TABLE OF CONTENTS

TABLE OF CONTENTS.................................................................................................... 1
1.0........................................................................................................................................ 1
1.0
INTRODUCTION .................................................................................................. 2
2.0
OBJECTIVE ........................................................................................................... 2
3.0
Scope: ...................................................................................................................... 2
4.0
References: .............................................................................................................. 3
5.0
Design Codes: ....................................................................................................... 34
6.0
Definitions and Abbreviations: ............................................................................. 45
6.1
Definitions: ....................................................................................................... 45
6.2
Abbreviations: ..................................................................................................... 5
7.0
Instrumentation System Design Process ................................................................. 6
7.1
Basic Steps of Detailed Engineering................................................................... 6
7.1.1
Order Review .............................................................................................. 6
7.1.2
Preparation for Kick3off Meeting ............................................................... 6
7.1.3
Kick3off Meeting ....................................................................................... 7
7.1.4
Detailed Engineering and Design Phase Procurement Related ............... 7
7.1.5
Procurement Phase ................................................................................... 14
7.1.6
Detailed Engineering and Design Phase Construction Related ............. 15
7.1.7
Post order Drawing/Document Verification ............................................ 21
7.1.8
Inspection and Testing ......................................................................... 2122
7.1.9
Installation and Commissioning Assistance ............................................ 22
7.1.10
As Built Drawing Preparation and Submission ................................... 2222
7.1.11
Prepare Close out Document with lessons learned .............................. 2223
8.0
Project Management ......................................................................................... 2223
9.0
Quality Management ......................................................................................... 2323
10.0 Annexure: .......................................................................................................... 2323
10.1 Work Instructions: ........................................................................................ 2323
10.2 Sample Formats/Templates:.......................................................................... 2324
1.0

1.0 INTRODUCTION
Controlsoft Engineering India Pvt Ltd is in the business of providing detailed
engineering services and consultancy for the Instrumentation requirements of both
new and existing plants/projects of various industries viz Chemical, PetroChemical,
Oil & Gas, Thermal Power, Water treatment & Water Distribution etc. The
Companys detailed engineering division is located at 110/111, Burma Colony,
Perungudi, Chennai.

2.0 OBJECTIVE
The objective of this detailed engineering Design Manual is to ensure that all
customer projects are being carried out with consistency following good engineering
practices and international standards and internationally accepted national standards.
This document shall be used as a reference while carrying our detailed engineering
activities and shall also be used to seamlessly train and induct new recruits who will
be carrying out detailed engineering activities..

3.0 Scope:
This manual provides guidelines to enable a degree of conformity to be achieved in
the preparation and checking of detailed engineering documentation and drawings
being prepared for the Instrumentation requirements of new and modernisation
projects, which are being carried out from Controlsoft Engineering office in Chennai.
The word Instrumentation above implies aspects of engineering other than Civil,
Process, Piping, mechanical and electrical. The design and detailed engineering scope
of a project is normally governed by the functional specifications, the User
Requirement Specifications and the Scope documents, as provided along with the
tender documents.
However, in general the design scope will cover the following aspects/activities:

Project Management

Instrumentation Design Basis

Instrument Index

IO List

Technical Specifications

Datasheets

Procurement Assistant

Control Philosophy

Cable Schedule

Cable Block Diagrams

Instrument/JB Location Plans

Instrument Tray Layout

Termination Drawings

Hook up Drawings

Loop Drawings

Material Take off

Inspection & Testing

Sizing and Calculations

As Built Drawings

Quality Checks

4.0 References:
The following documents from Client or his Consultant will be the basis for the
design scope and requirements.

Invitation to Bid

Functional Specification/User Requirement Specification

Scope of Work Document

Piping and Instrumentation Drawings

Plant Layout Drawings (Plan, elevations, sections)

Piping GA Drawings

Process and Operational Write up

Alarm and Trip Schedule

5.0 Design Codes:

The design of the instrumentation and control systems will be based on the relevant
international codes and standards, local laws and regulations, functional specifications
and design requirements as provided in the Clients tender documents and good
engineering practice.

In general the Instrumentation design of the customer projects shall comply with the
latest versions of the international codes and standards from the following bodies
(where applicable): 3
ABS

American Bureau of Shipping

ANSI

American National Standards Institute

API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing and Materials

AWS

American Welding Society

BS

British Standards

CENELEC

European Committee for Electrotechnical Standardization

DNV

Det Norske Veritas

ISA

Instrument Society of America

IEC

International Electrotechnical Commission

IMO

International Maritime Organization

IP

The institute of Petroleum

ISA

Instrumentation Society of America

ISO

International Standards Organization

MSS

Manufacturers Standardization Society

NACE

National Association of Corrosion Engineers

NEMA

National Electrical Manufacturers Association

NFPA

National Fire Protection Association

OSHA

Occupational Safety and Health Act

SOLAS

Safety of Life at Sea

TEMA

Tubular Exchangers Manufacturers Association

6.0 Definitions and Abbreviations:

6.1

Definitions:

CLIENT

The End user to whom the project is being built

CONSULTANT

The Consultant employed by End User

COMPANY

Controlsoft Engineering India Pvt Ltd

PROJECT

The project for which the order is received

6.2

Abbreviations:

KOM

Kick off Meeting

DCS

Distributed Control System

MDL

Master Deliverable List

IO

Input/Output

AI

Analog Input

AO

Analog Output

DI

Digital Input

DO

Digital Output

RTD

Resistance Temperature Detector

T/C

Thermocouple

7.0 Instrumentation System Design Process

The Instrumentation Detailed Engineering and Design process shall be carried out as
per the following Work Flow Chart:

7.1 Basic Steps of Detailed Engineering

7.1.1 Order Review

On Receipt of order from the client, the order shall be reviewed by the Project and
Sales team representatives for any deviations and discrepancies on both commercial
and technical front and the same will be listed and sorted out with client by the Sales
representative.

7.1.2 Preparation for Kick2off Meeting

The sales order file will then can be handed over to the Project/Engineering Manager
for his/her study. Based on the type and complexity of engineering involved, the
Engineering Manager will assign the team members. The engineering team will then
go through the customer input documents to understand the project and start preparing
their clarifications which are to be sorted out during the Kick off meeting.
The Engineering team will also prepare the Kick Off Meeting (KOM) agenda, the
venue, dates etc and forward the same to client. A typical KOM agenda (Word
format) is enclosed as Annexure xx.
The engineering team will also start preparing the following documents which are to
be reviewed and approved by the client during the kick off meeting:

Technical Clarification Points

Inputs that are needed from Client

Project Schedule (Gantt Chart)

Master Deliverable List (MDL) Excel Format

Deliverable Formats and Template Word, Excel or ACAD

7.1.3

Kick2off Meeting

The Kick off Meeting is generally arranged within 7 to 10 working days from Order
receipt and will be attended by the key project/engineering team members from
COMPANY, the CLIENTs representatives and their associates if any.
The meeting venue shall normally be the CLIENTs office and the meeting may
extend to 1 or 2 days depending on the size and complexity of the project.
During the KOM the following aspects will be sorted out and finalized:

Understanding the communication protocol between all the parties

Master Deliverable List and project schedule finalization

Understanding the deliverable submission and approval process

Understanding the plant process, operation and its control philosophies

Sorting out the technical clarifications and gaps

Approval of Deliverable formats and templates

Collecting the pre3final P and I Ds, process write up and Plant layout drawings
(if not ready finalize the date of receipt of these drawings as these are the
starting inputs for the project)

Minutes of meeting of KOM shall be prepared and distributed to all concerned.

Refer Annexure xx for a typical Kick3off Meeting Minutes.(Word format)

7.1.4 Detailed Engineering and Design Phase Procurement

Related
7.1.4.1 Instrumentation Design Basis
On completion of Kick3off meeting with CLIENT and understanding their design
requirements clearly, the Design Basis document is prepared. This document provides
the design guidelines and concepts for various types of instrumentation, its selections,
installations, process connections, DCS/PLC and other system configurations etc. The
document shall contain the following topics as minimum:

Field Instrumentation Selection and short descriptions

Brief Control System philosophy and the system architecture

Power Supply and other Utility requirements

Instrument Installation Details

Spare Philosophy

Fire and Gas Detection, where applicable

Safety Aspects

Environmental Protections

Engineering Standards to be followed

This document shall be submitted to the client for approval and based on the same the
detailed engineering activities will get started.
Refer Annexure xx for a detailed sample Instrumentation Design Basis. This
document shall be in Word format.
7.1.4.2 Instrument Database
7.1.4.3 Instrument Index
This document is prepared using the final P and I Diagram of the plant/project
(supplied by the CLIENT). The main purpose of this document is to have a list on the
various discrete instruments (tag number wise) that are to be procured for the project
and forms a cross reference document for datasheets, loop diagrams, hook up drawing
and purchase status. The main column headings that are generally covered in this
document are:
Tag No
Loop No
Area/Unit
Instrument Service Description
Type of Instrument
P and I D No (where this instrument tag appears)
Calibration Range
Plant Connection (Line or equip No)
Process Connection (type and size of tapping point)
Status (existing, new, replaced etc)
Location of Instrument
Datasheet No
Loop Drawing No
Hook up Drawing No
Purchase order No and Date
Manufacturer
Supplier

Remarks
The instrument Index does not show the tags of MCC or inputs/outputs from other
panels or software tags.
Also, the instrument index excludes the instruments that are being supplied as part of
vendor package. If these instruments are needed to be specified for completion, then
the status column shall be filled as By Vendor and the same is excluded from
procurement.
This document will be in Excel format.
Refer Annexure xx for a detailed sample Instrument Index.
7.1.4.4 IO List
This document is prepared to provide the list of Input and Output tags. Based on this
document only, the sizing of PLC/DCS is taken up (for procurement initiation). Also,
the document shows the type of input/output signals, voltage levels etc. The same
document is also used for allocating the IOs to the DCS/PLC racks/slots/channels by
the Control System vendor.
The Input/Output list includes all the analog and digital signals from the field as well
as the Input and Output signals from MCCs and other electrical equipments.
The column headings for this document are:
Instrument Tag
Instrument Service Description
Loop No
P and I Ref
Location of IO (origin of tag)
Type of IO (AI, DI, DO, AO, RTD, TC, Virtual etc)
Signal Type
Voltage Level
Calibration Range
Display Range
Hi Hi Alarm
Hi Alarm
Lo Alarm
Lo Lo Alarm
Control Setpoint
IO Cabinet No
Node No
Rack No

Slot No
Module Type
Channel No
Marshalling Cabinet No (if applicable)
Remarks
The IO list shall also show show the instruments that are being supplied as vendor
package, if they are hardwired to the DCS/PLC system.
This document will be in Excel format.
A separate document, if needed, is prepared for virtual IOs which are the Input/Output
tags connected to the DCS/PLC system via a communication network (ie these are the
soft tags and are not hardwired to directly to the PLC/DCS system). These IO details
are required as part of full database for graphic interface, data logging, alarm and
event logging etc.
Refer Annexure xx for a detailed sample IO list. This document will be in Excel
format.

7.1.4.5 Technical Specifications

Instrument Specifications are prepared for instrumentation items where a single page
datasheet is not sufficient to describe the requirements. Normally the specifications
will be more descriptive in nature and will have more detailed write up about the
features and functions of the instrument or its systems, the inspection requirements,
documents that are to be supplied by Vendors etc
Specifications will be prepared for the following instruments or their related systems:
DCS based Control system
PLC based Control Systems
SCADA
Fire and Gas detection/monitoring system
Emergency Shutdown systems
UPS
Control/Marshalling panels
Tank Gauging Systems
Custody Transfer Metering system
These documents will be of Word format.

Specifications for field instruments and valves can also be prepared if they are called
for as part of scope document.
Refer Annexure xx for sample tech specifications of various systems and
instruemntsinstruments. These documents will be of Word format.

7.1.4.6 Datasheets
Instrument Data Sheets are documents containing specification and information of an
instrument device. It specifies general information of instrument such as tag number
identification, service description, location (line number/equipment number), P&ID
number or drawing number reference, process data (if applicable), calibrated range (if
applicable), material, performance details (such as accuracy, linearity if applicable),
hazardous certification (for electrical device), accessories required, etc. The details of
information in data sheet may differ among each types of instrument such as
transmitter, switch, gauge, control valve.
For preparing the Instrument Datasheets we shall need the following ddocuments/
information:

Final P and I Diagram

Heat and Material Balance (if provided)

Instrument Index

Instrument Specifications

Vendor Catalogs

Piping Material Specifications

Line List

The following steps describe the work flow of preparing the datasheets:
P&ID provides

general information such as instrument tag number, service

description, line number/equipment number, P&ID number.

Process data.

Some of the following process data should be available for selection of

instrument; fluid type, fluid state (gas/liquid), design pressure, operating pressure,
design temperature, operating temperature, flow rate, density, viscosity, specific
gravity, ratio specific heat (gas), molecular weight (gas). However, the information of
process data which is required to be specified in the data sheet varies depends on the
instrument type. For example, a pressure gauge data sheet does not require ratio of
specific heat. By knowing those process data, Instrument engineer may select material
of instrument, calibrated range, body rating, etc. Process data can be obtained from
process discipline document named Heat and Material Balance. Other way,
instrument engineer may look to the line list, also issued by process discipline, to get
general process data. However, compared to HMB, only limited process data is
provided in line list document.
Project specification.

Company has specification which details minimum

requirement for instrumentation. In addition, it also provides standard that shall be

applied to instrument in order to have uniform specification for certain instrument

throughout the plant. This is intended to minimize the spare part and tools, also to
give ease of maintenance.
Calculation. Some instrument need to be calculated to have a proper size. This
calculation is required prior data sheet preparation. Control valve, pressure safety
valve, orifice plate, thermowell are some of instruments which need to be calculated.
Vendor catalog. It is recommended to refer vendor catalog during data sheet
preparation to ensure that the device is available on the market. Skipping this activity
could result difficulties in finding the instrument on the market during procurement
phase. If the instrument is not available on the market, it could change the design, not
only the instrument design but also could revert back up to process design. Not only
re3work, it also could result to project delay.
Code and Standard.

Last but not least, cross check to the related code and standard is
needed although this issue mostly has been covered in project specification.

The purpose of instrument data sheet:

When the data sheet completed, it is attached to requisition which to be sent to several
vendors. Vendors will offer their quotation with various model and manufacturer
among the offers. It is an instrument engineer responsibility to evaluate all quotation
and determine which offer is technically acceptable.
Having been considered its technical and commercial aspects, the instrument is
purchased. Following the purchase order, vendor will submit supporting document
and drawing. Based on vendor data, instrument data sheet may be updated to
accommodate details to make the data sheet as3built.
Finally, data sheet along with its supporting vendor data are stored in library or
document control and will be referred during construction, operation and
maintenance.
The Datasheets are prepared for the following instrument items:

Pressure Instruments

Temp. Instruments

Level Instruments

Flow Instruments

Analytical Instruments

Control Valves

Shutdown valves

Solenoid Valves

Signal Converters

Cables

Junction Boxes

Push Button Stations

Formatted: Bullets and Numbering

Datasheets will be of excel format and will have title block to enter customer and
project information, revisions etc.
Refer Annex xx for typical datasheets for each of the above types.
7.1.4.7 System Architecture
This drawing is prepared to show how the PLC/DCS/ICSS Control System
components and how they are interconnected. The system architecture shall show the
following components as minimum:
Operator/Engineer Workstations and Printers
PLC/DCS Control Processors (with or without redundancy)
Hardwired IO signals from different areas of the plant and MCCs
Softwired IO signals from other PLC/Control system
Various types of communication networks used
Network Interface Units
The system architecture drawing shall become part of the PLC/DCS technical
specification document which shall be sent to the Control System bidders.
This document shall be in Autocad format.
Refer annexure xx for a typical system architecture drawing.
7.1.4.8 Control/Equipment Room Layout
This drawing is prepared to show the location of various Instrumentation equipments
in such as marshalling cubicles, System cabinets, Operator Workstation consoles,
vendor supplied unit control panels (if applicable). Depending on the size of Control
System and their components,
7.1.4.9 Control Philosophy

7.1.4.10

Instrument Air Requirement Calculations

This document lists the Instrument air consumption points for the plant/project and
against each item the air consumption in terms of SCFM or Nm3/hr will be specified
to arrive at the total instrument air requirement. The final air requirement will be 1.5
times the actual air consumption. The consumer list shall contain any immediate or
near future consumption point too.
This document will be of Excel format.
Refer Annexure xx for a typical Instrument Air Requirement Calculation Sheet.
7.1.4.11

Instrument Power Requirement Calculations

This document lists the Instrument AC and DC power requirements for the Control
and instrumentation systems. The AC power shall normally be from UPS and shall be
used to power up the DCS/PLC processors, operator stations, 4 wire instruments etc.
DC power shall normally be of 24 V DC generated within the DCS/PLC Control
cubicle and is used as wetted voltage for digital inputs as well as to power up two
wire and 4 wire transmitters. DC power is also used to power up the solenoid valves
used for shutdown/on3off valves. Redundant DC power supply shall be advised due to
criticality of its usage. The consumption of these UPS and DC power supplies will be
estimated consumption point wise; this estimate will be used to size the DC power as
well as the UPS power needed for the plant.
Refer Annexure xx for a typical AC/DC power requirement calculation sheet.

7.1.5

Procurement Phase

7.1.5.1 RFQs
Once the Technical Specifications and Datasheets were prepared and approved by the
CLIENT, these documents were forwarded to CLIENT with a Request for obtaining
the Quotes from the Approved Vendor list. The enquiries for quotes are normally sent
by the CLIENT and they shall consolidate the quotes received from the Vendors
itemwise and forward the same to us for Bid evaluation.
7.1.5.2 Bid Evaluation
Once the bids for a specific type of Instruments/Valves/Systems are received from
CLIENT, the bids are evaluated with respect to the requirement
specification/datasheets forwarded to the bidder. If the bidder does not meet the
specification/datasheet, a Technical Query (TQ) will be prepared and forwarded to the
bidder for clarification and if needed, a revised quote shall be requested from the
bidder.
7.1.5.3 Bid Comparison & Technical Recommendation
Based on the technical verifications and adequacy checking, the bids will be accepted,
accepted with conditions or rejected and statements to that effect will be written on
the Bid Comparison document for CLIENTs review. The bid comparison statement
will be prepared for each type of RFQ where in the compliance and non3compliance
against each bid review points taken for evaluation.
Refer Annexure xx for a typical Bid Comparison & Technical Recommendation
document.

7.1.6 Detailed Engineering and Design Phase Construction

Related
7.1.6.1 Instrument and JB Location Plan
These drawings are prepared to indicate the approximate locations of various
instruments and valves that are having Input/output signals as per the Piping and
Instrumentation Diagrams and the junction boxes to which the signal cables from
these instruments/valves are connected to. The main three purposes of preparing these
drawings are:

To understand the density of locations of various instruments and valves in an

area and there by finalize the grouping of signals to various junction boxes.

To communicate to the instrumentation installation contractor about the

approximate locations of the instruments, valves and Junction boxes

To help the designer to estimate the Material take off of cables, trays etc

As a normal practice the signals are grouped to junction boxes as per the following
guidelines.

Separate Junction Boxes for Analog, Digital Inputs and Digital Outputs

Separate Junction Boxes for Intrinsic and Non3Intrinsic applications

Separate Junction boxes for Process Control, Emergency Shutdown and Fire
and Gas signals

However, refer the Instrumentation Design Basis document of the specific project to
understand the guidelines agreed for that project.
These drawings are prepared by using the final Equipment layout drawing, in ACAD
format, received from the CLIENT. The equipment drawings shall be modified to
remove all unwanted components/dimensions so as to have clarity and focus only on
the instrument and valve locations.
To prepare the Instrument and JB location plan drawings, following
documents/drawings are to be made available or prepared first:

Final P and I D (from CLIENT)

Final IO List

Final Equipment Layout Drawings (from CLIENT)

Final Piping GA Drawings (from CLIENT)

Vendor Drawings, where applicable (from CLIENT)

Nozzle Orientation Drawings for Vessel and Pipelines (from CLIENT)

Civil/Structural Plan/Elevation Drawings (from CLIENT)

Substation/MCC room Layouts (from CLIENT)

Refer Annexure xx for a typical Instrument and JB location plan drawing (ACAD)
7.1.6.2 Instrument Tray Layout

These drawings are prepared to show the routing of instrument cables on main trays
in the plant area, control room, MCC etc. In addition, instrument cable layout shows
the details related to instrumentation cable such as:

Location of field devices to be wired

Location of Junction boxes, Remote IO Cabinet and local control panels

Cable Tags (Number)

Cable going up/down listing

Tray support Indications

. The main two purposes of preparing these tray layout drawings are:

To communicate to the instrumentation installation contractor about the exact

routing of the Main cable trays and their supports.

To help the Instrument Designer to estimate the Material take off viz cable
length, tray length, requirements of tray bends, tees etc, requirement of tray
supports etc.

While preparing the Instrumentation Tray Layout drawings the following details are
to be taken into consideration:

Available sizes of Instrumentation trays in the market

Material of Trays

Availability of Tray accessories viz Bends, Tees etc

Allowable no of layers of cables to be laid

Cable diameters

Cable routing shall be as short as possible, however the designer shall consider some
factors such as high interference noise, hot source etc. Refer API 552 for more details.
These drawings are prepared by using the final Equipment and structural layout
drawings and final Piping GA Drawings, in ACAD format, received from the
CLIENT. As a general practice, the Instrumentation trays are routed on pipe supports
or pipe supporting racks, wherever possible/feasible. While routing the
Instrumentation trays care should be taken a distance of minimum 300 mm is
established between the power (electrical) and Instrumentation cable trays.
The piping GA/Equipment drawings shall be modified to remove all unwanted
components/dimensions so as to have clarity and focus only on the instrument trays
and their elevations/plans.
Refer Annexure xx for a typical Instrument and JB location plan drawing (ACAD)
7.1.6.3 Cable Block Diagram
Cable Block Diagrams are basically the Interconnection block diagrams showing
interconnection between each device including instrument, junction boxes,
marshaling cabinets, MCC, Local Control Panels, Unit Control Panels, etc. These

drawings can provide an overall view of Instrumentation cable connections for the
entire project.
The Cable Block Diagrams shall indicate the cable number and cable type of each
cable connecting two devices/equipments.
For preparing the Block diagrams the following documents and drawings are to be
made available/prepared:

IO List

Control System Architecture

Instrument Location Pland

Instrument Tray Layout

The Cable Block Diagrams form a reference for preparing junction box wiring
diagram/ connection list and marshaling cabinet wiring diagram which both
subsequently are required for preparing instrument loop diagram.
Together with instrument cable layout, this drawing is also used as a reference for
preparing instrument cable schedule.
Refer Annexure xx for a Cable Block Diagrams (ACAD)
7.1.6.4 Cable Schedule
This document lists the cables required to be laid for the entire plant (area wise if
needed). The list shows the list of cables per junction box as well as the
multicore/multipair cables to be laid between the junction box and control system
marshalling cubicle. The list shall also include direct cables from field to Marshalling
or system cabinets viz instrument power cables, cables not routed thro junction
boxes, cables between MCC and Marshalling cubicles, local panels to Marshalling
cubicles etc.
The cable schedule shall have the following fields as minimum:
Cable No
Origin Tag No (Tag number of Origin instrument/equipment)
Origin Description (Description of the Origin instrument/equipment)
Destination Tag No (tag number of destination equipment viz junction box,
marshalling cubicle etc)
Destination Description (description of destination equipment)
Cable Type (control, instrument signal, thermocouple, power etc)
Cable length (approx length of the cable between origin and destination
points)
Pair/Core Size (no of pairs/cores and its size)
Short Cable Spec
Cable Datasheet No

Cable Gland Type and size (Origin)

Cable Gland Type and Size (Destination)
The cable schedule will be used to estimate the different type of cables and their
length required for the plant. Also, this document will be used by the site contractor to
lay the cables.
7.1.6.5 JB/Equipment Schedule

7.1.6.6 JB Termination Drawings

7.1.6.7 Marshalling Termination Drawings

7.1.6.8 Hook Up drawings

Hook3up Drawings are detailed drawings showing typical installation of instrument in
a correct manner so that instrument operates properly (gives accurate indication and
prevent any issued which could potentially affect the measurement such as liquid trap
in gas impulse line).
Hook3up drawing indicates tubing slopes, position of instrument in reference to
process tapping point, scope break between instrument vs piping. Hook3up drawing
also gives information the requirement of bulk material for each installation. It also
details its specification (size, type and material) and the quantity.
There are two types of hook3up drawing:
Process Hook3Up
This hook3up drawing contains typical installations for instrument which connects to
the process
Pneumatic Hook3Up
This hook3up drawing contains typical installations for instrument which requires
instrument air such as control valve, actuated valve.
The hook up drawings are prepared with reference to the following
documents/drawings:

Piping and Instrumentation Drawings (P & ID)

Installation Detail Specification

Piping Specifications

P&ID tells the designer which instrument requires a hook3up drawing. A good
designer can also read whether the instrument tapped in gas service or liquid service.
Battery limit between instrument and piping shall be made clear, this is stated in
P&ID symbol and typical sheet or piping documents.

Installation detail specification will also specify items that should be utilized and
factor that should be considered in one installation
The purpose of Instrument Hook Up Drawing:

As stated earlier, information of the requirement of bulk material is stated for

installation on each sheet hence the bulk material required for the whole drawings
could be summarized and tabulated in a document named Material Take Off.
During project construction phase, this drawing is also referred as a guidance of how
to install the instrument properly.

7.1.6.9 Installation and Support Drawings

7.1.6.10

Instrument Tubing Layout

Instrument Tubing Layout shows routing of instrument tubing according to plant

layout and the location of source and destination points connected by tubing. In
addition, instrument tubing layout shows the details related to instrumentation tubing
such as:

Tubing number/identification

Tubing going up/down

Type of fluid carried inside the tubing i.e hydraulic or pneumatic (air/gas) by
appearance of different tubing symbol

Instrument tubing layout covers the following scope, but not limited to:

Tubing from instrument air distribution manifold instrument air header to

control valve and actuated valve.

Tubing for utility air from instrument air header to vendor package

Tubing for panel purging from instrument air header to panel enclosure

Tubing from chemical injection to process tapping point

Tubing for fusible plug loop

Those tubing may be drawn in separate instrument tubing layouts for convenience
The tubing layout drawing is prepared with reference to Instrument location plan,
disregarding instrument which does not require tubing. Point out the instrument which
requires instrument air such as control valve, actuated valve and utility air such as
vendor package, outdoor panel requiring purging
Instrument air header pipe could be extracted from piping plot plan
Location of process tapping could be obtained from piping plot plan
Routing should be as short as possible, however consider some factors which should
be avoided such as hot source, fire, accidental mechanical abuse, etc. Tubing slope
shall also be considered and pocket shall be avoided.

The purpose of instrument tubing layout:

Instrument tubing layout is to be used as a reference for preparing instrument tubing

schedule in determining the following:

List of the tubing required and its length

The point of source and destination of tubing

Instrument tubing layout is also a reference to identify the existence of all

instrument tubing in the plant.

7.1.6.11

Bulk Material Take Off

7.1.6.12

Loop Schematics

Loop schematics are diagrams which represent detailed electrical drawing showing a
signal connection from one point to control system. It could be signal connection
between:
Field instrument to control system (or vice versa)
Signal from Control Panel to control system (or vice versa)
Signal from MCC to control system (or vice versa)
Signal form one control system to another system
Loop diagrams show instrument (in a symbol) and its terminal numbers which are to
be connected, instrument cable, junction box number, terminal number assigned for
the specified instrument, multi3pair cable and pair number , marshaling cabinet
number, terminal number in marshaling cabinet, control system details (rack, slot, I/O
channel). It also clearly indicates location of each equipment by means of border line
as a limit.
Loop Diagrams usually show a single control loop which means it could only contains
just one input (sensor to control system), just one output (control system to final
element) or combination of both
To have the loop diagram completed and provide complete information, the following
are list of data required along with its source/reference:

Instrument Terminal number. Most instrument could be assumed to use (+)

and (3). Terminals. Instrument which needs special arrangement such as
smoke detector or instrument which in series loop, requires manufacturer
connection detail to make the cable is properly connected.

Junction box terminal number, this information could be obtained from JB

wiring connection

Marshaling terminal number, this information could be obtained from

marshaling wiring connection.

I/O point detail information. Obtain this information from I/O assignment
which is produced by system integrator or control system vendor.

It is used in checking of a correct installation and connection when tested during pre3
commissioning, commissioning and also for trouble shooting during operation.

7.1.6.13

Installation Contractor Scope Specifications

7.1.7

Post order Drawing/Document Verification

On placement of purchase order on vendors, the vendors shall be requested to submit

their datasheet, sizing calculations and manufacturing drawings for review and
approval before they start their manufacturing/fabrication. The vendor drawings are
essential for the following instruments:
In3line flow transmitters and elements
Control Valves
On3Off valves
Pressure Safety valves
Orifice Plates
Vessel Mounted level transmitters/switches
Analysers
Other than the field instruments, Control system vendors shall be requested to submit
their system drawings viz
GA Drawings of control panel
Wiring drawings
System architecture
Communication drawings
Functional Design spec
Test Specifications
QA and Inspection plans
IO allocation
Sequence and control Flow charts
Graphic functional spec etc
These drawings are to be verified and approved in consultation with client.

7.1.8

Inspection and Testing

7.1.9

Installation and Commissioning Assistance

7.1.10

As Built Drawing Preparation and Submission

7.1.11
learned

Prepare Close out Document with lessons

8.0 Project Management

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8..1 Master Deliverable List

8.2 Project Scheduling

Formatted: Normal

8.3 Project Reporting

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Formatted: Normal
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8.4 Document Numbering System

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8.5 Project Reviews

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8.6 Document Control

9.0 Quality Management

10.0 Annexure:
10.1 Work Instructions:

10.2 Sample Formats/Templates: