CONSTRUCTION ENGINEERING FOR INSTRUMENTATION

Overview The purpose of writing this document is to brief the fundamental points to be considered for Instrumentation Construction Engineering. Detail Engineering: 1. Plant General Layout & Shop Layout is based on the process and equipment data of basic engineering documents, plant general layout as well as the shop layouts for the various plant units and facilities will be developed. While developing the layout, site conditions will be kept in view and provision will be made for future expansion. 2. Division List of Supplies The preparation of division list of supplies of PLANT & EQUIPMENT to be obtained from indigenous and foreign sources. 3. Technical Specification Prepare technical specification and related drawings to invite tenders for supply of plant & equipment. Also evaluate the tenders and submit technical recommendations for award of contract. 4.0 Architectural, Civil & Structural Designs & Drawings 4.1 Civil Work Prepare working drawings for the following: Main Plant buildings Auxiliary buildings Buildings & Equipment foundations 4.2 Structural Steel Work Prepare design drawings, for structural steel work in buildings, staging and platforms. Shop detailed drawings (fabrication drawings) as in customary will be prepared by the fabricators. 5.0 Design & Drawings For Utilities & Services 5.1 Plant Water System Make arrangement for availability of adequate water at one point within the plant boundary. From this point onwards, design internal plant water distribution system including pumping, treatment & cooling facilities. Also design a suitable fire fighting system based on fire hydrants. 5.2 Power Supply & Distribution Make arrangements for getting adequate high-tension power at one point within the plant boundary. From this point design the plant substation power distribution and lighting systems including single line diagram. Also design a suitable emergency power system, if required. 5.3 Communication and Instrumentation System Prepare schematic drawing and specifications for the supply and installation of the communication and instrumentation system for the plant.

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION
5.4 Plant air, instrument air, Fuel, Steam & Other Utilities Design the Plant air, instrument air, fuel, steam and other utility systems and prepare outline drawings and specification. 5.5 Ventilation, Air Conditioning, Extraction System Design the ventilation, air conditioning, dust & fume control systems and prepare outline drawings and specification. 5.6 Storm Water Drainages & Effluent Disposal Systems For contaminated process water which need treatment before being discharged into plant drainage, prepare a scheme for treatment according to existing STANDARD and prepare drawings and specifications. 5.7 Sewerage System Design a sewerage system and prepare drawings and specifications for the construction of the same. 5.8 Roads, Fences & Gates Design and prepare drawings and specifications for construction of roads, fences and gates within the plant boundary. 5.9 Material Handling & Storage Design of storage and handling facilities within the plant boundary for raw materials and finished products and prepare outline drawings and specifications. 5.10 Auxiliary Facilities & Ancillary Buildings Design and prepare drawings for auxiliary facilities like repair & maintenance shop, central stores, plant laboratory and ancillary buildings such as administrative building, gate house, fire station, canteen, first aid station, charge rooms, parking lots, shop offices, garages, etc. 6.0 Assistance in Commissioning Render technical assistance during commissioning of the plant and equipment. Also witness the performance guarantee tests to be conducted by the equipment suppliers and assist for issuing Acceptance Certificate for taking over the equipment on satisfactory completion of the tests. 7.0 Master Network/Progress Schedule 7.1 Prepare overall project construction schedules including the initial master network. This will be updated and finalised taking into account the actual placement of order on different parties. Advise for corrective measures to be taken to maintain the overall time schedule. 7.2 Prepare quarterly progress reports indicating progress of construction and erection of the plant and equipment. These reports will indicate achievement against targets and spell out actions to be taken in specific areas, if any, to maintain the time schedule. 8.0 Designer's Supervision means: Interpretation of drawings, Interpretation of specifications and codes of practices, Variation in design and materials Design modifications due to site condition, Interpretation of test results, preliminary acceptance and final acceptance tests of the erected plant & equipment. Available resources are taken note of, as also the resources further needed and they are allocated. Contract documents are prepared keeping in the mind the role of the participating agencies to avoid ambiguities, duel responsibility and confusion at a later date. In case of small building projects, where the owner is the promoter, he arranges the finance himself and engages the contractors or suppliers, without going into the complexities of preparation of tender documents. But he also gets a detailed design from his consultant and fixes his terms, conditions and rate with his contractors and suppliers. Engineering is the activities where all the details study is being carried out such as preparation of instrument datasheets and all the construction details.

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION
Construction Layout: Layout is a systematic arrangement of an instrument items installation in Oil & Gas field as well as Refineries and Petrochemical complex. Types of Layouts are categories as follows. Construction Layouts: To prepare construction layout for Overall Instrument Cable tray trench routing basic input information required is overall plot plan where one can see or marked detail of all equipment, skids and packages are installed. With this one can start planning for instrumentation construction work like preparation of cable trench tray routing layout, JB location and Instrument location plans.

Fig.1: Overall Plot Plan Construction layouts are broadly categories as follows. 1. Overall Tray/Trench Layouts. 2. Instrument Location Layouts. 3. JB Location Layouts. Other, deliverable of Instrumentation design departments related to construction activities are as follows. 1. Hook Diagrams. a. Pneumatic Hook-ups b. Process Hook-ups 2. Cable schedule 3. Wiring Diagrams 4. Material MTO. 5. Details sections are explain in the subsequent article as follows. 1. Overall Tray /Trench Layouts: In this type of layout documents, entire cable tray /trench routing are shown for cable laying. Interconnections between control room to field are shown by this layout. Refer following fig for reference of such layout drawings.

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION
The tray /trench routing, elevation and type of cable tray, size of tray and all detail section are generally shown as minimum.

Fig. 2: Cable Tray layout

Fig. 3: Cable tray section detail

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION

Fig. 4 Actual Cable tray layouts

2. Instrumentation Location Layouts and JB Layouts: In this type of drawings generally instrument locations are marked at their respective elevation which is provided to us by piping departments. In some of the organization Instrument location layout and JB grouping are shown in the same layouts. Please refer layout as marked in below for Instruments as well as JBs.

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION

Instrument Hookup Drawings An engineering drawing prepared or it represents mechanical arrangement techniques for instrument installation. Instrument Hookup Drawings provides a utility that manages the installation details and components. The Hookup Diagram provides a dynamic Bill of Materials for Instrumentation.

Types of Hook-Ups: 1. Pneumatic Hookups. Pneumatic hook up means it is independent of process connection. This is basically a tubing/piping work.

2.

Process Hookups: Process hook ups means instruments are installed directly on process line.

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION
Pneumatic Hook Ups

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION

Cable Schedule:

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION
Material Take –Off (MTO): This is the total MTO of all the instrument items such as Cable tray, Cables (IS & Non-IS),JBs and instrument tube/pipe fittings. Also in these MTO depends upon the scope of work all structural steel required can be added. CONSTRUCTION MTO FOR INSTRUMENTATION ITEMS STT1 STT2 STB STW1 72-SBV31 Rema rks
Note 1

Sr.nos.
1 a

Description of items

Unit

ST-S

Total

Instrument cable trays - (Refer General Instrument specification for Packaged equipement:1806-5018-3 clause 5.4) 50mm W x 20 mm H ( SS316) M 35 35

b

300mm W x 50 mm H (SS316)

M

-

-

86

-

-

-

86

c

450mm W x 60 mm H(SS316)

M

-

-

90

-

-

-

90

2

160 dia. PVC Conduit for direct buried

M

370

160

-

50

30

30

640

3

160 dia. GI Conduit in Trench

M

330

-

-

-

-

-

330

4 a

Instrument Cables - (Refer General Instrument specification for Packaged equipement:1806-5018-3 clause 5.1) IS Cables TYPE 1(IS)-1P X 1.5 mm² M 676 160 64 128 64 1092

TYPE 1(IS)-1P X 2.5 mm²

M

-

-

-

-

-

80

80

TYPE 3(IS)-2P X 1.5 mm²

M

96

-

-

-

-

-

96

TYPE 3(IS )-5P X 1.5 mm²

M

112 0

-

284

208

336

-

1948

TYPE 3(IS)-10P X 1.5 mm²

M

464

-

-

104

-

-

568

TYPE 3 (IS)-10P X 2.5 mm²

M

-

208 0

-

-

-

1040

3120

TYPE 3(IS)-20P X 1.5 mm²

M

208

-

-

-

-

-

208

TYPE 4(IS)-2P X 1.5 mm²

M

-

-

-

48

-

-

48

TYPE 4(IS)-10P X 1.5 mm²

M

744

-

16

-

32

-

792

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION
TYPE 4(IS)-10P X 2.5 mm² M 16 16

Sr.nos.

Description of items
TYPE 4(IS)-20P X 1.5 mm²

Unit
M

STT1
476

STT2
208 0

STB
136

ST-S
32

STW1
224

72-SBV31
1040

Total
3988

Rema rks

TYPE 7 (IS)-1T X 1.5 mm²

M

24

-

8

-

-

-

32

TYPE 7 (IS)-1T X 2.5 mm²

M

-

-

-

-

-

16

16

TYPE 7 (IS)-2T X 2.5 mm²

M

-

32

-

-

-

-

32

b

Non IS Cables TYPE 1(NIS)-1P X 1.5 mm² M 628 48 64 740

TYPE 1(NIS)-1P X 2.5 mm²

M

-

160

-

-

-

32

192

TYPE 3 (NIS)-1P X 1.5 mm²

M

448

-

-

-

-

-

448

TYPE 3 (NIS)-2P X 1.5 mm²

M

-

-

228

-

224

-

452

TYPE 3 (NIS)-5P X 1.5 mm²

M

-

-

112

-

-

-

112

TYPE 3 (NIS)-10P X 1.5 mm²

M

48

-

48

96

32

-

224

TYPE 4(NIS)-1P X 1.5 mm²

M

-

208 0

32

-

-

-

2112

TYPE 4(NIS)-1P X 2.5 mm²

M

-

64

-

-

-

-

64

TYPE 4(NIS)-10P X 2.5 mm²

M

-

32

-

-

-

1088

1120

TYPE 4(NIS)-5P X 1.5 mm²

M

604

-

280

-

64

-

948

TYPE 4(NIS)-10P X 1.5 mm²

M

564

50

190

146

306

50

1306

TYPE 4(NIS)-20P X 1.5 mm²

M

100

50

370

258

162

50

990

TYPE 4(NIS)-30P X 1.5 mm²

M

160

-

136

208

112

-

616

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION
TYPE 4(NIS)-30P X 2.5 mm² M 1040 1040

Sr.nos.

Description of items
NON IS-10P X 2.5 mm²

Unit
M

STT1
-

STT2
-

STB
-

ST-S
-

STW1
-

72-SBV31
1040

Total
1040

Rema rks

CU/XLPE/SWB/PVC-1P X 1.5 mm²

M

416

-

-

-

224

-

640

CU/XLPE/SWB/PVC-2C X 2.5 mm²

M

-

-

228

-

-

-

228

c

Earthing wire Cable tray continuity: 16sqmm M 85 85

Note 2

Panel earth to electrical earthgrid: 6sqmm

M

400

400

400

400

400

400

2400

JB earths : 6sqmm

M

190

50

100

50

80

40

510

Instrument earthing: 4sqmm

M

770

140

220

120

140

100

1490

5 5.1. a

Instrument Junction boxes - (Refer General Instrument specification for Packaged equipement:18065018-3 clause 5.5) JB-IS (SS304 , IP 65) 20 terminal JBs ( IS ) NOS 6 1 1 8 Note 3

40 terminal JBs ( IS )

NOS

3

-

-

1

2

1

7

70 terminal JBs ( IS )

NOS

4

3

1

-

-

1

9

100 terminal JBs ( IS )

NOS

-

-

-

-

1

-

1

5.1. b

Spare plugs for JB-IS 20 terminal JBs NOS 12 2 2 16

Note 4

40 terminal JBs

NOS

9

-

-

3

6

3

21

70 terminal JBs

NOS

24

18

6

-

-

6

54

100 terminal JBs

NOS

-

-

-

-

9

-

9

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION
Instrument Cable Glands (SS316, complete with shroud) for IS JBs - (Refer General Instrument specification for Packaged equipement:1806-5018-3 clause 5.3) Cable gland (M20S) NOS 82 0 4 22 12 120

5.1. c

Sr.nos.

Description of items
Cable gland (M20)

Unit
NOS

STT1
16

STT2
26

STB
4

ST-S
-

STW1
-

72-SBV31
14

Total
60

Rema rks

Cable gland (M25)

NOS

12

-

6

2

6

-

26

Cable gland (M32)

NOS

22

-

2

4

2

-

30

Cable gland (M40)

NOS

8

12

2

0

4

4

30

Cable gland (M50)

NOS

-

4

2

-

-

2

8

5.2.a

JB-Non -IS (EExe,SS304, IP 65) 20 terminal JBs ( IS ) NOS 3 2 5

Note 3

40 terminal JBs ( IS )

NOS

2

-

2

1

3

1

9

70 terminal JBs ( IS )

NOS

1

2

3

1

1

0

8

100 terminal JBs ( IS )

NOS

-

-

1

1

1

1

4

5.2.b

Spare plugs for JB-Non IS 20 terminal JBs NOS 6 4 10

Note 4

40 terminal JBs

NOS

6

-

-

3

9

3

21

70 terminal JBs

NOS

6

12

18

-

-

0

36

100 terminal JBs

NOS

-

-

-

-

9

-

9

5.2.c

Instrument Cable Glands (SS316, complete with shroud) for Non IS JBs - (Refer General Instrument specification for Packaged equipement:1806-5018-3 clause 5.3) Cable gland (M20S) NOS 42 12 12 66

Cable gland(M20)

NOS

8

18

12

-

16

4

58

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION
Cable gland(M25) NOS 6 22 8 36

Cable gland(M32)

NOS

20

-

14

12

16

-

62

Sr.nos.

Description of items
Cable gland(M40)

Unit
NOS

STT1
-

STT2
4

STB
6

ST-S
2

STW1
4

72-SBV31
10

Total
26

Rema rks

Cable gland(M50)

NOS

-

4

-

-

-

-

4

Cable gland(M50S)

NOS

2

-

2

2

2

-

8

Cable gland(M60)

NOS

-

-

-

-

-

2

2

6 a

MTO -HOOK-UPS (Refer Inst. Process hook -up diagrams (Typical) : 1806-5022 & Inst. Pneumatic hook up diagrams (Typical) :1806-5029 ) Tubes 1/2"OD Tube x 0.065"WT (SS316L) M 100 30 5 45 10 12 202

1/2"OD Tube x 0.049"WT(SS316L)

M

50

40

30

0

40

12

172

1/4" OD Tube x 0.035"WT(SS316L)

M

11

6

1

7

2

2

29

3/8"OD x 0.049"WT(SS316L)

M

130

-

-

30

-

-

160

b

Tube fittings 1/2"NPT(M) X 1/2"OD Male Connector(SS316L) 1/2"NPT(M) X 1/2"OD Male Connector(SS316) 1/4"NPT(M) X 1/4"OD Male Connector(SS316L) NOS 35 6 1 15 2 2 61

NOS

40

32

24

-

32

10

138

NOS

22

12

2

14

4

5

59

1/4" NPT(F) Ball Valve(SS316L)

NOS

11

6

1

7

2

2

29

1/2" NPT(F) Ball Valve(SS316L)

NOS

5

-

-

2

-

-

7

1/4"Plug(SS316L)

NOS

11

6

1

7

2

2

29

1/2" OD Tube union(SS316L)

NOS

20

6

1

9

2

2

40

GUIDELINE FOR INSTRUMENT LAYOUT

CONSTRUCTION ENGINEERING FOR INSTRUMENTATION

1/2" OD Tube union(SS316)

NOS

15

12

9

-

12

4

52

Sr.nos.

Description of items
Tube adaptor 1/2"OD(SS316L)

Unit
NOS

STT1
18

STT2
12

STB
2

ST-S
10

STW1
4

72-SBV31
5

Total
51

Rema rks

1/2"NPT x 3/8"OD Male connector(SS316)

NOS

10

-

-

2

-

-

12

1/4" NPT x 3/8"OD(SS316)

NOS

6

-

-

2

-

-

8

3/8"OD Tube union(SS316)

NOS

20

-

-

4

-

-

24

1/2"OD Tube Tee compression type(SS316)

NOS

10

8

6

-

8

2

34

1/2" NPTF Pneumatic lock up valve(SS316)

NOS

5

4

3

-

4

1

17

c

Others Non return valve(SS316) 1/2"NPT NOS 5 4 3 4 1 17.2

Monoflange double block-bleed valve(SS316L) Gauge adaptor(SS316L) 1/2" NPT(F) x 1/2" NPT(M)

NOS

17

6

3

5

6

4

41

NOS

17

6

3

5

6

4

41

1/2" 150#RF Blind Flange(SS316L)

NOS

20

-

-

8

-

-

28

Sunshade(GRP)

NOS

9

6

1

5

2

2

25

Note 5

Note 1.Instrument cable tray heights are considerd as : Upto 100 mmW tray 20mm H, upto 400 mmW 50mmH & above 400mmW 60mmH Note 2. Earthing cable sizes and lengths are assumed. Note 3.No of terminals in JBs decided on size of mutlipair cables. Note 4. As per specifiction 30% spare plugs. Note 5. Sunshades for instruments in package, VEM flowmeterpackage considered as under vendor scope.

GUIDELINE FOR INSTRUMENT LAYOUT

Dattatray K. Nikam
Design Engineer ( Instrument)

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