10.2 Punch List – Final for Handover
3.10.2.1 Post Punch Check List for Commissioning
3.10.3 HAZOP and PSSR
3.10.4 Site Handover After I&C Works
4 Bulk Construction Material Specifications
4.1 Stanchions / Pipe Stands Specifications
4.2 Instrument Sunshade Specifications
4.3 Instrument Tag Plate Specifications
4.4 Junction Boxes Specifications
4.5 Cable Gland Specifications
4.6 Local Control Panel
4.7 Tubing and Tube Fitting Specifications
4.8 Valve Manifold Specifications
4.9 Instrument Cable Specifications
4.10 Network Cable Specifications
4.11 Instrument Concrete Duct Bank Specifications
4.12 Instrument Trays / Ladder Specifications
4.13 Conduit and Conduit Fitting Specifications
4.13.1 Conduits
4.13.2 Conduit Fittings
4.14 Multi-Cable Transit Specifications
4.15 Earthing / Grounding Material Specifications
5 Engineering Information
5.1 International Standards List
5.1.1 Standards Specific to I&C Construction Phase
5.1.2 Standards Specific to I&C Engineering Design
5.1.3 Associated Standards Useful to I&C
5.2 Useful Engineering Information
5.2.1 Thermocouple Tables
5.2.2 RTD Tables
5.2.3 Flange and Gasket Standards
5.2.3.1 Flanges
5.2.3.2 Gaskets
5.2.4 Corrosive Environment Class for Control Rooms
5.2.5 Hazardous Area Classification
5.2.6 Ingress Protection
5.2.7 Safety Integrity Limit (SIL)
5.2.8 Pressure Definitions
5.2.9 Typical Piping Connection Size for Instruments
5.2.10 Differential Pressure Level Measurement Suppression Elevation Calculation
5.2.11 Selected Engineering Conversions
5.2.12 Material Selection Table
5.2.13 Commonly Used Elastomers in Gaskets and Seals in Refineries
5.2.14 Control Valve Inherent Flow Characteristics
5.2.15 Physical Constants of Fluids
5.2.16 MODBUS – An Introduction
5.2.16.1 Introduction
5.2.16.2 How is the Data Stored in Standard MODBUS?
5.2.16.3 What is the Server ID?
5.2.16.4 What is a Function Code?
5.2.16.5 Error Checking
5.2.16.6 MODBUS Messages
5.2.16.7 Typical Wiring for MODBUS Communications
5.3 Typical Sample Drawings / Documents for Construction
5.4 Software in I&C Construction Management
5.4.1 Software Tools in Site Office Management
5.4.2 Field Bus Testing and Training Lab
5.4.3 Software Trends in Site Management
5.4.4 Loss and Profitability in Construction Contracts
6 Compendium of Forms
6.1 General
6.1.1 Site Office Personnel Forms Index
6.1.1.1 Employee Weekly Time Sheet Form
6.1.1.2 Employee Requisition Form
6.1.1.3 Travel Request Form
6.1.1.4 Position Specification Form
6.1.1.5 Employee Leave Request Form
6.1.1.6 Employee Expense Report Form – Sheets 1 and 2
6.1.2 Site Office Technical Forms Index
6.1.2.1 Customer Work Request Form – CWR
6.1.2.2 Internal Work Request Form – IWR
6.1.2.3 Information Request Form – IR
6.1.2.4 CHANGE Request Form – CR
6.1.2.5 Site Incident and Investigation Report Forms – SIR – Sheets 1 and 2
6.1.2.6 Goods Despatch Register Form – GDR
6.1.2.7 Goods Receipt Register Form – GRR
6.1.2.8 Stores Transaction Register Form – STR
6.1.2.9 SRR and SPIR Forms – Sheets 1 and 2
6.1.2.10 Work Permit and Clearance Forms (WCP)
6.2 Technical Forms – Typical
6.2.1 Trade Skill Test Forms
6.2.1.1 Instrument Fitter
6.2.1.2 Instrument Fabricator
6.2.1.3 Instrument Electrician
6.2.1.4 Instrument Technician (Calibration)
6.2.1.5 Instrument Supervisor
6.2.1.6 Instrument Foreman
6.2.2 Calibration Forms
6.2.2.1 Controllers and Receivers – Local
6.2.2.2 Control Valves – Actuators – Calibration and Inspection
6.2.2.3 Field Instrument – General
6.2.2.4 Field / Receiver Switch
6.2.2.5 Analyser Installation and Calibration Check
6.2.3 Field Installation Inspection Check Forms
6.2.3.1 Impulse Line Check
6.2.3.2 IA and Pneumatic – Piping System Check
6.2.3.3 IA and Pneumatic – Manifold System Check
6.2.3.4 Junction Box – Local Panel Check
6.2.3.5 Cable Drum Check
6.2.3.6 Cable Installation Check (Instrument and Fiber Optic Cables)
6.2.3.7 Cable Trunking Check
6.2.3.8 Field Cable Termination Check
6.2.3.9 Fieldbus Segment and Extension Check
6.2.3.10 Orifice Plate Check
6.2.3.11 Inline Flow Instrument Check
6.2.3.12 Online Flow Instrument Check
6.2.3.13 Level Instrument Check
6.2.3.14 Temperature Instrument Calibration and Check
6.2.3.15 MOV Installation Check
6.2.3.16 Safety Relief Valves Check
6.2.3.17 Package Instrument Installation Check
6.2.3.18 Analyser Shelter Installation Check
6.2.4 Control Room Works
6.2.4.1 Introduction
6.2.4.2 Control Room Requirements
6.2.4.3 Control Room Contracting Trends
6.2.4.4 Control Room Installation and Construction Phases
6.2.5 Loop Check Forms
6.2.5.1 Analogue Input Loop
6.2.5.2 Analogue Output – Control Valve Loop
6.2.5.3 Digital (Binary) Input Loop
6.2.5.4 Binary Output Loop
6.2.5.5 Motor and VSDS Loop
6.2.6 Pre-Commissioning Check Forms
6.2.6.1 Closed Loop Precomm Check Form
6.2.6.2 Open Loop Precomm Check Form
6.2.6.3 BPCS Precomm Check Form
6.2.6.4 Fire Detector Check Form
6.2.6.5 Gas Detector Check Form
6.2.7 Commissioning Check Forms
6.2.7.1 Instrument Commissioning Check Sheet – DCS
6.2.7.2 Alarm Action Commissioning Sheet
6.2.7.3 Interlock (Logic) Action Commissioning Check Sheet
6.2.7.4 Trip / Shutdown Action Commissioning Check Sheet
6.2.7.5 DCS Sequence Commissioning Test
6.2.7.6 Authorisation for Process Fluid Let In
Index
End User License Agreement
List of Tables
CHAPTER 01
Table 1.1 Stakeholder Definitions.
CHAPTER 02
Table 2.1 Direct – Indirect – Start-up cost division.
CHAPTER 03
Table 3.1 Contract Documents List.
Table 3.2 Engineering Drawings and Document List.
Table 3.3 Input / Output information.
Table 3.4 Field Installation Quantity information.
Table 3.5 Control Room Works information.
Table 3.6 Controls and Logics Quantity information.
Table 3.7 Man-hour Estimate.
Table 3.8 Construction Cost Estimate form - Field.
Table 3.9 Typical Engineering Cost Estimate form – Control room works.
Table 3.10 Testing Tools and Calibration Instrument.
Table 3.11 Typical Equipment and Manpower requirements.
Table 3.12 Instrument Accessibility Guidelines.
Table 3.13 Typical BOM for Stanchion.
Table 3.14 Cable Colour Coding.
Table 3.15 Cable categorisation.
Table 3.16 Field Trunk cabling and marshalling at CR.
Table 3.17 Sample Analyser Data form.
Table 3.18 Analysis Hazards.
Table 3.19 General types of analysers used in Refinery.
Table 3.20 Sampling system conditioning – Liquid and Ga.
Table 3.21 Safety Analysers based on guidelines by M/S Mines Safety Appliances (...
Table 3.22 Analyser Types by Calibration / Validation Method.
Table 3.23 BMS Interdisciplinary works table.
Table 3.24 F&G Detector application areas.
Table 3.25 OIML Accuracy Class for Custody Transfers.
Table 3.26 QA/QC and Activity Summary Plan.
Table 3.27 Activity Log Register.
Table 3.28 Inspection Control Plan. Abbreviation Notes.
Table 3.29 Loop Tuning DS.
Table 3.30 Punch List forms.
Table 3.31 HAZOP closeout report and PSSR...
CHAPTER 04
Table 4.1 Junction Box data sheet.
Table 4.2 Cable Gland data sheet.
Table 4.3 Ground / Earth wire colour codes.
Table 4.5 Cable DS.
Table 4.4 Wire Colour Codes (reproduced here again for easy reference).
CHAPTER 05
Table 5.1 I&C Construction Standards.
Table 5.2 I&C Engineering Design Standards.
Table 5.3 I&C Associated Standards.
List of Illustrations
CHAPTER 01
Figure 1.1 Hazardous Area...
Figure 1.2 PERT-CPM...
CHAPTER 02
Figure 2.1 Organisation...
Figure 2.2 Organisation...
Figure 2.3 Employee...
Figure 2.4 CRS or...
Figure 2.5 Scope Change...
Figure 2.6 Trade Skill...
Figure 2.7 Incident Report...
Figure 2.8 Incident Investigation...
Figure 2.9 Work Breakdown...
Figure 2.10 Work Breakdown...
Figure 2.11 Work Breakdown...
Figure 2.12 CPM network.
Figure 2.13 CPM Task...
Figure 2.14 PERT Chart.
Figure 2.15 Gantt chart.
Figure 2.16 Network plan.
Figure 2.17 S-Curve use.
Figure 2.18 S-Curve –...
Figure 2.19 S-Curve –...
Figure 2.20 S-Curve –...
Figure 2.21 S-“Banana...
Figure 2.22 Histogram. Note:...
Figure 2.23 Typical Project...
Figure 2.24 Typical Critical...
Figure 2.25 Cost Estimation...
Figure 2.26 Class and...
CHAPTER 03
Figure 3.1 Site organisation...
Figure 3.2 Typical SPI...
Figure 3.3 Typical SPI...
Figure 3.4 Typical Inspection...
Figure 3.5 Typical Instrument...
Figure 3.6 Typical Instrument...
Figure 3.7 Typical designs...
Figure 3.9 Typical Field...
Figure 3.11 Cable segregation...
Figure 3.12 Cable crossings...
Figure 3.13 Cable Ladder...
Figure 3.14 Cable Tray...
Figure 3.15 MCT Installation.
Figure 3.16 Cable from...
Figure 3.17 FF cabling...
Figure 3.18 FF cabling ...
Figure 3.19 FO network...
Figure 3.20 Fibre Optic...
Figure 3.21 FO – TDR...
Figure 3.23 Field Earthing...
Figure 3.24 Manifold...
Figure 3.25 Typical Direct...
Figure 3.26 Diaphragm assembly...
Figure 3.28 Draft range...
Figure 3.29 Venturi (D–D/2)...
Figure 3.30 Wedge flow...
Figure 3.31 Ultrasonic Flow...
Figure 3.32 Coriolis Flow...
Figure 3.33 Mag Flow meter...
Figure 3.34 Turbine Flow...
Figure 3.35 Pitot Tube...
Figure 3.36 Averaging...
Figure 3.37 Air / Gas...
Figure 3.38 GWR Mount...
Figure 3.39 Radar Antenna...
Figure 3.40 Radar Level...
Figure 3.41 Level DP...
Figure 3.42 Capacitance...
Figure 3.43 Vibrating fork...
Figure 3.44 Radiometric...
Figure 3.45 Tank Gauging...
Figure 3.46 ATG –...
Figure 3.47 HTG –...
Figure 3.48 Thermowell...
Figure 3.49 Sampling system.
Figure 3.50 Fast Loop.
Figure 3.51 Small Volume...
Figure 3.52 Probe for...
Figure 3.53 Water wash...
Figure 3.54 Steam Ejector...
Figure 3.55 High Pressure...
Figure 3.57 Pneumatic system...
Figure 3.58 pH control...
Figure 3.59 Analyser rangeability...
Figure 3.60 Overlap for...
Figure 3.61 Analyser shelter...
Figure 3.62 Single Line,...
Figure 3.63 Sample transport...
Figure 3.64 Extractive type...
Figure 3.65 pH – flow...
Figure 3.66 Sulphur Analyser...
Figure 3.67 Viscosity Analyser...
Figure 3.68 Freeze point...
Figure 3.69 Freeze and...
Figure 3.70 Flare Analyser...
Figure 3.71 Dissolved Oxygen...
Figure 3.72 High Temperature...
Figure 3.73 CEMS and...
Figure 3.74 Dry Sampling...
Figure 3.75 Wet Sampling...
Figure 3.76 Control valve...
Figure 3.77 Control valve...
Figure 3.78 Control valve...
Figure 3.79 Typical Safety...
Figure 3.80 Multi-Safety...
Figure 3.81 Typical Safety...
Figure 3.82 Inst Air...
Figure 3.83 Air manifold...
Figure 3.84 Calibration...
Figure 3.85 Accuracy FS...
Figure 3.86 Span and...
Figure 3.87 Typical Instrument...
Figure 3.88 Typical Inspection...
Figure 3.89 Calibration setup...
Figure 3.90 Calibration setup...
Figure 3.91 Level Suppression...
Figure 3.92 Control valve...
Figure 3.93 PST –...
Figure 3.95 Lab Validations...
Figure 3.96 Analyser 2-point...
Figure 3.97 Chromatogram and...
Figure 3.98 Typical Analyser...
Figure 3.99 Typical E...
Figure 3.100 Typical Interposing...
Figure 3.101 Typical UPS...
Figure 3.102 Typical Power...
Figure 3.103 Typical Earthing...
Figure 3.104 Typical MOV...
Figure 3.105 Typical VSDS...
Figure 3.106 Typical IRP...
Figure 3.107 Typical Fire...
Figure 3.108 Typical CR console...
Figure 3.109 Typical CR ring...
Figure 3.110 Process area...
Figure 3.111 System Architecture...
Figure 3.112 Typical Hierarchical...
Figure 3.113 Typical System...
Figure 3.114 Control room...
Figure 3.115 Typical Sample...
Figure 3.116 Typical Duct...
Figure 3.117 Typical Sample...
Figure 3.118 ISA chart...
Figure 3.119 ISA class G1...
Figure 3.120 Corrosion...
Figure 3.121 Surge Protection...
Figure 3.122 SPD Loop diagram...
Figure 3.123 SPD components...
Figure 3.124 CCTV Monitor...
Figure 3.125 Simplified System...
Figure 3.126 Common Cyber and...
Figure 3.127 System architecture...
Figure 3.128 Secured USB (Homel...
Figure 3.129 Auxiliary Packs...
Figure 3.130 Surge control...
Figure 3.131 Tank Gauging...
Figure 3.132 Typical SLTS...
Figure 3.133 Typical Ship...
Figure 3.134 Typical LNG...
Figure 3.135 Meter skid,...
Figure 3.136 HAZMAT transfer...
Figure 3.137 VSDS –...
Figure 3.138 HIPPS System...
Figure 3.139 HIPPS component...
Figure 3.140 Typical...
Figure 3.141 Typical Test...
Figure 3.142 Loop Folder...
Figure 3.143 Typical Transmitter...
Figure 3.144 Sequence of...
Figure 3.145 Subsystems for...
Figure 3.146 SAT and SIT...
Figure 3.147 Typical logic...
Figure 3.148 Typical Change...
Figure 3.149 Typical Pre...
Figure 3.150 Open Loop...
Figure 3.151 Motor Check...
Figure 3.152 Typical Handover...
Figure 3.153 Post Punch...
CHAPTER 04
Figure 4.1 Standpipe...
Figure 4.2 Stanchion ...
Figure 4.3 Sunshade fabrication.
Figure 4.4 Name-plate.
Figure 4.5 Valve Manifolds.
Figure 4.6 Condensate /...
Figure 4.7 Instrument cable...
Figure 4.8 Cable sizes...
Figure 4.9 Fiber Optic...
CHAPTER 05
Figure 5.1 Thermocouple...
Figure 5.2 RTD tables...
Figure 5.3 Flange tables.
Figure 5.4 Gasket details...
Figure 5.5 Hazardous Area...
Figure 5.6 Ingress Protection...
Figure 5.7 Typical layers...
Figure 5.8 Pressure definition.
Figure 5.9 Typical Piping...
Figure 5.10 Level–DPT...
Figure 5.11 Selected Engineering...
Figure 5.13 Elastomer table...
Figure 5.14 Control valve...
Figure 5.15 Physical constants...
Figure 5.16 Data Store...
Figure 5.17 Access to...
Figure 5.19 Typical Air...
Figure 5.20 Typical Cause...
Figure 5.21 Typical CCR...
Figure 5.22 Typical Equipment...
Figure 5.23 Typical Cable...
Figure 5.24 Typical System...
Figure 5.25 Typical I/O...
Figure 5.26 Typical Functional...
CHAPTER 06
Form 6.1 Site Office...
Form 6.2 Employee...
Form 6.3 Employee Requisition...
Form 6.4 Travel Request...
Form 6.5 Position Specifi...
Form 6.6 Leave Request...
Form 6.7 Employee Expense...
Form 6.7 Employee Expense...
Form 6.8 Site Office...
Form 6.9 Customer Work...
Form 6.10 Internal Work...
Form 6.11 Information...
Form 6.12 CHANGE Request...
Form 6.13 Site Incident...
Form 6.13 Site Incident...
Form 6.14 Goods Despatch...
Form 6.15 Goods Receipt...
Form 6.16 Stores Transaction...
Form 6.17 SPR (Site Purchase...
Form 6.18 SPIR (Spare...
Form 6.19 Clearance to...
Form 6.20 Clearance to...
Form 6.21 Clearance Log.
Form 6.22 Road Bridge...
Form 6.23 Excavation Permit.
Form 6.24 Confined Space...
Form 6.25 Hot Work ...
Form 6.26 Crane / Fork...
Form 6.27 High Voltage...
Form 6.28 Field Instrume...
Form 6.29 Instrument Control...
Form 6.30 Technical Forms...
Form 6.31 Instrument Fitter.
Form 6.32 Instrument Fabrica...
Form 6.33 Instrument Electri...
Form 6.34 Instrument Technician...
Form 6.35 Instrument Supervisor.
Form 6.36 Instrument Foreman.
Form 6.37 Controllers and...
Form 6.38 Control Valves...
Form 6.39 Field Instrument...
Form 6.40 Field / Receiver...
Form 6.41 Analyser Installat...
Form 6.42 Impulse Line Check.
Form 6.43 IA and Pneumatic...
Form 6.44 IA and Pneumatic...
Form 6.45 Junction Box...
Form 6.46 Cable Drum...
Form 6.47 Cable Installation...
Form 6.48 Cable Trunking...
Form 6.49 Field Cable...
Form 6.50 Fieldbus Segment...
Form 6.51 Orifice Plate...
Form 6.52 Inline Flow...
Form 6.53 Online Flow...
Form 6.54 Level Instrument...
Form 6.56 MOV Installation...
Form 6.57 Safety Relief...
Form 6.58 Package Instrument...
Form 6.59 Analogue Input...
Form 6.60 Analogue Output...
Form 6.61 Binary Input...
Form 6.62 Binary Output...
Form 6.63 Motor and...
Form 6.64 Closed Loop...
Form 6.65 Open Loop...
Form 6.66 BPCS Precomm...
Form 6.67 Fire Detector...
Form 6.68 Gas Detector...
Form 6.69 Instrument...
Form 6.70 Alarm Action...
Form 6.71 Interlock (Logic)...
Form 6.72 Trip / Shutdown...
Form 6.73 DCS Sequence...
Form 6.74 Authorisation for...
Guide
Cover
Title Page
Copyright Page
Table of Contents
About the Authors
List of Figures
List of Tables
List of Forms
Preface
Abbreviations
Begin Reading
Index
End User License Agreement
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About the Authors
K. Srinivasan
Advisor, Mentor and Contributor
Main sections contributed:
Section 1: Preface and Edits
Section 2: Construction Management – Site Operations
Section 3: Analysers Overview
Section 6: Non-Technical Forms
Educational Qualifications:
K. Srinivasan has an Honours degree in Physics, followed by a Post-Graduate diploma in Instrumentation from the Madras Institute of Technology Anna University, Chennai, Tamilnadu (MIT-AU), graduating in 1959.
Industrial Experience:
K. Srinivasan worked for 23 years with Imperial Chemical Industries (India). During this period he was Group Head on design, maintenance, construction and commissioning of chemical, explosive and fertilizer plant instrumentation. Then he moved to Australia and worked with the Foxboro and Leeds & Northrup companies for 22 years before retirement. During this period, he supervised the implementation of digital computer control in steel, power and cement plants. A pleasing aspect to him during this period was that the company started making profits on their bids.
Papers Presented:
i) Intelligent Automation, at the University of Sydney; ii) Is Advanced Control Relevant Only for Large Plants? at the University of New South Wales; iii) Advanced Control of Distillation Plants, at IIT Chennai.
Papers Published:
A series of articles on Advanced Control of Unit operations.
Teaching:
After retirement, he taught at the TAFE (Technical and Further Education) Sydney for four years on Instrumentation – measurement, installation, testing and commissioning. An extended course on flow meter engineering was given.
T.V. Vasudevan
Chief Editor and Contributor
Main sections contributed, besides all fill-ins:
Section 1: Introduction
Section 3: Site Operations Manual – I&C (part)
Section 4: Bulk Construction Material Specifications (part)
Section 5: Appendix – Standards and Engineering Information (part)
Section 6: Technical Forms
T.V. Vasudevan has a BSc in Physics followed by a Post-Graduate Diploma in Instrumentation Engineering (DMIT), graduating in 1975 from Madras Institute of Technology, Anna University, Chennai, Tamilnadu (MIT-AU).
Now retired, he moderates an online technical forum of Alumni of MIT-AU for I&C engineers. He had served with Engineers India Ltd., New Delhi; Kuwait National Petroleum Co., Kuwait; Stork Comprimo, Singapore; and as I&C Engineer on contract / consultancy in several Middle Eastern and S.E.A. companies. His professional experience is mainly in Design and Detailed Engineering of Oil and Gas, Refinery and Petrochemical Projects, Power plants, Cement plants, Pharmaceutical plants, Sugar plants, etc.
D. Ramesh Kumar
Contributor – Field Installations
Main sections contributed:
Section 3: Field Installations (part)
Section 3: Flow Instrument Installations (part)
Section 3: Level Instrument Installations (part)
Section 3: Temperature Instrument Installations (part)
Section 4: Bulk Construction Material Specifications (part)
D. Ramesh Kumar has a B.Tech in Instrumentation Engineering, graduating in 2001 from Madras Institute of Technology, Anna University, Chennai, Tamilnadu (MIT-AU).
Currently, he is with OQ, Oman Oil Refineries and Petroleum Industries Company in Oman as Lead Instrumentation & Control System Engineer. He has over 21 years’ experience in the field from feasibility studies, FEED, detailed engineering, etc. to Project Management, Installation, Commissioning of Oil and Gas, Refinery and Petrochemical Projects.
Among other major oil and gas, refinery and petrochemical companies, he worked for are Chennai Petroleum Corporation Limited (CPCL), India; Indian Oil Corporation Limited (IOCL), India; Petroleum Development Oman (PDO), Oman; Saudi Aramco, Saudi Arabia; SABIC, Saudi Arabia, etc.
S. Kannan
Contributor and Sub-Editor
Main sections contributed:
Section 2: Instrument Construction Tender Specifications
Section 3: Edits & Research: I&C Construction and Site Operations
Section 5: Appendix – Standards and Engineering. Information (part)
Section 6: Technical forms – Manpower Trade skills, Installation and Calibration, Loop Check, etc. Information
S. Kannan is a BSc (Physics) graduate and has a Post-Graduate Diploma (D.M.I.T) in Instrument Technology from Madras Institute of Technology, Anna University, Chennai, Tamilnadu (MIT-AU), graduating in 1976. He has 40 years’ experience in execution of Field Instrument Installation, Pre-commissioning works and Project Management of various Instrumentation Projects of Refineries, Petrochemicals, Power and Sugar plants, etc. He is associated with Alkan Engineering, Bombay; NRC Engineers (Madras); Sical Yamatake Limited; SABIC, Saudi Arabia; CEGELAC, Abu Dhabi; and BAPCO, Bahrain, and finally retired in 2016.
Grateful Acknowledgement to Other Information Contributors
T.C. Chandrasekar
has a BTech in Instrumentation Engineering, graduating in 1994 from Madras Institute of Technology, Anna University, Chennai, Tamilnadu (MIT-AU). He is currently a Manager (E&I) at M/S Petrofac, Sharjah.
Analyser
Analyser shelter
FAT & SAT
Change management
G.R. Omprakash
has a BTech in Instrumentation Engineering, graduating in 1993 from Madras Institute of Technology, Anna University, Chennai, Tamilnadu (MIT-AU). He is currently with M/S Deepak Group, Pune, India.
HVAC
Control Room works
V. Satis Kumar
is with Instrument Group at NPCC, Abu Dhabi.
QA/QC check forms
Thanks to members of MIT Instrument Engineers Alumni (Madras Institute of Technology, Chromepet, AU campus) technical forum (
https://groups.google.com/g/itmitians_tech
) for specific clarification / information on various topics.
List of Figures
1.1 Hazardous Area Classification map of plant area
1.2 PERT-CPM / CPD / Gantt definitions
2.1 Organisation structure – Head Office and SITE
2.2 Organisation structure – Site Office Personnel
2.3 Employee Requisition Form
2.4 CRS or Change Request for Systems
2.5 Scope Change Worksheet
2.6 Trade Skill Test – Typical form
2.7 Incident Report – Typical form
2.8 Incident Investigation Report – Typical form
2.9 Work Breakdown Structure – AWBS
2.10 Work Breakdown Structure – ZWBS
2.11 Work Breakdown Structure – PWBS
2.12 CPM network
2.13 CPM Task Weighted network
2.14 PERT Chart
2.15 Gantt chart
2.16 Network plan
2.17 S-Curve use
2.18 S-Curve – Progress
2.19 S-Curve – Cash
2.20 S-Curve – Quantity Output
2.21 S-“Banana” Curve
2.22 Histogram
2.23 Typical Project Gantt Chart
2.24 Typical Critical Path Diagram
2.25 Cost Estimation Plot
2.26 Class and Input availability matrix
3.1 Site Organisation structure for a medium-sized Refinery in India
3.2 Typical SPI “embedded data” Data sheet
3.3 Typical SPI “embedded data” Loop Sheet
3.4 Typical Inspection and Test Plan
3.5 Typical Instrument Stanchion – for Yoke or surface mounted Instrument
3.6 Typical Instrument Stanchion – for Multiple Instruments / accessories
3.7 Typical designs for other Stanchion Mounting possibilities
3.8 Typical SPI “embedded data” Loop Sheet
3.9 Typical Field Instrument name-plate
3.10 JB installation details
3.11 Cable segregation in paved and unpaved areas
3.12 Cable crossings – typical
3.13 Cable Ladder Installation
3.14 Cable Tray Installation
3.15 MCT Installation
3.16 Cable from Tray to Inst / JB
3.17 FF cabling – Field
3.18 FF cabling – Control room
3.19 FO network cabling – Distributed vs. Structured
3.20 Fibre Optic Link and Testing
3.21 FO – TDR testing
3.22 FO test check form
3.23 Field Earthing / Grounding at various locations
3.24 Manifold valve details
3.25 Typical Direct PG Mounting
3.26 Diaphragm assembly for Pressure gauges
3.27 Pressure and DP installations
3.28 Draft range transmitter installation
3.29 Venturi (D–D/2) and Flow Nozzle – as per standards
3.30 Wedge flow meters
3.31 Ultrasonic Flow meter
3.32 Coriolis Flow meter – preferred Orientations
3.33 Mag Flow meter – Empty Pipe Detection
3.34 Turbine Flow meter setup
3.35 Pitot Tube working illustration
3.36 Averaging Pitot Tube working illustration
3.37 Air / Gas Pitot array
3.38 GWR Mount and Level references
3.39 Radar Antenna Types and Installation
3.40 Radar Level Dimension considerations in Installation
3.41 Level DP arrangement
3.42 Capacitance probe principle
3.43 Vibrating fork Installation
3.44 Radiometric Detector Types
3.45 Tank Gauging – Hand dip
3.46 ATG – Servo
3.47 HTG – Hybrid Tank Gauging
3.48 Thermowell Mounting
3.49 Sampling system
3.50 Fast Loop
3.51 Small Volume Sample Probe
3.52 Probe for high temperature
3.53 Water wash Probe
3.54 Steam Ejector
3.55 High Pressure Sampling
3.56 Distillation Column and Volatility
3.57 Pneumatic system for distillation control sampling
3.58 pH control
3.59 Analyser rangeability control
3.60 Overlap for rangeability control
3.61 Analyser shelter layout
3.62 Single Line, Probe and Simple Fast Loop
3.63 Sample transport types
3.64 Extractive type gas sampling
3.65 pH – flow-through cell
3.66 Sulphur Analyser UV scheme
3.67 Viscosity Analyser sampling
3.68 Freeze and Cloud point graph
3.69 Freeze and Cloud point Analyser safety
3.70 Flare Analyser and sampling
3.71 Dissolved Oxygen Analyser principle
3.72 High Temperature Oxidation Analyser for TOC
3.73 CEMS and PEMS
3.74 Dry Sampling – EMS
3.75 Wet Sampling – EMS
3.76 Control valve in the field – with typical hook-ups
3.77 Control valve piping layouts
3.78 Control valve drain piping layouts
3.79 Typical Safety Valve Installation arrangement
3.80 Multi-Safety Valve Installation guidelines
3.81 Typical Safety Valve Piping downstream arrangement
3.82 Inst Air distribution scheme
3.83 Instrument Air manifold
3.84 Calibration standard levels
3.85 Accuracy Full Scale vs % Reading
3.86 Span and Range – Suppression and Elevation
3.87 Typical Instrument calibration report
3.88 Typical Inspection / Calibration Check List
3.89 Calibration setup for Pressure Transmitters
3.90 Calibration setup for Temperature Transmitters
3.91 Level Suppression / Elevation Ranges
3.92 Control valve calibration setup
3.93 PST – a typical schematic
3.94 Safety Valve Test setup
3.95 Lab Validations for analyser calibration
3.96 Analyser 2-point calibration setups
3.97 Chromatogram and Chromatograph
3.98 Typical Analyser / Detector calibration flow chart
3.99 Typical E&I Interface and Responsibility matrix
3.100 Typical Interposing Relay Panel power scheme
3.101 Typical UPS E–I interface
3.102 Typical Power supply – SLD–E–I scope in CR
3.103 Typical Earthing / Grounding – E–I Interface
3.104 Typical MOV – E–I Interface
3.105 Typical VSDS – E–I interface
3.106 Typical IRP and Pump / Machinery – E–I Interface
3.107 Typical Fire Panel Interface
3.108 Typical CR console Desk Ergonomics
3.109 Typical CR console layout concepts
3.110 Process area and console layout relationship
3.111 System Architecture – ISA95 model
3.112 Typical Hierarchical System architecture
3.113 Typical System Architecture Component Block diagram
3.114 Control room equipment layout Plan and Index
3.115 Typical Sample Chiller Utility Information diagram (UID)
3.116 Typical Duct Instrumentation diagram (DID)
3.117 Typical Sample Roof units (DID)
3.118 ISA chart for Reactive Contaminants classification
3.119 ISA class G1 air for CR
3.120 Corrosion monitor for CR
3.121 Surge Protection Device (SPD)
3.122 SPD Loop diagram
3.123 SPD components
3.124 CCTV Monitor system
3.125 Simplified System Interfaces and Interconnects
3.126 Common Cyber and other threats
3.127 System architecture with Cyber Security protection
3.128 Secured USB
3.129 Auxiliary Packs in Control room
3.130 Compressor Surge control
3.131 Tank Gauging system
3.132 Typical SLTS – MLTS ESD system
3.133 Typical Ship-Shore ESD Link
3.134 Typical LNG Loading arrangement
3.135 Meter skid, Bi-directional prover and instrumentation
3.136 HAZMAT transfer – UN class numbers
3.137 VSDS – VFDS
3.138 HIPPS System – minimum requirements
3.139 HIPPS component schematic. and possible HIPPS in O and G plants
3.140 Typical IBR Form C
3.141 Typical Test Handover and Site Acceptance form
3.142 Loop Folder with Loop Scheme
3.143 Typical Transmitter Loop Test Scheme
3.144 Sequence of Acceptance tests per IEC
3.145 Subsystems for Acceptance tests
3.146 SAT & SIT Relationship per IEC
3.147 Typical logic and control block Loop scheme
3.148 Typical Change Management form
3.149 Typical Pre-commissioning Check form
3.150 Open Loop Tuning parameter
3.151 Motor Check sheet
3.152 Typical Handover stages and Sign-off documents
3.153 Post Punch sample list for Commissioning
4.1 Standpipe / Stanchion Fabrication and BOM specification
4.2 Stanchion classification
4.3 Sunshade fabrication
4.4 Name-plate
4.5 Valve Manifolds
4.6 Condensate / Seal pot
4.7 Instrument cable sections
4.8 Cable sizes vs. Applications
4.9 Fiber Optic LAN cable
5.1 Thermocouple Table
5.2 RTD table
5.3 Flange tables
5.4 Gasket details and tables
5.5 Hazardous Area Classification
5.6 Ingress Protection classifications
5.7 Typical layers of Protection and SIL
5.8 Pressure definition
5.9 Typical Piping connection sizes
5.10 Level – DP – Suppression Elevation calculation
5.11 Selected Engineering Conversion and Data tables
5.12 Material Selection Table
5.13 Elastomer table and properties
5.14 Control valve characteristics
5.15 Physical constants of some common fluids in Refinery
5.16 Data Store Protocol in MODBUS
5.17 Access to Function code in MODBUS
5.18 Wiring used in MODBUS communication
5.19 Typical Air Piping layout
5.20 Typical Cause and Effect diagram
5.21 Typical CCR console layout
5.22 Typical Equipment layout – Control room
5.23 Typical Cable schedule
5.24 Typical System architecture
5.25 Typical I/O list headers
5.26 Typical Functional / Operational Logic diagrams (FLD)
List of Tables
1.1 Stakeholder Definitions
2.1 Direct – Indirect – Start-up cost division
3.1 Contract Documents List
3.2 Engineering Drawings and Document List
3.3 Input / Output information
3.4 Field Installation Quantity information
3.5 Control Room Works information
3.6 Controls and Logics Quantity information
3.7 Man-hour Estimate
3.8 Construction Cost Estimate form – Field
3.9 Typical Engineering Cost Estimate form – Control room works
3.10 Testing Tools and Calibration Instrument
3.11 Typical Equipment and Manpower requirements
3.12 Instrument Accessibility Guidelines
3.13 Typical BOM for Stanchion
13.14 Cable Colour Coding
3.15 Cable categorisation
3.16 FF Field Trunk cabling and marshalling at CR
3.17 Sampling system conditioning – Liquid & Gas
3.18 Analysis Hazards
3.19 General types of analysers used in Refinery
3.20 Sampling system conditioning – Liquid and Ga
3.21 Safety Analysers
3.22 Analyser Types by Calibration / Validation Method
3.23 BMS Interdisciplinary works table
3.24 F&G Detector application areas
3.25 OIML Accuracy Class for Custody Transfers
3.26 QA/QC and Activity Summary Plan
3.27 Activity Log Register
3.28 Inspection Test Control Plan
3.29 Loop Tuning DS
3.30 Punch List form
3.31 HAZOP close-out Report and PSSR (I&C) partial checklist
4.1 Junction Box data sheet
4.2 Cable Gland data sheet
4.3 Ground / Earth wire colour codes
4.4 Cable and Wire Colour Codes
4.5 Cable DS
5.1 I&C Construction Standards
5.2 I&C Engineering Design Standards
5.3 I&C Associated Standards
List of Forms
6.1 Site Office Personnel Forms Index
6.2 Employee Weekly Time Sheet Form
6.3 Employee Requisition Form
6.4 Travel Request Form
6.5 Position Specification Form
6.6 Leave Request Form
6.7 Employee Expense Report Form – Sheet 1
6.7 Employee Expense Report Form – Sheet 2
6.8 Site Office Technical Forms Index
6.9 Customer Work Request Form – CWR
6.10 Internal Work Request Form – IWR
6.11 Information Request Form – IR
6.12 CHANGE Request Form – CR
6.13 Site Incident Report Form – SIR – Sheet 1
6.13 Site Incident Investigation Report Form – SIR – Sheet 2
6.14 Goods Despatch Register Form – GDR
6.15 Goods Receipt Register Form – GRR
6.16 Stores Transaction Register Form – STR
6.17 Stores Purchase Record – SPR
6.18 Spare Parts List Interchangeability Record – SPIR
6.19 Clearance to Work and Permit flow chart
6.20 Clearance to Work Certificate
6.21 Clearance Log
6.22 Road Bridge Access Permit
6.23 Excavation Permit
6.24 Confined Space Permit
6.25 Hot Work Permit
6.26 Crane / Fork Lift Permit
6.27 High Voltage Isolation Permit
6.28 Field Instrumentation Permit
6.29 Instrument Control and Measuring Work permit – ICMWP
6.30 Technical Forms Index
6.31 Instrument Fitter (Trade Skill Test) Form
6.32 Instrument Fabricator (Trade Skill Test) Form
6.33 Instrument Electrician (Trade Skill Test) Form
6.34 Instrument (Calibration) Technician (Trade Skill Test) Form
6.35 Instrument Supervisor (Trade Skill Test) Form
6.36 Instrument Foreman (Trade Skill Test) Form
6.37 Controllers and Receivers – Local – Calibration Form
6.38 Control Valves – Actuators – Calibration and Inspection Form
6.39 Field Instrument – General – Calibration Form
6.40 Field / Receiver Switch – Calibration Form
6.41 Analyser – Installation and Calibration Check Forms
6.42 Impulse Line Check – Field Installation Inspection
6.43 IA and Pneumatic – Piping System Check – Field Installation Inspection
6.44 IA and Pneumatic – Manifold System Check – Field Installation Inspection
6.45 Junction Box – Local Panel Check – Field Installation Inspection
6.46 Cable Drum Check – Field Installation Inspection
6.47 Cable Installation Check (Instrument and Fiber Optic Cables) – Field Installation Inspection
6.48 Cable Trunking Check – Field Installation Inspection
6.49 Field Cable Termination Check – Field Installation Inspection
6.50 Fieldbus Segment and Extension Check – Field Installation Inspection
6.51 Orifice Plate Check – Field Installation Inspection
6.52 Inline Flow Instrument Check – Field Installation Inspection
6.53 Online Flow Instrument Check – Field Installation Inspection
6.54 Level Instrument Check – Field Installation Inspection
6.55 Temperature Instrument – Field Installation Inspection
6.56 MOV Installation Check – Field Installation Inspection
6.57 Safety Relief Valve Check – Field Installation Inspection
6.58 Package Instrument Installation Check – Field Installation Inspection
6.59 Analogue Input – Loop Check Form
6.60 Analogue Output – Control Valve loop – Loop Check Form
6.61 Digital (Binary) Input loop – Loop Check Form
6.62 Binary Output loop – Loop Check Form
6.63 Motor and VSDS Loops – Loop Check Form
6.64 Closed Loop Precomm Check Form
6.65 Open Loop Precomm Check Form
6.66 BPCS – Precomm Check Form
6.67 Fire Detector Check Form
6.68 Gas Detector Check Form
6.69 Instrument – Commissioning Check Form
6.70 Alarm Action Commissioning Check Sheet
6.71 Interlock (Logic) Action Commissioning Check Action Sheet
6.72 Trip / Shutdown Action Commissioning Check Sheet
6.73 DCS Sequence – Commissioning Check Sheet
6.74 Authorisation For Process Fluid Let In – Commissioning Check Form
Preface
Instrumentation for process industries is evolving, perhaps faster than most other technologies. The accuracy and speed at which plant data is made available to personnel is way ahead of what it was, even a decade back. The advent of digital technology and advances made in communication have enabled a revolution. Together with associated computers, relevant reports giving details on current production levels, bottlenecks, raw material stocks, finished goods levels, etc. are made available to board members and production executives, enabling them to take appropriate decisions almost on a real-time basis.
Yet, all this depends on one key factor – correct installation and commissioning of the instrumentation system. It is also essential to ensure long-term reliability without frequent breakdowns. For example, any form of analysis instrument, sophisticated or otherwise, is only as effective as its sampling system.
Digital technology and today’s communication capabilities have forced changes in office organization structures and office management. Similar changes will start happening in construction management. Traditional management structures, with managers using methods and styles based on their previous experiences at other sites, may be found to be inadequate. In addition, installation, calibration and testing of today’s instruments call for different skills and experiences. Experience in installation and testing are not the only skills needed from a site Instrument Installation Manager, whose job calls for man-power planning, recruitment, site safety, attendance in meetings, progress reporting, material management, cost control, change management, database management, delay management, E.O.T. (Extension-Of-Time for reaching completion), managing government regulations / forms and a host of other issues.
Against this background, we come up with a new set of qualifications needed for a site Instrument Installation Manager.
Addressing the above needs, this Handbook provides information on all aspects of site management together with details on the traditional installation, calibration and testing of instruments.
Section 1 provides a short Introduction and a roadmap to the Handbook.
Section 2 on “Construction Management” summarises a list of actions to be performed by the site Instrument Installation Manager. It deals with site administration and control, documentation management and cost control. This section also covers sub-contractor management, breach of contract, progress payments, delay claims, extension of time, documentation, site safety reports, and project completion and closeout. Site incidence reporting system is introduced.
Section 3 discusses details of field installation and provides recommendations on installation of pipes, cables, junction boxes, termination, fibre optic networking, grounding, earthing plans, etc. Impulse line connections to different type of services are discussed. Process analyser installations for different duties are given. Details on the calibration of various types of instruments, including HART & Smart instruments are given.
Control room I&C systems and building management systems and installations are discussed. Also provided are details on special packs such as – Compressor I&C packages, HVAC systems, Tank automation, Product Terminal systems, Meter-proving and custody transfer and VSD. QA/QC plans are also discussed.
Included in this section are Loop check procedures (procedures to be followed for analogue and digital signals). Site Acceptance Tests (SAT), pre-commissioning checks, etc. are described. Guidelines for basic loop tuning are given. Sign-off and handover procedures are discussed.
With change management, even after a detailed design effort, some oversight during design stages may lead to the requirement of additional instrumentation. It is not uncommon that during commissioning stages, such additional requirements may be highlighted. While some of the changes could be minor, others may not be so. All changes require time and personnel to handle them. Changes may also lead to further purchasing. In addition, while changes are being executed, associated documentation will need to be upgraded. These lead to additional costs. This Handbook provides procedures for handling change management and associated costing.
Section 4 discusses Bulk Construction Materials. From time to time, some items like sunshades, stanchions and name-plates may need to be manufactured or procured for site use. Drawings and specifications for some common items is given here. Specifications for cables are also given.
Section 5 is an Engineering Information compilation useful for I&C construction (really an Appendix of Information) that provides a list of standards generally referenced. Also, it has useful engineering standards for thermocouples. An RTD table is provided. Flange and Gaskets standards are provided. Information on Hazardous area classification and Safety Integrity Limits (SIL) are also provided.
Section 6 is a Compendium of Forms.
Site work essentially moves by approvals, witnesses and authorisations. Entries require authorisation, work on site will need to be permitted, test procedures will need to be authorised, and test results will need to be approved. So, the importance of documentation cannot be over-emphasised. This book has been written by engineers with extensive field experience in installation and commissioning. As such, recommendations made, procedures suggested and tabular forms provided are based on actual practical field experience, rarely, if at all, seen in contemporary literature.
After a satisfactory completion of testing, the plant is ready for commissioning. And commissioning is bringing on “stream” a process plant for production. This job is handled by the commissioning team who have a knowledge of all process operations. Though the job of Instrument Installation is complete by this stage, a small team from the installation group is usually retained to assist the commissioning team.
K. Srinivasan
Abbreviations
Technical Abbreviations
Abbreviations
Description
AWG
American Wire Gauge
BPCS
Basic Process Control System
BOM
Bill Of Material
C&E
Cause and Effect Diagram
CEM
Continuous Environmental Monitoring
DCS
Distributed Control System
EPA
Environmental Pollution Act
ESD
Emergency Shutdown System
FAT
Factory Acceptance Test
FBD
Functional Block Diagram
HMI /MMI
Human Machine Interface / Man Machine Interface
HMT /HMTD
Heat & Mass Transfer (D – Department)
HW or H/W
Hardware
ICS
Integrated Control System
I/O
Input / Output
MC
Mechanical Completion
MTO
Material Take Off
PAS
Process Automation System
PC
Personal Computer
PLC
Programmable Logic Controller
SAT
Site Acceptance Test
SIS
Safety Instrumented System
SIT
Site Integration Test
SW or S/W
Software
QMI
Quality Monitoring Instruments / Quality Measurement Instrumentation
Non-Technical Abbreviations
Abbreviations
Description
BOT
Build Operate Transfer
CBA
Commercial Bid Analysis
CM
Construction Management
CPD
Critical Path Diagram
CPM
Critical Path Method
CWR
Customer Work Request (form)
DE
Detailed Engineering
EPC
Engineering Procurement Construction
EPCC
Engineering Procurement Construction Commissioning
FEED
Front End Engineering Design
GANTT
Generalized Activity Normalization Time Table
IWR
Internal Work List
NIST
National Institute of Standards & Technology
NPL
National Physical Laboratory
MIV
Main Instrument Vendor
MAC
Main Automation Contractor
MSDS
