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2015 Herv 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 (herve.baron@gmail.com), which I will incorporate for the benefit of all.
Please download this file so that you can see my trainers notes in the top left corner latest Acrobat Pro feature.
Herv
2015 Herv Baron
HERVE BARON
Engineering Training
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PIPING
PIPELINE
INSTRUMENTATION
ELECTRICAL
2015 Herv Baron
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
2015 Herv Baron
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?
2015 Herv Baron
HERVE BARON
Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
PIPELINE
INSTRUMENTATION Field instrumentation Systems Installation
2015 Herv Baron
HERVE BARON
Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PIPING
PIPELINE
INSTRUMENTATION Field instrumentation Systems Installation
2015 Herv Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
2015 Herv Baron
HERVE BARON
Piping & Instrumentation Diagram (P&ID)
2015 Herv Baron
HERVE BARON
Instrument list
2015 Herv Baron
HERVE BARON
Instrument data sheet
2015 Herv Baron
HERVE BARON
Level sketch
2015 Herv Baron
HERVE BARON
Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
PIPELINE
INSTRUMENTATION Field instrumentation Systems Installation
2015 Herv Baron
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
2015 Herv Baron
HERVE BARON
PCS (Process Control System)
2015 Herv Baron
HERVE BARON
System requisition
2015 Herv Baron
HERVE BARON
System architecture drawing
2015 Herv Baron
HERVE BARON
Control narrative Gas inlet
Gas outlet
93-E161
2015 Herv Baron
HERVE BARON
Functional diagram
2015 Herv Baron
HERVE BARON
Mimic display drawings
2015 Herv Baron
HERVE BARON
Process automations & Process Shut Down (PSD)
2015 Herv Baron
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
2015 Herv Baron
HERVE BARON
Package instrumentation & control
PresenterPresentation NotesRight side (P2): cables from instruments to JB and JB included in Vendor scope of supply.
2015 Herv Baron
HERVE BARON
Package instrumentation & control
PresenterPresentation NotesRight 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
2015 Herv Baron
HERVE BARON
Package control
Package controlled by Central Process Control System
2015 Herv Baron
HERVE BARON
Package control
Package controlled by Central Process Control System
2015 Herv Baron
HERVE BARON
Package control
Package controlled by own Unit Control System
PresenterPresentation NotesVendor 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.
2015 Herv Baron
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
PresenterPresentation NotesExchange table
2015 Herv Baron
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?
PresenterPresentation NotesP&IDs, narrative, C&E, logic diagrams
2015 Herv Baron
HERVE BARON
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.
2015 Herv Baron
HERVE BARON
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. Which documents are needed by the Vendor?
2015 Herv Baron
HERVE BARON
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. Which documents are needed by the Vendor?
Engineering documents
Vendor documents
2015 Herv Baron
HERVE BARON
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. Which documents are needed by the Vendor?
Vendor documents
P&IDs
Control Narratives
Cause & Effects
2015 Herv Baron
HERVE BARON
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.
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:
2015 Herv Baron
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
2015 Herv Baron
HERVE BARON
Emergency Shutdown (ESD) System
PresenterPresentation NotesThe 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.
2015 Herv Baron
HERVE BARON
Emergency shutdown (ESD)
2015 Herv Baron
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:
2015 Herv Baron
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:
2015 Herv Baron
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:
2015 Herv Baron
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:
2015 Herv Baron
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
2015 Herv Baron
HERVE BARON
Emergency shutdown (ESD)
2015 Herv Baron
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
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)
2015 Herv Baron
HERVE BARON
SIL Study
Step 1: SIL Determination, assignment workshop
Deliverable: SIL assignment logsheet / worksheets
Summary:
What is the second step of the SIL?
2015 Herv Baron
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
PresenterPresentation NotesSometimes done by 3rd party for independence
2015 Herv Baron
HERVE BARON
SIL Study Step 2 SIS Performance verification Results
PresenterPresentation NotesSometimes done by 3rd party for independence
2015 Herv Baron
HERVE BARON
SIL Study
Step 2: calculations and recommendation - Summary
PresenterPresentation NotesSometimes done by 3rd party for independence
2015 Herv Baron
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
2015 Herv Baron
HERVE BARON
Fire & Gas system
2015 Herv Baron
HERVE BARON
Fire & Gas system
2015 Herv Baron
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
2015 Herv Baron
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:
2015 Herv Baron
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)
2015 Herv Baron
HERVE BARON
Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PIPING
PIPELINE
INSTRUMENTATION Field instrumentation Systems Installation
2015 Herv Baron
HERVE BARON
Field Instrumentation
PT JB
Process line
Field Marshalling
cabinet System
cabinet
Equipment room Control room
Operator
station
Secondary cable
Multi cable
PresenterPresentation NotesThe Marshalling cabinets contain terminal blocks and power supply unitsThe 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).
2015 Herv Baron
HERVE BARON
Main cable routings and Junction Box (JB) location drawing
2015 Herv Baron
HERVE BARON
Instrument location & secondary cable routing drawings
2015 Herv Baron
HERVE BARON
Telecommunication equipment layout drawing
2015 Herv Baron
HERVE BARON
Typical installation drawings
2015 Herv Baron
HERVE BARON
Junction box wiring
2015 Herv Baron
HERVE BARON
Instrument location & secondary cable routing drawings Cable list
2015 Herv Baron
HERVE BARON
Cable routing / section
2015 Herv Baron
HERVE BARON
Instrumentation installation standards
2015 Herv Baron
HERVE BARON
Instrument bulk material take-off
ITEM QUANTITY DESIGNATION
1 195 Gauge adapter x
2 37 Block manifold 2 valves (Gas)
3 23 Block manifold 5 valves (Gas)
4 0 Ball valve 12mm
5 300m Tubing 12mm OD x 1mm
6 200 Reducer 12mm x
7 50 Union tee 12 x 12 x 12mm
8 50 Female connector 12mm x
9 350 Male connector 12mm x
10 9 Plug NPTF
11 8 Plug NPTM
2015 Herv Baron
HERVE BARON
Equipment layout drawings
2015 Herv Baron
HERVE BARON
Instrument loop diagram
2015 Herv Baron
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
2015 Herv Baron
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
2015 Herv Baron
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?
PresenterPresentation NotesHardware freeze, for lead time of cabinets. Usually 3 month ahead of Software freeze.
2015 Herv Baron
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?
PresenterPresentation NotesHardware 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
2015 Herv Baron
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?
PresenterPresentation NotesAutomation 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
2015 Herv Baron
HERVE BARON
The Oil & Gas Engineering Guide 2nd edition
Do you want to know more... Much more?
2015 Herv Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
2015 Herv Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
This suite of training modules covered the discipline chapters of the book...
2015 Herv Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
The Guide contains much more:
The overall picture, interfaces, methods & tools, etc.
2015 Herv Baron
HERVE BARON
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
Engineering TrainingEngineering TrainingSlide Number 3Engineering disciplines: activities and deliverables Engineering disciplines: activities and deliverables Engineering disciplines: activities and deliverables Piping & Instrumentation Diagram (P&ID)Slide Number 8Instrument listSlide Number 10Level sketchEngineering disciplines: activities and deliverables Engineering disciplines: activities and deliverables Slide Number 14System requisitionSlide Number 16Control narrativeFunctional diagramMimic display drawingsProcess automations & Process Shut Down (PSD)Engineering disciplines: activities and deliverables Package instrumentation & controlPackage instrumentation & controlSlide Number 24Slide Number 25Slide Number 26Slide Number 27Slide Number 28Process Control SystemProcess Control SystemProcess Control SystemProcess Control SystemProcess Control SystemEngineering disciplines: activities and deliverables Slide Number 35Emergency shutdown (ESD)Emergency shutdown (ESD)SIL studyEmergency shutdown (ESD)SIL studyEmergency shutdown (ESD)SIL studyEmergency shutdown (ESD)SIL studyEmergency shutdown (ESD)SIL studyEmergency shutdown (ESD)Emergency shutdown (ESD)SIL studySIL StudySIL StudySIL StudyStep 2 SIS Performance verification ResultsSIL StudyEngineering disciplines: activities and deliverables Fire & Gas systemFire & Gas systemEngineering disciplines: activities and deliverables SystemsSystemsEngineering disciplines: activities and deliverables Field InstrumentationSlide Number 56Slide Number 57Slide Number 58Typical installation drawingsJunction box wiringSlide Number 61Slide Number 62Slide Number 63Instrument bulk material take-offEquipment layout drawingsInstrument loop diagramMain schedule Milestone for InstrumentationMain schedule Milestone for InstrumentationMain schedule Milestone for InstrumentationMain schedule Milestone for InstrumentationMain schedule Milestone for InstrumentationThe Oil & Gas Engineering Guide2nd editionThe Oil & Gas Engineering Guide - 2nd editionThe Oil & Gas Engineering Guide - 2nd editionThe Oil & Gas Engineering Guide - 2nd editionThe Oil & Gas Engineering Guide2nd edition
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