Successful Instrument and Control System Design

8/4/2019 Successful Instrument and Control System Design

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Successful Instrument and ControlSuccessful Instrument and Control

System DesignSystem Design

Part III (3/3) Ch 15 to 18

8th-Jul-2011

AgendaAgenda

Chapter 15 Panel Arrangement

Chapter 16 Procurement

Chapter 17Quality Control

The Integrated Design Check

Chapter 18 Phase Three

Construction Support


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Chapter 15Chapter 15 Panel ArrangementPanel Arrangement

Panel arrangement drawings accomplish

several things:

Contents and placement of front-panel equipment

such as control switches and lights.

Contents and placement of back-panel equipment.

Contents of any engraved labels.

Bill of material for each item.

The external enclosure to be sized with confidence.

Panel Arrangement SamplePanel Arrangement Sample

Graphic detail should be minimized, and no wiring detail need

to be included.


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Arrange a Junction Box DrawingArrange a Junction Box Drawing

Set up a scale

Metric units or Imperial units

Design the panel

How many terminals are needs?

What kinds of terminals should be used?

Most specifications require 50% spare capacity on a

new installation.

Explosion proof and enclosure protection.

Arrange a Junction Box DrawingArrange a Junction Box Drawing

For each item, place at least one bubble and leader. And

generate a bill of materials on the left side of graphic.

Generate a Bill of Materials


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Field Panel SampleField Panel Sample

Leaving a minimum of 1.5 inches

between a terminal and adjacent

wiring duct is good practice.

The space for cable entry shall be

consider.

SummarySummary


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Chapter 16Chapter 16 ProcurementProcurement A design package is built from the conceptual

to the actual andprocurementis about as

actual as it gets.

A frequent lament from the construction

partner is How can I build something if I

dont have the parts

Primarily two types of material are specifiedby the I&C design team:

Electrical material

Mechanical material

Bulk MaterialsBulk Materials

Electrical material

Including cable, conduit, enclosure, and termination

hardware.

Mechanical material

Including pneumatic tubing, flanges gaskets, and

mounting brackets.

These types of materials are called bulk materials.

Instruments, items that require long lead time for

manufacture, or other equipment items that require

individual specifications do not fall into the bulk

materials category.


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Typical Purchasing CycleTypical Purchasing Cycle

When a design is nearly complete, the design

team begins whats called a takeoff.

Someone begins building lists of materials for

purchase. These lists are called bill of

materials (B/M, or BOM.)

The BOM is a document that lists all the

materials required for construction. On large projects, it is critical that each BOM

be given a unique designation and that a bill of

materials index be maintained.

Typical Purchasing CycleTypical Purchasing Cycle

Once a bill of materials is produced, they are given to the

purchasing department. Purchasing pares the material,

reorganizing it according to vendor. A purchase order (PO) is

then produced for each vendor.


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Material ClassificationMaterial Classification

Bulk materials can be stored in bulkor in

detail.

The materials on the bulk bill of materials are

nonspecific materials.For example: cable, conduit, conduit fitting, cable tray, bolts &

nuts and hookup wiring.

The detail bill of materials is for Bulk materials that

have specific uses as shown on detail drawings.

For example: most instrument, and instrument fitting.

Bulk materials TakeoffBulk materials Takeoff

Cost-effective

Most vendors allow quantity discounts. The amounts

of these discounts very as the quantity rises, so it is

desirable to make large orders. Wastage and contingencies

We must always allow for wastage as the excess ends

will be clipped and disposed. We usually allow for at

least 20% wastage, plus about another 5-10% for

contingencies.

Takeoff quantity * 1.25 = Procured quantity


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Bulk materials TakeoffBulk materials Takeoff

SummarySummary


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Chapter 17Chapter 17Quality ControlQuality Control The Integrated Design CheckThe Integrated Design Check Having progressed to the end of the design

phase, it is now necessary to validate the work

before sending it to the field to be built.

If the design events are properly logged as theyare executed, then the design check at the end is

much easier and much time will be saved.

Goal of design check Zero defects will not occur

No showstoppers or major problem will stop the

construction effort.

CheckpointsCheckpoints

There are few specific issue to consider in

terms of establishing checkpoints. Two

different points of view need to be consider:

administrative and technical.Administrative content Individual Checks

Technical content Squad Check

Squad check roster

Design check summary


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Administrative contentAdministrative content Individual ChecksIndividual Checks

Non-technical experts should be designated to

page through the document set to check for

specific appearance aspects:

Is the title block correct in terms of drawing number,

revision level, and title?

Are the proper project data in place?

Are the proper initials in place? Designed, check, and

so on.

Are notes legible and grammatically complete?

Technical contentTechnical content Squad CheckSquad Check

Do the instrument specifications reflect the intent of

the P&ID, and will they meet the scope

requirements?

Do the elementaries reflect the intent of the

instrument specs and the P&ID?

Do the wiring diagram reflect the intent of the

elementaries?

Do the BOM reflect the needs presented on process

plans and cabinet arrangement?

Are all these properly reflected in the instrument

database?


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Technical contentTechnical content Squad CheckSquad Check

The revised drawing should always be attached to its

original markup to retain the document trail.

When the design check is complete, the markups

should be rescued and stored. They should be

retained for one year after plant startup.

In CTCI I&C department principle:

Using design input/output check sheet.

Squad check rosterSquad check roster

Who should be on squad-check team?

For the most part, the design team itself.

If possible, the members not check their own work.

Rotating the personnel away from their own work does acouple of good things:

First, it makes sense. If a mistake was made once, it will

probably be missed if the same person look at it again.

Another benefit is the cross-training aspect.

One other addition to the squad should be an

experienced outsider. (AE)


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Design check summaryDesign check summary

All the designers prepare for the check by

logging their progress in the database, by

keeping a personal log of potential problems

to watch out for, and by communicating with

each other. At the end of the project, the

database can be used as a checking tool that

streamlines the squad-check process andmaximizes the effectiveness of the time spent

in its execution.

summarysummary


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Chapter 18Chapter 18Phase ThreePhase Three Construction SupportConstruction Support

Phase two has ended, and phase three has

begun (E C)

The designers may be able to spend some extra time

on-site with the constructor as well. Construction

support and support during checkout and startup are

key to the success of the design team as a whole.

If the designers are in the field and known to be

helpful, then perceptions will be enhanced all

around.

Construction SupportConstruction Support

There are two kinds of construction support:

on-site and off-site. It is a good idea to

determine ahead of time the periods that are

critical for on-site support and have people

available continuously through those periods.Otherwise, having someone on call off-site is

usually acceptable.

The construction phase breaks down into

several periods, each with a different set of

needs in terms of the design team.


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Construction Phase PeriodsConstruction Phase Periods

Kickoff Meeting:

Each construction activity should begin with a kickoff

meeting. At this meeting, the phase-three lead for

the design team should present the package. The

presentation should cover, at a minimum, the

following topics:1. Bill of material

2. Design overview

3. Off-site support infrastructure

4. On-site support plan


Construction Period:

Construction activities usually provide a bit of a lull

for the design team. Some members of the team

may be reassigned to other duties at this time, never

to return to the project. Others may monitor theproject, getting involved only when a problem arises.

During certain predefined periods of particular risk to

the project, design team representative(s) may travel

to the site to observe and provide direct support.

Construction activities during this time include

installation and verification.


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Checkout(Bump and Stroke):

The checkout period increases the level of attention

needed by design team. The following activities

occur during this time:1. Each analog sensor is checked for proper ambient reading

and electrically disconnected.

2. Each digital input is forced by either making it react to its

process condition or by shorting across its terminals.3. Motors are bumped to verify proper direction of rotation.

4. Valves are stroke to make sure they function and their

travel is not obstructed.


Startup:

Upon successful completion of the checkout phase,

the system is ready to run. At this point, the

customer begins to take command of the system.

The customers operators will have recevied trainingfrom the system integrator. It is now time to light

the candle.

This is the time for the customer and the system

integrator to assume primary roles.

The design and construction teams stand by to

respond should a need be identified.


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Adjustment of Document to ReflectAdjustment of Document to ReflectConstruction ModificationConstruction Modification

Construction drawings are usually copied,

since redlines only exist there and cannot be

removed from the site. These copies are sent

to the engineering service provider to be

formally incorporated into the document.

As soon after startup as practical, thedrawings should be released back into

customers possession. This is an official

turnover of responsibility for the project.

Finally, the entire project is shipped to the customer.

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