METHOD STATEMENT

Method Statement for

INSTRUMENT INSTALLATION
DOC. NO. :IONE-AA00-MS-IN-0002
KARBALA REFINERY PROJECT Rev. 1 Page 1/30
Ref. FEED DOC. No. : N/A

PMC REVIEW STATUS CODE

CODE 1: REJECTED

CODE 2: REVIEWED WITH COMMENTS

CODE 3: NO COMMENTS
Method Statement
Refer to: IONE-AA00-PE-PM-0005 for code
description

gfitch@technip.co
m
2018.10.22 10:59:45
for
+03'00'

INSTRUMENT INSTALLATION

PROJECT : KARBALA REFINERY PROJECT

LOCATION : KARBALA, IRAQ

EMPLOYER : STATE COMPANY OF OIL PROJECTS (SCOP)

1 11 SEP 2018 ISSUED FOR CONSTRUCTION D.J.KIM S.C.PARK Y.S.KIM Y.B.IM H.S.HWANG

0 05 APR 2016 ISSUED FOR CONSTRUCTION D.J.KIM J.P.KIM Y.S.KIM B.H.SHIM H.S.HWANG

A 23 FEB 2016 ISSUED FOR REVIEW D.J.KIM J.S.KIM Y.S.KIM B.H.SHIM H.S.HWANG

REV REVD REVD APPRD CONFD

DATE DESCRIPTION PRPD CHKD
. (PQM) (PM) (PD) (SCOP)

Joint Venture of Hyundai Engineering & Construction Co., Ltd., GS Engineering & Construction Co., Ltd., SK Engineering
& Construction Co., Ltd., and Hyundai Engineering Co., Ltd.,

Note :

a) Revision bar(vertical line) shall be placed in the right hand margin to indicate where the changes has been made
b) PRPD = Prepared by, CHKD = Checked by, REVD = Reviewed by, APPRD = Approved by, CONFD = Confirmed by
 METHOD STATEMENT
Method Statement for
INSTRUMENT INSTALLATION
DOC. NO. :IONE-AA00-MS-IN-0002
KARBALA REFINERY PROJECT Rev. 1 Page 2/30
Ref. FEED DOC. No. : N/A

REVISION HISTORY

Rev. Date Description Page

A 23 FEB 2016 Initial Issued -

Revision Issued as below

- Included reference document for project specification
and Licensor standard specification (Page 7)
- Included reference document for vendor drawings
(Page 15~16)
- Revised section 5.1.1 Stanchions (Page 17)
- Revised section 6.1 and 6.2 installation requirement
(Page 18~20)
- Included support detail and maximum number of
instrument for piping and tubing installation (Page 22)
0 05 APR 2016 - Revised section 6.6 Cable tray (Raceway) installation
(Page 22~23)
- Revised section 6.7 Junction box installation (Page 23)
- Revised section 6.8 Cable installation (Page 25)
- Revised section 6.9 FO Cable installation (Page
25~26)
- Revised Section 6.10 Special instrument installation
(Page 26~27)
- Included Safety Work Method on Section 9 (Page
28~29)
- Included Test Equipment & Tool List on Attachment #2
Revision Issued as below
1 11 SEP 2018 - Revised Revision History as per comments (Page 2~3)
- Revised 6.9 FO Cable Installation as per comment
 METHOD STATEMENT
Method Statement for
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(Page 25)
- Revised 6.10 Special Instrument Installation as per
comments (Page 26)
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INSTRUMENT INSTALLATION
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TABLE OF CONTENTS

1. PURPOSE ...................................................................................................................................................6

2. SCOPE OF WORK .....................................................................................................................................6

3. REFERENCE DOCUMENTS ......................................................................................................................6

3.1. Project Specification .................................................................................................................... 6
3.2. Codes ............................................................................................................................................. 7
3.3. Project Drawings ........................................................................................................................14
3.4. Vendor Drawings ........................................................................................................................15

4. RESPONSIBILITIES .................................................................................................................................17
4.1. Construction Manager ...............................................................................................................17
4.2. Instrument Manager / Engineer .................................................................................................17
4.3. Supervisor and Foreman ...........................................................................................................17

5. GENERAL INSTALLATION PROCEDURES ...........................................................................................17

5.1. Local Fabrication ........................................................................................................................17
5.2. Stanchions ..................................................................................................................................17
5.3. Frame Bracket .............................................................................................................................18
5.4. Tools ............................................................................................................................................18

6. INSTALLATION PROCEDURE IN THE PLANT ......................................................................................18

6.1. General ........................................................................................................................................18
6.2. Process Instruments Installation ..............................................................................................18
6.3. Instrument Panel and Racks Installation .................................................................................20
6.4. Instrument Piping and Tubing ...................................................................................................20
6.5. Conduit Installation for Stud-up ...............................................................................................22
6.6. Raceway Installation ..................................................................................................................22
6.7. Junction Box Installation ...........................................................................................................23
6.8. Cabling Works ............................................................................................................................23
6.9. Fiber Optic Cable Installation ....................................................................................................25
6.10. Special Instruments Installation ...............................................................................................26

7. INSPECTION AND TESTING AFTER INSTALLATION ...........................................................................27

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7.1. Piping and Tubing Leak Test Procedure ..................................................................................27

7.2. Cable Test Procedure .................................................................................................................28

8. CHECK AND TEST SHEETS AFTER INSTRUMENT INSTALLATION & TEST.....................................28

9. SAFETY ....................................................................................................................................................28
9.1. Safety Work method ...................................................................................................................28
9.2. Safety of Personnel and Equipment .........................................................................................29

10. ATTACHMENT ..................................................................................................................................30

10.1. Attachment #1. Safe Work Method Statement for Installation work for Instrumentation (8
Sheets) .....................................................................................................................................................30
10.2. Attachment #2. Test Equipment & Tool List ............................................................................30
 METHOD STATEMENT
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1. PURPOSE

The purpose of this Method Statement is to establish general guideline for the Installation of Instruments,
including loosed instruments supplied with package equipment in order to assure that the works are in
compliance with project design, drawings and specifications for Karbala Refinery Project.
This Method Statement is intended to be a master guide that included most possible activities associated
with the Instrument Installation in accordance with EMPLOYER engineering standards, drawings and
mandatory requirements.

2. SCOPE OF WORK

This Method Statement covers the general requirements for the instrument installation activities during
the construction phase of all instrumentation and control works as the next work of Instrument Calibration
activity and the former work of Instrument loop checking and commissioning works for Karbala Refinery
Project.

3. REFERENCE DOCUMENTS

3.1. Project Specification

2342-AA00-JSD-0001-01 Basic Design Data
2342-AA00-JSD-1530-01 Job Design Specification for Telecommunication
Systems
2342-AA00-JSD-1300-01 Piping Classes Summary
2342-AA00-JSD-1300-03 General Design Rules for Steam Tracing
2342-AA00-JSD-1501-01 Job Design Specification for Instrument Numbering
2342-AA00-JSD-1600-01 General Specification for the Electrical Systems
2342-AA00-JSD-2000-01 Job Design Specification for Buildings
2342-AA00-JSM-501 Quality Management Requirement for EPC Contractor
2342-AA00-JSM-603-00 Spare Parts Requirements
2342-AA00-JSM-501 HSE Requirements
2342-AA00-JSM-902_0 Training Requirements EPC Contractor
2342-AA00-JSS 1300-01 General Supply Specification for Piping Material
2342-AA00-JSS-1310-01 Detailed Supply Specification for Valve
IONE-AA00-PE-PC-0008 Material Handling and Storage Procedure
IONE-AA00-PE-QA-0004 Receiving Inspection Procedure
IONE-AA00-PE-QA-0024 Construction Quality Plan
IONE-AA00-PE-CO-0004 Field Material Control Procedure
 METHOD STATEMENT
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IONE-AA00-PE-HS-0001 Project HSE Plan

IONE-AA00-SP-IN-0001 Instrument Specification for Process Control System
IONE-AA00-SP-IN-0002 Specification for Flow Metering Package
IONE-AA00-SP-IN-0003 Specification for Tank Gauging System
IONE-AA00-SP-IN-0004 Specification for Analyzer System & Shelters
IONE-AA00-SP-IN-0005 Specification for Mechanical Package
IONE-AA00-SP-IN-0006 Instrument General Specification
IONE-AA00-ITP-IN-0001 Inspection and Test Plan for Instrument work
IONE-AA00-ITP-EL-0001 Inspection and Test Plan for Electrical work
IONE-AA00-MS-PI-0007 Method Statement for Installation of above ground
piping system

UOP Standard Specifications

6-14-5 Control Valves
6-18-3 Flow Meters and Pressure Instruments
6-101-5 Pressure Gauge Piping Assemblies
6-102-4 Pressure Instrument Piping Assemblies
6-105-6 Thermowells
6-106-5 Thermometer Assemblies
6-107-6 Temperature sensor Terminal Head Assemblies
6-108-5 Thermowell and Skin Thermocouple Installation
6-109-5 External displacement and other chamber type Level Instrument Piping Assemblies
6-111-6 Orifice Plates
6-112-3 Piping Arrangements for Orifice Plate Installations
6-115-7 Orifice meter Piping Assemblies for Dry Gas Service
6-116-7 Orifice meter Piping Assemblies for Liquid, steam, or Condensable Vapor Service
6-122-5 Powdered Catalyst Instrument Piping Assemblies
6-144-5 Differential Pressure Instrument Piping Assembly for condensable Vapor Service
6-156-5 Flanged Multi-Thermowell Assembly with Integral Support
6-158-4 Flanged Multi-Thermowell Assembly
6-159-2 Differential Pressure Instrument Piping Assembly for Dry Gas Service.
6-161-2 Non-Purged Reactor Differential Pressure Instrument Piping Assembly
8-101-6 gauge Glass Piping Assemblies General Service

Haldor Topsoe Specifications

J21 WBS 61 General Specification for Instrumentation

3.2. Codes
ANSI/ASME B-16.34 Hydraulic Test for Control Valves
ANSI/ASME B-16.5 Pipe Flanged and Flanged Fittings
ANSI/ASME B-16.10 Face-to-Face and End-to-End Dimension of Valves
 METHOD STATEMENT
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ANSI/ASME B-1.20.1 Pipe thread General Purpose

MC-96.1 Temperature Measurement Thermocouples
ANSI/FCI 70-2 Control Valves Seat Leakage
ANSI/TIA/EIA-568-B Commercial Building Telecommunications Cabling
Standard
ANSI/TIA/EIA-568-B.1 General Requirements
ANSI/TIA/EIA-568-B.2 100-Ohm Balanced Twisted-Pair Cabling Standard
ANSI/TIA/EIA-568-B.3 Optical Fibre Cabling Component Standard
ANSI/TIA/EIA-569 Commercial Building Standard for
Telecommunications Pathways and Spaces
ANSI/TIA/EIA-606 Administration Standard for the Telecommunications
Infrastructure of Commercial Building
ANSI/TIA/EIA-607 Grounding and Bonding Requirements for
Telecommunications in Commercial Buildings
ANSI/TIA/EIA-455-B Standard Test Procedure for Fibre Optic Fibres,
Cables, Transducers, Sensors, Connecting and
Terminating Devices, and other Fibre Optic
Components.
ANSI/TIA/EIA-598-C Optical Fibre Cable Colour Coding - (January 2005)
ITU-T & ITU-R International Telecommunication Union
Telecommunication Standardization Sector and Radio
communication Sector
American Petroleum Institute (API)
RP-505 Recommended Practice for Classification of Locations
for Electrical Installations at Petroleum Facilities
Classified as Class I, Zone 0, Zone 1, and Zone 2
RP-520 Sizing, Selection and Installation of Pressure Relieving
Systems in Refineries. Part I and II
RP-521 Guide for Pressure Relieving and Depressurizing
Systems
ST-2534 Turbine Meters
ST-1101 Positive Displacement Meters
ST-2531 Meter Provers
ST-526 Flanged Steel Safety Valves
ST-527 Commercial Seat Tightness of Safety Valves with
 METHOD STATEMENT
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INSTRUMENT INSTALLATION
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Metal to Metal Seats

ST-598 S Safety Valves Inspection and Test
RP-540 Electrical Installations in Petroleum Processing Plants
RP-551 Process Measurement Instrumentation
RP-552 Transmission System
RP-553 Refinery Control Valves
RP-554 Process Instrument & Control
RP-555 Process Analyzers (in press)
RP-556 Instrumentation & Control System for Fired Heaters
and Steam Generation
Publication 2218 Fire Proofing Practices in Petroleum and
Petrochemical Processing Plants.
RP-2000 Tank venting
RP-2510 Design and construction of LPG installation
STD-607 Fire Test for Soft-Seated Quarter Turn Valves
STD-598 Valve Inspection and Testing
STD-670 Machinery Protection Systems
STD-682 Pumps Shaft Sealing Systems
STD-526 Flanged Steel Pressure Relief Valves
STD-527 Commercial Seat Tightness of Safety Valves with Metal
to Metal Seats
MPMS Manual of Petroleum Measuring Standards:
Ch. 3: Tank Gauging
Ch. 4; sect. 2: Displacement Provers
Ch. 4; sect. 3: Small volume Provers
Ch. 4; sect. 6: Pulse interpolation
Ch. 4; sect. 8: Operation of proving systems
Ch. 12; sect. 2; Part 3: Proving reports
Ch. 6; sect. 6: Pipeline Metering System
International Society of Automation (ISA)
S-5.1 Instrument Symbols and Identification
S-5.2 Binary Logic Diagrams for Process Operation
S-5.3 Graphic Symbols for Distributed Control/Shared
Display Instrumentation, Logic and Computer
Systems.
S-5.5 Graphic Symbols for DCS Display
 METHOD STATEMENT
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INSTRUMENT INSTALLATION
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S-5.4 Instrument Loop Drawing

SP-18.1 Annunciator Sequences and Specifications;
S-75.01 Valve Cv Calculation. Flow Equation for Control
Valves Sizing.
ISA 50.02 Fieldbus Standard for Use in Industrial Control Systems
Part 2 Physical Layer Specification and Service Definition
Part 3 Data Link Service Definition
Part 4 Data Link Protocol Specification
Part 5 Application Layer Service Definition
Part 6 Application Layer Protocol Specification
ISA TR50.02 Fieldbus Standard for Use in Industrial Control
Systems
Part 3 & 4 Technical for Fieldbus Data Link Layer-Tutorial, Part 9
User Layer Technical Rep
DIN (Deutsche Institut fuer Normung)
DIN 43760 Temperature Conversions Table for Pt 100 Ohm @
0°C Resistance Elements.
ISO International Organization for Standardization
ISO-5167 Measurement of Fluid Flow by Orifice Plates, Nozzles
and Venturi Tubes inserted in circular cross section
conduits running full.
ISO 8473 Information Technology – Protocol for providing the
Connectionless – Mode Network Service
ISO 8802 Information Technology – Telecommunications and
Information – Exchange between Systems Local and
Metropolitan Area Networks – Specific Requirements
IEC International Electro Technical Commission
IEC 60079-0 to 19 Electrical apparatus for explosive gas atmospheres
IEC 60227 Polyvinyl Chloride insulated cables of rated voltages
up to including 450/750V
IEC 60228 Conductor of insulated cables
IEC-60529 Classification of Degrees of Protection Provided by
Enclosure
IEC-6092.3 Cables (construction, testing and installation)
IEC-60331 Fire Resisting Characteristics of Electric Cables
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IEC-60332 Flame Retardant Characteristics of Electric Cables

IEC-60332-1 Tests on Electrical Cables under Fire Conditions
IEC-60332-3 Tests on Electrical Cables under Fire Conditions
IEC-60801 Electromagnetic Compatibility for Industrial Process
Measurement and Control Equipment
IEC 60811 Common test methods for insulating and sheathing
materials of electric cables
IEC 61000 Electromagnetic Compatibility for Industrial Process
Measurement and Control Equipment
IEC 61131 Programmable Logic Controllers – Parts 2 and 3
IEC 61511 Functional safety – Safety instrumented systems for
the process industry sector
IEC-61508 Functional Safety of E/E/PE Safety-related Systems.
IEC 61158-2 Fieldbus Standard for use in Industrial Control System
(ISA S50.20) Part 2 – Physical Layer Specification and
Service Definition
IEC 61158-3 Fieldbus Standard for use in Industrial Control System
Part 3 – Data Link Service Definition
IEC 61158-4 Fieldbus Standard for use in Industrial Control System
Part 4 – Data Link Protocol Specification
IEC 61158-5 Fieldbus Standard for use in Industrial Control System
Part 5 – Application Layer Service Definition
IEC 61158-6 Fieldbus Standard for use in Industrial Control System
Part 6 – Application Layer Protocol Specification
IEC 61643-1 Surge Protective Devices Connected to Low Voltage
Power Distribution System Part 1 – Performance
Requirements and Testing Methods
IEC 61643-21 Surge Protective Devices Connected to Low Voltage
Power Distribution System Part 21 – Surge Protective
Devices Connected to Telecommunication and
Signaling Networks – Performance Requirements and
Testing
Method
IEC 61643-21 Information Technology – Open System
Interconnection Basic Reference Model – Conventions
for the Definition of OSI Services
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Institute of Electrical and Electronics Engineers (IEEE)

IEEE STD 518 Guide for Installation of Electrical Equipment to
Minimize Electrical Noise Inputs to Controllers from
External Sources.
IEEE 1100 Recommended Practice for Powering & Grounding
Electronic Equipment – IEEE Emerald Book
IEEE 1451.1 Standard for a Smart Transducer Interface for Sensors
and Actuators – Network Capable Application
Processor Information Model
IEEE 802.3 Standard for Information Technology –
Telecommunications and Information Exchange
between Systems – Local and Metropolitan Area
Networks Specific Requirements.
Part 3 Carrier Sense Multiple Access with Collision
Detection (CSMA/CD) Access Method and Physical
Layer Specifications.
IEEE 802.4 Token bus
European Committee for Electro technical Standardization (CENELEC)
EN 50014 Electrical apparatuses for potentially explosive
atmosphere – general requirements
EN 50018 Electrical apparatuses for potentially explosive
atmosphere – flameproof enclosures “d”
EN 50020 Intrinsic Safety “i”
EN 50170 Profibus DP
EN 50307 Lead and lead alloy sheaths and sleeves of electrical
cables
EN 60073 Basic and Safety Principles for Man-Machine Interface,
Marking and Identification – Coding Principles for
Indication Devices and Actuators
EN 60079-0 Electrical apparatus for explosive gas atmospheres:
General requirements
EN 60079-1 Electrical apparatus for explosive gas atmospheres:
Flameproof Enclosures “d”
EN 60079-2 Electrical apparatus for explosive gas atmospheres:
Pressurized Enclosures “p”
EN 60079-7 Electrical apparatus for explosive gas atmospheres:
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Increased Safety “e”

EN 60079-10 Electrical apparatus for explosive gas atmospheres:
Classification of Hazardous Areas
EN 60079-11 Electrical apparatus for explosive gas atmospheres:
Intrinsically Safe “i”
EN 60079-14 Electrical apparatus for explosive gas atmospheres:
Electrical Installation in Hazardous Areas
EN 60079-15 Electrical apparatus for explosive gas atmospheres:
Type of protection 'n'
EN 60079-18 Electrical apparatus for explosive gas atmospheres:
Construction, test and marking of type of protection
encapsulation “m”
EN 60534-4 Industrial-process control valves - Part 4: Inspection
and routine testing
EN 60534-8-3 Industrial-process control valves – Part 8-3: Noise
considerations - Control valve aerodynamic noise
prediction method
EN 60708 Low-Frequency Cables with Polyolefin Insulation and
Moisture Barrier Polyolefin Sheath
EN 60885 Electrical Test Methods for Electrical cables
EN 61034 Smoke Density of Electric Cables Under Fire
Conditions
EN 61784 Digital data communication for measurement & control
Engineering Equipment and Material Users Association (EEMUA)
Publication No. 189 Guide to Fieldbus Application for the Process
Industry, 1997
United States Nuclear Regulatory Commission (USNRC)
USNRC Regulatory Guide 7.3 Procedures for picking up and receiving package of
radioactive material.
USNRC Regulatory Guide 6.5 General Safety Standard for Installation using non-
medical sealed Gamma – Ray sources.
International Commission of Radiological Protection (ICRP)
ICRP Publication N°26, 1977 Recommendation of the International
Commission of Radiological Protection.
International Atomic Energy Agency (IAEA)
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IAEA Safety series N°6 (1985 Edition) Regulation fo r the safe Transport of
Radioactive Material
IAEA Safety series N°9 (1982 Edition) Basic Safety standards for Radiation
European Atomic Energy Community (JV or Euratom)
Council Directive 96/29/Euratom of 13 May 1996 basic safety standards for the protection of the
health of workers and the general public against the dangers arising from ionizing radiation
European Commission Services considerations with regard to natural radiation sources in BSS
Directive (16-January-2009 Not Yet Released)
NACE International (NACE)
NACE MR0103 Materials Resistant to Sulfide Stress Cracking in
Corrosive Petroleum Refining Environments
ASME PTC 19.3 Part 3 Temperature Measurement Instruments and
Apparatus
NFPA 70 National Electric Code
NFPA 72 National Fire Alarm Code

3.3. Project Drawings

IONE-AA00-DW-IN-0001 Instrument Symbol & Legend
IONE-AA00-DW-IN-0002 System Architecture drawings for all systems
IONE-AA00-DW-IN-4007 Typical Installation Detail Drawing
Control Room & Process Interface Building
IONE-NZNN-DW-IN-1101
Equipment Layout
IONE-NZNN-DW-IN-1201 Instrument Wiring Layout
IONE-NZNN-DW-IN-1401 Gas Detector Wiring Layout
IONE-NZNN-DW-IN-1501 Instrument Main Cable Routing Layout
IONE-NZNN-DW-IN-1601 Instrument Cable Tray Routing Layout
IONE-NZNN-DW-IN-1701 Instrument Air Piping Layout
IONE-NZNN-DW-IN-4007 Instrument Index
IONE-NZNN-DW-IN-4002 Instrument I/O List
IONE-NZNN-DW-IN-4003 Logic Diagrams
IONE-NZNN-DW-IN-4004 Loop diagrams
IONE-NZNN-DW-IN-4005 Hook-up drawings
IONE-NZNN-DW-IN-4006 Instrument Wiring Connection Diagram
IONE-NZNN-DW-IN-4008 Instrument Cable Schedule
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Note 1: Document Numbering System as below

IONE – NZNN – XX – XX – ZZZZ

(A) (B) (C) (D) (E)

(A): Project Job Code – IONE

(B): First 2 Digits (WBS Code) and Second 2 Digits (Unit Code)
(C): Document Type – DW (Drawing)
(D): Discipline Code – IN (Instrument)
(E): Serial Number
X: Alphabet N: Numeric Z: Mix of Alphabet & Numeric

3.4. Vendor Drawings

IONE-VP-00-IE4101-001
IONE-VP-00-IE4101-002
IONE-VP-00-IE4101-003
IONE-VP-00-IE4101-004
IONE-VP-00-IE4101-005
IONE-VP-00-IE4101-006
IONE-VP-00-IE4101-007
IONE-VP-00-IE4101-008
IONE-VP-00-IE4101-009
IONE-VP-00-IE4101-010
IONE-VP-00-IE4101-011
IONE-VP-00-IE4101-012
IONE-VP-00-IE4101-013
IONE-VP-00-IE4101-014
IONE-VP-00-IE4101-015
Vendor Print Index and Schedule
Specification and Calculation Sheet
Actuator Sizing Sheet
Dimensional Drawing
Schematic Drawing (Electrical, Pneumatic)
Catalogue
Installation, Operation and Maintenance Manual
Commissioning Spare Parts List
2 Years Spare Part List
Utility Consumption List (Air, Nitrogen, etc)
Certificate (Explosion proof, SIL)
Inspection and Test Plan
Test and Inspection
Inspection and Test Report
Sub-Vendor List

Note 1: Vendor Document Numbering System as below

General Common Document Numbering system for Vendor Drawing
IONE - VP – XX – XXXXXX - DDD
(A) (B) (C) (D) (E)

(A): Project Code - IONE

(B): Identification for Vendor Print - VP
(C): Unit No. - (Common : "00")
(D): Suffix of Requisition No. (Note 2)
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(E): Sequential No. - Starting from 001

Example) "Requisition No. : IONE-00-MR-IE-4101" will be numbered as "IONE-VP-00-IE4101-001"

Note 2: (D) Suffix of Requisition No.

IS-0001 Process Control System
IS-4001 Flow Metering System
IS-1002/4002/7002 Analyser Package with Shelters
IS-4004 Truck Loading System
IS-4005 Air Quality Monitoring System
IE-1101/4101/7101 Control and On-Off Valve (Globe, Angle, Plug)
IE-1102/4102/7102 Control and On-Off Valve (Butterfly)
IE-1103/4103 Control Valve (Ball)
IE-1104/4104/7104 On-Off Valve (Ball)
IE-4105 Control Valve (Mandatory)
IE-1107/4107 On-Off Valve (Special Check)
IE-1108/4108/7108 MOV (Ball, Butterfly)
IE-1110/4110 Pressure Regulating Valve
IE-1111/4111A/B/7111 Pressure Safety Valve
IE-4112 Rupture Disc
IE-4115 Slide Valve
IE-1201/4201/7201 Flowmeter (Vortex, Mass)
IE-1202/4202/7202 Flowmeter (Magnetic, Ultrasonic)
IE-1203/4203 Rotameter
IE-1204/4204/7204 Sight Glass
IE-1205/4205/7205 Flow Element (Orifice, Flow Nozzle, Venturi)
IE-1206/4206/7206 Flow Element (Averaging Pitot Tube)
IE-1301/4301/7301 Level Transmitter (GWR)
IE-1302/4302/7302 Level Transmitter (Displacer)
IE-1305/4305/7305 Level Gauge
IE-1402/4402/7402 Temperature Element (TC, RTD, Thermowell)
IE-1403/4403 Multipoint TC
IE-1501/4501/7501 Field Transmitter
IE-1502/4502/7502 Local Gauge
IE-1503/4503/7503 Gas Detector
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4. RESPONSIBILITIES

4.1. Construction Manager

4.1.1. Controlling the overall construction activities

4.2. Instrument Manager / Engineer

4.2.1. Delivering the relevant documentation and the required materials to the Subcontractor

4.2.2. Checking the adequacy of Subcontractors’ personnel, equipment and promoting any required
actions necessary to achieve the construction targets

4.2.3. Implementation and supervision of the work activities

4.2.4. Notification after the work completed to Quality Group (Employer & Contractor)

4.2.5. Taking part in the definition of any corrective actions required ensuring the correct resolution of
the non-conformity

4.3. Supervisor and Foreman

4.3.1. Execution of all the related works as per this method statement

5. GENERAL INSTALLATION PROCEDURES

5.1. Local Fabrication

Supports and frameworks, etc., necessary for proper installation of the instruments and their
interconnecting piping which are not supplied in prefabricated form, shall be fabricated locally by
the Contractor to be available in accordance with project specification.
All material shall be hot dip galvanized.
Steel works to fabricate various types of supports are as follows:

5.1.1 Stanchions
The stanchions shall be supplied in prefabricated form on the base support which is steel plate
or pipe strap or applicable support material such as channel. The base of the stanchion will be
directly bolted in paved areas or concrete or metal pillars. In non-paved areas, the instrument
support base shall be installed on an adequately sized concrete foundation. If the base support
install on process piping, pipe strap or channel will be bolted by using U-bolt or proper bolt.
 METHOD STATEMENT
Method Statement for
INSTRUMENT INSTALLATION
DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

5.1.2 Frame Bracket

This is for Frames, brackets, stands and the like to support and fix junction boxes, and aux.
instruments. All the brackets must be of the sufficient rigidity and a particular attention shall be
paid to instruments to avoid the transmission of vibrations to the instruments. In such cases,
instruments shall be suitably supported and process nozzles for instrument impulse pipe shall
be bracketed. Instruments connected to small size process pipes or pipes made of synthetic
material shall be suitably supported.

5.1.3 Tools
It shall be ensured that the correct tools are always used for installation work. The tools shall
be available in sufficient quantities to meet the planned work requirements. The list and type of
tools to be used shall be informed to the responsible Instrument Engineer. This engineer shall
have the right to inspect the tools on a regular basis and have them replaced as deemed
necessary. All tools shall have where required up to date of calibration/certification.

6 INSTALLATION PROCEDURE IN THE PLANT

6.1 General
6.1.1 It covers installation work of all instruments and accessories including supports, stanchions,
and brackets. All instruments and control system shall be installed in accordance with the
reference documents and drawings and Engineering Standards attached to the CONTRACT
and the requirements of the present technical specification and the general installation, if
required refer to Licensor / vendor installation requirements and recommendation. The
CONTRACTOR shall strictly adhere to site regulations attached to the CONTRACT. For
preventing damage, the CONTRACTOR shall transport and handle instruments with the
utmost care. All covers and plugs on instrument connections and flange facings shall be left in
place as long as possible. Instruments shall be protected against general construction site
hazards; all openings shall be properly sealed if the connections are not made immediately.
Instruments such as pressure gauges and thermometers shall be installed shortly before
commissioning and all other instruments shall be isolated from process lines and mechanically
protected if commissioning is delayed.
6.1.2 Pre-installation check shall be done according to the approved Doc. No. IONE-AA00-ITP-IN-
0001, Inspection and test Plan for Instrumentation.

6.2 Process Instruments Installation

6.2.1 Piping and Instrumentation Diagram (P&ID), Instrument Hook-up Drawing and Typical
Installation Detail Drawing shall be verified to make sure that the instrument type, nameplate,
mounting direction and location is correct.

6.2.2 In all case, all instruments shall be installed as close as practicable to the process connection.

6.2.3 All tapping points of primary elements and in-line instruments shall be checked for proper
 METHOD STATEMENT
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DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

direction of flow, orientation and insertion depth.

6.2.4 All instruments and its primary elements, manifolds and valves shall be permanently
accessible from grade, platforms or walkways for easy reading, operation and maintenance
access.

6.2.5 Instruments for liquid and steam measurement shall be located below the tapping points from
process piping or equipment and the instruments for air and gas measurement shall be
located above the tapping points.

6.2.6 The CONTRACTOR shall ensure that the pressure gauge blowout discs are not obstructed by
supports or insulation.

6.2.7 All instruments shall be adequately protected from dirt or moisture entering the device, sudden
movements or shocks, and possible damage during the construction period.

6.2.8 Stanchions and all structural supports shall be finished smoothly free from sharp edges; top of
stanchion shall be closed to prevent water accumulation.

6.2.9 All instruments shall be installed taking consideration that they are subjected to withstand
maximum vibrations and not be mount on piping or equipment which is subject to vibration
problems and from lines in cryogenic service and on handrails, ladders, or in pathways.

6.2.10 All the electronic field instruments shall be provided with suitable sunshades as per
specification requirement. And for other instruments with suitable enclosures as applicable.

6.2.11 The following Instruments should have close co-ordination with piping section to ensure the
proper installation of instrument-associated works by piping. (E.g. Thermowells, Orifice plates,
control valves, etc.)

6.2.12 The HP/LP connections of flow and pressure differential transmitters shall be oriented on right
/ left hand side respectively while facing the instrument in order to match the existing
philosophy.

6.2.13 All Instruments or Valves with its accessories such as volume tank, PST positioner, lock-up
valve, limit switch, SOV, air filter regulator etc. shall be inspect according to approved
Inspection and Test Plan, IONE-AA00-ITP-IN-0001.

6.2.14 The following In-Line instruments shall not be handled, but included in the piping work to be
done by other discipline as per refer to Document number IONE-AA00-MS-PI-0007; Method
 METHOD STATEMENT
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DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

Statement for Installation of above Piping System.

a) Control Valves, On-Off Valves, MOV, Pressure Safety Valves
b) In-Line Flow meter and flow element

6.3 Instrument Panel and Racks Installation

6.3.1 Equipment type, nameplate, facing direction and location shall be verified before moving to the
place of installation.

6.3.2 The basement for mounting shall be aligned and levelled.

6.3.3 All panels and racks shall be mounted on channel bases or raised floor and shall be installed
in accordance with the approved installation drawings or instructions available from the
supplier.

6.3.4 The proper type and size of anchor bolts shall be selected and installed complying with the
anchoring instructions from the equipment supplier.

6.3.5 Nuts of anchor bolts shall be screwed tight after the hardening of mortar.

6.3.6 Panel or rack mounted instruments shall be installed with sufficient spacing between them to
facilitate maintenance.

6.3.7 After installation of cabinet channel base or raised floor, the control room and equipment room
shall be swept clear and vacuum cleaning to remove all foreign materials and dust around all
equipment.

6.3.8 The panels and racks shall be covered with plastic film and/or using any other means to
protect them from possible damage and dust contamination during the construction work. All
painting damages shall be retouched in accordance with the manufacturer recommendation.

6.3.9 Checking of the earth system shall be carried out to ensure that the earth bonding connections
for instrument panels and racks are completed complying with the approved design
requirements before any kind of testing starts.

6.4 Instrument Piping and Tubing

6.4.1 General Procedure
6.4.1.1 Piping and tubing runs shall have a minimum number of turns, consistent with good
practice and neat appearance.
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6.4.1.2 Piping and tubing shall be worked with proper tools designed for bending and cutting
works to prevent kinks or flattening and shall be square-cut for inter-connection.

6.4.1.3 The compression type tube connections shall be carried out in accordance with the
approved manufacturer’s instructions

6.4.1.4 After every piping and tubing works are completed, lines shall be blown-out using clean
compressed air to remove any scale of dirt, moisture and other foreign materials. End
cap shall be provided to all tubing that cannot be connected immediately, but these
open ends shall be covered with a durable material on temporary basis till the
permanent plugs are restored.

6.4.2 Pressure Leads and Sample Lines

6.4.2.1 Pressure leads and sample lines shall generally be limited to a maximum length of 30
feet and must slope up or down toward the instrument at least 1 inch per foot.

6.4.2.2 Pressure leads and sample lines shall be adequately supported and properly fastened
to ensure the rigidity of installation.

6.4.2.3 Wherever possible, pressure leads and sample lines shall be installed in such a
manner as to minimize the transmission of strain and vibration from process line to the
instruments.

6.4.2.4 Factory-filled system capillary tubing shall be continuously supported and protected
using a suitable type instrument tray and shall run independently of all lines.

6.4.3 Instrument Air and Signal Lines

6.4.3.1 Piping and tubing shall run horizontally and vertically with diagonal routing minimized.

6.4.3.2 The size of the sub-header shall be 1, 3/4 or 1/2 inch and be carbon steel pipe for the
instrument air sub-header.

6.4.3.3 316 SS fittings shall be used for pneumatic line. All tube fittings shall be the double
ferruled type.

6.4.3.4 All field mounted instruments that requires air supply must be fitted with combination
air filter and regulator, which shall be mounted vertically downwards.
6.4.3.5 Allowable number of instruments that can be connected for every sub-header is
follows;
 METHOD STATEMENT
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DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

1/2” sub-header = 3 instruments + 1 spare

3/4” sub-header = 8 instruments + 2 spare
1” sub-header = 16 instruments + 4 spares

6.4.3.6 Drain valve shall be provided at any low-point pockets between sub-header drain and
the air set drain.

6.4.3.7 Piping/tubing supports shall be fastened and tightened at max. 2.0 meter intervals.

6.4.3.8 Connection of the pressure tubes shall be carried out with proper unions according to
manufacturer’s instructions.

6.4.3.9 Instrument’s process piping and tubing shall be blown out to remove foreign material,
dust and condensate before pre-commissioning

6.4.3.10 The tubing will be supported by steel angle with tube clamp. Tubing will be properly
supported, and avoid being fastened to process pipe, or instrument air pipe for support

6.5 Conduit Installation for Stud-up

Cables shall be protected by stud-up conduit where directly buried cables are extended above
grade. Conduit shall be extended at least 3 inches above grade for cable protection.

6.6 Raceway Installation

6.6.1 Single cable runs from the Junction box to the instrument in the field shall be routed,
supported and protected against mechanical damage with cable trays. These shall not be
supported by process piping. Use of conduits is not allowed.

6.6.2 Cable ladders, trays and/or ducts shall be easily and safely accessible for maintenance
reasons.

6.6.3 All underground field cables entering to MCB/PIB buildings shall be run on cable trays to the
underside of the respective cabinet/panels.

6.6.4 In case where cable enter to MCB/PIB Buildings, special care should take account into
preventing ingress of water and gas by using Duct seal & Foam.

6.6.5 Ensure that bonding jumper and grounding are installed and connected.
 METHOD STATEMENT
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DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

6.6.6 Cable ladders support shall be fastened and tightened at max. 6.0 meter intervals on steel
structure or additional channel support. Cable trays support shall be fastened and tightened at
max. 3 meters intervals on steel angle or unistrut channel.

6.6.7 Interconnection between cable tray joints by using bolts according to Vendor recommendation.

6.6.8 Instrument cable trays for above ground shall be separated as following group :
Group 1: Intrinsic safe circuit
Group 2: Non-Intrinsic safe circuit
Group 3: Power supply

6.7 Junction Box Installation

6.7.1 Junction boxes for instrument cables shall be installed at the locations indicated on the layout
drawings in such a way that they are permanently accessible.

6.7.2 All junction boxes shall be kept closed except when work is being performed upon them and
properly grounded as per electrical requirement.

6.7.3 Cable inlets shall be kept closed until cables are installed. Spare inlets shall be sealed.

6.7.4 There shall be 20% spare terminals and branch cable entries for future use. Spare cable
entries into the junction box shall be sealed using certified plugs of the same material and IP
rating.

6.7.5 Connections inside the junction boxes shall be aligned so as to allow easy access to any wire.

6.7.6 Cable glands with PVC shroud on junction boxes and field-mounted equipment shall only be in
the bottom.

6.8 Cabling Works

6.8.1 Instrument cables shall not be clamped to equipment, process piping, handrails, structure steel
etc.

6.8.2 The hand “push/pull” method is usually preferred, and the end of cables shall be properly
sealed during and after installation in wet location. The Cable shall be installed with sufficient
length left at the ends of the cable, so as to enable making termination at all equipment or
devices. All cables shall be temporarily identified in a suitable manner.

6.8.3 Near the instrument, a cable slack of at least 0.5 meter shall be provided to facilitate
 METHOD STATEMENT
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DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

termination/disconnection. This portion of the cable shall be protected against mechanical

damage.

6.8.4 All redundant cables shall be routed in diverse route in different trenches/trays/raise ways and
shall not cross each other.

6.8.5 Electronic and signal shall be separated from power cables and electrical equipment to
minimize interference.

aa. Spacing between underground cable center shall be

- Between 125 Vac power cables and instrument cables ; 300 mm
- Between 250 Vac power cables and instrument cables ; 430 mm
- Between 440 Vac power cables and instrument cables ; 600 mm
- Between 5k Vac power cables and instrument cables ; 1,200 mm
- With 90 degree crossing, a vertical separation of 300 mm shall be provided.
bb. A minimum spacing of 300 mm shall be maintained between cables and high
temperature surface.

6.8.6 Where trenches for signal cables cross with those for electric power cable, the separation
between the highest cable in the lowest trench and the lowest cable in the highest trench shall
be at least 0.3 m.

6.8.7 Cables shall be securely fastened by stainless steel plastic coated cable ties, at point when
they enter or leave a cable tray and shall also be fastened as close as practicable to the point
of cable termination to avoid point of termination supporting its cable weight.

6.8.8 Cables shall run between terminating points continuously, whenever practicable. Where splice
is unavoidable, it is to be made from splicing materials recommended by manufacturer.

6.8.9 Special cables shall be laid according to the relevant standard and/or Manufacturer
recommendation.

6.8.10 Wiring termination shall be connected to the designated terminal blocks using pre-insulated
lugs and pressed by compatible termination tools.

6.8.11 At the instrument end of the cable, the screen tapes shall be cut back from the bedding or
bundles to ensure electrical isolation from any moisture ingress, etc.
 METHOD STATEMENT
Method Statement for
INSTRUMENT INSTALLATION
DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

6.8.12 Cables shall not be subjected to a bending radius less than the minimum recommended by
manufacturer for the particular type, size and form of construction of the cable concerned.

6.8.13 Cable marker tags shall be attached to all cables when they are laid. Markers shall be spaced
at proper intervals and fixed around the cable so as to be readily and easily visible when the
cable is exposed (in case of buried cables). Cable identification shall also be provided and
fixed just below the cable glands at all entries into equipment, junction boxes or through joints

6.9 Fiber Optic Cable Installation

6.9.1 The fiber optic cable shall be coiled on cable reels; each cable end shall be secured in order to
withstand all conditions of transportation.

6.9.2 Both flanges of cable drums shall be distinctly marked with manufacturer’s nameplate and
details of supply and specifications.

6.9.3 Inspection and testing of cable drum shall be performed in presence of representative of
EMPLOYER in the CONTRACTOR’s storage area.

6.9.4 The CONTRACTOR shall install cable in accordance with the manufacturer’s
recommendations for the respective type and make of cable and in compliance with technical
specifications. Pulling tension, side pressure, bending radius and similar parameters governing
cable installation practice shall all be held within the limits approved by the EMPLOYER.

6.9.5 At each joint location, extra cable length of 2 meters shall be left for future.

6.9.6 Cable Roller shall be used to protect the outer serving/sheath of the cable.

6.9.7 All fibers shall be spliced through at the splice locations, if have, all fibers shall be tested and
splice loss recorded.

6.9.8 All fibers shall be tested in receiving inspection time or just before laying cable.

6.9.9 End to end test shall be done after cable laying. End-to-End power meter is used to determine
the loss of an individual section of cable. Test shall be taken using optical fiber light source and
power meter from one point of termination to another.

6.9.10 After the cable testing is found acceptable, splicing/termination can be done by fusing splicing
machine / optical fiber cleaver or as per manufacturer’s recommendation
 METHOD STATEMENT
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INSTRUMENT INSTALLATION
DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

6.9.11 Once cables are spliced and terminated, each splice loss shall be measured in both directions
by means of OTDR meter according to IONE-AA00-ITP-EL-0001.

6.9.12 Additional tool for splices

a) Optical fiber splicing kit
b) Approved cable cleaner
c) Approved Cleaver Tool
d) Means of communication
e) Approved mechanical stripping tool to remove fiber coating.

6.10 Special Instruments Installation

6.10.1 Special Instruments List

- Analysers package instruments

- Air Quality Monitoring System

- Corrosion Coupon System

- Gas and Fire Detection System

- Flow metering System

- Truck Loading System

- Tank Gauging System

- Radioactive Level Transmitter

- Leak Detection System

- Other special package instruments, if any

6.10.2 Special Instruments shall be installed according to Manufacture’s recommendation or manual,

which shall be submitted as vendor data to ensure that each instrument is functionally correct.

6.10.3 Prior to the transportation of cabinet and rack to the work site, the place shall be checked to
ensure that location is ready for the installation. Ensure that cabinet and rack to be installed
are inspected and approved by EMPLOYER.

6.10.4 The foundation size and location of anchor bolt to be checked before installation.

6.10.5 Use appropriate carrying equipment when transferring cabinet and rack to one place to
another. Transportation and handling shall be in upright position.
 METHOD STATEMENT
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INSTRUMENT INSTALLATION
DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

6.10.6 Carefully mount the cabinet and rack to their location. Extra care must be provided for the
cabinet and rack not to be unintentionally dropped, damaged or scratched while handling them
into their fixing points.

6.10.7 All doors shall be properly closed after the installations. During construction period, equipment
doors shall be closed appropriately

6.10.8 Installation works shall be done by CONTRACTOR according to Vendor’s recommendation

and manual. CONTRACTOR will dispatch vendor engineer for installation supervision of
special instruments if required.

7 INSPECTION AND TESTING AFTER INSTALLATION

Upon completion of the installation, CONTRACTOR field engineer in coordination with CONTRACTOR-
QC shall perform the required inspection to assure that all requirements are met. All inspection and
testing shall be performed in accordance with EMPLOYER approved Inspection and Test Plan, which
will be developed by CONTRACTOR-QC section later.

7.1 Piping and Tubing Leak Test Procedure

7.1.1 General Procedure
7.1.1.1 The pressure gauges to be used shall have a range between 1.5 to 3 times the
maximum test pressures.

7.1.1.2 All line or system shall be checked visually before applying test pressure to ensure that
all parts intended not to be included in the test are isolated.

7.1.1.3 Prior to hydraulic testing of HP systems, safety warning will be displayed at the test
boundary line.

7.1.1.4 The test pressure should be gradually increased until the desired test pressure is
reached. If test fails, all of suspected leaking parts and joints should be checked with
any suitable bubble fluid. Repaired points shall be tested by the same procedure.

7.1.1.5 After completion of the test, lines shall be blown with dry compressed air and all
connections shall be returned to prevent foreign material in entering the line.

7.1.2 Pressure Leads and Sample Lines

7.1.2.1 The line to be tested shall be filled from its lower side and all vents shall remain
opened until the test fluid overflows.
 METHOD STATEMENT
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INSTRUMENT INSTALLATION
DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

7.1.2.2 Pneumatic pressure test shall be 1.4 barg and test medium shall be air or nitrogen and
holding time to detect leakage is 10 minutes.

7.1.3 Air Supply Line

7.1.3.1 Pneumatic test pressure shall be normal operating pressure, if operating pressure is
not more than 10.3 barg and the maximum operating pressure, if operating pressure is
over 10.3 barg.

7.1.3.2 Test medium shall be instrument air and holding time to detect leakage is 10 minutes.

7.2 Cable Test Procedure

7.2.1 Before doing the final termination of instrument and control cables, prior to energizing and
functional circuit/loop check, the cable shall be tested to ensure fitness for service.

7.2.2 Test voltage for all instrument and control cables shall be 500V DC and the minimum
insulation resistance required shall be 1.5 Mega Ohms.

7.2.3 After the completion of insulation resistance test, wire leads shall be shorted before
termination to discharged conductor-stored energy.

7.2.4 The tests on the factory-assembled cables, if required, will be performed during checking out
the packaged system equipment.

8 CHECK AND TEST SHEETS AFTER INSTRUMENT INSTALLATION & TEST

Upon completion of the instrument installation and test, Contractor field engineer in coordination with
Contractor-QC shall perform the required inspection to assure that all requirements are met.
All inspection for instrument installation and test shall be performed/recorded in accordance with the
Inspection and Test Plan and Inspection Test Report.

9 SAFETY

9.1 Safety Work method

9.1.1 The regulation for safety of personnel and equipment as stipulated by principal and as
required by the local authorities shall be strictly adhered to. All personnel shall be fully aware
of these regulations, and shall know the arrangements for first aid, medical facilities, fire-
fighting equipment and general emergencies. (Refer to attachment #1. Safe work method
 METHOD STATEMENT
Method Statement for
INSTRUMENT INSTALLATION
DOC. NO. :IONE-AA00-MS-IN-0002
KARBALA REFINERY PROJECT Rev. 1 Page 29/30
Ref. FEED DOC. No. : N/A

statement for Installation work for Instrumentation)

9.1.2 Work permit for the works to be executed shall be obtained prior to start the works daily basis.
9.1.3 Place barricade or warning sign boards, if required, at the location of working area during the
works in order to prevent from entering work site by the unauthorized person.
9.1.4 Check adequacy and availability of all tools and equipment for the works before
commencement of the installation works.
9.1.5 The Safety officer shall inspect and verify that all the necessary and applicable documents,
related to the safest operation, are in possession before commencing the job, including work
permits.

9.2 Safety of Personnel and Equipment

The regulation for the safety of personnel and equipment as stipulated by the principal and as
required by the local authorities shall be strictly adhered to. All personnel shall be fully aware of
these regulations, and shall know the arrangements for first aid, medical facilities, fire-fighting
equipment and general emergencies.

9.2.1 Fire Prevention

Smoking shall be strictly prohibited in all construction area and in the area where inflammable
and combustible materials are stored or handled.
All equipment or tools to be used in areas classified as hazardous shall be of approved
explosion proof design, unless the area has been cleared, ventilated and certified by as being
safe from hazard. A current calibration / test certificate shall be available to view.
No electrical equipment enclosures shall be opened or dismantled unless isolated elsewhere.
Charged and operative fire extinguishers shall be located near the work place when welding or
heating operations are carried out in field and fire proof fabric or metallic barriers shall be put
on combustible materials or installations near the place of welding at site.

9.2.2 Personnel Safety Gear

Safety goggles shall be used where potential eye hazards are present.
Full face shield shall be worn while grinding, chipping……etc.
Safety shoes shall always be used in the construction area.
Hearing protection shall be worn when working in excessively noisy area.
Head protection helmets shall always be used at all times in the construction area.
Respiratory protection of suitable type shall be used when exposed to harmful gases, their
immediate hazard or operating in a confined space.
Safety harness/safety belt of proper type shall be used by all personnel working at elevation
(above 2 meters).

9.2.3 First Aid & House Keeping

Construction area, especially operating/running plant area shall always be kept clean of
installation debris.
Oil, grease and other liquid spilling shall be attended immediately and area cleaned up.
Each working group shall be responsible for house-keeping in their respective working area.
 METHOD STATEMENT
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INSTRUMENT INSTALLATION
DOC. NO. :IONE-AA00-MS-IN-0002
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Ref. FEED DOC. No. : N/A

10 ATTACHMENT

10.1 Attachment #1. Safe Work Method Statement for Installation work for
Instrumentation (8 Sheets)
10.2 Attachment #2. Test Equipment & Tool List
 ATTACHMENT #1. Safe work method for Installation work for Instrumentation

Work Activity/Task: Installation work for Instrumentation Project Name/No:

Codes/Standards applicable: KARBALA Refinery Project

Prepared by: J. S. Kim / Instrument Construction Manager Contractor: HDGSK JV

Signature: Subcontractor:
Date: 23 Feb 2016 Representative:
Responsibility: The Contractor/Sub-contractor doing the work is responsible for carrying out a particular action, as listed in this SWMS. The supervisor is responsible to ensure that the Contractor/Sub-contractor
is competent and satisfied with the proc

Job Step
Identified Hazard and Assessment Control Measures Responsibility
Item (Break the job
(What can cause a high degree of harm?)
(What are you going to do to make this step as safe as possible, include equipment
down into steps) to be used where appropriate). (Responsible Person)

1. Mobilization of 1.1 Over speeding of vehicle and incompetent person 1.1.1 The vehicle operator and rigger must be trained and have a valid driver’s license.
Materials resulting to Motor Vehicular Accident and fall of load. 1.1.2 Materials must be secured properly.
1.1.3 All traffic rules and signs should be strictly followed.

1.2 Overloading of passengers/ materials 1.2.1 No worker is allowed to ride on the pick up or truck bed while moving.
1.2.2 Supervisors must closely monitor the loading of materials.

2. Unloading of 2.1 Fall of load; Damage to equipment and property due 2.1.1 Use approved lifting equipment and gear. A valid TPI Certificate must be ready
Materials to unprepared area and incorrect lifting gear (SWL). and available.
2.1.2 Lifting gears must be inspected before use.
2.1.3 The unloading area must be cleared and prepared beforehand.
2.1.4 Barricade the area to isolate other workers and warn incoming pedestrians.

2.2 Unsafe condition and unsafe act resulting to human 2.2.1 Manual handling shall be covered in daily toolbox talk and implemented on site.
injury (manual handling and horse playing) Workers must be trained about the good hand/ body positioning.
2.2.2 Use mechanical lift if possible.
2.2.3 Proper supervision must be observed.

2.3 Slip/ Trip/ Fall Hazard 2.3.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
 ATTACHMENT #1. Safe work method for Installation work for Instrumentation

2.3.2 Provide safe access/ emergency walkways (free from any materials).
2.3.3 Proper material management.

3. Installation of 3.1 Personal Injury due to lack knowledge, experience 3.1.1 Only competent/ experienced/ skilled worker are allowed to do the task.
Base Rack and training, overconfidence and carelessness. 3.1.2 Workers must be daily advised to wear the proper and appropriate PPE.
3.1.3 Proper tools must be used and undergo daily inspection and maintenance to avoid
further injury to the worker.

3.2 Slip/ Trip/ Fall Hazard 3.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
3.2.2 Provide safe access/ emergency walkways (free from any materials).
3.2.3 Proper Cable management

3.3 Electrocution 3.3.1 Do regular maintenance and inspection of power tools.

3.3.2 Do proper cable management.
3.3.3 Wear proper PPE for the task.

3.4 Fire Hazard 3.4.1 Provide fire extinguisher/ blanket.

3.4.2 Assign fire watchmen.
3.4.3 Remove combustible materials near the hot work area.
3.4.4 Only qualified welder/ worker shall do the welding works.
3.4.5 Regular maintenance/ inspection of power tools must be implemented.
3.4.6 Do proper cable management.
3.4.7 All around inspection after the activity.

3.5 Lack of supervision resulting to human injury and 3.5.1 Clear the work area by providing safety warning/ signage and barricade.
damage to property. 3.5.2 Proper supervision must be observed.
3.5.3 Engage competent person to do the task.

4. Setting/ 4.1 Physical injury and damage to property due to lack 4.1.1 The activity must be discussed in daily toolbox talk.
installation of of knowledge, training, improper use of tools and 4.1.2 Always remind the workers to use proper and appropriate PPE.
Panel supervision. 4.1.3 Close supervision must be implemented.
4.1.4 Qualified/ competent/ skilled worker must do the task.
4.1.5 Regular maintenance and inspection of hand tools must be implemented.
4.1.6 Only proper/ appropriate tools must be used in setting/ installing panel.
4.1.7 Protection must be put in the panel after installation.
4.1.8 Panel must be secured properly.
 ATTACHMENT #1. Safe work method for Installation work for Instrumentation

4.2 Slip/ Trip/ Fall Hazard 4.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
4.2.2 Provide safe access/ emergency walkways (free from any materials).
4.2.3 Proper material management.

5. Pulling of 5.1 Unsafe condition and unsafe act resulting to 5.1.1 Manual handling shall be covered in daily toolbox talk and implemented on site.
Instrument Cable personal/ human injury (manual handling, horse Workers must be trained about the good hand/ body positioning.
playing, use of improper tools, injury to other 5.1.2 Proper supervision must be observed.
worker) 5.1.3 Regular maintenance and inspection of hand tools must be implemented.
5.1.4 Only proper/ appropriate tools must be used in excavation.
5.1.5 Barricade the work area to isolate other worker.
5.1.6 Safety warning/ signage must be posted in the visible area.
5.1.7 Always advise the worker to use/ wear proper/ appropriate PPE for the task.

5.2 Slip/ Trip/ Fall Hazard 5.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
5.2.2 Provide safe access/ emergency walkways (free from any materials).
5.2.3 Proper material management.

5.3 Environmental Hazard (Dust Hazard, Heat Stress) 5.3.1 Advise the worker to use dust mask.
5.3.2 Workers must work in schedule to avoid over exposure to heat that will lead to
exhaustion. Rest Shelter near the work area must be provided.
5.3.3 Cold drinking water to be provided.

6. Termination of 6.1 Physical injury and damage to property due to lack 6.1.1 The activity must be discussed in daily toolbox talk.
Instrument Cable of knowledge, training and supervision. 6.1.2 Always remind the workers to use proper and appropriate PPE.
6.1.3 Close supervision must be implemented.
6.1.4 Qualified/ competent/ skilled worker must do the task.

6.2 Slip/ Trip/ Fall Hazard 6.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
6.2.2 Provide safe access/ emergency walkways (free from any materials).
6.2.3 Proper material management.

6.3 Electrocution and Fire Hazard due to electrical faulty 6.3.1 Provide fire extinguisher/ blanket.
wiring (electrical tools). 6.3.2 Do proper cable management.
 ATTACHMENT #1. Safe work method for Installation work for Instrumentation

6.3.3 Regular maintenance and inspection of electrical tools

6.3.4 Wear appropriate hand gloves

7. Installation of 7.1 Unsafe condition and unsafe act resulting to 7.1.1 Manual handling shall be covered in daily toolbox talk and implemented on site.
Foundation personal/ human injury (manual handling, horse Workers must be trained about the good hand/ body positioning.
(Manual playing, use of improper tools, injury to other 7.1.2 Proper supervision must be observed.
Excavation) worker) 7.1.3 Regular maintenance and inspection of hand tools must be implemented.
7.1.4 Only proper/ appropriate tools must be used in excavation.
7.1.5 Barricade the work area to isolate other worker.
7.1.6 Safety warning/ signage must be posted in the visible area.
7.1.7 Always advise the worker to use/ wear proper/ appropriate PPE for the task.

7.2 Slip/ Trip/ Fall Hazard 7.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
7.2.2 Provide safe access/ emergency walkways (free from any materials).
7.2.3 Proper material management.

7.3 Environmental Hazard (Dust Hazard, Heat Stress) 7.3.1 Advise the worker to use dust mask.
7.3.2 Workers must work in schedule to avoid over exposure to heat that will lead to
exhaustion. Rest Shelter near the work area must be provided.
7.3.3 Cold drinking water to be provided.

8. Installation of 8.1 Physical injury and damage to property due to lack 8.1.1 The activity must be discussed in daily toolbox talk.
Stanchion of knowledge, training and supervision. 8.1.2 Always remind the workers to use proper and appropriate PPE.
8.1.3 Close supervision must be implemented.
8.1.4 Qualified/ competent/ skilled worker must do the task.

8.2 Slip/ Trip/ Fall Hazard 8.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
8.2.2 Provide safe access/ emergency walkways (free from any materials).
8.2.3 Proper material management.

8.3 Electrocution and Fire Hazard due to electrical faulty 8.3.1 Provide fire extinguisher/ blanket.
wiring (electrical tools). 8.3.2 Do proper cable management.
8.3.3 Regular maintenance and inspection of electrical tools
8.3.4 Wear appropriate hand gloves
 ATTACHMENT #1. Safe work method for Installation work for Instrumentation

9. Installation of 9.1 Physical injury and damage to property due to lack 9.1.1 The activity must be discussed in daily toolbox talk.
instrument. of knowledge, training, improper use of tools and 9.1.2 Always remind the workers to use proper and appropriate PPE.
supervision. 9.1.3 Close supervision must be implemented.
9.1.4 Qualified/ competent/ skilled worker must do the task.
9.1.5 Regular maintenance and inspection of hand tools must be implemented.
9.1.6 Only proper/ appropriate tools must be used in installing instruments.
9.1.7 Instruments must be protected after installation.

9.2 Slip/ Trip/ Fall Hazard 9.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
9.2.2 Provide safe access/ emergency walkways (free from any materials).
9.2.3 Proper material management.

10. Installation of 10.1 Physical injury and damage to property due to lack 10.1.1 The activity must be discussed in daily toolbox talk.
Tubing and of knowledge, training, improper use of tools and 10.1.2 Always remind the workers to use proper and appropriate PPE.
Support supervision. 10.1.3 Close supervision must be implemented.
10.1.4 Qualified/ competent/ skilled worker must do the task.
10.1.5 Regular maintenance and inspection of hand tools must be implemented.
10.1.6 Only proper/ appropriate tools must be used in installing tube.
10.1.7 Follow the Engineering drawing/ instruction.

10.2 Slip/ Trip/ Fall Hazard 10.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
10.2.2 Provide safe access/ emergency walkways (free from any materials).
10.2.3 Proper material management.

10.3 Electrocution and Fire Hazard (Power tools) 10.3.1 Provide fire extinguisher/ blanket.
10.3.2 Assign fire watchmen.
10.3.3 Remove combustible materials near the hot work area.
10.3.4 Only qualified welder/ worker shall do the welding works.
10.3.5 Regular maintenance/ inspection of power tools must be implemented.
10.3.6 Do proper cable management.
10.3.7 All around inspection after the activity.

11. Touch up painting 11.1 Ingestion and exposure to chemical 11.1.1 MSDS must be ready and available.
11.1.2 Container must be properly labeled.
11.1.3 Provide cover all clothing. Wear dust mask / hand gloves.
 ATTACHMENT #1. Safe work method for Installation work for Instrumentation

11.1.4 Spills to be cleaned immediately.

11.2 Fire Hazard 11.2.1 Provide fire extinguisher/ blanket.

11.2.2 Keep the paint away from hot work area.

12. Installation of 12.1 Unsafe condition and unsafe act resulting to 12.1.1 Manual handling shall be covered in daily toolbox talk and implemented on site.
foundation personal/ human injury (manual handling, horse Workers must be trained about the good hand/ body positioning.
(Manual playing, use of improper tools, injury to other 12.1.2 Proper supervision must be observed.
Excavation for worker) 12.1.3 Regular maintenance and inspection of hand tools must be implemented.
unpaved area) 12.1.4 Only proper/ appropriate tools must be used in excavation.
12.1.5 Barricade the work area to isolate other worker.
12.1.6 Safety warning/ signage must be posted in the visible area.
12.1.7 Always advise the worker to use/ wear proper/ appropriate PPE for the task.

12.2 Slip/ Trip/ Fall Hazard 12.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
12.2.2 Provide safe access/ emergency walkways (free from any materials).
12.2.3 Proper material management.

12.3 Environmental Hazard (Dust Hazard, Heat Stress) 12.3.1 Advise the worker to use dust mask.
12.3.2 Workers must work in schedule to avoid over exposure to heat that will lead to
exhaustion. Rest Shelter near the work area must be provided.
12.3.3 Cold drinking water to be provided.

13. Installation of 13.1 Physical injury and damage to property due to lack 13.1.1 The activity must be discussed in daily toolbox talk.
Rack and Junction of knowledge, training and supervision. 13.1.2 Always remind the workers to use proper and appropriate PPE.
Box 13.1.3 Close supervision must be implemented.
13.1.4 Qualified/ competent/ skilled worker must do the task.

13.2 Slip/ Trip/ Fall Hazard 13.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
13.2.2 Provide safe access/ emergency walkways (free from any materials).
13.2.3 Proper material management.

13.3 Electrocution and Fire Hazard due to electrical faulty 13.3.1 Provide fire extinguisher/ blanket.
wiring (electrical tools). 13.3.2 Do proper cable management.
13.3.3 Regular maintenance and inspection of electrical tools
 ATTACHMENT #1. Safe work method for Installation work for Instrumentation

13.3.4 Wear appropriate hand gloves

14. Installation of 14.1 Physical injury and damage to property due to lack 14.1.1 The activity must be discussed in daily toolbox talk.
Conduit Stub-up. of knowledge, training, improper use of tools and 14.1.2 Always remind the workers to use proper and appropriate PPE.
supervision. 14.1.3 Close supervision must be implemented.
14.1.4 Qualified/ competent/ skilled worker must do the task.
14.1.5 Regular maintenance and inspection of hand tools must be implemented.
14.1.6 Only proper/ appropriate tools must be used in installing conduit stub-up.

14.2 Slip/ Trip/ Fall Hazard 14.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
14.2.2 Provide safe access/ emergency walkways (free from any materials).
14.2.3 Proper material management.

15. Installation of 15.1 Personal Injury due to lack knowledge, experience 15.1.1 Only competent/ experienced/ skilled worker are allowed to do the task.
Cable Tray and and training, overconfidence and carelessness. 15.1.2 Workers must be daily advised to wear the proper and appropriate PPE.
Support (cutting, 15.1.3 Proper tools must be used and undergo daily inspection and maintenance to avoid
welding, grinding). further injury to the worker.

15.2 Slip/ Trip/ Fall Hazard 15.2.1 Housekeeping shall be discussed in daily toolbox topic and be implemented on site
on a daily basis.
15.2.2 Provide safe access/ emergency walkways (free from any materials).
15.2.3 Proper Cable management

15.3 Electrocution 15.3.1 Do regular maintenance and inspection of power tools.

15.3.2 Do proper cable management.
15.3.3 Wear proper PPE for the task.

15.4 Fire Hazard 15.4.1 Provide fire extinguisher/ blanket.

15.4.2 Assign fire watchmen.
15.4.3 Remove combustible materials near the hot work area.
15.4.4 Only qualified welder/ worker shall do the welding works.
15.4.5 Regular maintenance/ inspection of power tools must be implemented.
15.4.6 Do proper cable management.
15.4.7 All around inspection after the activity.

15.5 Lack of supervision resulting to human injury and 15.5.1 Clear the work area by providing safety warning/ signage and barricade.
 ATTACHMENT #1. Safe work method for Installation work for Instrumentation

damage to property. 15.5.2 Proper supervision must be observed.

15.5.3 Engage competent person to do the task.

16. Demobilization 16.1 Poor Housekeeping 16.1.1 Clear the area by remove all materials/ scraps in the area.
(Work completion) 16.1.2 Rubbish must be thrown or placed on the proper bins or area.
16.1.3 Good housekeeping practice must be implemented.
16.1.4 Proper material management.
16.1.5 Tools must be returned on its proper storage.

Before this or any SWMS is used it must be checked and adjusted to suit a person's individual work, method, as long as hazards are identified and controlled. Additional steps will need to be
added to suit particular circumstances. A main function of the

If required for a specific site, detail the method of control for any additional hazards. Attached additional pages if space is insufficient

Reviewed by: Position: Signature: Date:

Accepted by: Position: Signature: Date:

Attachment #2

Instrument Work Test Equipment & Tool List

No. Equipment description Company Model Range Accuracy Remark
# TEST EQUIPMENT LIST
1 Pressure Calibrator Druck DPI 610 -1 - 2 barg 0.05%
2 Pressure Calibrator Druck DPI 610 0 - 400 barg 0.05%
3 Pressure Calibrator Druck DPI 610 -1~20 Bar 0.05%
4 Resistance Decade Box Time 1067 10mΩ - 10KΩ 0.05%
5 Vernier Caliper Mitutoyo 0 - 300 mm
6 Insulation Megger Tester Megger MIT-310 250V/1Kv 0.05%
7 Hart Communicator EMERSON MODEL 475
8 DC Power Supply TOYOTECH DP30-03A 0-30 V
9 Temperature Calibrator (Dry Block) Ametek. Jofra CTC650A 100°C~650°C ±0.06°C
10 TC and RTD Calibrator Pyragon TSC8802 K,J,E 0.05%
11 Digital Multi Meter FLUKE 87V
12 Hand Pump (for Vacuum) Ametek T-975 -27inHg~580psi
13 Pressure Calibrator w/ Hand pump Ametek CE PPC 0~70Bar
14 Hydraulic Pressure Pump Ametek TQD-400 0~1000Bar
15 Pressue Indicator 3D Instrument Accu-Drive 0~10kg/cm2 0.05%
16 Pressue Indicator 3D Instrument Accu-Drive 0~100kg/cm2 0.05%
17 Pressue Indicator Cyrstal XP2i 0~2000psi 0.05%
18 Pressure Indicator/ Test Gauge 3D Instrument Accu Drive 0 - 2 bar 0.25%
19 Pressure Indicator/ Test Gauge 3D Instrument Accu Drive 0 -10 bar 0.25%
20 Pressure Indicator/ Test Gauge 3D Instrument Accu Drive 0 - 140 bar 0.25%
21 Pressure Indicator/ Test Gauge 3D Instrument Accu Drive 0 - 35 bar 0.25%
22 Pressure Indicator/ Test Gauge 3D Instrument Accu Drive 0 - 70 bar 0.25%
23 Process Meter FLUKE 789 or 787
24 Safety Valve Calibration Bench SCADA SRV-025
25 PROXIMITY SYSTEM TEST KIT BENTLY NEVADA
26 FREQUENCY COUNTER EZ-DIGITAL 3.7GHZ
27 FIELDBUS MONITOR-6 FBT-6
# CONSTRUCTION EQUIPMENT & TOOL LIST
1 Boom Truck
2 Forklift
3 Manlift
4 Welding Machine (Elect)
5 Welding Machine (Diesel)
6 Generater
7 Crane
8 Glinder
9 Adjustable Wrench
10 Diagonal Cutting Plier
11 L-Wrench Set
12 Clamping Tool
13 Magnetic Level
14 Dry core Drill
15 Rigid Tube Bender
16 Dry Oven (For Welding Rod)
17 Multi Purpose Scissor
18 Ratchet Wrench
19 Screw Driver
20 Stripper
21 Extension Wire
22 Pipe Wrench
23 Knife
24 Saw