design checklist-instrumentation & control systems (typical / guideline)

DOCUMENTATION

DESIGN CRITERIA / CHECKLIST

1 Instrument Index /IO Report

(Company) Standard

Generated by ( xxxx)

Generated by ( xxxx)

Client Standard ( xxxxx)

Other ( xxxx)

2 Loop Diagrams

(Company ) StandardProduced on AUTOCAD

Generated by ( xxxx)Client Standard (xxxx)Other : ( xxxx) ; Speclink loop termination report

A PurposeThe loop sheet is to be used primiraly for the following purposes

1 Construction and startup of the facility

2 Maintenance of wiring systems

3 Maintenance of wiring and tubing systems

4 Maintenance of instruments, (wired only) wiring and tubing

B Loop Function Description1 None Required

2 General notes as required

3 English language description of loop function a control action

4 Symbolic representation of loop function and control action

C Loops are required

The following types of instruments will be shown on loop sheets1 All instruments

2 All instruments with wiring

3 Instruments which require calibration

4 Wired instruments only

5 Analog instruments only

6 Discrete instruments only

D Information RequiredThe following information shall appear on the loop sheets.

1 All associated instruments

2 Major process equipment associated with the loop (P&ID graphic representation)

3 Process lines associated with loop

a. Piping line number not shown

b. Piping line number shown( ) only on CAD generated loops.

4 All associated wiring

All associated tubing

5 Instrument specifications

a. None Required on the loop

b. Skeleton Information

c. Full definition for spec./maint.

6 Location Information:

a. None Required on the loop

b. Column line grid coordinates

c. Elevation

b. Column line grid coordinates

c. Elevation

3 Instrumentation Specifications

( Company ) Standard

Generated by ( xxxx) ( ISA format)

Generated manually

Client Standard

Other

Specification Organization

(Master Set of Specifications)A Organized in individual file folders, one per control loop with calculations, loop drawings and process data sheets.

B. Organized into files by Purchase Order Number.

C. Contained in Purchase Order files.

D.

4 Calculations

A. Required for all appropriate devices with submittal for review, approval and issue with specifications for bid and purchase.

B. Required for all appropriate devices but not required to be submitted for review and approval with specifications.

C. Not required.

D.

Class Vendor Program

Control Valves Fisher

Masoneilan

Val-tek

Jordan

Dezurik

Instra-Calc

Vortex Meters Foxboro

Mass Flow Meters Endress & Hauser

Relief Valves Consolidated

Instra-Calc

Rupture Disc Continental

BS&B

Orifice Plate Instra-Calc

Organized into ring binders by alpha-numeric order of specification number.

Vendor calculation programs to be used to perform calculations on appropriate classes of instruments.(Ö )

5 Installation Detail Sheets

( Company ) standard

1 ( drg size 1 ) final issue produced on CAD with FD standard frame and symbols, and bill of materials.

2 ( drg size 2) final issue produced on CAD with FD standard frame and symbols, and bill of materials.

Client standard

Other

6 Location and Routing Drawings

( Company ) standard

1 ( drg size) final issue produced on CAD with FD standard frame and symbols by instrument department.

2 Instrumentation to be shown on Electrical department conduit and power plans (Only off-line instruments will be shown

Client standard

Other: No location drawings in scope.

7 Control Room Layout Drawing

( Company ) standard : Automation Equip.Room for Servers,printers etc;

1 (drg size) final issue produced on CAD with FD standard frame and symbols.

Client standard:

Other: No central control room , local operations PLC,controllers and associated instruments will be located in designated local

control panel

8 Purchase Documents

( Company ) standard :

RFQ, Bid Analysis and PO on Fluor Daniel documents

Client standard:

Other : RFQ and RFP Documents prepared by ADPM (Specs and Technical Bid Analysis by Comapany )

9 Software Documentation

A. Control, Monitoring and Reporting Software

Users requirements document

Functional requirements Specification

Unit and phase description documents

Annotated source code

B. System Configuration DocumentationAnalog control

Discrete control

Alarming

Recording/trending

Data collection

Group Displays

Graphic displays

C. Logic DiagramsLadder logic format

Documented and approved software development standards(Ö )

Boolean logic format

Other

To be determined after system selection.

D. Data Flow Diagrams

E. Truth Tables

F. Time Sequence Diagrams

G.

10 Hardware Documentation

A.

B.

C.

D.

E.

11 Vendor Documentation

A.Manuals, specifications spare parts and data sheets

Shipped directly to client (Manuals)

Organized into files per purchase orders

Organized into manuals with equipment documents

Other

A Certified Material Test CertificatesRequired for the following types of devices.

Control Valves

Relief Valves

Rupture Discs

All in-line devices in sanitary service.

B Equip. Vendor SoftwareDocumented software development standards

Quality audit by client personnel

Shipped directly to client

Organized into files per purchase orders

Organized into manuals with equipment documents

Other

C Number of Copies(Refer to vendor data requirements form specification 685.255.17110)Manuals

Specifications

Data Sheets

Software documentation

Other : To be determined after system selection

DCS Requirements Specification

Equipment List / Bill of Materials

Rack Loading Diagrams : Report format

I/O List : Report format

Local Panel / Rack Layout Drawings : Detail Dwgs. by Panel Vendor.

Distribution - Copies to: # of copies

Engineering

Construction Contractor

Client

Document Control

Validation

12 Documentation - General

A. Text based documentation to be executed by:1 Hand written documentation.( )

2 Typed documentation.( )

3 Word Processor generated on a personal computer.

a. ( Company ) standard.

b. Client Standard Microsoft WORD

B. Database Documentation To Be Executed By:1 ( Company ) standard - Dbase compatible.

2 Lotus compatible spreadsheet.

3 Client standard

C. Issued Documentation To Be Transmitted By:1 Hardcopy only.

2 Hardcopy with computer readable magnetic media copy

3 Computer readable magnetic media copy only.

4 Electronically transmitted via Network connection or modem with confirming transmittal form.

13 Numbering and Tagging System

Instrument Tag:( Company ) standard

Instrument sequence identifier 01 through 99

ISA functional description

Process area identifier / Unit No

Building number

Client standard

Specification Sheet ID( Company ) standard

Sheet No.

Group Sequence

Inst. Group

Building No.

Client standard

Loop Numbers( Company ) Standard

Client standard

Loop Sheets( Company) standard

Dwg revision level

Loop serial number

Discipline identification and drawing classification

Project number

Client Standard

Installation Details( Company) standard

Dwg revision level

Detail serial number


Project number

Location and Routing Drawings ( Company) standard

Dwg revision level

Drawing serial number


Project number

Client standard

Other: None Required

Purchase Order Documents ( Company) standard

ADPM standard

Request for Quotation - (RFQ):

RFQ change number

Requisition number

Project number

Request for Purchasing Action - (RFP):

Change order number

Purchase Order number

Project number

Project Standard:( )

14 General Instrumentation

Control SystemsThe following types of control systems are covered with the scope of this project.

Existing local control systems

Pneumatic local control (None Anticpated)

3-15 psig( )

6-30 psig( )

Electronic local control

4-20 ma input

1-5 vdc input

10-50 vdc input

Pneumatic panel control

3-15 psig

0-80 psig ; On/Off valves

Client Standard:(Ö )

Electronic panel control

4-20 ma input

1-5 vdc input

10-50 vdc input

Existing control system

New control system , DCS with DAS package

Existing central computer( )

New central computer( )

Signal Levels, Indications and AlarmsA. Discrete Signal Level

120 VAC

24 VDC

125 VDC

Power Source

Control System

External Power Supply

B. Analog Signal Level4-20 ma input (Isolated)

1-5 vdc input

Pulse freq. Input

Power Source

Control System

External Power Supply , 24 VDC

C. Pneumatic Signal Level3-15 psig

6-30 psig

D. Smart TransmittersHoneywell standard , Or Other

HART standard , Only where calibration benefits can be documented

Other , Not required.

E. Local IndicationsNot required

Required for all loops

Required as shown on the P&Ids

Integral with transmitter

Separate from transmitter

As shown on P&ID

F. Local Recorder ChartsRequired as shown on the P&IDs

Not required

Engineering UnitsDraft Range In WC

Pascals

Mass Flow lb/hr

kg/hr

lb/min

kg/min

Gas flow SCFM Plant utilities only

SCFH

SCLM

SCLH

SLPM

Level 0-100 %

Feet

Inches

Gallons

Liters

Liquid flow GPM , Plant utilities only

LPM

Pressure PSIG

PSIA

Bar

Kpa

Steam lbs/hr , Plant utilities only

lbs/min

kg/hr

kg/min

kjoules/hr

Temperature Deg F

Deg C , Process and Utilities

Vacuum In Hg

mm Hg

In WC

Microns (High Vac)

H. Tag on InstrumentsTwo required

Manufacturer's standard

Stainless steel stamped; riveted or bolted on

Stainless steel stamped; glued or riveted

Plastic wired on (for operations / validation )

Information required:

Instrument tag

Vendor/Manufacturer name

Manufacturing date

Purchase order number

Model number

Other

Size:


1/2" x 2"

1/4" x 2"

Other

Lettering size:


1/4"

1/8"

Other

15 Electrical Classification Requirements

A. Non-Hazardous Locations:1 General Purpose Enclosures, NEMA 1 , In I/O rooms or Grey spaces

2 General Purpose Enclosures, NEMA 12 Stl. Stl , In Process (Hygienic Areas) and Clean Utilities

3 General Purpose Enclosures, NEMA 12 , In Plant Utility Areas)

B. Hazardous Locations:1

2 Intrinsically safe

3 General Purpose Instruments mounted in purged field panels.

4 General Purpose Instruments mounted in remote non hazardous location

16 Instrument Specification General Guidelines

A. AnnunciatorsElectronic

Microprocessor

Relay

Window -:

Single point

Dual point

Integral

Remote logic

B. CapillaryMaximum protection vendor offers

Bare

SS armored

PVC covered , In sanitary areas

C. Conductivity and pHTwo wire transmitters

Four wire transmitters

D. Consistency transmitterRotating sensor

Blade sensor

Probe sensor

Other

Explosion Proof Enclosures, NEMA 7&9.(Ö ) As indicated on Area Classification Dwg.

E. Filter RegulatorsPurchased with instrument

Bulk ordered by ( Company)

Furnished by Contractor

Adjustable pressure

Fixed pressure

F. Magnetic flow metersPulsed DC

AC

Totalizing

Non-totalizing

Remote mounted electronics to suit particular application.

Direct mounted electronics to suit particular application

Cable bulk ordered on spools

Cable purchased with each meter

Spool pieces purchased with meter by (Company)

Spool pieces by Piping Contractor

No spool pieces

G. Manifolds, Three-Way ValvesSupplied mounted on instrument

Supplied loose with instrument

Purchased separately by tag

Purchased separately - bulk order

Purchased by Contractor

H. Recorders3 x 6 recorders

6 x 6 recorders

DIN recorders

Multi-point recorders

Two pens maximum per recorder

One pen per recorder

I. Signal ConditioningRack-mounted high density

Individual modules

J. Solenoid ValvesUniversal operation

Directional operation

Brass body for air/water in-line service

Stainless steel body for air/water in-line service

High Density block style,panel mtd

24 VDC coil

24 VDC low power consumption coil

120 VAC high temp coil

Conduit hub and terminals ( )

K. ThermometersBi-metal

Liquid in glass

Filled system with dial indicator

Three pens maximum per recorder

Every-angle connection

Fixed-angle connection

L. Transmitters

Pressure/Differential Pressure - mtd remotely on pipe stand to suit particular application

Temperature - mounted remotely on pipestand ( ) to suit particular application.Min distance with capillary.

Temperature – Rack mounted

M. Mass Flow MetersLocal electronics

Remote mounted electronics to suit particular application.

Totalizing to suit application

Non-totalizing to suit application

N. Control Valves (modulating)Positioners required:

On all valves

Critical applications

Separate regulator mounted and piped

Share regulator with I/P

Bypass and gauges required

I/P transducer

mounted on valve Integral when positioner is specified

mounted separately

separate regulator mounted and piped

Actuator

Diaphragm type

Piston type

Diaphragm or piston type

Spring return

Double acting

Stem position indicator required:

All valves

None Required

Loading pressure on valves:

15 psig, Modulating Valves

30 psig

60 psig

80 psig

Other 80 psig for ON/OFF valves

Tubing supplied with valves:

Copper plant utilities only

PVC coated copper

316 stainless steel

304 stainless steel, Hyg areas

Other

Pressure/Differential Pressure - mounted on manifold(Ö )

pH control

Other Special Applications

O. Automated Discrete Valves

Feedback position switches :

Required on critical valves( )

Required on both closed and open positions( )

Required on open position only( )

Actuator

Diaphragm type

Piston type

Diaphragm or piston type

Spring return

Double acting

Solenoids mounted on valve mounted in switch pkg. housing

Solenoids mounted separately mounted in local enclosures to suit valve clusters.

P. Orifice PlatesOrifice flanges purchased with plates

Orifice flanges supplied by piping

Concentric bore

With weep holes as required

Segmented bore

Q. Field Switch ContactsDPDT for all applications

SPDT for single input applications

Hermetically sealed if available

Vibration Resistant if available

R.

3" flanged connections

1-1/2" flanged connection

1-1/2" screwed connection

3" pancake

1-1/2" pancake

1-1/2" sanitary seals

2" sanitary seals

S. TemperaturePreferred type of sensor:

RTD with transmitter

Thermocouple with transmitter

RTD without transmitter

Thermocouple without transmitter

Fixed Length

Adjustable length

Spring Loaded

Thermowell purchased/shipped with element

Thermowell purchased/shipped separately

Ball Valve-Full Port required(Ö ) Hyg. Services

Ball Valve-Standard Port required(Ö ) Utilities

Diaphragm Valve- Diaphragm Mat. TFE (Ö )

Required on all on/off valves(Ö )

Required on closed position only(Ö ) Lower switch is closed when valve is closed

Seals (refer to each inst type )

T. Rupture DiscsType:

Conventional

Reverse Buckling

Knife Blade

Vacuum support as required by process

Material:

Metal as required by process

Metal with liner to protect from corros

Composite

Holder:

Full flange

Wafer

Insertion

Sanitary Outlet

Options:

Break detector switch

Excess flow/pressure bleed valve

Pressure switch

Corrosion protection membrane to suit application.

17 Installation

Process ConnectionsA. Pressure

Direct Connections

1/2" NPT

3/4" NPT

Other

Isolation Seals

a Pipeline1" NPT

1" Flanged


2" sanitary seals

Saddle mount

Other

b Vessel3" Flanged


2" sanitary seals

Other

B. Level

1-1/2" Flanged( )

1-1/2" sanitary seals( )

2" sanitary seals( )

3" Flanged(Ö )

Sanitary tank spud with 2" extension(Ö )

Sanitary tank spud with 6" extension( )

Other 2-1/2" TC (MTS) ( )

C. Temperature

a Pipeline

3/4" NPT

1" NPT

1" Socket Weld

1-1/2" sanitary connection

2" sanitary connection

Other Special small bore wells in sanitary piping

b Vessel

1-1/2" Flanged

3" Flanged



Other Weld in Style

D. Flow

a Orifice Plates

Flange Taps

Pipe Taps

b Meter Connections

Flanged

Screwed

c Straight Run Requirements

As recommended by manufacturer/standards

15 Pipe diameters upstream



10 Pipe diameters downstream

5 Pipe diameters downstream

Flow straighteners as required

E.

a Preferred Connection Type

Flanged

Screwed

Wafer

Lug , Butterfly valves

Sanitary

b Preferred Valve Types (modulating)

Globe

Ball

Butterfly

Diaphragm

Plug

c Preferred Valve Types (on/off)

Ball

Butterfly

Valves

Diaphragm

Plug

F. Impulse Lines316 Stainless Steel Tubing - ASTM

304 Stainless Steel Tubing - ASTM

Steel Pipe

Other

G. Tube FittingsCrawford Fitting - Swagelok

Hoke - Gyrolok

Imperial Eastman - Hi-duty

Parker Hannifin - CPI

Tylok - Tylok

H. Heat TracingAll instrument impulse tubing

Impulse tubing outside and open bldgs

None

Electric - Pretraced Tube

Electric - Field Installed

Steam - Pretraced Tube

Steam - Field Installed

I. Individual Air Supplies (Include isolation valves per pipe spec) Copper , Plant utilities only

304 Stainless Steel Tubing , Hyg.Areas

316 Stainless Steel Tubing

J. Instrument Air Branch HeadersGalvanized C.Steel

Aluminum

304 Stainless Steel , Hygienic areas only

316 Stainless Steel

Carbon Steel

K. Thermowells

a Types

Straight Shank

Stepped Shank

Tapered Shank

3" Lagging Extension , Where applicable

Union with Extension

Nipple-union-Nipple Extension



Van Stone Flanges

b Materials

Brass

304 SS minimum

316 SS minimum

Appropriate to service / pipe spec.

L. Instrument MountingMounted on Pipeline

Pipestand Mounting near process connection

Mounting in clusters

Mounted in instrument field panels

In grey space where possible

M. Panel Union LabelsRequired

Not Required

N Instrument EnclosuresRequired for field instruments for winterizing.

Prefabricated

Custom fabricated/designed

O Instrument ApprovalsU.L.

C.S.A.

18 Vendor Selection

AnalyzersA. Chlorine

Blanket Order

Purchase from (xxxx)

Specific bid spec

Procedure stated by Client

B. CO/CO2Blanket Order


Specific bid spec


C. CombustiblesBlanket Order

Purchase from ( xxxx)

Specific bid spec


D. Conductivity and pHBlanket Order


Specific bid spec


E. NOxBlanket Order


Specific bid spec

F.M.


F. OpacityBlanket Order


Specific bid spec


G. OxygenBlanket Order


Specific bid spec


H. PhosgeneBlanket Order

Purchase from ( xxxx )

Specific bid spec


I. RefractometerBlanket Order

Purchase from (xxxx )

Specific bid spec


J. SO2Blanket Order


Specific bid spec


K. Gas ChromatagraphBlanket Order


Specific bid spec


L. Liquid ChromatagraphBlanket Order


Specific bid spec


M Air Quality MonitorSpecific bid spec.

N Moisture analyzerSpecific bid spec.

O T.O.C. AnalyzerSpecific bid spec.

Control PanelsBlanket Order


Specific bid spec


ControllersBlanket Order


Specific bid spec


CountersBlanket Order


Specific bid spec


Converters

A. I/P

Blanket Order


Specific bid spec


B. P/I

Blanket Order


Specific bid spec


Damper DrivesBlanket Order


Specific bid spec


Data LoggersBlanket Order


Specific bid spec


Distributed Control SystemBlanket Order


Specific bid spec


Draft Type Panel GagesBlanket Order


Specific bid spec


FlowA. Orifice and Nozzles

Blanket Order


Specific bid spec


B. Pitot TubeBlanket Order


Specific bid spec


C. MagneticBlanket Order


Specific bid spec


D. Positive DisplacementBlanket Order


Specific bid spec


E. RotametersBlanket Order


Specific bid spec


F. TurbineBlanket Order


Specific bid spec


G. VortexBlanket Order


Specific bid spec


H. Mass FlowBlanket Order


Specific bid spec


I. SonicBlanket Order


Specific bid spec


Panel Mounted InstrumentsBlanket Order


Specific bid spec


LevelA. Capacitance

Blanket Order


Specific bid spec


B. DisplacementBlanket Order


Specific bid spec


C. Sight GlassBlanket Order


Specific bid spec


D. UltrasonicBlanket Order


Specific bid spec


E. FloatBlanket Order


Specific bid spec


Manifold - Three ValveBlanket Order


Specific bid spec


With primary instrument

Pressure GaugesBlanket Order


Specific bid spec


Signal Conditioning ModulesBlanket Order


Specific bid spec


Solenoid ValvesBlanket Order


Specific bid spec


SwitchesA. Pressure

Blanket Order


Specific bid spec


B. TemperatureBlanket Order


Specific bid spec


C. FlowBlanket Order


Specific bid spec


TemperatureA. RTD

Blanket Order


Specific bid spec


B. ThermocoupleBlanket Order


Specific bid spec


C. ThermometersBlanket Order


Specific bid spec


D. ThermowellsBlanket Order


Specific bid spec


TransmittersA. Pressure, Differential Pressure

Blanket Order


Specific bid spec


B. TemperatureBlanket Order


Specific bid spec


C. TurbidityBlanket Order


Specific bid spec


D. pH and ConductivityBlanket Order


Specific bid spec


ValvesA. Ball

Blanket Order


Specific bid spec


B. ButterflyBlanket Order


Specific bid spec


C. Butterfly (Lined)Blanket Order


Specific bid spec


D. GlobeBlanket Order


Specific bid spec


E. DiaphragmBlanket Order


Specific bid spec


F. Knife GateBlanket Order


Specific bid spec


G. PlugBlanket Order


Specific bid spec


H. Self Contained RegulatorsBlanket Order


Specific bid spec


I. ReliefBlanket Order


Specific bid spec


J. Special ServiceBlanket Order


Specific bid spec


Conservation Vents - Flame ArrestorsBlanket Order


Specific bid spec


Viscosity MetersBlanket Order


Specific bid spec


Rupture DisksBlanket Order


Specific bid spec


19 Validation

Application programming standards

Vendor equipment instrumentation specification Specification # xxxxxxxxxx

Vendor AuditsA. ( Company ) only

B. Client only

C. ( Company) and Client.

Support Validation EffortsA. Review and comment on protocols

B. Review and comment on calibration procedures

C. Support field validation efforts

design checklist-instrumentation & control systems (typical / guideline)

Engineering

control loop

loop drawings

associated instruments

loop sheets1

maintenance of instruments

wiring3 instruments

types of instruments

fd standard frame