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Instrumentation, Control, Fire
& Gas and SIS Design
Engineering
|
Instrument and
Systems engineering, design, documentation and
management for the entire plant lifecycle
AVEVA Instrumentation is a proven, feature-rich software
suite for Instrumentation and Control engineering. Its advanced graphical
user interfaces, extensive use of design rules and catalogues for data
creation, and maximum workflow flexibility make AVEVA Instrumentation the
preferred choice for projects of all sizes. Stand-alone or fully
integrated, AVEVA Instrumentation is functionally rich, both for the
Engineering Contractors in design and for the Owner Operator in everyday
plant operations. When used as part of an integrated AVEVA software
deployment, it adds instrumentation data into the complete project
information model, exposing it to the full range of AVEVA’s design,
engineering, collaboration and lifecycle management technologies. |
A good instrumentation design requires the production of a large
number of design drawings and other documentation, usually in conjunction with some kind of Instrument
Database such as AVEVA
Instrumentation. A list of the more usual ones is detailed below;
DESIGN DOCUMENTS
Instrument Design
Instrument Index
An Instrument Index is a super
starting point for any design, it is really a database of all the necessary
references which are required in an instrument design, all referenced from the
tag number. It would include fields such as Tag Number, Service, Line /Equipment
No , Instrument Type, Location, Location Dwg, Cable Routing Diagram, Junction
Box Layout Drawing, Manufacturer, Model, Calibration, Measuring, Size &
Process Connection, P & ID Number, Process Datasheet Number ,
Instrumentation Datasheet Number, Hookup Drawings Number, Bill of Materials
Number, Loop Diagram Number, Fieldbus Segment Drawing Number and Instrument
Standard Number, Relevant Standard Numbers and Purchase Order Number. You will
find that some "non instrument" people will say that it is an unnecessary
document BUT THIS IS NOT TRUE!
The following link shows a Typical
Instrument Index
Instrument Hook Ups
Instrument Hook Up Diagrams
detail the accessory and tubing hookup for both process and pneumatic
instruments based on the tag number. It should include standard specifications
for the welding of hook-up piping, heat tracing & insulation and
pressure testing & painting requirements. Generally included are;
-
Tag number
-
Numbers of the loop drawing.
-
Layout & routing drawing and isometric piping drawing
containing the particular control loop component.
-
Elevations of both the primary control loop component and
process connection.
-
Tagging of mechanical (piping or equipment) to
instrumentation interface
-
Tagging of all elements/fittings & valves with item
numbers.
-
Direction of slopes in hook-up lines.
-
Elevation of Instrument.
-
Maximum allowable lengths of hook-up lines.
-
Accessories often detailed include Monoflanges, Double Block
and Bleed Valves and Fittings etc.
-
Material take off with part numbers, number of particular
fittings, size, connection, material type, mounting type.
-
weather shield and tubing specification.
Instrument Pneumatic Hookup Diagrams
Typical
Pneumatic Hookup
Process Hookup Diagrams
Typical
Process Hookup
Instrument Loop Diagrams
Instrument Loop Diagrams detail
the instrument connection and wiring from the field instrument to the control
system Input/Output (I/O) card. Included are termination box details,
connections, wiring including screens etc. A Typical
Instrument Loop Diagram from Creative Engineers is shown on this link,
however you will have to rotate it to show it in the correct orientation.
Instrument Fieldbus Segment Diagrams
Instrument Fieldbus Segment
Diagrams are similar to Instrument Loop Diagrams, except they detail all the
fieldbus field instruments along with their respective "spurs",
terminators and the connection interface to the fieldbus trunk.
An
Engineering & Construction Firm Tackles Foundation Fieldbus -
Kvaerner Shares Experience With Designing Field-Based Control Architectures. -
Andrew Houghton and David Hyde - Foundation fieldbus is quickly
gaining acceptance in process automation and control. While initial fieldbus
installations tended to be nervously watched trials and demonstrations running
non-critical processes, more recent applications have successfully attacked
mainstream controls projects. Houston-based Kvaerner’s experiences in recently
completing the development of a major chemical plant application show that IEC
61158 Foundation fieldbus has definitely achieved prime-time status, not only
for user-developed projects but also for confident acceptance by Engineering
& Construction firms. To be successful, however, we found that E&C
companies need to change their working practices and develop new procedures and
tools to make the leap from conventional DCS techniques to the scalable,
field-based automation architectures permitted by fieldbus. This paper shows the
required design steps, along with a typical segment drawing - from Emerson
Process Management.
Instrument Fieldbus Segment Checkers
There are several
"free" tools which check the segment design.
- Emerson
Process Management Segment Design Tool
- Pepperl+Fuchs
Segment Checker
- Yokogawa
Segment Checker
- MTL
Segment Checker
Instrument Block Diagram
The Instrument Block Diagram
shows all the instruments in an overview format.
Instrument Datasheet
An Instrument Datasheet is the
primary design Instrumentation purchase document, it details all the technical
and process data required to select an instrument.
SA-TR20.00.01-2006
Specification
Forms in Microsoft Word Format - 3rd Edition - The 3rd edition of the
ISA Specification Forms in Word Format on CD-ROM provides electronic forms that
greatly aid the design, purchase, and manufacture of process measurement and
control instrumentation. The 77 reusable forms, covering a wide range of
instrumentation, include operating parameters, device specifications, general
requirements, and more. Supplementary listings for each form provide ready
guidance on entering data and units.
Today, on small and large projects an Instrument Design Software
tool is an essential part of completion of the design documentation detailed in
the various line items on this Comprehensive page thanks to AVEVA
Instrumentation. Just click on the link above to access information of all
aspects of Instrumentation Design Documentation.
Instrument Cable Schedule
The Instrument Cable Schedule
provides details of all the cables utilised, it typically lists type of cables,
source, destination, terminal, size, core, length etc.
Typical
Cable Schedule
Instrument Specifications
Instrument Specifications are
generally produced by the End User company or Engineering design Houses. They
provide a detailed description of the design requirements.
Instrument Layout
The Instrument Layout details the
location of the instrument and cable routes or pneumatic lines on a "plot
plan".
Instrument Air Supply Diagrams
Instrument Air Supply
diagrams show the various configurations of instrument air manifolds.
Instrument Tubing/Cable Tray Support Layout / Detail
These drawings detail the tray layout, design of the tray and Material Take
Off.
Cable Penetration Layout
Details the penetrations into
a panel, showing the cable transit frame and block configuration.
Process Control System Design
It is worthwhile considering the extensive use of a database
system in the production of the design documents which are to be used as input
documentation by the system supplier.
Base Graphics
The generation of 'base graphics' MUST be configured by the
operating company since a supplier just does not have the experience to produce
graphics which accurately reflect the process. It is not simply a job of
'copying' the P&IDs. The most effective way of configuring these base
graphics which the supplier enhances is to use the supplier configuration
package, thus having the ability to transfer the data to the supplier database
easily.
It is also a great idea to use a Database for creation of the
Instrument Index , Cable data Sheets, I/O schedules, Message Lists and Motor
Schedules as data can then be effectively transferred from one database to
another. This does have the added advantage in that errors are minimised once
one database has been checked. Mind you if adequate checking does not occur then
the problem will be multiplied.
The following input documents should be produced for issue to
the Process Control System (PCS) supplier. Some operators consider that it is more effective for the PCS
suppliers to create some of these documents but that is just not so in that they
just CANNOT have adequate experience to provide a comprehensive enough package.
(1) I/O SCHEDULES
These are the base documents around
which configuration revolves, information contained within it should include tag
number, whether it is an Intrinsically safe or Non I.S. loop, digital or
analogue, range, units, critical or non critical loop, report input and alarming
priority.
(2) FUNCTIONAL LOGIC DIAGRAMS
These are the base
documents which the supplier uses for motor and sequence control. They are
usually drawn utilising logic blocks around the logic symbols which are
identified in AS 1102.9 - 'Graphical Symbols for Electrotechnology - Part 9
Binary Logic Elements'.
(3) MESSAGE LISTS
These lists are the base document
which are used for the generation of reports, alarm and special messages. They are usually configured using a database format which the
supplier can easily transfer to his own database.
(4) BASIC GRAPHICS
The rudimentary graphics which are
initially passed to the operating company OPERATIONS GROUP for comment and then
used by the supplier as the base graphic background which the supplier then
enhances.
(5) CABLE DATA SHEETS
These sheets are used rather like
termination diagrams where normal termination diagrams do not exist.
(6) MOTOR SCHEDULE
This document details the
requirements needed by the energy management system ie priority of tripping.
(7) TERMINATION DRAWINGS
Details of all incoming/outgoing terminations and cables.
(8) FUNCTIONAL DESIGN SPECIFICATION
This document
specifies the functional and technical requirements of the system. It should be
comprehensive and miss nothing. 'Slimline' specifications DO NOT work and leave
the customer wide open for variations.
THE CONTROL AND INSTRUMENTATION 'TAIL END CHARLIE SYNDROME'
It has always been the case that the Controls/
Instrumentation design could not be finalised until the piping design has been
completed because the instrument locations are unable to be adequately
determined. This of course is true if total accuracy is required, however, if
you have a schedule problem there is a method of achieving 90% accuracy at a
very early stage, picking up the remaining 10 % at a later time.
This method utilises the base vessel layout and allocates
instrument positions on a 'best guess' basis (usually they are very close to the
final position) and 'driving' package vendor terminations at edge of skid. The
suppliers we have found are not adverse to this approach as it does do a fair
bit of design for them.
THE 'LOST' INTERNAL SYSTEM INSTRUMENT TAGS
It is always a problem as to just where you pick up internal
system tags and tags which do not appear on the P&IDs. A convenient method
of picking up these tags is to use a document called a Instrument Line Diagram.
The ILD is essentially a point list and can be in diagrammatic or data format.
This document however must be treated with great care in that
it can become a monster if you are not careful. Keep it as simple as possible,
utilise it by all means as a tool for creating 'temporary P&IDs' when
package P&IDs are not available but ensure that the tagging system used does
not cause problems later.
INSRUMENT AND CONTROL DESIGN CHECKING
It is absolutely essential that all documents produced are
cross checked, to not check is false economy as eventually the supplier will
pick up errors and it takes significantly more effort at that time to rectify
them. Considerable cost overruns can result from poor cross checking.
Safety Instrumented System Design
Documents
The utilises several documents to develop the necessary
logic these being:-
SHUTDOWN PHILOSOPHY
This is the most important
document associated with the Combined Safety System in that it lays down the
philosophy applicable to it. In this document are listed the hierarchical
shutdowns. One must not lose sight of the fact that although the system has the
ability to implement very critical shutdown features it also implements less
critical unit and process Shutdowns.
For instance on offshore platforms the usual stages of
shutdown are as follows:-
-
UNIT SHUTDOWN - this, the lowest level of shutdown,
causes the individual units to stop.
-
PROCESS TRAIN SHUTDOWN - an individual Process Train will
shutdown on occurrence of any applicable trip.
-
PROCESS SHUTDOWN - on this occurrence the complete
process stops but utilities remain running, in effect it is a process 'stop'
with NO BLOWDOWN in order to facilitate a easier startup on rectification of
the problem.
-
EMERGENCY SHUTDOWN - This action results generally from
fire or Gas being sensed on the platform, obviously a fire in the Galley or
in a room in the accommodation does not cause a ESD but more serious events
in the Process, Wellhead or other critical areas will result in an ESD. An
ESD is actually a Process Shutdown with Blowdown and isolation of the
platform trunkline. The blowdown results in flaring of the gas component of
the platform inventory whilst the liquid component is maintained within the
various process vessels. When co-incident fire detection in the process or
wellhead areas occurs one of the two strategically placed firepumps start
and deluge occurs automatically.
On some platforms main power is shutdown and the emergency
generator starts when an ESD occurs whilst on others main power is maintained
by the generators switching to Diesel except when there is fire in a critical
area such as the wellheads. This approach is advocated in that maintaining
lighting ensures that at night the firefighting crew can see what they are
doing.
-
TOTAL PLATFORM SHUTDOWN - This shutdown hopefully will
never require operation during the life of the platform since it usually is
the result of abandonment. There are generally only two or three TPSD
pushbuttons which are under the control of the Platform Operations Manager.
The result of this action is total blackout of the platform including
isolation of batteries except for some navaids which continue to run. The
intent of this shutdown is to maintain some battery power for when the
'black start team' reboard the platform.
Other documents used in the development of the CSS
configuration are as follows:-
INPUT/OUTPUT (I/O) SCHEDULES
these detail the fundamental
configuration such as tag number, IS or NIS, alarm limits, analogue ranges etc.
PSD/ESD CAUSE AND EFFECTS
These documents which are
based on the Process Cause and Effects are used by the CSS supplier as the basis
for the logic. The usual appearance of them is to have the cause on the left
hand side with the effect at the top with a 'X' matrix.
FIRE AND GAS CAUSE AND EFFECTS
These documents are
similar to the PSD/ESD C&E described above except that they do not have
logic symbols incorporated (matrix only).
The logic is developed by the vendor based on the above
documentation on the CSS CONFIGURATION PACKAGE. This package is deliberately
separate from the executive software of the system since it is very important
that software previously developed is not corrupted in any way. After completion
the software is tested extensively before being included in the overall software
package. Great emphasis is placed on ensuring that the executive software cannot
be accessed by unauthorised personnel and once the system is operational the
configuration package is usually located onshore.
MESSAGE LISTS/CABLE DATA SHEETS/ TERMINATION DRAWINGS
As previously described for PCS.
DESIGNING AND SPECIFYING A COMBINED SAFETY
SYSTEM (CSS)
When designing and specifying a CSS it is important to
remember that it does have a fundamental common mode failure point this being of
course the software. It is all very well to have duplicated and triplicated
hardware but if there is a common software bug just what can be done to overcome
the problem. Well the answer is that the requirements of API RP14C should be
followed in that there should be a primary and secondary safety system. Usually
the primary being the electronic system and the secondary, safety relief valves.
Where there is no possible alternative to having a single
electronic system then it is absolutely imperative that DUAL sets of software
are used which have been written by DIFFERENT personnel. Having to use this
route has great disadvantages in that it is very complex, extremely costly and
difficult to maintain. The RULE is therefore - devise some form of secondary
system.
Construction
Engineering for Instrumentation - Dattatray Nikam - This is an excellent
document which details the fundamentals for Instrumentation Construction
Engineering.
General Process Design Documentation
PROCESS AND INSTRUMENTATION DIAGRAMS
How
to read P&IDs - Dave Harrold - Instrumentation
detail varies with the degree of design complexity. For example, simplified or
conceptual designs, often called process flow diagrams, provide less detail than
fully developed piping and instrumentation diagrams (P&IDs). Being able to
understand instrumentation symbols appearing on diagrams means understanding
ANSI/ISA's S5.1-1984 (R 1992) Instrumentation symbols and identification
standard. S5.1 that defines how each symbol is constructed using graphical
elements, alpha and numeric identification codes, abbreviations, function
blocks, and connecting lines. Thanks to Control Engineering
Useful Instrument and Process Design Tools
4.11
Reading
a P&ID - This self-study workbook offers a concise course in how to
read and understand Piping and Instrumentation Drawings (P&IDs). These
drawings, also known as Process and Instrumentation Diagrams, or Process and
Control Diagrams, are essential to many industrial operations. After completing
the workbook you should be able to identify symbols and function labels commonly
found on P&IDs, describe how system components are related, and trace
process stream flow and control loop functions. Included are sample P&IDs,
reference material explaining ISA symbology, answers to the problems, and a
demonstration exercise that pulls together the skills taught in the course. The
workbook, which has been reviewed for compliance with ISA standards and
practices, covers the following subjects: Information on a typical P&ID,
master sheets, symbols, instruments, line designations, tracing process flow,
and controlling process operations.
4.11
Control
System Documentation: Applying Symbols and Identification, 2nd Edition -
This ISA classic provides the symbols and identification commonly used
throughout the process industries. It contains sample P&ID and numerous
examples of symbols and tagging concepts. It also provides most of the symbols
and identifiers that are unique to instrumentation and gives practical examples
of their use. Documentation changes and the evolution of control systems
engineering and design work over the past decade are included in this edition.
It is the intent of the authors to help people communicate ideas and concepts
through the use of symbols and identifiers. Ideal for engineers, managers, sales
people, technicians, and students, this book will improve and strengthen
communications among not only instrumentation specialists, but all interested
professionals.
1.12
Human
Factors Engineering (HFE) in Projects - This excellent 84 page
Recommended Practice (RP) is an essential design document for anyone involved in
the design of facilities. Just have a look at the
examples in it! It adopts a practical,
cost-effective and balanced approach to applying HFE on oil & gas projects.
It recognises that many HFE issues can be controlled simply by ensuring
compliance with existing technical standards. However, there are times where
there is a gap between what can be specified in technical standards and the
design features needed to support efficient, reliable and safe human
performance. This RP involves three elements for
controlling HFE-related risk: (1) Compliance with relevant technical
specifications (2) HFE specific design analysis and design
validation and (3) Organisation and competence to deliver
appropriate standards of HFE quality control. Compliance
with this RP should normally satisfy requirements from national regulators for
evidence that HFE has been adequately considered in design. The process allows
projects to demonstrate that consideration has been given to reducing the HFE
risks and the potential for human error to a level that can be shown to be As
Low As Reasonably Practicable (ALARP) through engineering and design - from
International Association of Oil & Gas Producers.
Project Management
Make
or Break with Project Management - Bill Lydon - Project management is
critical to ensuring projects are implemented correctly, on time and within
budget. Good project management also communicates to your management or
stakeholder that you are a professional. These are thoughts from my
experience managing many projects and consulting to clients on projects. The
most valuable lessons were learned when taking over projects that were in
serious trouble - from Automation.com
Walking
the Fine Line - Scott Sommer and Christopher Russell - Systems
integration is tough work. Often we implement someone else’s design to the
complete satisfaction of the owner. Every project produces a list of
lessons; the challenge after completing the project is to learn from those
lessons and avoid repeating the same mistakes. We have compiled 25 lessons in
hopes that systems integrators, end users, and managers alike will not only gain
respect for the role of systems integration in industrial project execution, but
also avoid pitfalls and errors that keep a good project from becoming an
excellent one - from ISA and InTech
Communicate:
Avoid Assumptions like the Plague - Michael Whitt - There are certain
design tasks and group interactions key to the development of a computerized
process control system. Systems integration (SI) represents a vast category in
that development, and it includes software development, data communications, and
operability issues - from ISA and InTech.
6.11
General Instrument and Control Engineering Tips
| The
following articles are contained in IDCs Steve Mackays "Little
Red" book which is not so little at 160 pages. There are some really
useful tips to be found here. This pdf is worth putting on your computer
for reading on those long trips. You
can get it for free here. |
| Be foolish more
often in engineering |
Don’t spend
another penny on formal training |
Fearsomely
outstanding engineering presentations |
Engineering
innocence |
| Is there anything
left for us to do? |
Where have all our
engineers and technicians gone? |
Roadshow through
the Outback |
The Great Move |
| Fingertip
engineering knowledge |
Have
we forgotten the important aspect of our business |
Excellence
in Australian engineering |
Why our engineering education system is
broken and what to do about it |
| Woz – What an
inspiring engineer |
Real time
engineering collaboration |
Giving it all away
– or retirement from engineering |
Tethered to your
desk and smothered by your work – whilst mobile |
| Safety –
different countries/different standards or not? |
Invest in your
people before you lose ‘em |
As an engineering
professional – what are you really worth? |
Where on earth has
the electronics (or indeed, plain old) hobbyist gone to? |
| Where have all our
engineering leaders gone? |
The (erratically)
mobile engineer |
In the thrall of
politicians |
Putting your engineering brain into
overdrive – with guaranteed improvements |
| Trust your guts
and not always your engineering brain |
Nuclear power: to
hell? Or maybe, just maybe … heavenly bliss |
What on earth do
you expect the world to do with your rubbish? |
One of education’s
greatest confidence tricks – lectures |
|
Making up for the problem solving toolbox
defect in our formal engineering education |
How many of us are guilty of negligent
engineering and potential disasters? |
Don’t communicate with a battering ram or
a twisted whisper, but with engineering panache! |
Don’t
despise engineering advice from so-called simpletons |
| Accountants are
killjoys and engineers over-engineer |
Why nanotechnology
is important to engineers |
Are we tilting at
windmills with solar or wind energy |
The myth of
bottling your techie’s know-how before they leave |
| How
to avoid engineering career killers – 11 tips |
Can
we make engineering safety standards work? |
Welcome
to another brilliant year |
Engineering
and the ‘long tail’ distribution |
| Testing
engineering systems: but only perfunctorily |
Power travails of Africa or Don’t let
your politician walk over you |
Common sense with
safety is not so common around here |
A sure-fire way to
electrocution and immediate sacking |
| Why is battery
technology so slow in growing up? |
Hard-won experience makes you master of the
engineering universe |
Innovation in
engineering using (mainly) the KISS principle |
Engineering
multi-skilling in your part of the universe |
|
Invisible engineers and technicians –
undervalued, disappearing and needing your support |
Engineering
conference papers for you |
Originally from the Wild West, we engineers
now need to be attuned to style and culture |
Grasp
the engineering nettle in biology and medicine |
| Beat a
gadget-strewn path to your local geek fair |
Collaborate in
creating your next engineering project |
Freely-available know-how and our
Automation and conversions guides |
Engineering cloud
computing |
| Your list of
favourite engineering videos |
What’s better?
Real engineering or styling and marketing? |
We all need an engineering mentor (or
advisor, teacher, role model, friend) |
Does management know how to retain
engineering professionals? |
| Fossil fuels are
almost done for |
|
|
|
Safety Design of Offshore Installations
11.11
Technical
safety - This NORSOK standard describes the principles and requirements for the development of the safety design
of offshore installations for production of oil and gas. Where applicable, this NORSOK standard may also be
used for mobile offshore drilling units. This NORSOK standard, together with ISO 13702, defines the required standard for implementation of
technologies and emergency preparedness to establish and maintain an adequate level of safety for
personnel, environment and material assets.
Electrical, Instrumentation and Telecommunication
Installation
11.11
Electrical,
Instrumentation and Telecommunication Installation - This Offshore
Petroleum NORSOK standard covers functional and technical requirement related to installation of
electrical, instrumentation and telecommunication equipment. In addition the standard establish basis for engineering of typical areas like cable segregation, cable
requirements, Ex-philosophies, equipment enclosures etc.