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.

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 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.

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 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.

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 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

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 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.

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 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:

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 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

ST- ST- ST- ST- 72-SBV- Rema

Sr.nos. Description of items Unit ST-S Total
T1 T2 B W1 31 rks
Instrument cable trays - (Refer General Instrument specification for Packaged equipement:1806-5018-3
1 Note 1
clause 5.4)
a 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

Instrument Cables - (Refer General Instrument specification for Packaged equipement:1806-5018-3

4
clause 5.1)
a 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

112
TYPE 3(IS )-5P X 1.5 mm² M - 284 208 336 - 1948
0

TYPE 3(IS)-10P X 1.5 mm² M 464 - - 104 - - 568

208
TYPE 3 (IS)-10P X 2.5 mm² M - - - - 1040 3120
0

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

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TYPE 4(IS)-10P X 2.5 mm² M - - - - - 16 16

ST- ST- ST- ST- 72-SBV- Rema
Sr.nos. Description of items Unit ST-S Total
T1 T2 B W1 31 rks
208
TYPE 4(IS)-20P X 1.5 mm² M 476 136 32 224 1040 3988
0

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

208
TYPE 4(NIS)-1P X 1.5 mm² M - 32 - - - 2112
0

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

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TYPE 4(NIS)-30P X 2.5 mm² M - - - - - 1040 1040

ST- ST- ST- ST- 72-SBV- Rema
Sr.nos. Description of items Unit ST-S Total
T1 T2 B W1 31 rks
NON IS-10P X 2.5 mm² M - - - - - 1040 1040

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 Note 2

Cable tray continuity: 16sqmm M - - 85 - - - 85

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

Instrument Junction boxes - (Refer General Instrument specification for Packaged equipement:1806-
5
5018-3 clause 5.5)
5.1. a JB-IS (SS304 , IP 65) Note 3

20 terminal JBs ( IS ) NOS 6 - 1 1 - - 8

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 Note 4

20 terminal JBs NOS 12 - 2 2 - - 16

40 terminal JBs NOS 9 - - 3 6 3 21

70 terminal JBs NOS 24 18 6 - - 6 54

100 terminal JBs NOS - - - - 9 - 9

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Instrument Cable Glands (SS316, complete with shroud) for IS JBs - (Refer General Instrument
5.1. c
specification for Packaged equipement:1806-5018-3 clause 5.3)
Cable gland (M20S) NOS 82 0 4 22 12 - 120
ST- ST- ST- ST- 72-SBV- Rema
Sr.nos. Description of items Unit ST-S Total
T1 T2 B W1 31 rks
Cable gland (M20) NOS 16 26 4 - - 14 60

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) Note 3

20 terminal JBs ( IS ) NOS 3 - 2 - - - 5

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 Note 4

20 terminal JBs NOS 6 - 4 - - - 10

40 terminal JBs NOS 6 - - 3 9 3 21

70 terminal JBs NOS 6 12 18 - - 0 36

100 terminal JBs NOS - - - - 9 - 9

Instrument Cable Glands (SS316, complete with shroud) for Non IS JBs - (Refer General Instrument
5.2.c
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

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Cable gland(M25) NOS 6 - 22 - 8 - 36

Cable gland(M32) NOS 20 - 14 12 16 - 62

ST- ST- ST- ST- 72-SBV- Rema
Sr.nos. Description of items Unit ST-S Total
T1 T2 B W1 31 rks
Cable gland(M40) NOS - 4 6 2 4 10 26

Cable gland(M50) NOS - 4 - - - - 4

Cable gland(M50S) NOS 2 - 2 2 2 - 8

Cable gland(M60) NOS - - - - - 2 2

MTO -HOOK-UPS (Refer Inst. Process hook -up diagrams (Typical) : 1806-5022 & Inst. Pneumatic hook -
6
up diagrams (Typical) :1806-5029 )
a 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
NOS 35 6 1 15 2 2 61
Connector(SS316L)

1/2"NPT(M) X 1/2"OD Male

NOS 40 32 24 - 32 10 138
Connector(SS316)

1/4"NPT(M) X 1/4"OD Male

NOS 22 12 2 14 4 5 59
Connector(SS316L)

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

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1/2" OD Tube union(SS316)

NOS 15 12 9 - 12 4 52
ST- ST- ST- ST- 72-SBV- Rema
Sr.nos. Description of items Unit ST-S Total
T1 T2 B W1 31 rks
Tube adaptor 1/2"OD(SS316L) NOS 18 12 2 10 4 5 51

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

NOS 10 8 6 - 8 2 34
type(SS316)

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

NOS 17 6 3 5 6 4 41
valve(SS316L)

Gauge adaptor(SS316L) 1/2" NPT(F) x 1/2"

NOS 17 6 3 5 6 4 41
NPT(M)

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.

Dattatray K. Nikam
GUIDELINE FOR INSTRUMENT LAYOUT Design Engineer ( Instrument)