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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 trainers notes
in the top left corner latest Acrobat Pro feature.
Herv
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2015 Herv Baron
HERVE BARON
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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2015 Herv Baron
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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?
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2015 Herv Baron
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Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
PIPELINE
INSTRUMENTATION Field instrumentation Systems Installation
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Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PIPING
PIPELINE
INSTRUMENTATION Field instrumentation Systems Installation
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Piping & Instrumentation Diagram (P&ID)
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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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Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PLANT LAYOUT & PIPING
PIPELINE
INSTRUMENTATION Field instrumentation Systems Installation
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Engineering disciplines: activities and deliverables
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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Engineering disciplines: activities and deliverables
INSTRUMENTATION Field instrumentation Systems:
Process Control System Unit Control System Emergency Shutdown
System Fire & Gas System Other systems
Installation
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Package instrumentation & control
PresenterPresentation NotesRight side (P2): cables from
instruments to JB and JB included in Vendor scope of supply.
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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
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Package control
Package controlled by Central Process Control System
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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
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.
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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
PresenterPresentation NotesExchange 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?
PresenterPresentation NotesP&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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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?
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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. Which
documents are needed by the Vendor?
Engineering documents
Vendor documents
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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. Which
documents are needed by the Vendor?
Vendor documents
P&IDs
Control Narratives
Cause & Effects
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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.
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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Engineering disciplines: activities and deliverables
INSTRUMENTATION Field instrumentation Systems:
Process Control System Unit Control System Emergency Shutdown
System Fire & Gas System Other systems
Installation
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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.
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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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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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2015 Herv Baron
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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?
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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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:
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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
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Emergency shutdown (ESD)
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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)
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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
PresenterPresentation NotesSometimes done by 3rd party for
independence
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SIL Study Step 2 SIS Performance verification Results
PresenterPresentation NotesSometimes done by 3rd party for
independence
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SIL Study
Step 2: calculations and recommendation - Summary
PresenterPresentation NotesSometimes done by 3rd party for
independence
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Engineering disciplines: activities and deliverables
INSTRUMENTATION Field instrumentation Systems:
Process Control System Unit Control System Emergency Shutdown
System Fire & Gas System Other systems
Installation
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Fire & Gas system
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Fire & Gas system
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Engineering disciplines: activities and deliverables
INSTRUMENTATION Field instrumentation Systems:
Process Control System Unit Control System Emergency Shutdown
System Fire & Gas System Other systems
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?
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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2015 Herv Baron
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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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2015 Herv Baron
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Engineering disciplines: activities and deliverables
PROCESS
PLANT LAYOUT
EQUIPMENT
SAFETY & ENVIRONMENT
CIVIL
PIPING
PIPELINE
INSTRUMENTATION Field instrumentation Systems Installation
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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
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).
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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 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
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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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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
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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 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.
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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 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
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2015 Herv Baron
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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 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
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The Oil & Gas Engineering Guide 2nd edition
Do you want to know more... Much more?
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2015 Herv Baron
HERVE BARON
The Oil & Gas Engineering Guide - 2nd edition
Table of Contents
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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...
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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.
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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