instrumentation & control engineering

© 2015 – Hervé Baron

HERVE BARON

Engineering Training

Welcome to this presentation.

It is part of a suite of Engineering training modules.

It shows the activities and deliverables of the Instrumentation & Control discipline.

Comments are most welcome ([email protected]), which I will incorporate for the benefit of all.

Please download this file so that you can see my trainer’s notes in the top left corner – latest Acrobat Pro feature.

Hervé


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Engineering Training

PROCESS

PLANT LAYOUT

EQUIPMENT

SAFETY & ENVIRONMENT

CIVIL

PIPING

PIPELINE

INSTRUMENTATION

ELECTRICAL


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Process design

PFDs

H&M balance

Rotating Pressure vessels Fired equipment Heat exchangers Packages etc.

P&IDs

Piping

Instrumentation

Layout

Civil

Electrical

Process data sheet

Equipment specification

Vendor drawings

We are here


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Engineering disciplines: activities and deliverables

PROCESS

PLANT LAYOUT

EQUIPMENT


CIVIL

PIPING

PIPELINE

INSTRUMENTATION

The discipline is commonly split in 3 specialties. Which ones?


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PROCESS

PLANT LAYOUT

EQUIPMENT


CIVIL

PLANT LAYOUT & PIPING

PIPELINE

INSTRUMENTATION • Field instrumentation • Systems • Installation


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PROCESS

PLANT LAYOUT

EQUIPMENT


CIVIL

PIPING

PIPELINE



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Piping & Instrumentation Diagram (P&ID)


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Instrument list


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Instrument data sheet


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Level sketch


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PROCESS

PLANT LAYOUT

EQUIPMENT


CIVIL

PLANT LAYOUT & PIPING

PIPELINE



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INSTRUMENTATION • Field instrumentation • Systems:

Process Control System Unit Control System Emergency Shutdown System Fire & Gas System Other systems

• Installation


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PCS (Process Control System)


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System requisition


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System architecture drawing


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Control narrative Gas inlet

Gas outlet

93-E161


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Functional diagram


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Mimic display drawings


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Process automations & Process Shut Down (PSD)


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• Installation


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Package instrumentation & control

Presenter

Presentation Notes

Right side (P2): cables from instruments to JB and JB included in Vendor scope of supply.


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Package instrumentation & control

Presenter

Presentation Notes

Right side (P3): Package control system included. In both cases: Cables 2 supplied and installed by Vendor. Cables 3 supplied and installed by Purchaser. Cables 4 are special cables (encoder etc.) supplied by Vendor. Some brands of PLC may be specified in the « Instrumentation Requirements for Packaged Units »


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Package control

Package controlled by Central Process Control System


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Package control

Package controlled by own Unit Control System

Presenter

Presentation Notes

Vendor supplies its own system when proper control/shutdown function is linked to warranty. It is always the case for gas turbine/compressors. For boilers, the code (NFPA 85) requires independent burner management system (item 4.1.7.1 « The burner management system shall be provided with independent logic, independent logic solving harware, independent input/output systems, and independent power supplies and shall be a device functionally and physically separate from other logic systems »). The burner management safety functions (item 4.11.7.3) shall include purge interlocks and timing, safety shutdowns, trial timing for ignition and flame monitoring.


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Package control

What documents from the package Vendor are needed by the DCS Vendor in this case?

Package controlled by own Unit Control System

Presenter

Presentation Notes

Exchange table


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Package control

Package controlled by Central Process Control System

What documents from the package Vendor are needed by the DCS Vendor in this case?

Presenter

Presentation Notes

P&IDs, narrative, C&E, logic diagrams


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Process Control System

Process Control System Engineering by Vendor

Hardware Software The Process Control System is engineered by the Vendor based on information supplied by Engineer.


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Hardware Software The Process Control System is engineered by the Vendor based on information supplied by Engineer. Which documents are needed by the Vendor?


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Engineering documents

Vendor documents


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Vendor documents

P&IDs

Control Narratives

Cause & Effects


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Hardware Software The Process Control System is engineered by the Vendor based on information supplied by Engineer.

P&IDs

Control Narratives

Cause & Effects

Packages with Unit Control System:

Exchange table with PCS

P&IDs

Control Narratives

Cause & Effects

Control & logic diagrams

Packages controlled by Central Control System:


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• Installation


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Emergency Shutdown (ESD) System

Presenter

Presentation Notes

The ESD System is also called the Instrumented Protection System (IPS). It implements all the Safety Instrumented Functions shown on the P&IDs. The IPS architecture is usually 2oo3Triple Modular Redundant. For all critical interlocks, 3 field devices shall be provided with 2 out of 3 (TMR) voting.


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Emergency shutdown (ESD)


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Emergency shutdown (ESD) SIL study

Have you heard about SIL studies? What does it mean?

What does SIL, SIF and SIS mean?

Terms defined in ANSI/ISA-84.00.01-2004 (IEC 61511-1) Functional Safety: Safety Instrumented Systems for the Process Industry Sector

SIF: Safety Instrumented Function

SIS: Safety Instrumented System: Sensor + logic solver + final element

SIL: Safety Integrity Level: Level used for specifying the safety integrity requirement of SIFs. There are 4 levels:


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Have you heard about SIL studies? What does it mean?


ANSI/ISA-84.00.01-2004 (IEC 61511-1)

Functional Safety: Safety Instrumented Systems for the Process Industry Sector





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Step 1: SIL Determination, “assignment workshop”

Identification of Instrumented Interlocks on the P&IDs = inventory of Safety Instrumented Function (SIF)

For each SIF: • Qualitative evaluation of consequences if the event the SIF is

designed to safeguard from • Qualitative evaluation of the likelihood of the event • Determination of risk level (likelihood * consequence) and

resulting SIF required performance (SIL level)

Deliverable: SIL assignment logsheet / worksheets


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Emergency shutdown (ESD)


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LIKELIHOOD CATEGORY DEFINITION POTENTIAL FREQUENCY

A Possibility of repeated incidents 20 or more times per Facility life B Possibility of isolated incidents 5 times per Facility life C Possibility of occurring sometime Once in Facility life D Not likely to occur Once every 10 Facility lives E Practically impossible Once every 100 Facility lives

CONSIDERATIONS CONSEQUENCE CATEGORY Health/Safety Public Disruption Environmental Impact Financial Impact

Abbreviation S – Safety P – Public E – Environmental F – Financial

I Fatalities/ Serious Impact on Public

Large Community (10,000+)

Major/Extended Duration/ Full Scale

Response

Major Impact to Company

(>$50 million)

II Serious Injury to

Personnel/ Limited Impact on Public

Small Community (1,000 to 10,000)

Serious/Significant Resource

Commitment

Significant Impact To Company ($2 - $50 million)

III Medical Treatment for Personnel/ No Impact

on Public

Minor (10 to 100)

Moderate/Limited Response of Short

Duration

Moderate Impact To Company

($500M - $2 million)

IV Minor Impact on Personnel

Minimal to None

(1 or 2)

Minor/Little or No Response Needed

Minor Impact To Company

($50M-$500M)


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SIL Study

Step 1: SIL Determination, “assignment workshop”

Deliverable: SIL assignment logsheet / worksheets

Summary:

What is the second step of the SIL?


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SIL Study

Step 2: calculations and recommendation

SIS Performance Verification

Evaluate the performance of each SIF, based on device selection, architecture, voting, testing etc.

Compare to required SIL level and specify modifications to the SIF design (device selection, component redundancy) or testing intervals

Deliverable: SIS Performance Verification Results and recommendations

Presenter

Presentation Notes

Sometimes done by 3rd party for independence


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SIL Study Step 2 – SIS Performance verification Results

Presenter

Presentation Notes



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SIL Study

Step 2: calculations and recommendation - Summary

Presenter

Presentation Notes



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• Installation


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Fire & Gas system


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• Installation


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Systems

The main systems are: the Process Control System (DCS), and Emergency Shutdown System (ESD),

usually integrated: ICSS (Integrated Control and Safety System) the Fire & Gas system (F&G)?

What other systems do we find?


Terms defined in ANSI/ISA-84.00.01-2004 (IEC 61511-1) Functional Safety: Safety Instrumented Systems for the Process Industry Sector





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Systems

The main systems are: the Process Control System (DCS), and Emergency Shutdown System (ESD),

usually integrated: ICSS (Integrated Control and Safety System) the Fire & Gas system (F&G)?

What other systems do we find? Packaged equipment Control systems Machinery Monitoring System (MMS) for vibration & temperature monitoring Burner Management System (BMS) Compressor Anti-Surge System (CCC) Analyzers Data Acquisition system Fiscal Metering Systems afor Custody transfer and allocation Storage tank data acquisition (gauging) system Continuous Emissions Monitoring System (CEMS) Process Operator and Information System (POIS) / SCADA Advance Process Control (APC)


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PROCESS

PLANT LAYOUT

EQUIPMENT


CIVIL

PIPING

PIPELINE



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Field Instrumentation

PT JB

Process line

Field Marshalling

cabinet System

cabinet

Equipment room Control room

Operator

station

Secondary cable

Multi cable

Presenter

Presentation Notes

The Marshalling cabinets contain terminal blocks and power supply units The System cabinets contain main processors, I/O modules, communication modules and power supply units. The Instrument room is sometimes called Instrumentation Technical Room (ITR) or Satellite Instrument House (SIH).


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Main cable routings and Junction Box (JB) location drawing


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Instrument location & secondary cable routing drawings


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Telecommunication equipment layout drawing


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Typical installation drawings


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Junction box wiring


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Instrument location & secondary cable routing drawings Cable list


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Cable routing / section


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Instrumentation installation standards


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Instrument bulk material take-off

ITEM QUANTITY DESIGNATION

1 195 Gauge adapter – ½” x ½”

2 37 Block manifold 2 valves (Gas) – ½”

3 23 Block manifold 5 valves (Gas) –½”

4 0 Ball valve ½” – 12mm

5 300m Tubing – 12mm OD x 1mm

6 200 Reducer – 12mm x ¼”

7 50 Union tee – 12 x 12 x 12mm

8 50 Female connector – 12mm x ½”

9 350 Male connector – 12mm x ½”

10 9 Plug – ½” NPTF

11 8 Plug – ½” NPTM


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Equipment layout drawings


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Instrument loop diagram


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Main schedule Milestone for Instrumentation

The main schedule Milestones are the commitments to the Control System Contractor. There are 2 commitments: - Hardware freeze, for the manufacturing of the marshalling and I/O cabinets,

- Software freeze, for the configuration of the DCS

PT JB

Process line

Marshalling

Cabinet System

Cabinet

Secondary cable

Multi cable

Operator

station


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- Software freeze, for the configuration of the DCS


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- Software freeze, for the configuration of the DCS In your opinion, which Milestone is required to be reached first?

Presenter

Presentation Notes

Hardware freeze, for lead time of cabinets. Usually 3 month ahead of Software freeze.


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- Software freeze, for the configuration of the DCS In your opinion, which Milestone is required to be reached first? What are the Engineering documents required to reach each Milestone?

Presenter

Presentation Notes

Hardware freeze: Instrument index 100% complete. Number, type and location of instruments, including within packages for centrally controlled packages. Documents required: P&IDs, Plot Plan Software freeze: IFC P&IDs, C&E, narratives, control & logic diagrams


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- Software freeze, for the configuration of the DCS In your opinion, which Milestone is required to be reached first? What are the Engineering documents required to reach each Milestone? What is challenging to meet the schedule?

Presenter

Presentation Notes

Automation Systems Supply: when several automation systems are integrated and control systems of machinery and packages engineered by Vendor are included, the consolidation of information to be transfered to the Integrated Control System Supplier is complex and requires a specific schedule to coordinate the achievement on time of HW & SW Freeze


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The Oil & Gas Engineering Guide 2nd edition

Do you want to know more... Much more?


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The Oil & Gas Engineering Guide - 2nd edition

Table of Contents


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Table of Contents

This suite of training modules covered the discipline chapters of the book...


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Table of Contents

The Guide contains much more:

The overall picture, interfaces, methods & tools, etc.


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The Oil & Gas Engineering Guide 2nd edition

Order direct from the publisher:

http://www.editionstechnip.com/en/catalogue-detail/1111/oil-gas-engineering-guide-the.html




instrumentation & control engineering

Education

package control system

gas system

vendor scope of supply

trainers notes