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Instrumentation & Control Engineering

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Work and deliverables of Instrumentation & Control disciplines

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Instrumentation & Control Engineering

  1. 1. ©2015–HervéBaron 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 (herve.baron@gmail.com), 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
  2. 2. ©2015–HervéBaron HERVE BARON Engineering Training  PROCESS  PLANT LAYOUT  EQUIPMENT  SAFETY & ENVIRONMENT  CIVIL  PIPING  PIPELINE  INSTRUMENTATION  ELECTRICAL
  3. 3. ©2015–HervéBaron HERVE BARON 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
  4. 4. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  PROCESS  PLANT LAYOUT  EQUIPMENT  SAFETY & ENVIRONMENT  CIVIL  PIPING  PIPELINE  INSTRUMENTATION The discipline is commonly split in 3 specialties. Which ones?
  5. 5. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  PROCESS  PLANT LAYOUT  EQUIPMENT  SAFETY & ENVIRONMENT  CIVIL  PLANT LAYOUT & PIPING  PIPELINE  INSTRUMENTATION • Field instrumentation • Systems • Installation
  6. 6. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  PROCESS  PLANT LAYOUT  EQUIPMENT  SAFETY & ENVIRONMENT  CIVIL  PIPING  PIPELINE  INSTRUMENTATION • Field instrumentation • Systems • Installation
  7. 7. ©2015–HervéBaron HERVE BARON Piping & Instrumentation Diagram (P&ID)
  8. 8. ©2015–HervéBaron HERVE BARON Piping & Instrumentation Diagram (P&ID)
  9. 9. ©2015–HervéBaron HERVE BARON Instrument list
  10. 10. ©2015–HervéBaron HERVE BARON Instrument data sheet
  11. 11. ©2015–HervéBaron HERVE BARON Level sketch
  12. 12. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  PROCESS  PLANT LAYOUT  EQUIPMENT  SAFETY & ENVIRONMENT  CIVIL  PLANT LAYOUT & PIPING  PIPELINE  INSTRUMENTATION • Field instrumentation • Systems • Installation
  13. 13. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  INSTRUMENTATION • Field instrumentation • Systems: Process Control System Unit Control System Emergency Shutdown System Fire & Gas System Other systems • Installation
  14. 14. ©2015–HervéBaron HERVE BARON PCS (Process Control System)
  15. 15. ©2015–HervéBaron HERVE BARON System requisition
  16. 16. ©2015–HervéBaron HERVE BARON System architecture drawing
  17. 17. ©2015–HervéBaron HERVE BARON Control narrative Gas inlet Gas outlet 93-E161
  18. 18. ©2015–HervéBaron HERVE BARON Functional diagram
  19. 19. ©2015–HervéBaron HERVE BARON Mimic display drawings
  20. 20. ©2015–HervéBaron HERVE BARON Process automations & Process Shut Down (PSD)
  21. 21. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  INSTRUMENTATION • Field instrumentation • Systems: Process Control System Unit Control System Emergency Shutdown System Fire & Gas System Other systems • Installation
  22. 22. ©2015–HervéBaron HERVE BARON Package instrumentation & control
  23. 23. ©2015–HervéBaron HERVE BARON Package instrumentation & control
  24. 24. ©2015–HervéBaron HERVE BARON Package control Package controlled by Central Process Control System
  25. 25. ©2015–HervéBaron HERVE BARON Package control Package controlled by Central Process Control System
  26. 26. ©2015–HervéBaron HERVE BARON Package control Package controlled by own Unit Control System
  27. 27. ©2015–HervéBaron HERVE BARON Package control What documents from the package Vendor are needed by the DCS Vendor in this case? Package controlled by own Unit Control System
  28. 28. ©2015–HervéBaron HERVE BARON Package control Package controlled by Central Process Control System What documents from the package Vendor are needed by the DCS Vendor in this case?
  29. 29. ©2015–HervéBaron HERVE BARON Process Control System Process Control System Engineering by Vendor Hardware SoftwareThe Process Control System is engineered by the Vendor based on information supplied by Engineer.
  30. 30. ©2015–HervéBaron HERVE BARON Process Control System Process Control System Engineering by Vendor Hardware SoftwareThe Process Control System is engineered by the Vendor based on information supplied by Engineer. Which documents are needed by the Vendor?
  31. 31. ©2015–HervéBaron HERVE BARON Process Control System Process Control System Engineering by Vendor Hardware SoftwareThe Process Control System is engineered by the Vendor based on information supplied by Engineer. Which documents are needed by the Vendor? Engineering documents Vendor documents
  32. 32. ©2015–HervéBaron HERVE BARON Process Control System Process Control System Engineering by Vendor Hardware SoftwareThe Process Control System is engineered by the Vendor based on information supplied by Engineer. Which documents are needed by the Vendor? Vendor documents P&IDs Control Narratives Cause & Effects
  33. 33. ©2015–HervéBaron HERVE BARON Process Control System Process Control System Engineering by Vendor Hardware SoftwareThe 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:
  34. 34. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  INSTRUMENTATION • Field instrumentation • Systems: Process Control System Unit Control System Emergency Shutdown System Fire & Gas System Other systems • Installation
  35. 35. ©2015–HervéBaron HERVE BARON Emergency Shutdown (ESD) System
  36. 36. ©2015–HervéBaron HERVE BARON Emergency shutdown (ESD)
  37. 37. ©2015–HervéBaron HERVE BARON 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:
  38. 38. ©2015–HervéBaron HERVE BARON 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:
  39. 39. ©2015–HervéBaron HERVE BARON Emergency shutdown (ESD) SIL study Have you heard about SIL studies? What does it mean? What does SIL, SIF and SIS mean? 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:
  40. 40. ©2015–HervéBaron HERVE BARON Emergency shutdown (ESD) SIL study Have you heard about SIL studies? What does it mean? What does SIL, SIF and SIS mean? 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:
  41. 41. ©2015–HervéBaron HERVE BARON Emergency shutdown (ESD) SIL study 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
  42. 42. ©2015–HervéBaron HERVE BARON Emergency shutdown (ESD)
  43. 43. ©2015–HervéBaron HERVE BARON Emergency shutdown (ESD) SIL study 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 CONSIDERATIONSCONSEQUENCE 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)
  44. 44. ©2015–HervéBaron HERVE BARON SIL Study Step 1: SIL Determination, “assignment workshop”  Deliverable: SIL assignment logsheet / worksheets  Summary: What is the second step of the SIL?
  45. 45. ©2015–HervéBaron HERVE BARON 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
  46. 46. ©2015–HervéBaron HERVE BARON SIL Study Step 2 – SIS Performance verification Results
  47. 47. ©2015–HervéBaron HERVE BARON SIL Study Step 2: calculations and recommendation - Summary
  48. 48. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  INSTRUMENTATION • Field instrumentation • Systems: Process Control System Unit Control System Emergency Shutdown System Fire & Gas System Other systems • Installation
  49. 49. ©2015–HervéBaron HERVE BARON Fire & Gas system
  50. 50. ©2015–HervéBaron HERVE BARON Fire & Gas system
  51. 51. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  INSTRUMENTATION • Field instrumentation • Systems: Process Control System Unit Control System Emergency Shutdown System Fire & Gas System Other systems • Installation
  52. 52. ©2015–HervéBaron HERVE BARON 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? 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:
  53. 53. ©2015–HervéBaron HERVE BARON 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)
  54. 54. ©2015–HervéBaron HERVE BARON Engineering disciplines: activities and deliverables  PROCESS  PLANT LAYOUT  EQUIPMENT  SAFETY & ENVIRONMENT  CIVIL  PIPING  PIPELINE  INSTRUMENTATION • Field instrumentation • Systems • Installation
  55. 55. ©2015–HervéBaron HERVE BARON Field Instrumentation PT JB Process line Field Marshalling cabinet System cabinet Equipment room Control room Operator station Secondary cable Multi cable
  56. 56. ©2015–HervéBaron HERVE BARON Main cable routings and Junction Box (JB) location drawing
  57. 57. ©2015–HervéBaron HERVE BARON Instrument location & secondary cable routing drawings
  58. 58. ©2015–HervéBaron HERVE BARON Telecommunication equipment layout drawing
  59. 59. ©2015–HervéBaron HERVE BARON Typical installation drawings
  60. 60. ©2015–HervéBaron HERVE BARON Junction box wiring
  61. 61. ©2015–HervéBaron HERVE BARON Instrument location & secondary cable routing drawings Cable list
  62. 62. ©2015–HervéBaron HERVE BARON Cable routing / section
  63. 63. ©2015–HervéBaron HERVE BARON Instrumentation installation standards
  64. 64. ©2015–HervéBaron HERVE BARON 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
  65. 65. ©2015–HervéBaron HERVE BARON Equipment layout drawings
  66. 66. ©2015–HervéBaron HERVE BARON Instrument loop diagram
  67. 67. ©2015–HervéBaron HERVE BARON 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
  68. 68. ©2015–HervéBaron HERVE BARON 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
  69. 69. ©2015–HervéBaron HERVE BARON 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 In your opinion, which Milestone is required to be reached first?
  70. 70. ©2015–HervéBaron HERVE BARON 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 In your opinion, which Milestone is required to be reached first? What are the Engineering documents required to reach each Milestone?
  71. 71. ©2015–HervéBaron HERVE BARON 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 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?
  72. 72. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide 2nd edition Do you want to know more... Much more?
  73. 73. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide - 2nd edition Table of Contents
  74. 74. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide - 2nd edition Table of Contents This suite of training modules covered the discipline chapters of the book...
  75. 75. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide - 2nd edition Table of Contents The Guide contains much more: The overall picture, interfaces, methods & tools, etc.
  76. 76. ©2015–HervéBaron HERVE BARON The Oil & Gas Engineering Guide 2nd edition Order direct from the publisher: http://www.editionstechnip.com/en/catalogu e-detail/1111/oil-gas-engineering-guide- the.html

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