Professional Documents
Culture Documents
DOD-MST-INS-002, MST For Installation of Field Instruments.-Rev-1
DOD-MST-INS-002, MST For Installation of Field Instruments.-Rev-1
DOD-MST-INS-002, MST For Installation of Field Instruments.-Rev-1
METHOD STATEMENT
FOR
INSTALLATION OF FIELD INSTRUMENTS
DOCUMENT NUMBER
: DOD-MST-INS-002
REVISION NUMBER :1
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 DEFINITIONS
5.0 RESPONSIBILITIES
6.0 PROCEDURE
7.0 DOCUMENTATION
The purpose of this Method Statement is to accomplish the Installation of Field Instruments in
accordance with applicable Project Specifications, Codes and Standards.
2.0 SCOPE
This scope covers Installation of field instruments which are covered within the
subcontractor’s scope of work for RasGas Onshore Expansion Project, Phase2.
3.0 REFERENCES
4.0 DEFINITIONS
5.2 E&I MANAGER / DEPUTY E&I MANAGER:- Shall be responsible for the
implementation of this Method Statement and ensure the required HSE and Quality
standards, practices and procedures are maintained for the Installation of Field
Instruments.
5.4 INST SITE- ENGINEER / SUPERINTENDENT:- Shall be responsible for the execution
of instrumentation works as per approved IFC drawings, project specifications &
standards. He shall be responsible for overall site supervision of work execution with
strict adherence to this method statement and required HSE and Quality standards,
practices and procedures at site. He shall be responsible to raise RFI for the works to be
inspected and attend punch points as required.
5.5 INSTRUMENT FOREMAN: Shall be responsible for the executing the instrumentation
work as per approved IFC Drawings, Specifications & Standards, method statement and
responsible for required HSE and Quality standards, practices & procedures at site.
5.7 SAFETY OFFICER shall ensure that all the Equipment, Tools and Tackles are certified
in accordance with the site HSE Requirement. All manpower, directly or indirectly
involved in this activity shall be informed of the hazards and risk factor. All regular Safety
Equipments (PPE) shall be used like helmet, goggles, work gloves, safety harness etc.
6.1 Safety
6.1.1 All equipment and accessories shall be verified for adequate capacity according to HSE
requirements. Refer JSA No.: DOD-MST-INS-002
6.1.2 All personnel involved in Installation of field Instruments shall be informed of hazards
and will adopt preventive measures while undertaking subject instrumentation works.
6.1.3 All personnel must use their Safety Equipments and Personnel Protective Equipments
(PPE).
6.1.4 Tool Box meeting shall be held daily, prior to start of the work
6.2 MATERIALS
All Materials shall be supplied by M/s CTJV based on the M/s RasGas Standard,
and Project purchase documents & approved manufacturer’s specification.
All materials purchased by Dodsal will be approved before usage by
CTJV QC vía “MAR” (Material Approval Request) form no: DOD-RGX-F037
The Dodsal Document Control Deptt shall ensure that all approved construction
drawings procedures & other necessary documents have been issued to the personnel-
in-charge of the work.
6.4.1 All material received at site shall be inspected, handled and stored upon receipt
in accordance with ITP DOD-RGX-F051.
6.4.2 All tests shall be conducted by qualified and experienced Instrument Technician under
the supervision of Instrument Site Engineer / Supervisor and QC Inspector.
6.4.3 Field QA/QC inspection item check list sheet shall be used to report the status of
completed installations.
6.4.4 The tests shall be recorded as defined herein and witnessed by the CTJV and
Company in accordance with the Contract Procedures. Prior to issuing the report forms,
this requirement will be signed by the Instrument QC Inspector.
6.4.5 All installation activities shall be checked to confirm that location, mounting,
accessibility, protection, maintenance provisions and installation workmanship is in
accordance with the requirements of the project specifications, standards and approved
construction drawings.
6.4.7 Local panels shall be suitably boxed for protection during installation work as per
DOD-MST-INS-001.
6.4.8 All instrument items will be covered during painting operation in their vicinity.
6.4.9 Instrument cases shall be positioned so that when doors are fully opened, covers
removed, vent holes are not impeded and all adjustments, controls and connections
shall be easily accessible.
6.4.10 Instruments shall not be mounted on handrails unless specially called for and
agreed in writing from the company.
6.4.12 Instrument panels shall be installed as defined in the installation drawings, and be
aligned horizontally & vertically by plumb and level. Securing devices shall be
installed for panels proper protection to be provided when stored outside. The
transporting and handling of panels shall always be with the correct tools and
equipment with full protection provided for the panel finish.
6.4.13 Special precaution shall be taken to guard against ingress of dust or dirt into
instrument connections and all temporary plugs etc, shall be retained in place
until replaced for the final connection. Throughout the construction period,
instruments shall be protected with plastic covers.
6.4.14 Special care shall be taken to prevent the ingress of moisture into instrument
casings. Silica Gel drying bags shall be retained as provided.
6.4.15 Process impulse and airlines shall be capped or plugged when temporarily
disconnected from the associated instruments. For every short period, ends may
be covered using masking tapes.
6.4.16 Instruments shall not be installed till all the necessary support structure are Installed
and inspected in order to protect the instrument. This includes support for capillary
connections etc.
6.4.17 When threaded fittings are used, DODSAL to ensure that mating thread forms are
compatible and where required the correct sealant area.
6.4.18 Pipe Bending shall be done using correct pipe bender apparatus and shall be free
from kinks or flats as per DOD-MST-INS-004.
6.4.19 Instrument connected to process pipes which vibrate heavily shall be provided with
additional independent supports with the lines arranged so as to be sufficiently
flexible, in order to minimize the vibration and to prevent the lines from vibrating at
resonant frequency.
6.4.20 Instrument shall not be supported by process lines, unless specifically designed
for direct mounting and capable of withstanding induced vibrations.
6.5.2 During the final installation inspection at Field / Site, any mechanical damage
noticed, the same shall be recorded on the Damage Report form no: DOD-RGX-F049
by Instrument QC Inspector.
6.6.2 Prior to shifting to site, the support frame, stand and / or bracket shall be inspected
and checked against the detailed drawing.
6.6.3 Particular attention shall be paid to the fixing points for correct sizing and orientation.
6.6.4 All rough edges shall be removed; the assembly primed and painted in accordance
with the Project Specifications.
6.6.5 The supports shall be located in accordance with the instrument layout drawing. The
final location shall be decided in the field with CTJV / Company personnel and shall
be as close as possible to the process tapping point.
The installation shall not obstruct access ways, exits or passage to equipment.
Sufficient access shall be maintained to allow maintenance in a safe manner.
The installation shall be positioned so that process piping wherever possible does
not pass over equipment.
Field Instruments shall be considered grounded by means of the cable gland via the
field cable steel wire armour otherwise an earth wire connected between the
manufacturers earth boss on the field instrument and bonded tray or main 1
structure.
Supports shall generally be attached to structural items and not process vessels,
lines or handrail etc. In cases, where other arrangements are required, the approval of
CTJV / Company must be obtained in writing before taking up the supports work.
Galvanized steel angle protector and cable tray / ladder can be used for
Capillaries of filled systems shall be run independently of all other lines and shall be
supported continuously by using galvanized steel angles with clips at 0.5 mtr.
Intervals.
Tray routes along faces of structural steel works that requires painting should be
stood off sufficiently to allow for future painting.
The installed support shall be inspected to ensure it’s level, vertical and the whole
assembly is rigid.
Where supports are installed on pre-cast concrete foundations, the fixings shall
be checked to ensure they are tight and secure.
Supports bolted to structural steel shall be checked to ensure all bolts etc. are
correctly installed and securely fixed.
Where supports are to be welded to structural steel, ensure welding work is carried
out in accordance with approved procedure. Touch-up paint shall be applied where
required.
All cables shall have cable markers fitted at both ends and any intermediate junction
where relevant cable numbers shall be visible at the instrument.
Each air header shall be clearly tagged and in the case of air manifolds each take-off
valve shall be individually tagged with the tag no of the associated instruments.
All junction boxes, relay boxes etc, shall be clearly identified using legible traffalyte
labels secured permanently to the front, or other approved means.
All field instruments shall be identified by equipment nameplate made from non
corrosive stainless steel and securely fixed to the instrument by stainless steel wire.
All indicating and controlling instruments and control valves shall have a clearly
visible label adjacent to them giving the tag number and brief description of the
process function. They should be made from white / black / white laminated plastic
with the exception of shutdown service shall be made from red/white/red laminated
plastic.
Where radioactive instruments or other hazardous items are installed, DODSAL shall
ensure that the appropriate safety warning labels are prominently displayed and any
necessary barriers correctly installed.
Identification shall be shown on all field components in a loop to make all personnel
are fully aware of the status of the installation.
Document No. DOD-MST-INS-002, Rev. 1
MST for Installation of Field Instruments. Page 10 of 15
6.8 Protection to Instruments and Installations:
Cut ends of galvanized steel tray shall be treated with a suitable zinc rich paint to
prevent corrosion.
The Sunshade shall be fixed to the mounting plate in such a way , that quick
installation and removal is guaranteed.
6.9.1 Prior to installation the instrument will have been “Bench Verified / Calibrated “ in
accordance with QCP, DOD-QCP-INS-002. The instrument shall be identified by “
Tag” number and checked to ensure it is color coded” Blue” signifying pre-
calibration has been carried out.
6.9.2 Upon installation the instrument shall be checked to ensure the mounting is as per
the approved method and fixing is secured.
The instrument elevation is as per the approved drawing and is above or below the
process tapping points as specified.
The orientation is such that process connections can be made with the minimum
number of bends.
Where the installed instrument has a local indicator or dial, the indication can be
read from grade or platform and where relevant also visible from any associated
control items such as control valve.
6.9.4 Where specified, sunshades shall be inspected to ensure they are as per the
detailed drawing and are securely fixed.
6.9.6 The Instrument Installation shall be recorded on the Form No: DOD-RGX-F420
6.10.2 Where instruments are to be flange mounted, the following shall be checked prior
to installation:-
Cable tray is suitably supported and routed for cabling
Flange orientation, to ensure the instrument installed vertically.
Mating faces of flange and instrument diaphragm are compatible.
Gasket is of correct material and dimension.
Bolts, nuts and washers are of correct material, length and diameter.
Where dual fixing is required, the two flanges are correctly spaced and their
alignment is corrected.
6.10.3 Bolts shall be tightened in sequence ensuring the gasket remains central and the
assembly is securely fixed.
6.10.4 Where dual flanges are employed, particular attention shall be paid to ensure no
undue stress or misalignment of the instrument flanges.
6.10.5 Where instruments are installed on screwed connections, the assembly shall be
checked to ensure it is as per the detailed instrument hook-up drawings.
610.6 Particular attention shall be paid to ensure that, all threaded connections are properly
tightened.
a) As most of the gas detectors other than optical type are sensitive to environmental
conditions. Manufacturer recommendation / instructions on storage shall be
followed.
b) Installation of sensors (part of Gas Detector ) shall only be carried out after
Completion of mechanical activities like welding, painting etc. In general,
installation of sensors shall be delayed to the latest possible moment and
sensors shall not be left without power supply once installed except during
loop checking.
b) Sensor heads shall be installed such that they are not adversely affected by
strong winds, sand / dust, water sprays etc., which can block the sensor heads or
cause excessive drift or reduced output signals.
c) Sensor heads spacing and the location shall be in accordance with approval for
d) Sensor heads shall be located in a position that would readily detect hazards and
provide safe access for periodic maintenance and calibration . Power supply and
electronic circuit shall be located in a non-hazardous area, preferably in auxiliary
room of control center or field auxiliary room.
f) Where required, climatic protection shall be provided e.g. sunshades / rain hoods
for detectors, horns, beacons etc.
g) The post installation checks shall include but are not limited to the following:
Tag numbers or equipment numbers are provided and numbers are clearly visible from
the ground level.
A visual inspection of the complete installation including equipment, sensor heads and
associated cabling.
Inspection for correct polarity of alarms devices, bells, sirens, beacons etc. and all other
items where correctness of polarity is required
h) After on-site installation the sub-contractor shall perform agreed tests and pre-
commissioning of the system as loop test according to Vendor’s instruction manual of
Fire & Gas Systems. All Test forms / sheets and records shall be prepared and
submitted by DODSAL to CTJV / Company as per Project Specifications :
RG6-S-00-1370-083
6.12.1 In-line instruments such as flow meters, orifice plates, valves etc., shall be identified
and checked as in 6.6
6.12.2 In-line instruments shall be installed by the piping Erection group in accordance
with this procedure and supervised by the Site Instrument Supervisor. Particular
attention shall be paid to ensure no undue stress on the instrument flanges.
6.12.3 Where in-line instruments have been installed to facilitate pipe-work erection, these
shall be removed and replaced by spools prior to flushing.
6.12.4 Where on/off, control and modulating valves are to be subjected to site test as
defined in QCP No: DOC-QCP-INS-002. This test shall be carried out prior to
installation in line.
6.12.5 During final installation particular attention shall be paid to the direction of flow to
6.13.1 On line analyzers and analyzer houses shall be installed and inspected as per
Project specification RG6-S-00-1370-028 and analyzer system vendor drawings.
6.13.2 Analyzer house location shall be shown on main plot drawing to ensure that an
adequate area is provided for enclosures.
6.13.3 The location and installation of the sample acquisition and return points shall be as
per analyzer system vendor drawings.
6.13.4 All components up stream of the takes off block valve and down stream of the
return block valve shall confirm to relevant process line specifications.
6.13.5 All sample piping and tubing’s shall be according to analyzer system vendor
drawings.
6.13.6 Sample take and return block valves shall be installed so that it is accessible from
grade platform or permanent ladder.
6.13.7 Installations and tubing’s connection of gas cylinders for calibrating samples,
carries gas and other utilities as per analyzer system vendor drawings.
6.13.8 All the wirings connections to the JB which is installed external of the analyzer
house shall be as per vendor supplied wiring diagram and this shall be checked
and recorded as per Quality Control Procedure : DOD-QCP-INS-003.
6.13.9 All inlet piping, tubing and bulkhead connection shall be labeled as per project
Specification RG6-S-00-1370-028, 5.1.10.
6.13.10 All the sample pipes and tubes shall be pressure tested and results shall be
recorded on the form no:
6.14 Certification:
6.14.1 After successful completion of each test, the instrument shall be marked with a
colored label bearing the date of the test and the initials of the witnessing party.
6.15.3 Check whether the instrument supports installed rigidly and painting done.
7 DOCUMENTATION