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FGP/WPMP

Farnborough Office

SLO Electrical & Instrumentation


Fabrication Lessons Learned

October 2016

© Tengizchevroil 2013
Contents

 Cable Trays
 Cable Routing
 Junction Boxes
 Instrumentation
 Instrument Tubing Installation
 Deck Penetrations

© Tengizchevroil 2016 Insert Doc №. 2


1. Cable Trays

Do’s & Don'ts

 Do not route at deck level.


 Do not route across access walkways or in front of
maintenance access.
 Route in the shadow of steelwork or other permanent
structures.

© Tengizchevroil 2016 Insert Doc №. 3


1. Cable Trays
 Cable tray interference with flange.
 Cable tray not flush at the top; results in a sharp edge.

© Tengizchevroil 2016 Insert Doc №. 4


1. Cable Trays
 Cable tray routed through pipe support in 3D model.
 3D model revised to show as-built cable tray routing.

© Tengizchevroil 2016 Insert Doc №. 5


1. Cable Trays
 Conduit pipes and cable trays not to 3D model - recorded in Vendor
change log report.

© Tengizchevroil 2016 Insert Doc №. 6


1. Cable Trays
 Insufficient space for cable tray, encroached by adjacent personnel
protection around pipe.
 3D model does not show personnel protection around pipe.

© Tengizchevroil 2016 Insert Doc №. 7


1. Cable Trays
 Cable tray layout not as per 3D model.

© Tengizchevroil 2016 Insert Doc №. 8


1. Cable Trays
 Cable tray located on base of the pump motor.
 Operators shall not be required to stand on nearby pipes, cable trays,
handrails or any other elevated surface not specifically designed to be used
as a standing surface (SID Section 10.4.18)

© Tengizchevroil 2016 Insert Doc №. 9


1. Cable Trays
 Valve lever clash with cable tray - finger trap.
 Proposed solution in 3D model: remove cable tray section in this area
and relocate the tubing to obtain the required clearance.

© Tengizchevroil 2016 Insert Doc №. 10


1. Cable Trays
 Valve lever clash with cable tray - finger trap.

© Tengizchevroil 2016 Insert Doc №. 11


1. Cable Trays
 Ensure cable trays do not limit
maintenance access and
equipment removal.

© Tengizchevroil 2016 Insert Doc №. 12


1. Cable Trays
 Cable Tray not located as per 3D model.
 The problem is that there is now no access to TE.

© Tengizchevroil 2016 Insert Doc №. 13


1. Cable Trays
 The 3D model shows a cable tray but no conduit.

© Tengizchevroil 2016 Insert Doc №. 14


1. Cable Trays
 Cable tray is not routed as per 3D model.
 Access to nuts of U-bolt is now limited.

© Tengizchevroil 2016 Insert Doc №. 15


2. Cable Routing

Do’s & Don'ts

 Avoid clashes with piping.


 Ensure correct entry (bottom vs. side entry).
 Provide adequate support.

© Tengizchevroil 2016 Insert Doc №. 16


2. Cable Routing
 Cable clash with flange bolts.
 3D model shows the JB and flange face to be flush; JB is installed too
high.

© Tengizchevroil 2016 Insert Doc №. 17


2. Cable Routing

© Tengizchevroil 2016 Insert Doc №. 18


2. Cable Routing
 Cables must be supported.
 Cable entry must be from the
bottom.

© Tengizchevroil 2016 Insert Doc №. 19


2. Cable Routing
 Instrument cable touching pipe & flange because JB is installed higher than
in 3D model.
 Relocate JB lower to ensure cables are not touching pipework, whilst also
ensuring flange bolt access.

© Tengizchevroil 2016 Insert Doc №. 20


3. Junction Boxes

Do’s & Don'ts

 Ensure JB and panel door swings are 180 degrees and


unobstructed.
 Shall be located in a manner that facilitates
easy/compliant access.
 Ensure sufficient room for panel removal and door
swings.
 Adequate signage for all equipment subject to operation
and/or manipulation.
 Provide adequate supports attaching to multi discipline,
off of existing structures.
 Do not locate instrument posts or JBs in designated
access or maintenance areas.

© Tengizchevroil 2016 Insert Doc №. 21


3. Junction Boxes
 Junction Boxes not mounted centrally on support post per 3D model.
 Conduit position not as in the 3D model.

© Tengizchevroil 2016 Insert Doc №. 22


3. Junction Boxes
 Junction Box and panel door swings are 180 degrees and unobstructed.

© Tengizchevroil 2016 Insert Doc №. 23


3. Junction Boxes
 Junction Box height must be updated in 3D model.

© Tengizchevroil 2016 Insert Doc №. 24


4. Instrument Tubing Installation

Do’s & Don'ts

 Do not route at deck level.


 Do not route across walk ways or in front of
maintenance access spaces.
 Provide adequate supporting.
 Avoid use of coupling in long runs, which may cause
vibration issues.

© Tengizchevroil 2016 Insert Doc №. 25


4. Instrument Tubing Installation
 Tubing run was re-routed during fabrication (not as per 3D model).

© Tengizchevroil 2016 Insert Doc №. 26


4. Instrument Tubing Installation
 Unsupported free tubing lengths are excessive.
 Ensure adequate tubing support.

© Tengizchevroil 2016 Insert Doc №. 27


4. Instrument Tubing Installation
 Unsupported free tubing length is excessive.

© Tengizchevroil 2016 Insert Doc №. 28


4. Instrument Tubing Installation
 Tubing connection at manual valve not as per the 3D model.

© Tengizchevroil 2016 Insert Doc №. 29


4. Instrument Tubing Installation
 Good tubing installation.

© Tengizchevroil 2016 Insert Doc №. 30


4. Instrument Tubing Installation
 Tubing breakout connections need to be flared out for spanner access.

© Tengizchevroil 2016 Insert Doc №. 31


4. Instrument Tubing Installation
 Cable tray extends beyond the exit of the cable, and tubing routed
over the cable tray.
 Tubing was re-arranged to run below cable tray. Preferred option.

© Tengizchevroil 2016 Insert Doc №. 32


4. Instrument Tubing Installation
 Pyrometer tubing must be supported.

© Tengizchevroil 2016 Insert Doc №. 33


4. Instrument Tubing Installation
 Provide personnel protection for surfaces greater than 60 degrees C.
 Personnel protection missing around tubing.

© Tengizchevroil 2016 Insert Doc №. 34


4. Instrument Tubing Installation
 Instrument tubing on the left not as per 3D model.
 Instrument tubing on the right after correction.

© Tengizchevroil 2016 Insert Doc №. 35


5. Instrumentation

Do’s & Don'ts

 Do not block access or maintenance areas in front of


equipment, valves, instruments etc.
 Do not block withdrawal or laydown areas.
 Maintain SID height access requirements – must not
exceed max/min allowable.
 Ensure that all instruments are visible and accessible.
 Provide adequate supports attaching to multi discipline,
off of existing structures.
 Do not locate instrument posts or JBs in designated
access or maintenance areas.

© Tengizchevroil 2016 Insert Doc №. 36


5. Instrumentation
 Ensure displays are located within the SID range.

© Tengizchevroil 2016 Insert Doc №. 37


5. Instrumentation
 Ensure displays are located within the SID range.
 Will operator stand next to or on the skid?

© Tengizchevroil 2016 Insert Doc №. 38


5. Instrumentation
 Ensure displays are located within the SID range.

© Tengizchevroil 2016 Insert Doc №. 39


5. Instrumentation
 Incorrect orientation of Rosemount head.
 Excessive bolt length.

© Tengizchevroil 2016 Insert Doc №. 40


5. Instrumentation
 Flow glass and gate valve not installed as per 3D model.
 Open Gate Valve overhangs skid edge.

© Tengizchevroil 2016 Insert Doc №. 41


5. Instrumentation
 Provide sufficient space to allow the pressure indicator to be removed
without removing other equipment or guards.

© Tengizchevroil 2016 Insert Doc №. 42


5. Instrumentation
 Pressure gauge mounted in different orientation as shown in 3D model.
 Pressure gauge on Lube Oil Console needs support in this orientation.

© Tengizchevroil 2016 Insert Doc №. 43


5. Instrumentation
 Cable Tray clash with Temperature Element.

© Tengizchevroil 2016 Insert Doc №. 44


5. Instrumentation
 This TP is facing to the inside of skid.
 Rotate 180 degrees as shown in the 3D model.

© Tengizchevroil 2016 Insert Doc №. 45


5. Instrumentation
 Lube Oil FG needs to be rotated 90 degrees to be readable while
operating Filling Valve (as per note on P&ID).

Filling Valve

Lube Oil FG

© Tengizchevroil 2016 Insert Doc №. 46


5. Instrumentation
 The Level Gauge has no vent
and drain valves installed.
 These valves are identified on
the PI&D and TCO standard
drawing (LO Rundown Tank).

© Tengizchevroil 2016 Insert Doc №. 47


6. Deck Penetration

Do’s & Don'ts

 Provide toeboard as per SID.

© Tengizchevroil 2016 Insert Doc №. 48


6. Deck Penetration
 Good deck penetration and toeboard provided.

© Tengizchevroil 2016 Insert Doc №. 49


6. Deck Penetration
 Good deck penetration provided on plated deck.

© Tengizchevroil 2016 Insert Doc №. 50


6. Deck Penetration
 Non-compliant deck penetrations.

© Tengizchevroil 2016 Insert Doc №. 51


6. Deck Penetration
 SID compliant deck penetrations.

© Tengizchevroil 2016 Insert Doc №. 52


QUESTIONS?

© Tengizchevroil 2016 Insert Doc №. 53