Instrumentation Engineering Department

Activities Overview

Presentation By

Santhosh V S

12-08-04 1
 CONSULTANCY

PROJECT

OWNER /
CLIENT
OWNER’S ENGR. EPC CONTRACTOR

EPC ENGR.

MAINLY REVIEW DETAIL ENGINEERING

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 INSTRUMENTATION
ENGINEERING
WORK PROCESS

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12-08-04 International Development and Engineering Associates 3

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DESCRIPTION BASIC ENGINEERING PHASE DETAILED ENGINEERING PHASE

DESIGN
INPUT

INSTRUMENTATION
DESIGN ACTIVITIES

PLANNING & BASIC DESIGN DETAILED DESIGN CONSTRUCTION DRAWING

DESIGN OUTPUT
SCHEDULING & PROCUREMENT

MILESTONE ACTIVITIES

REFERENCE DOCUMENTS
 PLANNING & SCHEDULING

PROJECT INPUTS FROM

CONTRACT
PROCESS INPUTS
CO-ORDINATION
DOCUMENT
EXISTING
DESIGN & EXECUTION
PROCEDURE -PROCESS DATA PLANT
INPUT CONTRACT PROJECT EXECUTION SHEETS PLOT PLAN
SPECIFICATION PROCEDURE -BASIC ENGG.
FACILITIES AVAILABLE
DESIGN /TO BE INTEGRATED WITH
PROJECT ENGINEERING
EXECUTION
-P&IDS THE PROJECT TERMINAL
SPECIFICATION POINTS
PROCEDURE -REFERENCE
PROJECT DOCUMENTS FROM ENGG. STDS FOR
SCHEDULE PREVIOUS EXISTING PLANT
PROJECTS

BASIC ENGINEERING

INST. DESIGN EXECUTION REVIEW PROJECT

ACTIVITIES PLANNING DESIGN INPUT STANDARDS

CONTRACT COMMENTS/
REVIEW REPORT CLARIFICATION ON
DESIGN INPUT

ENGINEERING SCHEDULE ENGG. STDS DRAFTING STDS

DESIGN (FURNISH INFORMATION -DESIGN BASIS -DRAFTING
OUTPUT TO PROJECT MANAGER PROCEDURE
FOR PREPARATION OF -ENGINEERING
PACS) PROCEDURE & FORMATS
-DRAWING TITLE
BLOCK FORMAT
-MTO PROCEDURE
MANPOWER SCHEDULE MR, TBA & PORN
PROCEDURE -TYPICAL FORMAT
OF DELIVERABLES
-CHECK LIST FOR -REVISION CONTROL
FILING SYSTEM VARIOUS DELIVERABLES
(MANUAL & ELECTRONIC)

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ENGINEERING SCHEDULE.
MILESTONE

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ACTIVITIES
 BASIC DESIGN

P&ID PIPING EQUIP. INPUT BASIC

DESIGN UFD PROCESS
SPEC. DATA SHTS. FROM OTHER ENGINEERING INPUT FROM
DATA SHEET PROCESS/ DISCIPLINES PACKAGE PLANT
INPUT (IFR) MECHANICAL (PREL.)

BASIC ENGINERING

INST. DESIGN ACTIVITIES PREPARATION PREPARATION OF

REVIEW DESIGN INSTRUMENT
OF INPUT
DESIGN BASIS INDEX

INSTRUMENT
INSTRUMENT COMMENTS ON INDEX(PREL)
DESIGN BASIS P&ID / UFD
DESIGN
OUTPUT

MILESTONE ACTIVITIES PREV NEXT

INSTRUMENT DESIGN BASIS

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 DETAILED DESIGN & PROCUREMENT

DESIGN P&ID/UFD IPDS CLIENT ELECTRICAL AREA

INPUT LINE LIST PIPING SPEC. SPECIFICATION INFORMATION CLASSIFICATION

DETAILED ENGINEERING FOR PROCUREMENT

PREPARE MR FOR INTER

INST. DESIGN FIELD CONNECTION
ACTIVITIES INSTRUMENTS CHECK

PREPARE PREPARE MR
INSTRUMENT FOR CONTROL
INDEX SYSTEM TBA/PORN FOR VENDOR DWG.
INSTRUMENTS REVIEW

INSTRUMENT MR FOR FIELD INSTS. -TBA/PORN VENDOR DWG.

MR FOR DCS
INDEX REPORTS FOR COMMENTS
-TRANSMITTER
-TEMPERATURE INST. ITEMS -NOZZLE
COMMENT ON
ELEMENT -FINALISE ORIENTATION
P&ID/UF MR FOR ESD
-FLOW ELEMENT ERECTION & ELEVATION
(PLC)
-CONTROL VALVE, TENDER
COMMENTS ON etc.
DESIGN VALVE LIST
OUTPUT
COMMENTS ON
CABLE TRAY
ROUTING DWG.(ELEC)

COMMENTS ON PIPING
DRAWING

INSTRUMENT INDEX MR FOR FIELD INSTRUMENTS PREV NEXT

MILESTONE MR FOR DCS TBA FOR ABOVE

ACTIVITIES` MR FOR ESD (PLC)
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 CONSTRUCTION DRAWING

PLOT PLAN ENGG. DWG. MR FOR VENDOR DWG.

DESIGN INSTRUMENT
P&ID / UFD -PIPE GA DWG. - FIELD
FOR INST.
INPUT INSTRUMENTS INDEX
LINE LIST -EQUIPMENT (FINAL)
- CONTROL SYSTEM
LAYOUT

PREPARATION OF DESIGN DOCUMENTS

PIPING DESIGN REVIEW OF LOGIC LAYOUT WIRING AS-BUILT DATA

ACTIVITIES DESIGN INPUT STUDY STUDY DRAWING BY ERECTION
STUDY CONTRACTOR

FINAL MTO

COMMENT ON LOGIC CONTROL ROOM FINAL OVERALL

DESIGN INPUT DIAGRAM LAYOUT CABLE SCHEDULE MTO TO ERECTION
DATA
CONTRACTOR
FIELD LAYOUT INST. CABLE
INSTRUMENT ELECTRICAL ROUTING
INDEX

DESIGN FIELD LAYOUT

AS-BUILT
OUTPUT PNEUMATIC LOOP DRAWINGS
DRAWINGS

INSTRUMENT
LOCATION
LAYOUT

PREV NEXT

MILESTONE
INSTRUMENT INDEX(FINAL)

LOGIC DIAGRAM
CONTROL ROOM LAYOUT

OVERALL MTO
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ACTIVITIES
 Instrumentation Engineering Work Process
Reference Documents

1. INPUT TO ENGINEERING STANDARDS 4. PROCEDURE FOR ENQUIRY/ TECHNICAL BID LEGEND:

- INSTRUMENTATION DESIGN BASIS (GENERAL) ANALYSIS/ PURCHASE ORDER REQUISTION
- INSTRUMENTATION GUIDELINES MTO – MATERIAL TAKE-OFF
- CHECK LISTS (GENERAL) MR – MATERIAL REQUISTION
5. ENGG. DWGS FOR FOLLOWING ITEMS
- MR, TBA, PORN PROCEDURE TBA – TECHNICAL BID ANALYSIS
COLUMN, VESSEL, REACTOR, STORAGE TANKS, P & ID – PIPING & INSTRUMENTATION DIAGRAM
HEAT EXCHANGER, FURNACE, PUMP, TURBINE, UFD – UTILITIES FLOW DIAGRAM
AIR COOLER, COMPRESSOR, SILENCER ETC. IFR – ISSUED FOR REVIEW
2. INPUT TO DRAFTING STANDARDS (AS APPLICABLE) IFA – ISSUED FOR APPROVAL
- DRAFTING PROCEDURE (GENERAL) 6. PROCESS,CIVIL, ELEC. & PIPING INFORMATION IFC – ISSUED FOR CONSTRUCTION
- INST. DESIGN PRACTICE (GENERAL) - ELECTRICAL CABLE TRAY LAYOUTS PACS – PROJECT ACTIVITY CONTROL STATUS
- DRAWING NUMBERING PROCEDURE - EQUIPMENT LAYOUT IPDS _ INST. PROCESS DATA SHEET
- REVISION CONTROL PROCEDURE - PIPING GA DRAWING DCS _ DISTRIBUTED CONTROL SYSTEM
- STD DWG. –FOR ALL DELIVERABLES - IPDS PLC _ PROGRAMMABLE LOGIC CONTROLLER
- FILING SYSTEM PROCEDURE (GENERAL)

3. EQPT. DATA SHEET FOR FOLLOWING ITEMS

7. PROCEDURE/FORMATS FOR INFORMATION DWG.
COLUMN, VESSEL, REACTOR, STORAGE TANKS,
HEAT EXCHANGER, FURNACE, PUMP, TURBINE,
AIR COOLER, COMPRESSOR, SILENCER ETC.
(AS APPLICABLE)

PREV

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 P&I DIAGRAMS

AND

INSTRUMENTATION DELIVERABLES
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 P & I DIAGRAM
 Expanded as Piping and Instrumentation Diagram or
Process and Instrumentation
Diagram
 Is a schematic illustration of functional relation ship of
Process, Piping & Instrumentation of any plant
 Shows all piping including the physical sequence of branches,
reducers, valves
 Shows all Instruments- whether Local/ Remote
 Different symbols are used for identifying the location of
Instruments
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
 P & I DIAGRAM
 Shows all the Instruments with Tag numbers
 Shows Process piping, Sizing & Identification
 Shows miscellaneous items like:
Vents
Drains
Special fittings
Sampling lines
 Shows Flow directions
 Shows
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 P & I DIA GRAM

 Shows Material specification

 Shows Scope demarcation
 Shows Design Temperature/ Pressure /Flow rates
 Shows Operating Temperature/ Pressure /Flow rates
 Shows Insulation Specification- Size / Material
 Is the basic input document for preparation of almost all
Instrumentation deliverables

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 INSTRUMENTATION DELIVERABLES
 Instrumentation Design Basis
 Instrument Index
 Instrument Specification
 Instrument Datasheet
 Distributed Control System (DCS) Specification
 Programmable Logic Controller (PLC) Specification
 Instrument Junction Box Wiring diagram
 Instrument Cable Schedule
 Instrument Installation Diagrams
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 INSTRUMENTATION DELIVERABLES

 Instrument Location Layout

 Instrument Cable routing Layout
 Instrument Pneumatic tubing layout
 Instrument Loop Diagrams
 Instrument Sizing Calculations

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 INSTRUMENTATION DESIGN BASIS
 Units of Measurement
 Air supply at Battery limit
 Power supply for various systems like:
DCS / PLC
Emergency Shut Down
Analyzers / Chromatographs
Control panels
Field Instruments
Package Instrumentation
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 INSTRUMENTATION DESIGN BASIS

Flow Measurement

 Type : Head or Mass flow or Vortex flow etc.

 If Head type, Std: ISO 5167 or others
 Taps for Orifice: Flange for line size up to 12”
D-D/2 for > 14”

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 INSTRUMENTATION DESIGN BASIS

Level Measurement

 Transmitter Type: Differential Pressure /

Displacer/ Float and Tape

 Switch type: External Ball float / Internal Ball

float/Displacer

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 INSTRUMENTATION DESIGN BASIS

Temperature Measurement
 Local Gauges: Bimetallic or Mercury in steel type
 For remote measurement: Thermocouple / RTD
Generally up to 300 deg C RTD is
used for temperature > 300 deg C Thermocouple is used.
 Temperature Transmitter: Required /Not i.e
Thermocouple or RTD signal is going to be converted to mA signal
or not.
 Mounting of Temperature Transmitter: Integral/Remote
i.e. if Temperature transmitter is there then whether it is head
mounted or mounted away from the head.
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
 INSTRUMENTATION DESIGN BASIS

Control Valve
 Type: Globe/ Ball/ Butterfly
 Trim char.:Equal % / Linear/ On-Off
 End Connection: Flanged / Welded
 Accessories: Position Transmitter
 Air filter Regulator
 Solenoid Valve
 I/P Converter or E/P Positioner
 Limit Switches etc.
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 INSTRUMENTATION DESIGN BASIS

Safety Valve
 Type: Conventional/ Pilot operated/ Balanced bellows
 Generally Conventional type is used.
 For clean service where Operating
pressure >90% of Set point- Pilot operated valve
is used.
 For corrosive service When built up Back
pressure > 10% of Set point- Balanced bellows
is used.
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 INSTRUMENTATION DESIGN BASIS

Process Switch
 Flow: Independent receiver switch (through transmitter)
 Level:Directly actuated or through transmitter
 Pressure: Directly actuated or through transmitter
 Temperature: Independent receiver switch
 Special Instruments: Independent receiver switch

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 INSTRUMENTATION DESIGN BASIS

Hazardous Area Protection

 Analog Insts.: Intrinsically safe
 Switches:Explosion Proof / Intrinsically safe
 Local panels: Purged
 Junction Boxes: Explosion Proof
 Cable Gland: Explosion Proof

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 INSTRUMENTATION DESIGN BASIS

Control Philosophy
 Mode of plant operation: Centralised / Local – Generally
the main plant operation is centralized and package plant operations
can be local, for example, Instrument Air compressor.
 No. of Control room: will be decided based on the size of
the plant
 Plant Controls: whether through DCS or standalone PLC
 Final Control Element: Pneumatic or Electric or Hydraulic
 Field Transmitter: Field bus compatible / Smart /
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 INSTRUMENT INDEX

Generally the following fields will be covered in Instrument Index.

 Tag Number
 Service
 Line / Equipment Number
 Operating conditions Pressure / Temperature / Flow
 Type of Instrument
 Signal Type
 Location of Instrument
 Range / Set point
 Unit

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 INSTRUMENT INDEX

 Make
 Model Number

 Requisition Number

 Installation diagram number

 Loop diagrams number

 Field Junction Box Number

 Revision number

Etc.

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 INSTRUMENT SPECIFICATION/ DATA SHEET

Generally the specification / data sheet are prepared for the

following Instruments:
 Pressure Gauge
 Pressure / dp Transmitter
 Pressure switches
 Temp. Gauge
 Temp. Transmitter
 Temp. Elements
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 Flow Transmitter
 INSTRUMENT SPECIFICATION/ DATA SHEET

 Level Gauge
 Level Transmitter
 Level switches
 Analyzers
 Control Valves
 Safety valves
For preparation of Instrument Datasheets, Process Data sheet for
each instrument tag will be furnished by the Process.
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 INSTRUMENT SIZING CALCULATIONS

 Control Valve
 Flow Elements
 Safety valves
 Rupture Disc
 Thermo-well Depth
 Restriction Orifice

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 DCS SPECIFICATION / PLC SPECIFICATION
 Control System Architecture shows where all redundancy is
required
 Generally Processor/ Power supply / Communication
redundancy is specified
 I /O redundancy is provided only for critical I/O’s
 Requirement of number of operator consoles is specified
 Third party integration – Integrating the PLC’s given by the
Package vendors
 MIS connectivity – to the Top Management
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 INSTRUMENT JUNCTION BOX SCHEDULE

 Junction box required to reduce Cabling

Generally following grouping will be followed:

 Analog (IS)
 Analog (Non-IS)
 Digital Input
 Digital Output
 Thermocouple (If directly taken to Control room)

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 INSTRUMENT CABLE SCHEDULE

 Lists out all cables used for the Project

 Single pair cables are used from field Instruments to
Junction boxes
 Multi pair cables / Multi core cables are used from
Junction boxes to Marshalling cabinet

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 INSTRUMENT INSTALLATION DRAWING

Process piping details

•

Air Piping / Tubing details

•

 Process Piping: Generally up to 600# rating SS tubes &

fittings will be used. For 900# & greater, piping and pipe fittings
will be used. Impulse pipe material should be same as or better
than that of the parent pipe material.
 Shows MTO for Heat tracing requirement, if applicable
 Air piping details show Air headers & tubing to control
valves
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 OTHER DESIGN DOCUMENTS

 Instrument Location layout

 Instrument cable routing layout

 Instrument pneumatic tubing layout

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 OTHER DESIGN DOCUMENTS
 Reference Drawings required: P & ID’s/Instrument Index/
Design Basis/ Plot plan / Piping GAD’s
 These are prepared after the receipt of Piping GAD’s
 Location layout shows location of all Transmitter/
Switches /Gauges etc..
 Instrument cable routing layout shows location & routing of
main trays (ie) Trays from junction boxes to Control room
 Pneumatic tubing layout shows locations of all Pneumatic
instruments like I/P converter, Control calves etc. and shows
Tubing trays and Purging connections for control panel, if
applicable.
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 OTHER DEPARTMENTS INTERACTION

 With Electrical, Interface with Electrical equipments like

MCC, Switchgears, Switchyard etc & Cable Routing
 With Civil, Control Room Opening for cable entry, Door Size
in Control Room, Cable Trench Size etc.
 With Mechanical, Equipment layout for Instrument Location
& Cable Routing Layouts, Instruments on Equipments etc.
 With Process, P&ID’s and Instrument Process Datasheets etc.
 With Piping, P&ID, Tap Points on Piping, Nozzle Orientation
in vessel, On-Line Instruments requirements etc.
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 Thank you for a patient hearing!!

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