TVET PROGRAM TITLE: Mechatronics and Instrument Servicing

Management level IV
MODULE TITLE: Installing process instrumentation
and controlling cabling and tubing
MODULE CODE: ELE MIS4 M09 0814
NOMINAL DURATION:30hrs
MODULE DESCRIPTION: This module covers the
installation and termination of instrument and control
apparatus cabling and tubing for chemical, industrial or food
processing systems. It encompasses working safely and to
standards, routing cables and tubing to specified locations,
terminating cables and tubing and connecting wiring at
accessories and at instruments and control apparatus and
completing the necessary installation documentation
LEARNING OUTCOMES:
At the end of this module the trainer
will be able to
LO1: Prepare to install cabling and
tubing
LO2: Install cabling, tubing and
accessories
LO3: Completion and report
installation activities
 MODULE CONTENTS:
LO1: Prepare to install cabling and tubing
•OH&s procedures and policies
•Read and interpret drawings related to cable and tube layout
•Select tools and equipment and testing devices for the installation
•Legislation, regulation, polices and work place procedure
LO2: Install cabling, tubing and accessories
2.1 Terminate electronic cable and conductor
2.2 Terminate tubes and cables
2.3 Install accessories at the required locations
with acceptable tolerance
2.4 Routing ,placing and securing cable and
tubing
2.5 Install cabling and tubing
LO3: Completion and report installation
activities
3.1 Follow OH&S work completion risk
control measures
3.2 Clean work site and make safe
3.3 Make final check to the installed
wiring
3.4 Report the installation activities
Install process instrumentation and
control cabling and tubing
installation and termination of instrument and
control cabling and tubing for chemical, industrial or
food processing systems or equipment used in
medical procedures. It encompasses working safely
and to standards, routing cables and tubing to
specified locations, terminating cables and tubing
and connecting wiring at accessories and at
instruments and control apparatus and completing
the necessary installation documentation.
 Licensing/Regulatory Information
License to practice
Conditions may apply in some jurisdictions subject to regulations related to electrical
work. Practice in the workplace and during training is also subject to regulations
directly related to occupational health and safety and where applicable contracts of
training such as apprenticeships.
Note: 1. Compliance with permits may be required in various
jurisdictions and typically relates to the operation of plant,
machinery and equipment such as elevating work platforms,
powder operated fixing tools, power operated tools, vehicles,
traffic control and lifting equipment. Permits may also be required
for some work environments such as confined spaces, working
aloft, near live electrical apparatus and site rehabilitation.
2. Compliance may be required in various jurisdictions relating to
currency in First Aid, confined space and lifting and risk safety
measures.
 ELEMENT PERFORMANCE CRITERIA
 OHS procedures for a given work area are identified,
obtained and understood Prepare to install cabling and
tubing.
 Health and safety risks are identified, and established risk
control measures and procedures in preparation for the work
are followed.
 Safety hazards that have not previously been identified are
noted, and established risk control measures are
implemented.
 Installation of cabling and tubing is prepared in consultation
with other affected by the work and sequenced appropriately.
 Cable and tube routes are planned within the constraints of
the building and plant structure,Significant and regulations.
 OHS risk control measures and procedures for carrying out
the work are followed. Install cabling, tubing and
accessories.
 Cabling, tubing and accessories are installed to comply with
technical standards and job specifications and requirements
with sufficient excess to affect terminations.
 Cables and conductors are terminated at accessories in
accordance with manufacture's specifications and regulatory
requirements.
 Tubing is terminated at accessories in accordance with
manufacture's specifications and regulatory requirements.
 Cabling and tubing installation is carried out efficiently
without waste of materials and energy or damage to
apparatus.
 REQUIRED SKILLS AND KNOWLEDGE
• Evidence shall show that knowledge has been acquired
of safe working practices and installing process
instrumentation and control cabling and tubing. All
knowledge and skills detailed in this unit should be
contextualised to current industry practices and
technologies.
 Cables in buildings, structures and premises
Electronic cable and conductor termination
The evidence guide provides advice on assessment and
must be read in conjunction with the Performance
Criteria. In some circumstances, assessment in part or
full can occur outside the workplace. However, it must
be in accordance with industry and regulatory policy.
• The critical safety nature of working with electricity,
electrical equipment, gas or any other hazardous
substance/material carries risk in deeming a person
competent. Sources of evidence need to be 'rich' in
nature to minimise error in judgment. Activities
associated with normal everyday work influence
how/how much the data gathered will contribute to
its 'richness'. Some skills are more critical to safety
and operational requirements while the same skills
may be more or less frequently practised. These
points are raised for the assessors to consider when
choosing an assessment method and developing
assessment instruments.
Install process instrumentation and control cabling and tubing as listed as described in

A .Reading and interpreting drawings related to cable and tube

layouts, schedules and process control apparatus locations
B .Routing, placing and securing cables and tubing to comply
with requirements
C . Placing and securing accessories accurately
D . Maintaining fire integrity
E .Terminating cables and tubing to comply with requirements.
F. Dealing with unplanned events by drawing on essential
knowledge and skills to provide appropriate solutions
incorporated in a holistic assessment with the above listed
items.
 This should include:
• OHS policy and work procedures and
instructions.
• Suitable work environment, facilities, equipment
and materials to undertake actual work as
prescribed by this unit.
These should be part of the formal
learning/assessment environment.
Note
• Where simulation is considered a suitable strategy for
assessment, the conditions must be authentic and as far as
possible reproduce and replicate the workplace and be
consistent with the approved industry simulation policy.
• The resources used for assessment should reflect current
industry practices in relation to installing process
instrumentation and control cabling and tubing. Wiring
systems include armoured cable; fire performance cables e.g.
MIMS; thermoplastic insulated cable; thermoplastic sheathed
cable; UTP, FTP, STP and coaxial communications cables.
• Tubing types include low pressure metallic and non-metallic
tubing and high pressure tubing
• Generic terms used throughout this Vocational Standard shall
be regarded as part of
• The Range Statement in which competency is demonstrated.
NOTE: tolerances are to be used when
comparison of test results is by split samples. A
tolerance of plus or minus two (2) standard
deviations shall be used when comparison of
test results is by proficiency samples.
Legislation 
• Acts/Statutes, and delegated/subordinate
legislation, such as rules, regulations and by-
laws. The Commonwealth now refers to
delegated legislation as legislative instruments.
Principal and amending Acts
Acts which are still in force may be amended by a later
Act/s, known as the amending Act/s. The original Act is
then referred to as the Principal Act (if it is an Act which
deals comprehensively with an area of law) so as to
distinguish between it and the later amending Act/s.
Cable Management
 Cable management can be a hassle, but these low-
profile options are easy to use and quick to install. Add
these to any office that uses numerous electronics for a
clean, professional look, no matter how many cables
there are. Plus, you can reduce safety hazards by
keeping loose cords off the floor.
 Tubing: tube(conveyance) pvc plastic tubing for use as a conduit for
electric wires. a tube or tubing is a long hollow cylinder used for moving
fluids (liquids or gases)or to protect electrical or optical cables and wires.
the terms ‘’pipe’’ & ‘tube’ are almost interchangeable, although minor
distinctions exist-generally,a tube has tighter energineering
requirements than a pipe. both pipe & tube imply a level of rigidity &
permanence, where as a hose is usually portable & flexible. a tube
&pipe may be specified by standard pipe size designations. Many types
of tubing are specified by actual inside diameter, outside diameter, or
wall thickness.
Hard plastic tubing can easily hold a number of cables. These cord management
tubes are flexible, allowing you to move them around desk legs and corners to fit
exactly where they are needed. Tubes are typically stiff enough to protect cords
and wires from being damaged from wandering feet or chair legs. 
Ties and Straps
Ties and straps help bundle cords together without fully covering the
entirety of the wires. Use these options for areas with many
computer cables, because they can easily bundle a high number of cords.
These are ideal for use in server rooms or entertainment areas with many
cords going in the same direction. 
 Electrical wiring

Building wiring is the electrical wiring and associated devices

such as switches, meters and light fittings used in buildings or
other structures. Electrical wiring uses insulated conductors.
 Wiring safety codes
Wiring safety codes are intended to protect people and property
from electrical shock and fire hazards. Regulations may be
established by city, county, provincial/state or national
legislation, usually by adopting a model code (with or without
local amendments) produced by a technical standards-setting
organisation, or by a national standard electrical code.
 In a light commercial environment, more frequent wiring
changes can be expected, large apparatus may be installed
and special conditions of heat or moisture may apply. Heavy
industries have more demanding wiring requirements, such
as very large currents and higher voltages, frequent changes
of equipment layout, corrosive, or wet or explosive
atmospheres. In facilities that handle flammable gases or
liquids, special rules may govern the installation and wiring
of electrical equipment in hazardous areas.
 Wires and cables are rated by the circuit voltage,
temperature rating and environmental conditions (moisture,
sunlight, oil, chemicals) in which they can be used. A wire or
cable has a voltage (to neutral) rating and a maximum
conductor surface temperature rating. The amount of
current a cable or wire can safely carry depends on the
installation conditions.
 securing wiring that are now obsolete include:
• Re-use of existing gas pipes when converting gas light
 installations to electric lighting. Insulated conductors were
pulled through the pipes that had formerly supplied the gas
lamps. Although used occasionally, this method risked
insulation damage from sharp edges inside the pipe at each
joint.
• Wood mouldings with grooves cut for single conductor wires,
covered by a wooden cap strip.
• A system of flexible twin cords supported by glass or porcelain
buttons was used near the turn of the 20th century in Europe.
• During the first years of the 20th century, various patented
forms of wiring system such as Bergman and Peschel tubing
were used to protect wiring; these used very thin fiber tubes,
or metal tubes which were also used as return conductors.
• A cable may carry multiple usage ratings for
applications, for example, one rating for dry installations
and another when exposed to moisture or oil.
Cables for industrial, commercial and apartment buildings
may contain many insulated conductors in an overall
jacket, with helical tape steel or aluminium armour, or
steel wire armour, and perhaps as well an overall PVC or
lead jacket for protection from moisture and physical
damage. Cables intended for very flexible service or in
marine applications may be protected by woven bronze
wires. Power or communications cables (e.g., computer
networking) that are routed in or through air-handling
spaces (plenums) of office buildings are required under
the model building code to be either encased in metal
conduit, or rated for low flame and smoke production.
Cables usually are secured by special fittings where they enter
electrical apparatus; this may be a simple screw clamp for jacketed
cables in a dry location, or a polymer-gasketed cable connector that
mechanically engages the armour of an armoured cable and provides a
water-resistant connection. Special cable fittings may be applied to
prevent explosive gases from flowing in the interior of jacketed cables,
where the cable passes through areas where inflammable gases are
present. To prevent loosening of the connections of individual
conductors of a cable, cables must be supported near their entrance to
devices and at regular intervals through their length. In tall buildings,
special designs are required to support the conductors of vertical runs
of cable. Usually, only one cable per fitting is allowed unless the fitting
is otherwise rated.
Special cable constructions and termination techniques are required
for cables installed in ocean-going vessels; in addition to electrical
safety and fire safety, such cables may also be required to be pressure-
resistant where they penetrate bulkheads of a ship. Resistance to 
corrosion caused by salt water or salt spray is also required.
 Termination
It is the process of connecting lug or connectors to
the wires well as the preparation of cable ends
(wire ends) etc.
 a signal involves providing a terminator at the end
of a wire or cable to prevent an RF signal from being
reflected back from the end, causing interference.
The terminator is placed at the end of a 
transmission line
 Electrical terminations.
Electrical termination is an electrical industry term used
to describe the specific point at which a conductive
device, such as wire or cable, ends or starts. The
conductive device may or may not pass the carried
electricity or signal onto another conductive device at
this point. A common point of electrical termination is at
a terminal block. A wire typically ends, or terminates, at
the terminal block; but the electricity or signal may be
passed onto the terminal connectors.
Signal termination is a very different type of termination
which often requires the installation of a special device,
known as a terminator, at the end of a wire or cable to
prevent an RF signal from being reflected back from the
end, causing interference.
Forced Perfect Termination (FPT)
Forced Perfect Termination can be used on single
ended buses where diodes remove over and
undershoot conditions. The signal is locked between
two actively regulated voltage levels, which results in
superior performance over a standard active terminator.
Cable Termination & Wire Connectors
If you need to terminate your wires and/or splice them
together, you've come to the right place. Our selection of
wire connectors features plenty of options, including
winged and non-winged, twist-on, push-in, and even
transparent connectors to allow for post-connection
inspection. We also have metal lugs for compression
and grounding applications.
Designed to save time and give you instant visual
confirmation of a successful splice, require only low
insertion force, and install in half the time of traditional
butt splices.
 CABLE MANAGEMENT
Splicing and termination of underground electrical
distribution cable requires that the integrity of cable
conductor and insulation be maintained throughout its
length. A large number of commercial cable splice and
termination kits are available which are claimed to fulfill
these requirements. Special interest was the slip-on
cable splice and cable termination for solid dielectric
insulated cable. To splice electrical power cable,
insulation material is wrapped. Around the joined
conductor. With the development of solid
dielectric Insulated cables came the premolded or
'slip-on'' splice kit, a large number of which are
commercially available
The manufacturers claim that the kits provide the same or
improved splice quality when compared to the hand-
wrapped type, with less training and experience required
of the installation personnel. The objective of testing these
splice kits is to evaluate their electrical properties, safety,
durability, reproducibility, ease, and time and cost of
installation. Electrical power is normally distributed by
copper or aluminum Conductors. In overhead distribution
systems where conductor separation from ground and
each other can be maintained, insulation is not necessary.
This is not the case where the electrical distribution system
is underground or is accessible to personnel. Oil-
impregnated paper, varnish cambric, or a solid dielectric
material is used to insulate high voltage power cable. The
first two types of insulation
require a lead sheath to protect the insulation from the
environment. Because of the lead sheath, splicing and
termination of cables with these types of insulation
must be performed by a highly skilled cable splicer.
The solid dielectric insulated cables have a rubber or
rubber-like material covering the conductor to provide
both insulation and environmental protection. Splicing
of this type of cable requires use of insulation material
to build up the insulation over the joined conductors.
The finished result must be electrically equivalent to
the original cable insulation. Several different types of
termination and splice kits are available to simplify this
procedure. They include: kits that provide tape and
directions, kits that have precut tape, and premolded
slip-on cable splices.
Beyond cable shield types, two common configurations are used:
• Single conductor...consisting of one conductor per cable or three
cables for a three-phase system.
• Three conductor...consisting of three cables sharing a common
jacket
Each component is vital to an optimally performing power
cable and must be understood in order to make a
Dependable splice or termination.
 Splicing
A splice may be considered as two or more conductors joined with a
suitable connector...reinsulated, reshielded and rejacketed with compatible
materials...applied over a properly prepared surface. Whenever possible,
splicing is normally avoided. However splicing isoften an economic
necessity. There can be many reasons for building splices such as:
• The supplied length of cable is not sufficient to perform the intended
job...... only so much cable can be wound on a reel (reel ends)... only so
much cable can be pulled through so much conduit, around so many bends,
etc.
• Cable failures
• Cables damaged after installation
• A tap into an existing cable (tee or wye splices) In all the above cases, the
option is to either splice the cable or replace the entire length. The economy
of modern splicing products in many cases makes splicing an optimal
choice. Whatever the reason to splice, good practice dictates that splices
have the same rating as the cable. In this way the splice does not derate the
cable and become the weak link in the system.
Instrumentation cable is generally used to
transmit a low power signal from a transducer
(measuring
For example, pressure, temperature, voltage,
flow, etc.) To a PLC or DCS process control
computer or to
a manually operated control panel. It is normally
available in 300 or 600 volt constructions with a
single
Overall shield, or with individual shields over
each pair (or triad) and an overall shield.
Control cable
with overall
shield
Thermocouple Wire
A thermocouple is a temperature measuring device consisting of two
conductors of dissimilar metals or
alloys that are connected together at one end. At this thermocouple
junction, as it is called, a small
voltage is produced. Electronic instrumentation senses this voltage and
converts it to temperature.
Thermocouple wire or extension grade wire is recommended for use in
connecting thermocouples to
the sensing or control instrumentation. The conditions of measurement
determine the type of thermocouple wire and insulation to be used.
Temperature range, environment, insulation requirements,
response, and service life should be considered
Unshielded Twisted Pair (UTP) and Shielded Twisted Pair (STP) are low
pair count cables (usually
2 to 8 pairs) that have been designed for use in local area networks such as
Token Ring, Ethernet,
etc.
 ADDITIONAL
STP, UTP, FTP Cable
When it first became available, shielded cables were used in
areas such as factory floors, areas with high concentrations of
electrical equipment, and secure communications applications.
Today, shielded cable is prevalent in many types of
applications, including government, healthcare and even
education.
(UTP)Unshielded twisted pair a popular type of cable that
consists of two unshielded wires twisted around each other. Due to its low
cost, UTP cabling is used extensively for local-area networks (LANs) and
telephone connections.
(STP)  shielded twisted pair wiring protects the transmission
line from electromagnetic interference leaking into or out of
the cable. STP cabling often is used in Ethernet networks, especially fast
data rate Ethernets. Contrast with UTP.
(FTP), fully shielded (or Foiled)
Twisted Pair is a Shielded twisted pair
(STP or STP-A) STP cabling includes
metal shielding over each individual pair of
copper wires.
Coaxial cable or coax is a type of cable that
has an inner conductor surrounded by a tubular
insulating layer, surrounded by a tubular
conducting shield. Many coaxial cables also
have an insulating outer sheath or jacket.
Legislation (or "statutory law") is law which has
been promulgated (or "enacted") by a legislature or
other governing body or the process of making it.
Legislation can have many purposes: to regulate, to
authorize, to outlaw, and to provide (funds), to
sanction, to grant, to declare or to restrict. It may be
contrasted with a non-legislative act which is adopted
by an executive or administrative body under the
authority of a legislative act or for implementing a
legislative act.
Routing is the process of selecting best paths in a network.
Routing is performed for many kinds of networks, including the 
public switched telephone network (circuit switching), 
electronic data networks (such as the Internet), and 
transportation networks. This article is concerned primarily with
routing in electronic data networks using packet switching
 technology.
In packet switching networks, routing directs packet forwarding
 (the transit of logically addressed network packets from their
source toward their ultimate destination) through intermediate 
nodes. Intermediate nodes are typically network hardware
 devices such as routers, bridges, gateways, firewalls, or 
switches. General-purpose computers can also forward packets
and perform routing, though they are not specialized hardware
and may suffer from limited performance. The routing process
usually directs forwarding on the basis of routing tables, which
maintain a record of the routes to various network destinations
Thus, constructing routing tables, which are held in the
router's memory, is very important for efficient routing.
Most routing algorithms use only one network path at a
time. Multipath routing techniques enable the use of
multiple alternative paths.
Routing, in a more narrow sense of the term, is often
contrasted with bridging in its assumption that 
network addresses are structured and that similar
addresses imply proximity within the network.
Structured addresses allow a single routing table entry
to represent the route to a group of devices. In large
networks, structured addressing (routing, in the narrow
sense) outperforms unstructured addressing
(bridging). Routing has become the dominant form of
addressing on the Internet. Bridging is still widely used
 INDIVIDUAL ASSIGNMENT
1.What is the d/nce and similarity b/n
termination And splice consider the
mechatronic system.
2.What is the d/nce b/n tube & pipes.
3.Why need have installed in mechatronic
device.
4.What is necessary cabling and tubing
regulator.
5.What is the purpose of amending act
consider the install cabling & tubing
6.How do you do manages cable.
7. Write the purpose pvc.
8.What is d/nce & similarity of
cable and tube.
9.Write the use wiring safety codes.
10.Describe the term of install.