INDUSTRIAL INSTRUMENTATION & CONTROL SYSTEMS
Installation, Quality Control, Pre-Commissioning & Commissioning Services
We provide field services for instrumentation and control systems that support process monitoring, control and safe plant operation. Serving oil and gas, petrochemical, refinery, power, water treatment and other process industries, we offer project-specific technical support from field device installation and quality inspections to calibration, loop testing and system commissioning.
Working against approved project documentation, client specifications and manufacturer instructions, we help verify installation quality, measurement accuracy and system functionality. We coordinate with clients, EPC contractors, PMCs and equipment manufacturers on new installations, expansions, upgrades and shutdown projects.
1. FIELD INSTRUMENTS AND PROCESS MEASUREMENT DEVICES
Depending on the project scope, we support installation, inspection, calibration, testing and commissioning of:
- Pressure: Pressure and differential pressure transmitters, pressure gauges, pressure switches and manifolds.
- Temperature: RTDs, thermocouples, temperature transmitters, indicators, switches and thermowells.
- Flow: Electromagnetic, Coriolis, ultrasonic, vortex and differential pressure flowmeters; orifice plates and associated primary elements.
- Level: Radar, guided-wave radar, ultrasonic, hydrostatic and differential pressure level transmitters; level switches and indicators.
- Analysis: pH, conductivity, dissolved oxygen, gas, moisture and dew point analysers; sampling and sample conditioning systems.
- Machinery monitoring: Vibration, axial displacement, speed and bearing temperature sensors, including field interfaces to monitoring systems.
- Auxiliary devices: Proximity sensors, limit switches, position transmitters, pressure regulators, filter-regulators and electro-pneumatic converters.
Instrument tags, models, ranges, units, process connections, materials, orientation and accessibility are checked against approved documentation.
2. INSTRUMENTATION INSTALLATION SERVICES
- Installation of field instruments, stanchions, brackets, supports and protective enclosures.
- Manifold, valve assembly, impulse line and instrument tubing installation against approved hook-up drawings.
- Checks of tubing routing, slope, supports, fittings and instrument accessibility.
- Installation of instrument air lines, distribution manifolds and pneumatic connections.
- Support for instrument cable trays, conduits, cables, fibre optics and communication cabling within the agreed scope.
- Installation of junction boxes, marshalling cabinets, control panels and field panels.
- Cable glanding, termination, ferruling, screen connections and cable identification.
- Protective earthing, instrument earthing and screening arrangements in accordance with project design.
- Inspection of hazardous area Ex equipment, glands and connections by competent personnel.
Process connections and work affecting pressure boundaries are coordinated with the responsible disciplines and performed under approved procedures.
3. CONTROL VALVES AND ACTUATORS
We provide installation checks, adjustment, testing and commissioning support for control valves and automated on/off valves.
Our scope may include control valves, on/off valves, shutdown and emergency shutdown valves (SDVs/ESDVs), blowdown valves (BDVs), motor-operated valves (MOVs), pneumatic, electric and electro-hydraulic actuators, and associated accessories.
Typical activities include:
- Verification of tags, models, flow direction, valve and actuator details.
- Checks of positioners, I/P converters, solenoid valves, limit switches and position feedback devices.
- Inspection of air supplies, filter-regulators and pneumatic tubing connections.
- Positioner adjustment, input-to-position correlation and feedback verification.
- Full stroke, open/close, travel time and end-position tests.
- Verification of the specified fail-open, fail-close or fail-in-position action.
- Testing of local/remote operation, permissives and interlocks.
- Partial stroke testing support where required by approved procedures.
- Support for, or witnessing of, leakage and seat leakage testing against defined test conditions and acceptance criteria.
Safety relief valve set-pressure adjustment and certification are treated as a separately authorised specialist scope.
4. FIRE & GAS DETECTION SYSTEMS
We support inspection and functional testing from Fire & Gas field device installation through to control system integration.
Devices and equipment may include:
- Point infrared and catalytic combustible gas detectors.
- Open-path gas detectors and ultrasonic gas leak detectors where specified.
- H2S, CO and other toxic gas detectors; oxygen deficiency/enrichment detectors.
- UV, IR and combined flame detectors.
- Smoke, heat and combined detectors; linear heat and aspirating smoke detection systems.
- Manual call points, sounders, beacons and audible/visual warning devices.
- Fire & Gas panels, I/O modules and associated field connections.
- Monitoring and control interfaces to deluge, fire suppression, HVAC and damper systems.
Checks may cover location, orientation, line of sight, access, identification, wiring, addressing and control system signals. Gas detector activities include bump testing, calibration and alarm verification using manufacturer-approved test gas and equipment. Other detectors are functionally verified using suitable test equipment.
We test alarm, fault, inhibit and communication states, together with outputs defined in the approved Cause & Effect matrix. Detector location checks refer to approved layouts and coverage studies; they do not constitute an independent detection coverage design service.
Tests that could trigger suppression discharge or plant shutdown are performed with client authorisation, an approved isolation/override plan and coordination with the relevant disciplines. Removal of test overrides and inhibits is recorded on completion.
5. CONTROL AND SAFETY SYSTEMS
- Distributed Control Systems — DCS.
- Programmable Logic Controllers — PLC.
- Supervisory Control and Data Acquisition systems and Human-Machine Interfaces — SCADA/HMI.
- Safety Instrumented Systems and Emergency Shutdown Systems — SIS/ESD.
- Fire & Gas control systems.
- Package equipment panels and skid control systems.
- Remote I/O, marshalling, barrier and isolator cabinets.
- HART, Foundation Fieldbus, PROFIBUS, Modbus and industrial Ethernet interfaces.
Within the approved scope, we support I/O verification, signal mapping, scaling, communications and package interface testing. Alarm, trip, permissive, interlock and sequence functions are checked against approved control narratives and test procedures. Software and configuration changes are subject to client authorisation and change management.
6. QUALITY CONTROL AND FIELD INSPECTION — QA/QC
- Material receiving inspections, including model, tag, quantity and physical condition checks.
- Review of datasheets, certificates, calibration records and manufacturer documents.
- Installation verification against P&IDs, instrument indexes, I/O lists, hook-ups, loop diagrams and wiring drawings.
- Verification of cable continuity, core identification, polarity, terminals and screen connections.
- Insulation resistance checks using approved methods and protection of sensitive devices.
- Inspection of tubing, fittings, supports and pneumatic lines; pressure/leak testing within the agreed scope.
- Preparation of RFIs and inspection records under the project ITP and Method Statements.
- Punch list and NCR tracking, corrective action verification and close-out inspections.
- Verification of valid calibration and traceability records for test instruments.
7. PRE-COMMISSIONING AND COMMISSIONING
- Mechanical Completion checks and system-based field walkdowns.
- Instrument calibration, range, unit and configuration verification.
- End-to-end loop checks for AI, AO, DI and DO signals between field devices and control systems.
- Verification of control room indications, alarm limits, trip settings and feedback signals.
- Control valve stroke tests and automated valve functional tests.
- Cause & Effect, interlock, permissive and sequence testing.
- SAT and integrated system testing; FAT witnessing and technical follow-up where included.
- Interface testing between package equipment and the main control system.
- SIS functional verification and proof test support under approved procedures.
- Troubleshooting support for signals, instruments and control loops during start-up.
Test methods clearly distinguish physical device stimulation, simulation and software forcing. Commissioning and proof test support do not, by themselves, constitute SIL verification or an independent functional safety assessment.
8. REPORTING AND HANDOVER DOCUMENTATION
Depending on the project scope, we prepare calibration certificates, loop check sheets, valve test records, Fire & Gas test reports, I/O checklists, SAT records, punch lists, NCR close-outs, red-line drawings and Mechanical Completion/commissioning dossiers.
Through traceable records and system-based handover, we support the delivery of organised technical documentation to plant operations and maintenance teams.
9. SPECIALIST PERSONNEL AND PROJECT SUPPORT
We provide instrumentation technicians, control system specialists, supervisors and inspection personnel to suit project requirements for installation, quality control, pre-commissioning, commissioning and shutdown activities. Assignments are defined according to personnel competence and the agreed scope.
From field instruments to the control room, contact us for support in installing, testing and preparing your instrumentation and control systems for operation.
