TVET PROGRAM TITLE: Mechatronics and Instrument Servicing Management level IV

MODULE TITLE: Installing process instrumentation and controlling cabling and tubing
MODULE CODE: ELE MIS4 M09 0814
NOMINAL DURATION:30hrs
MODULE DESCRIPTION: This module covers the installation and termination of instrument and
control apparatus cabling and tubing for chemical, industrial or food processing systems.
It encompasses working safely and to standards, routing cables and tubing to specified locations,
terminating cables and tubing and connecting wiring at accessories and at instruments and control
apparatus and completing the necessary installation documentation

LEARNING OUTCOMES:
At the end of this module the trainer will be able to
LO1: Prepare to install cabling and tubing
LO2: Install cabling, tubing and accessories
LO3: Completion and report installation activities

MODULE CONTENTS:
LO1: Prepare to install cabling and tubing
1.1 OH&s procedures and policies
1.2 Read and interpret drawings related to cable and tube layout
1.3 Select tools and equipment and testing devices for the installation
1.4 Legislation, regulation, polices and work place procedure
LO2: Install cabling, tubing and accessories
2.1 Terminate electronic cable and conductor
2.2 Terminate tubes and cables
2.3 Install accessories at the required locations with acceptable tolerance
2.4 Routing ,placing and securing cable and tubing
2.5 Install cabling and tubing
LO3: Completion and report installation activities
3.1 Follow OH&S work completion risk control measures
3.2 Clean work site and make safe
3.3 Make final check to the installed wiring
3.4 Report the installation activities

Install process instrumentation and control cabling and tubing

Installation and termination of instrument and control cabling and tubing for chemical, industrial or food processing
systems or equipment used in medical procedures. It encompasses working safely and to standards, routing cables
and tubing to specified locations, terminating cables and tubing and connecting wiring at accessories and at
instruments and control apparatus and completing the necessary installation documentation.
Licensing/Regulatory Information
License to practice
Conditions may apply in some jurisdictions subject to regulations related to electrical work. Practice in the
workplace and during training is also subject to regulations directly related to occupational health and safety and
where applicable contracts of training such as apprenticeships.
Note
1. Compliance with permits may be required in various jurisdictions and typically relates to the operation of plant,
machinery and equipment such as elevating work platforms, powder operated fixing tools, and power operated

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tools, vehicles, traffic control and lifting equipment. Permits may also be required for some work environments such
as confined spaces, working aloft, near live electrical apparatus and site rehabilitation.
2. Compliance may be required in various jurisdictions relating to currency in First Aid, confined space and lifting
and risk safety measures.
ELEMENT PERFORMANCE CRITERIA
 OHS procedures for a given work area are identified, obtained and understood Prepare to install cabling and tubing.
 Health and safety risks are identified, and established risk control measures and procedures in preparation for the work
are followed.
 Cable and tube routes are planned within the constraints of the building and plant structure, Significant and
regulations.
 OHS risk control measures and procedures for carrying out the work are followed. Install cabling, tubing and
accessories.
 Cabling, tubing and accessories are installed to comply with technical standards and job specifications and
requirements with sufficient excess to affect terminations.
 Cables and conductors are terminated at accessories in accordance with manufacture's specifications and regulatory
requirements.
 Tubing is terminated at accessories in accordance with manufacture's specifications and regulatory requirements.
 Cabling and tubing installation is carried out efficiently without waste of materials and energy or damage to
apparatus.
REQUIRED SKILLS AND KNOWLEDGE
 Evidence shall show that knowledge has been acquired of safe working practices and installing process
instrumentation and control cabling and tubing. All knowledge and skills detailed in this unit should be
contextualised to current industry practices and technologies.
 Cables in buildings, structures and premises
 Electronic cable and conductor termination
 The evidence guide provides advice on assessment and must be read in conjunction with the Performance
Criteria. In some circumstances, assessment in part or full can occur outside the workplace. However, it
must be in accordance with industry and regulatory policy.
 The critical safety nature of working with electricity, electrical equipment, gas or any other hazardous
substance/material carries risk in deeming a person competent. Sources of evidence need to be 'rich' in
nature to minimise error in judgment. Activities associated with normal everyday work influence how/how
much the data gathered will contribute to its 'richness'. Some skills are more critical to safety and operational
requirements while the same skills may be more or less frequently practised. These points are raised for the
assessors to consider when choosing an assessment method and developing assessment instruments.
Install process instrumentation and control cabling and tubing as listed as described in
A .Reading and interpreting drawings related to cable and tube layouts, schedules and process control apparatus locations
B .Routing, placing and securing cables and tubing to comply with requirements
C. Placing and securing accessories accurately
D. Maintaining fire integrity
E .Terminating cables and tubing to comply with requirements.
F. Dealing with unplanned events by drawing on essential knowledge and skills to provide appropriate solutions
incorporated in a holistic assessment with the above listed items.
This should include:
• OHS policy and work procedures and instructions.
• Suitable work environment, facilities, equipment and materials to undertake actual work as prescribed.
These should be part of the formal learning/assessment environment.
• Where simulation is considered a suitable strategy for assessment, the conditions must be authentic and as
far as possible reproduce and replicate the workplace and be consistent with the approved industry
simulation policy.
• The resources used for assessment should reflect current industry practices in relation to installing process
instrumentation and control cabling and tubing. Wiring systems include armoured cable; fire performance

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 cables .thermoplastic insulated cable; thermoplastic sheathed cable; UTP, FTP, STP and coaxial
communications cables.
• Tubing types include low pressure metallic and non-metallic tubing and high pressure tubing
• Generic terms used throughout this Vocational Standard shall be regarded as part of
• The Range Statement in which competency is demonstrated.
 Legislation
• Acts/Statutes, and delegated/subordinate legislation, such as rules, regulations and by-laws. The
Commonwealth now refers to delegated legislation as legislative instruments.
Principal and amending Acts
Acts which are still in force may be amended by a later Act/s, known as the amending Act/s. The
original Act is then referred to as the Principal Act (if it is an Act which deals comprehensively with
an area of law) so as to distinguish between it and the later amending Act/s.
Cable Management
Cable management can be a hassle, but these low-profile options are easy to use and quick to install.
Add these to any office that uses numerous electronics for a clean, professional look, no matter how
many cables there are. Plus, you can reduce safety hazards by keeping loose cords off the floor.
Tubing:- tube (conveyance) pvc plastic tubing for use as a conduit for electric wires. a
tube or tubing is a long hollow cylinder used for moving fluids (liquids or gases)or to protect
electrical or optical cables and wires. the terms ‘’pipe’’ & ‘tube’ are almost interchangeable,
although minor distinctions exist-generally,a tube has tighter energineering requirements
than a pipe. both pipe & tube imply a level of rigidity & permanence, where as a hose is
usually portable & flexible. a tube &pipe may be specified by standard pipe size designations.
Many types of tubing are specified by actual inside diameter, outside diameter, or wall
thickness.
Hard plastic tubing can easily hold a number of cables. These cord management tubes are flexible,
allowing you to move them around desk legs and corners to fit exactly where they are needed.
Tubes are typically stiff enough to protect cords and wires from being damaged from wandering
feet or chair legs. 
Ties and Straps
Ties and straps help bundle cords together without fully covering the entirety of the wires. Use
these options for areas with many computer cables, because they can easily bundle a high number
of cords. These are ideal for use in server rooms or entertainment areas with many cords going in
the same direction. 
Electrical wiring
Building wiring is the electrical wiring and associated devices such as switches, meters and light fittings used in
buildings or other structures. Electrical wiring uses insulated conductors.
 Wiring safety codes
Wiring safety codes are intended to protect people and property from electrical shock and fire hazards. Regulations
may be established by city, county, provincial/state or national legislation, usually by adopting a model code (with
or without local amendments) produced by a technical standards-setting organisation, or by a national standard
electrical code.
 In a light commercial environment, more frequent wiring changes can be expected, large apparatus may be
installed and special conditions of heat or moisture may apply. Heavy industries have more demanding
wiring requirements, such as very large currents and higher voltages, frequent changes of equipment layout,
corrosive, or wet or explosive atmospheres. In facilities that handle flammable gases or liquids, special rules
may govern the installation and wiring of electrical equipment in hazardous areas.

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  Wires and cables are rated by the circuit voltage, temperature rating and environmental conditions (moisture,
sunlight, oil, chemicals) in which they can be used. A wire or cable has a voltage (to neutral) rating and a
maximum conductor surface temperature rating. The amount of current a cable or wire can safely carry
depends on the installation conditions.
 securing wiring that are now obsolete include
• Re-use of existing gas pipes when converting gas light installations to electric lighting. Insulated conductors were
pulled through the pipes that had formerly supplied the gas lamps. Although used occasionally, this method risked
insulation damage from sharp edges inside the pipe at each joint.
• Wood mouldings with grooves cut for single conductor wires, covered by a wooden cap strip.
• A system of flexible twin cords supported by glass or porcelain buttons was used near the turn.
• A cable may carry multiple usage ratings for applications, for example, one rating for dry installations and another
when exposed to moisture or oil.
Cables for industrial, commercial and apartment buildings may contain many insulated conductors in an overall jacket,
with helical tape steel or aluminium armour, or steel wire armour, and perhaps as well an overall PVC or lead jacket
for protection from moisture and physical damage. Cables intended for very flexible service or in marine applications
may be protected by woven bronze wires. Power or communications cables (e.g., computer networking) that are
routed in or through air-handling spaces (plenums) of office buildings are required under the model building code to
be either encased in metal conduit, or rated for low flame and smoke production .
 Cables usually are secured by special fittings where they enter electrical apparatus; this may be a simple
screw clamp for jacketed cables in a dry location, or a polymer-gasketed cable connector that mechanically
engages the armour of an armoured cable and provides a water-resistant connection. Special cable fittings
may be applied to prevent explosive gases from flowing in the interior of jacketed cables, where the cable
passes through areas where inflammable gases are present. To prevent loosening of the connections of
individual conductors of a cable, cables must be supported near their entrance to devices and at regular
intervals through their length. In tall buildings, special designs are required to support the conductors of
vertical runs of cable. Usually, only one cable per fitting is allowed unless the fitting is otherwise rated.
 Special cable constructions and termination techniques are required for cables installed in ocean-going
vessels; in addition to electrical safety and fire safety, such cables may also be required to be pressure-
resistant where they penetrate bulkheads of a ship. Resistance to corrosion caused by salt water or salt
spray is also required.
Termination
It is the process of connecting lug or connectors to the wires well as the preparation of cable ends (wire ends) etc.
 a signal involves providing a terminator at the end of a wire or cable to prevent an RF signal from being reflected
back from the end, causing interference. The terminator is placed at the end of a transmission line .
Electrical terminations.
Electrical termination is an electrical industry term used to describe the specific point at which a conductive device,
such as wire or cable, ends or starts. The conductive device may or may not pass the carried electricity or signal
onto another conductive device at this point. A common point of electrical termination is at a terminal block. A wire
typically ends, or terminates, at the terminal block; but the electricity or signal may be passed onto the terminal
connectors.

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Signal termination is a very different type of termination which often requires the installation of a special device,
known as a terminator, at the end of a wire or cable to prevent an RF signal from being reflected back from the end,
causing interference.
Forced Perfect Termination (FPT)
Forced Perfect Termination can be used on single ended buses where diodes remove over and undershoot
conditions. The signal is locked between two actively regulated voltage levels, which results in superior
performance over a standard active terminator.
Cable Termination & Wire Connectors
If you need to terminate your wires and/or splice them together, you've come to the right place. Our selection of
wire connectors features plenty of options, including winged and non-winged, twist-on, push-in, and even
transparent connectors to allow for post-connection inspection. We also have metal lugs for compression and
grounding applications.
Designed to save time and give you instant visual confirmation of a successful splice, require only low insertion
force, and install in half the time of traditional butt splices.
CABLE MANAGEMENT
Splicing and termination of underground electrical distribution cable requires that the integrity of cable conductor and
insulation be maintained throughout its length. A large number of commercial cable splice and termination kits are available
which are claimed to fulfill these requirements. Special interest was the slip-on cable splice and cable termination for solid
dielectric insulated cable. To splice electrical power cable, insulation material is wrapped. Around the joined
conductor. With the development of solid dielectric Insulated cables came the premolded or 'slip-on'' splice kit, a

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large number of which are commercially available. The manufacturers claim that the kits provide the same or
improved splice quality when compared to the hand-wrapped type, with less training and experience required of the
installation personnel. The objective of testing these splice kits is to evaluate their electrical properties, safety,
durability, reproducibility, ease, and time and cost of installation. Electrical power is normally distributed by copper
or aluminum Conductors. In overhead distribution systems where conductor separation from ground and each other
can be maintained, insulation is not necessary. This is not the case where the electrical distribution system is
underground or is accessible to personnel. Oil-impregnated paper, varnish cambric, or a solid dielectric material is
used to insulate high voltage power cable. The first two types of insulation

require a lead sheath to protect the insulation from the environment. Because of the lead sheath, splicing and
termination of cables with these types of insulation must be performed by a highly skilled cable splicer. The solid
dielectric insulated cables have a rubber or rubber-like material covering the conductor to provide both insulation
and environmental protection. Splicing of this type of cable requires use of insulation material to build up the
insulation over the joined conductors. The finished result must be electrically equivalent to the original cable
insulation. Several different types of termination and splice kits are available to simplify this procedure. They
include: kits that provide tape and directions, kits that have precut tape, and premolded slip-on cable splices.
Beyond cable shield types, two common configurations are used:
• Single conductor...consisting of one conductor per cable or three cables for a three-phase system.
• Three conductor...consisting of three cables sharing a common jacket

Each component is vital to an optimally performing power cable and must be understood in order to make a
Dependable splice or termination.

Splicing
A splice may be considered as two or more conductors joined with a suitable connector...reinsulated, reshielded and
rejacketed with compatible materials...applied over a properly prepared surface. Whenever possible, splicing is
normally avoided. However splicing isoften an economic necessity. There can be many reasons for building splices
such as:
• The supplied length of cable is not sufficient to perform the intended job...... only so much cable can be wound on
a reel (reel ends)... only so much cable can be pulled through so much conduit, around so many bends, etc.
• Cable failures

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 • Cables damaged after installation
• A tap into an existing cable (tee or wye splices) In all the above cases, the option is to either splice the cable or
replace the entire length. The economy of modern splicing products in many cases makes splicing an optimal
choice. Whatever the reason to splice, good practice dictates that splices have the same rating as the cable. In this
way the splice does not derate the cable and become the weak link in the system.

Instrumentation cable is generally used to transmit a low power signal from a transducer (measuring
For example, pressure, temperature, voltage, flow, etc.) To a PLC or DCS process control computer or to
a manually operated control panel. It is normally available in 300 or 600 volt constructions with a single
Overall shield, or with individual shields over each pair (or triad) and an overall shield.

Control cable with overall shield

Thermocouple Wire
A thermocouple is a temperature measuring device consisting of two conductors of dissimilar metals or
alloys that are connected together at one end. At this thermocouple junction, as it is called, a small
voltage is produced. Electronic instrumentation senses this voltage and converts it to temperature.
Thermocouple wire or extension grade wire is recommended for use in connecting thermocouples to
the sensing or control instrumentation. The conditions of measurement determine the type of
thermocouple wire and insulation to be used. Temperature range, environment, insulation requirements,
response, and service life should be considered
Unshielded Twisted Pair (UTP) and Shielded Twisted Pair (STP) are low pair count cables (usually
2 to 8 pairs) that have been designed for use in local area networks such as Token Ring, Ethernet,
etc. STP, UTP, FTP Cable
When it first became available, shielded cables were used in areas such as
factory floors, areas with high concentrations of electrical equipment, and
secure communications applications. Today, shielded cable is prevalent in
many types of applications, including government, healthcare and even
education.
(UTP)Unshielded twisted pair a popular type of cable that consists of two
unshielded wires twisted around each other. Due to its low cost, UTP cabling is used
extensively for local-area networks (LANs) and telephone connections .
(STP)  shielded twisted pair wiring protects the transmission line from
electromagnetic interference leaking into or out of the cable. STP cabling often is used in
Ethernet networks, especially fast data rate Ethernets. Contrast with UTP.
(FTP), fully shielded (or Foiled) Twisted Pair is a Shielded twisted pair (STP
or STP-A) STP cabling includes metal shielding over each individual pair of
copper wires.
Coaxial cable or coax is a type of cable that has an inner conductor surrounded by a
tubular insulating layer, surrounded by a tubular conducting shield. Many coaxial
cables also have an insulating outer sheath or jacket.

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Legislation (or "statutory law") is law which has been promulgated (or "enacted") by
a legislature or other governing body or the process of making it. Legislation can have
many purposes: to regulate, to authorize, to outlaw, and to provide (funds), to sanction, to
grant, to declare or to restrict. It may be contrasted with a non-legislative act which is
adopted by an executive or administrative body under the authority of a legislative act or
for implementing a legislative act.
Routing is the process of selecting best paths in a network. Routing is
performed for many kinds of networks, including the public switched telephone
network (circuit switching), electronic data networks (such as the Internet),
and transportation networks. This article is concerned primarily with routing in
electronic data networks using packet switching technology.
In packet switching networks, routing directs packet forwarding (the transit of
logically addressed network packets from their source toward their ultimate
destination) through intermediate nodes. Intermediate nodes are
typically network hardware devices such
as routers, bridges, gateways, firewalls, or switches. General-purpose
computers can also forward packets and perform routing, though they are not specialized
hardware and may suffer from limited performance. The routing process usually directs
forwarding on the basis of routing tables, which maintain a record of the routes to various
network destinations. Thus, constructing routing tables, which are held in the
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router's memory, is very important for efficient routing. Most routing algorithms use only
one network path at a time. Multipath routing techniques enable the use of multiple
alternative paths.
Routing, in a more narrow sense of the term, is often contrasted with bridging in its
assumption that network addresses are structured and that similar addresses imply
proximity within the network. Structured addresses allow a single routing table entry to
represent the route to a group of devices. In large networks, structured addressing
(routing, in the narrow sense) outperforms unstructured addressing (bridging). Routing
has become the dominant form of addressing on the Internet. Bridging is still widely used
within localized environments.