LANL Engineering Standards Manual STD-342-100 Chapter 8 – I&C

D3060/F1050 – Attachment C, Instrumentation & Controls Design Review Rev. 2, 09/29/14

ATTACHMENT C
INSTRUMENTATION AND CONTROLS DESIGN REVIEW GUIDANCE

(PROGRAMMATIC AND FACILITY)

TABLE OF CONTENTS

1.0 PURPOSE AND SCOPE ................................................................................................................. 2

2.0 DEFINITIONS .............................................................................................................................. 2
3.0 METHODOLOGY ......................................................................................................................... 3
ATTACHMENT 1: CONTROL SYSTEM DESIGN CHECKLIST ...................................................................... 4

RECORD OF REVISIONS

Rev Date Description POC OIC

0 11/17/03 Initial issue. Mel Burnett, Gurinder Grewal,
FWO-DECS FWO-DO
1 10/10/06 IMP and ISD number changes based on new Mike Clemmons, Kirk Christensen,
Conduct of Engineering IMP 341.
FM&E-DES CENG
2 09/29/14 Administrative change. Changed from Allen Hayward, Lawrence Goen,
Appendix to Attachment. ES-EPD ES-DO

CONTACT THE I&C STANDARDS POC

for upkeep, interpretation, and variance issues

Section D3060/F1050 App C Instrumentation & Controls POC/Committee

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LANL Engineering Standards Manual STD-342-100 Chapter 8 – I&C
D3060/F1050 – Attachment C, Instrumentation & Controls Design Review Rev. 2, 09/29/14

1.0 PURPOSE AND SCOPE

This appendix provides guidance for the conduct of design reviews of Instrumentation and
Control (I&C) systems. The appendix provides the means to improve consistency, overall design,
equipment specification, and lifecycle maintenance. It also provides guidance for addressing
technology obsolescence.

2.0 DEFINITIONS
Component Location Identifiers – A labeling designation used to identify the location of a
component. It generally consists of a combination of designations such as the component area,
system, equipment type, and number.
Control Philosophy – A control system design approach that consists of: (1) establishing process
control objectives (functional performance descriptions, process monitoring requirements,
operational limits, etc.), (2) applying the most appropriate control techniques (ratio control, feed-
forward control, cascade control, etc.), and (3) ensuring control system attributes (diversity,
separation, isolation, redundancy, fault diagnostics, testability, etc.) are available for the reliable,
efficient, and safe control of a facility / process.
Engineering Standards Task Matrix – An application matrix that provides for the selection of a
minimum set of national codes and standards to be addressed for I&C systems. Refer to I&C
Chapter, Section D3060/F1050, Subsection 3.4.
Functional Classification – A graded classification system used to determine the minimum
requirements for Systems, Structures, and Components (SSCs) (e.g. design, operation,
procurement, and maintenance requirements). The four Functional Classifications in order of
precedence are ML-1 and/or SC, ML-2 and/or SS, ML-3, and ML-4.
Instrument Range – The region between the limits within which a quantity is measured,
received, or transmitted, expressed by stating the lower and upper range values. It is often
expressed as the difference between the upper and lower measurable limits.
Instrument Scale – The graduated series of marking on an instrument display, usually used in
conjunction with a pointer to indicate a measured value.
Instrument Sensitivity – The smallest change in actual value of a measured quantity that will
produce and observable change in an instrument’s output.
Measurement and Test Equipment (M&TE) – Portable or fixed equipment used for
acceptance, calibration, measurement, gauging, testing, and/or inspection of equipment in order to
control or acquire data to verify conformance to specified requirements or for reference
information (monitoring and data collection).
Safety Significant Instrumented System – An SS system or 29 CFR 1910.119 hazardous
process independent protection layer that requires instrumentation, logic devices and final control
elements to monitor and detect an SS event, and which will result in automatic or operator action
that will bring the facility or process system to a safe state.

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LANL Engineering Standards Manual STD-342-100 Chapter 8 – I&C
D3060/F1050 – Attachment C, Instrumentation & Controls Design Review Rev. 2, 09/29/14

3.0 METHODOLOGY
A. An attachment to this appendix (Attachment 1) provides a checklist that can be used to
address the quality of an I&C system design. The questions are worded such that the
desirable answer is “Yes”. It is, however, understood that not all questions are applicable to
all I&C systems. The number of questions that are applicable and are answered “Yes” will be
indicative of the quality of design.

B. Maximum benefit is obtained when the attached checklist is used throughout the design
phase. Completing the checklist at the beginning of a design task insures that the proper
considerations are given and can reveal inconsistencies in the design approach. The checklist
should be used during design reviews to assess the extent of progress in meeting the intent of
the questions. For the final design review, the checklist provides a means to assess the
completeness and quality of the system design.

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LANL Engineering Standards Manual STD-342-100 Chapter 8 – I&C
D3060/F1050 – Attachment C, Attachment 1 Rev. 2, 09/29/14

Attachment 1: Control System Design Checklist

Obsolescence
1. Is there a provision in the bid specification for migration to newer
technologies?
 Yes  No  N/A

2. Does the supplier have a migration plan to newer technology covering

the next 5 to 10 years?
 Yes  No  N/A

3. Is there a good balance between proven and new technology?

(e.g., Equipment is not approaching obsolescence, but is not untested  Yes  No  N/A
technology either.)
4. Are spare parts available as “off-the-shelf” items?  Yes  No  N/A
5. Has the supplier provided a product support plan that covers at least five
years following product delivery?
 Yes  No  N/A

6. Are there alternate sources available for the chosen components and are
they compatible?
 Yes  No  N/A

7. Does the supplier have a good record of product support?  Yes  No  N/A
8. Is the supplier considered to be a stable, viable supplier?  Yes  No  N/A

Consistency
1. Has the I&C system design been reviewed for consistency of design?
(See five sub-questions below)
 Yes  No  N/A

1.1 Can the system be operated and maintained without any significant
additional site training for operations or maintenance personnel?
 Yes  No  N/A

1.2 Can existing facility procedures be utilized, or slightly modified in

use, in order to operate the new control system?
 Yes  No  N/A

1.3 Can a common set of spare parts be used to maintain the proposed
new system and exiting facility systems?
 Yes  No  N/A

1.4 In the event of multiple design groups or engineers, have difference

segments of the new I&C system been designed so that the same  Yes  No  N/A
control strategy is used
1.5 In the event of similar existing systems within the facility, has the
new I&C system been designed so that it employs the same control  Yes  No  N/A
strategy as the existing systems?
2. Does the I&C system design support a uniform and consistent operating
philosophy? (See four sub-questions below)  Yes  No  N/A
2.1 Are instruments that make similar measurements the same type of
instruments? (e.g., all similar flows measured with the same type of  Yes  No  N/A
flow meter?)

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2.2 Are alerts/alarms/interlocks for similar functions applied, prioritized,

and handled in a consistent manner?
 Yes  No  N/A

2.3 Is process data being presented (display/engineering units/accuracy)

in a consistent manner for similar applications?
 Yes  No  N/A

2.4 Is the instrument scale consistent with instruments that make similar
measurements?
 Yes  No  N/A

3. Is the I&C system design consistent with the requirements established for
the proposed functional classification?
 Yes  No  N/A

4. Have Component Location Identifiers (CLI) been assigned in a consistent

manner with other similar systems in the facility?
 Yes  No  N/A

5. Are process displays consistent with applicable standards and existing

conventions?
 Yes  No  N/A

6. Is the new I&C system equipment compatible with existing

telecommunications equipment?
 Yes  No  N/A

7. Is the new I&C system compatible with existing systems with which it
interfaces?
 Yes  No  N/A

8. Are databases (e.g., instrument index, I/O, alarm setpoint) established in

the design consistent with existing databases?
 Yes  No  N/A

Technology
1. Has control software been developed in accordance with the specified
facility software requirements?
 Yes  No  N/A

2. Is the instrumentation the most appropriate for the type and range of
measurement?
 Yes  No  N/A

3. Can the supplier provide an upgrade path for the I&C components to
provide compatibility with fieldbus architecture if applicable?
 Yes  No  N/A

4. Does the I&C system utilize industry standard communication protocols

instead of proprietary ones?
 Yes  No  N/A

5. Does the I&C system have the capability to easily add more I/O points or
drops?
 Yes  No  N/A

6. Are on-line and/or self-diagnostics included in the system design?  Yes  No  N/A
7. Does the system provide on-line help for operators and engineers?  Yes  No  N/A
8. Can the system provide printouts of its configurations, logic, and
executables for documentation purposes?
 Yes  No  N/A

Good Design Practice

1. Is a control philosophy established for the facility?  Yes  No  N/A
2. Are commercial “off-the-shelf” products being used to the maximum
extent in the new design?
 Yes  No  N/A
3. Has energy efficiency been considered between design alternatives?  Yes  No  N/A

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4. Has the heat load on the HVAC system resulting from the installation of
additional equipment been taken into consideration?
 Yes  No  N/A

5. Has a human factors approach been applied in the design of operator

workstations and any other Human Machine Interfaces?
 Yes  No  N/A

6. Have power sources been identified for electrical load studies?  Yes  No  N/A
7. Has the system been designed to be fail-safe?  Yes  No  N/A
8. Has the National Codes and Standards Task Matrix been reviewed for
applicable I&C design standards for the proposed functional  Yes  No  N/A
classification?
9. Has the system been reviewed for security requirements established for
computer-based control systems?
 Yes  No  N/A

10. Have all instruments been placed so that they meet guidelines for
accessibility and proper operation?
 Yes  No  N/A

11. Have all instruments and actuators been sized to meet minimum,
maximum, and nominal process operating conditions.
 Yes  No  N/A

12. Has the instrument, instrument range, and instrument sensitivity been
selected based on operational process sensitivity requirements?
 Yes  No  N/A

13. Has the design team agreed on the design standards that will be applied?  Yes  No  N/A
14. Has space for expansion been provided if required for operation in the
future?
 Yes  No  N/A

15. Are I&C materials of construction compatible with process materials and
the operating environment?
 Yes  No  N/A

16. Has the system availability and reliability requirements been identified
and met in the design?
 Yes  No  N/A

17. Has a life cycle cost analysis been performed and is the selected system
competitive when compared to other designs?
 Yes  No  N/A

18. Has the supplier been qualified and placed on an approved supplier’s list?  Yes  No  N/A
19. Does the design specification include a factory acceptance test?  Yes  No  N/A
20. Does the supplier specification require that the supplier be compliant with
NQA-1 and that the supplier identify, in his proposal, all deliverables  Yes  No  N/A
including lifecycle documentation?
21. Has the appropriate design requirements been applied to ML-2 / Safety
Significant instrumented systems?
 Yes  No  N/A

22. Has the control system design been reviewed to ensure it does not
interfere with existing monitoring, alarm, and safety systems?
 Yes  No  N/A

23. Is the proper level of receipt inspection included in the purchasing

documents?
 Yes  No  N/A

24. Is documentation for the application of DOE G 420.0 standards

provided?
 Yes  No  N/A

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Maintenance
1. Has instrumentation been modularized where possible for low
maintenance and repair costs?
 Yes  No  N/A

2. Does the purchase requisition require the vendor to supply specification

sheets in hard and electronic copy?
 Yes  No  N/A

3. Does the design allow for maintenance to be conducted with minimum or

no impact to plant operation?
 Yes  No  N/A

4. Does the purchase requisition require the vendor to supply calibration

certification, M&TE requirements, and procedures for any unique or  Yes  No  N/A
special instruments?
5. Has the Procurement Department’s controlled product list been reviewed
to ensure no suspect materials are being used as critical components?
 Yes  No  N/A

6. Are appropriate features available for calibrating / testing?  Yes  No  N/A

7. Are items accessible and oriented for support by construction and
maintenance?
 Yes  No  N/A

8. Can the system be maintained without special calibration equipment or

procedures?
 Yes  No  N/A

9. Has weather protection been provided where necessary?  Yes  No  N/A

10. Has the I&C system design taken into consideration ALARA issues for
maintenance and operational personnel?
 Yes  No  N/A

11. Does the supplier offer training for maintenance personnel on its I&C
components if necessary?
 Yes  No  N/A

12. Does the I&C system design incorporate features to limit system
susceptibility to electrical noise, ground loops, static electricity, lightning  Yes  No  N/A
strikes and electrical surges?
13. Has the supplier demonstrated a good quality assurance program and a
quality product? (e.g., Records do not indicate quality concerns with the  Yes  No  N/A
supplier’s products)

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