DESCON ENGINEERING LIMITED MS/EI/04

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METHOD STATEMENT
FOR
FIELD INSTRUMENTS INSTALLATION

0 Initial Issue May17, 2002 A.Hameed Q.Mannan

Rev. Comments Date Prepared by Checked by Approved by Client

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INDEX

1. PURPOSE

2. SCOPE

3. REFERENCES

4. DEFINITIONS

5. RESPONSIBILITIES

6. PROCEDURE

7. TOOLS AND EQUIPMENTS

8. SAFETY INSTRUCTIONS

9. ATTACHMENTS
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1. PURPOSE
The objective of this method statement is to provide general guidelines for
calibration and installation of field instrumentation at project site.

2. SCOPE

Scope of this method statement covers the following activities.

 Material handling
 Procedure
 Precautions
 Inspection

3. REFERENCES

3.1 PROJECT DRAWINGS

 Instruments Layout Drawings.

 Installation Standards
 Others.

3.2 PROJECT QUALITY PLAN (PQP)

 Project Quality plan for Field Instrumentation

3.3 CODES AND STANDARDS

Related latest Standard Codes and Specifications

4. DEFINITIONS
CL Client
PM Project Manager
SM Site Manager
CM Construction Manager
DE Discipline Engineer
ITP Inspection and Test Plan
QC Quality Control
QCI Quality Control Inspector
PQP Project Quality Plan
PPE Personal Protection Equipment
HSE PLAN Health Safety & Environment Plan.
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5. RESPONSIBILITIES
 It is overall responsibility of PM/SM to organize resources to perform
construction activities as per project specification, in compliance with quality,
schedule & safety requirements.

 It is the responsibility of CM that construction activities are executed according

to the relevant project specifications, in compliance with quality, schedule &
safety requirements.

 DE will ensure that all the works are performed safely as per latest Approved
for Construction (AFC) drawings & specifications.

 The relevant DE and Supervisor will ensure that all the piping work is
conducted in accordance with this method statement and project
specifications

 The QC Inspector will ensure that all work is executed according to PQP and
that requirements of quality dossier are full filled.

 Safety and Construction activities shall be carried out with the close
coordination of client.

6. PROCEDURES – METHOD OF WORKS – INSTRUCTIONS

6.1 RECEIPT AND STORAGE OF MATERIAL

 The instruments received from client shall be stored in the designated area of 3
the warehouse. 1

 Arrangements shall be made, and maintained, to ensure protection against the

effects of local weather and construction environment.

 During shifting of the instruments special care shall be taken to protect from
any damage. Proper lifting and transporting equipment shall be used as 3
required. 1

 The material shall be placed on storage racks. They shall be adequately

supported to minimize damage.

 All material shall be segregated accordingly to facilitate location of the items.

6.2 PROCEDURE

6.2.1 Pre-Installation and Function / Calibration Checks

 All instruments are to be checked, on receipt, for identification and tagging.

Missing identification marks are to be provided.
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 Each instrument is to be mounted in test lab in a position similar to its field

mount and put to simulated function test check for calibration.

 Function check and / or calibration data of the instrument is to be recorded

giving date and time of checks.

 All instruments are to be stored properly, after laboratory tests, safe from
dust, heat and humidity until required for field installation.

 All mal-functioning instruments are to be reported to client immediately after

laboratory tests are completed.

 Mounting of instruments including the pedestal-mounted instruments shall

be in accordance with location and detail drawings. These instruments along
with equipment shall be located in accordance with the following guidelines.

 Each instrument or equipment to be installed shall be inspected to check

that its data meets with the specification. The instrument shall then be
examined for calibration and installed in its intended location on brackets, a
sub-panel, mounting post or pedestal ensuring that it is leveled and firmly
secured. The instruments which require re-calibration as specified by
customer shall then be bench tested / calibrated prior to installation.

 Instruments and associated equipment shall be supported in accordance

with methods shown on typical drawings.

 Instrument location generally should not obstruct equipment access or

walkways. A check shall be implemented to ensure that access to hand
valves and equipment is not impaired. Repositioning of control valve hand
wheels or positioners may be carried out, with approval of the Customer.

 All instruments and instrument scales shall be installed in a vertical

orientation (unless otherwise specified). It is ensured that all indicating
instruments shall be readable from floor level or permanent ladders or
platforms. All isolation, vent and drain valves shall be operateable from
permanent platform or ladders.

 Where capillary systems are used, they shall be continuously supported and
protected and any excess length neatly coiled on a former. The installation
shall not introduce any standing errors.

 Mounting materials shall be selected to avoid electrolytic corrosion.

 Protective enclosures shall be provided for instruments as specified and

shall be installed in locations where maximum access is provided for
maintenance purposes.

 Care shall be taken that the forces developed by the expansion of piping or
vessels shall not damage instruments or impulse piping.
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 Control valves shall be located in accordance with piping detail drawings

and, in general, shall be accessible from floor level or permanent platforms.
Clearance shall be allowed above the control valve to allow for servicing of
the actuator and below for servicing the valve internals where applicable.
Suitable clearances shall also be allowed to give access to manual hand
wheels and valve positioners.

 Care shall be taken in locating tapping points to keep the impulse lines as
short as possible. Allowance shall also be made for withdrawal as
necessary.

6.2.3 INSPECTION

 Quality inspection plan (QIP) specific to project requirements shall be made

and inspection activities are recorded on the formats as given in para related
documents or client supplied formats may be used.

PRECAUTIONS
6.3.1 Existing Installations

 No one shall be allowed to interfere with or work on, or work in the immediate
vicinity of, any existing electrical installations or equipment without a valid
permit to work. This applies to both temporary and permanent electrical
installations and equipment.

 Where it would be required to work in the vicinity of electrical equipment all

necessary precautions to avoid accidental contact with live conductors etc.
would be taken.

 Installation, modification or work in the immediate vicinity of any electrical

equipment shall only be carried out under full time supervision by a competent
qualified electrician.

 Only persons under full time supervision by a competent qualified electrician

shall be permitted inside substations, unless with written permission from the
Client’s Representative.

6.3.2 New Installations

 The electrical supply to powered hand tools shall not exceed 24 volts. Where
this is not possible, due to the type of tool being used, the approval of the
Client’s Representative must be sought. But these electrical supplies must be
protected by ELCBs (Earth Leak Circuit Breakers)

 Electrical lighting for use in confined spaces shall not exceed 24 volts.
Powered hand tools used in confined spaces shall, be air operated. Where
this is not possible, all such tools shall be equipped with a dead-man’s switch.

 All works on electrical equipment shall be in accordance with Client’s

Representative Lock Out/Tag Out procedure.
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 The temporary electrical network installed for job would be protected by

ELCBs (Earth Leak Circuit Breakers) to avoid any accidental contact.

 All E&I equipment in stores, should be safe guarded from fire by placing
suitable fire extinguishers.

 All panels shall be kept lock in order to avoid theft of small components
present in the panels.

 Proper rigging shall be ensured during lifting of panels/switch gears.

 Winch shall be operated by an experienced person and not by a helper or

some untrained person.

 Suitable fire extinguishers shall be provided in electrical/instrument panel

rooms. Preferably CO2.

 Panel rooms shall be kept lock and entry should be prohibited for
unauthorized persons.

 Excavation permit may be introduced while excavation of trenches for cables

 For excavation in rocky area while using jack hammer ear protection shall be
provided.

 Unfilled excavated trenches must be provided with warning lights during night.

 Area of cable pulling winch & cable drums jacks should be cordoned off /
guarded. Hand signals shall be used while pulling cables.

 Persons shall be provided hand protection (gloves) while pulling cables

manually.

 Chemical resistance gloves must be used while plugging the cable entries
with chemical sealant.

 Splices of cables with cable knife shall be carried by experience workers & not
helpers in order to avoid injury.

 Cables in open trenches shall be protected from welding sparks and other
falling objects by using GI sheets etc.

 Signs shall be posted after back filling of cable trenches showing “ELECT
CABLE UNDER GROUND”.

 Properly protected ladder shall be used while fixing brackets/supports.

 Cable insulation scrap shall be removed on daily basis from panels/control

rooms.
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 Do not operate tags shall be placed on valves of inst. air supply where
necessary.

 Hazard data sheet for mercury & air pressure shall be provided in instrument
lab.

 Fire extinguisher shall be provided while filling oil in transformer and smoking
should not be allowed in vicinity of oil filling activities.

 A work permit system shall be established prior to testing/checking/energizing

of electrical equipment to avoid any incident.

 It will be preferable that inspection/testing of electrical/instrument equipment

should be carried out through checklist.

 Heat and smoke detecting system must be functional in sub-stations/G.

rooms, before energizing the main panel.

 Hazard warning signs should be placed on all live electrical panels.

 “DO NOT TOUCH’ tags should be placed on all switches in order to refrain
persons touching/pressing etc.

6.3.3 Scaffolding

 Scaffolding shall not be disturbed or altered by any unauthorized persons

where alterations are required authorized scaffolders would be contacted who
shall carry out the work under competent supervision.

 Where materials are to be positioned on scaffolding it shall be ensured that

the scaffolding is not overloaded.

 A prominent “DO NOT USE” sign shall be clearly displayed for

incomplete/unsafe scaffolding.

 Before use, scaffolding shall be inspected by an authorized scaffold

inspector/coordinator who shall put a green tag in a prominent position at the
base of all ladder access points.

 Scaffold shall be inspected at weekly intervals by scaffold

inspector/coordinator who shall sign and date the “Scaftag” after each
inspection.

 A scaffold register shall be kept by the scaffolding inspector/coordinator

containing the following information.

 Date of first & subsequent weekly inspections.

 Individual identifications of all scaffolds, which shall be, cross-referred to the

scaftag identity number.
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 Clear name and signature of the authorized scaffold inspector against each
separate scaffold inspected.

 If there is any doubt about the security of any anchorage, suspension points
or ties for a scaffold, e.g., strength of existing buildings/structures, or these
under construction, the Client’s representative shall be consulted before
proceeding with erection.
 All scaffolds shall be provided with suitable access and where ladders are
used for this purpose. They shall be of an adequate length and properly
secured by lashing or fixing to prevent displacement.

7.0 HAND AND POWER TOOLS

 Correct type, size and weight of tool shall be used for each job.

 Properly insulated and non-conductive tools shall be used for electrical work.

 Screwdrivers - A screwdriver shall have the correct size of tip to fit the slot of
the screw. Screwdrivers shall not be hammered or twisted with pliers or
wrenches. Screwdrivers shall not be carried in the pockets.

 Hammers - Right kind of hammer shall be selected for the job. Eye protection
shall be worn when hammering.

 Chisels - Cutting edges shall be kept sharp. Chisels heads that have
mushroomed shall be repaired. Eye protection shall be worn when using a
cold chisel.

 Picks and shovels shall be maintained in a serviceable condition. Shovel

blades shall not be allowed to become blunt, turned, split, or jagged, Pick
head points shall be kept sharp and heat-treated so that the metal wears
down in use and does not splinter or chip off. Shafts of picks and shovels
shall be kept free from cracks and splinters.

 Spanners and wrenches - Right type and size shall be used. Extension on
spanners and wrenches shall not be used unless the wrenches are designed
for such use. A pipe wrench shall not be used as a hammer. A wrench
(except slugging wrenches) shall not be hammered to tighten a bolt.

 Pliers shall not be used as wrenches. It will be ensured that scrap does not
fly off and cause injury when cutting metal with pliers. Only long handled
pliers shall be used to cut wire under tension. Pliers with insulated handles
shall be used for electrical work.

 Jacks shall be positioned under the center of the load and placed on a solid
support. Jacks shall be operated slowly. It shall be ensured that no one gets
under items being picked up.

 Hacksaws - Correct type of blade shall be selected to suit the material to be

cut. The blade should be set in a hacksaw frame so that the teeth are
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pointing in the forward direction and sufficient tension shall be applied to

ensure the blade is maintained rigid.

 Power Tools - All portable power tools shall be stored in clean dry conditions.
Power tools shall not be left lying around the job site where they may be
damaged.
 Rotating tools shall be switched off and held until rotation has completely
stopped before they are set down. Tools shall be disconnected before
changing bits, blades, cutters, or wheels.
 All portable power tools shall be equipped with properly functioning "dead-
man switches".

 Grinding Machine - Care shall always be taken to ensure that the grinding
wheel is free from defect before mounting.
 The proper size and type of wheel shall be fitted to the tool so that the
maximum permissible periphery speed of the wheel does not exceed the
maximum speed displayed on the machine. No grinding machine shall be
used unless the maximum speed is clearly marked on the case. All wheels
shall be fitted with adequate guards.

8.0 SAFETY INSTRUCTIONS

During the installation all measures shall be adopted to ensure safe working.
 Client site management system shall be implemented

 Prior to start of job, an HSE (DESCON) person shall deliver the specific safety
instruction to the concerned personnel.

 All personnel involved will use necessary PPE as required.

 The workers will be made aware of safety requirements related to this activity
through daily, weekly and monthly toolbox and safety talks.

 Safety notice board will be installed.

 All equipment will be inspected by HSE (DESCON) prior to use.

 Access and good housekeeping should be maintained.

 Fire extinguisher should be available in all working areas.

 All activities at height should be provided with suitable working platform.

Platform should be free from combustibles/flammables.

 When working on height, proper fall protection measure shall be taken.

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 All access ladders and scaffoldings shall be secured and tagged before use.

 Welding sets should be checked and maintained regularly for wear and tear.

 Waste Management should be strictly followed to keep the job site neat and clean.

9.0 ATTACHMENTS
 Nil