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1

Project

William G. Andrew

A guide to the overall duties and responsibilities of the instrument group is needed by those who do the work as well as those who must work with them in any way. Probably, the nature of work done by instrument people is more rnis .. understood than any other discipline in the engineering and building a f process units. The misunderstanding comes generally because few people understand the amount of detailed information that must be assembled, digested and used to apply instrumentation properly to a process.

Guidelines and suggestions are given here which outline the organization and execution of an engineering project as it relates to instrumentation. It lists documents which are necessary for communication between owner and builder, communication within the contractor organization during the engineering phase and the necessary information for construction. Coordination requirements with other groups are discussed, planning hints are given, and a check list for project control is suggested to ensure the successful completion of the project. The principles outlined apply to projects whose capital investments range from a few hundred thousand dollars to the largest of projects.

The viewpoint presented is most applicable to the person responsible for the application, selection, purchasing and installation of instruments and control systems. The documentation necessary for a com plete record of a project is outlined. Even though the viewpoint is slanted toward the responsible project instrument engineer, other owner and Contractor personnel-project managers, process people and leaders of other disciplines-t-will profit by an understanding or how the job is organized, developed and executed.

Many jobs appear complex until they are organized and broken down into cornponen ts or units easily understood and accomplished. This is certainly true of instrument work.

Specific documents are required for the work-Jar installalion and later for maintenance. Scheduling, purchasing, installation and calibration must be done. The following paragraphs discuss what these functions are and how they are carried out.

Documents to be Produced

Most projects requ ire the followi ng engineering documents for a complete job. When the job is small, some of the functions may be combined in the interest of space, time and economy. On large jobs, additional documents may be needed. Generally, however, requirements adhere quite closely to those mentioned below.

Process Flow Sheets

Process flow sheets consist of a pictorial representation of the major pieces of equipment required with major lines of now to and from each piece (Figure I. I). Material balances generally are shown. Additional in formation often given includes operating conditions at various stages of the process (flows, pressures, temperatures, viscosities, etc.), equipment size and configuration and, in some cases, utility requirements. instrumentation on process flow sheets mayor may not be essentially complete, In some instances, practically all of the instrumentation is included; in others, only the major control systems are shown.

In most processes the primary control variables have been determined and verified through laboratory and/or pilotplant operations if the process is new. On old processes, previous commercial operations have verified proper or improper control techn iques. The responsible instrument people may be consulted or may offer suggestions to improve

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Instrument Project Control

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6 Applied Instrumentation

control. The extent of involvement depends primarily on the experience backgrounds of the process and instrument people assigned to the job.

Mechanical Flow Sheets

Meehan ical flow sheets or P& I (Process and In strument) diagrams (Figure 1.2) provide much detailed, mechanical information not shown on process flow sheets, while omitting much of the process information shown on the process now sheets. They repeat all the major equipment and piping lines as well as show:

l . AI! other equipment items with design temperatures and pressures

2. All interconnecting piping with size, material and fabrication specifications indicated

3. Utility requirements including pipe sizes, materials and fabrication methods

4. All major instrument devices

J n many situations, mechanical flow sheets show schematically every process and utility line that appears on detailed drawings. They provide a valuable reference for proper project installation. The instrument engineer uses it as a source for many documents which must be prepared.

Complete process and mechanical now sheets are needed prior to the bulk of the engineering effort on a job. Changes arc often made as jobs progress, however, particularly on rnecha nical now sheets.

Instrument Index Sheets

The instrument index sheets provide a summary of all instruments required for the job, listing each numberidentified item of each loop (see Figure l.J), The list should be made near the stu rt of a job and used to check progress in specification writing, purchasing, expediting, delivery and installation. As items are added, the list increases; deletions should be lined out (not erased), thus serving as a record of changes. Even th ough information IS not corn plete, the list should be issued early in the job so that project engineers and others concerned with the job may use it to gauge the job requirements.

Instrument index. sheets may serve strictly as an index of items required and provide illinimull1 information, or they may be expanded to provide a summary of information about the loop itself, including service conditions of the line or vessel with which it is associated.

instrument Specificatlon Sheets

To facilitate and speed up the specification and purchase of instrument items, forms have been developed which list the main features available and desirable in various categories or instruments. The Instrument Society of America has been Instrumental in [his effort and has developed standard forms for 27 categories of instrument items. Figure 1.4 is typical-s-a speci fication sheet for

pressure instruments. A blank form is included in these standards which can be used to hand-write specifications not already covered on the other 26 forms.

The ISA forms were revised in 1975 and republished in 1976 (reference "Standard ISA-S20", Standards and Prac[ices for Instrumentation, 5th Edition, Instrument Society of America, 400 Stanwix Street, Pittsburgh, PA 15222). This upgrading of content and format eliminated many of the deficiencies of earlier forms, although the forms in their present state must still be modified to include information such as electrical area classification and flowsheet numbers. Use of the forms is encouraged by the lSA, and copies are available at nominal cost through their headquarters. The forms may be modified (company headings. new columns, etc.) and reproduced for internal use (not for commercial sale), so long as permission is obtained from the ISA.

Specification sheets serve a fourfold purpose.

I. They contain information relating to the process and/or other instruments which is necessary for COI11- plete systems engineering.

2. They provide the purchasing department and other interested people information necessary [or fulfilling their jobs efficiently-a communications channel.

J. They serve as permanent records for plant use-for installation. production and maintenance groups.

4. They provide specifications to bidders, using a format familiar to both parties.

Loop Wiring Diagrams

Electronic loop wiring diagrams arc electrical schematic drawings which are prepared for individual (or typical) electronic loops. The simplest loop is one that contains only a transmitter and a receiver. Other loops may contain many items=-transmitter, recorder. controller, alarm units, control valve, transducer, integrator and perhaps other items.

The amount of documentation on the schematic varies.

Some are relatively simple, showing only the locations of the instruments, their identification numbers and termination of the interconnecting wiring. Cable routing, wire size, intermediate terminal points and other pertinent information (IfC necessarily shown on other drawings.

Other loop wi ri ng di agra ms are more cornprehensi ve (Figure 1.5), providing not only the information previously described but also showing intermediate junction box terminals properly identified, wire and cable information, complete terminal layout of individual instruments and other useful information. Included may be the transmitter range and calibration and pneumatic hookup information on the transducer and the control valve.

Some loop diagrams are much more complex. especially if ihe loop contains several components. Complete documentation, however, makes presiarrup checkout and maintenance much easier. Since the loop information is well documented, additional drawings are seldom needed for maintenance or the instruments.

8 Applied lnstrurnentatlon

s. I ~ P • f S. LP. NO. e-7S3 PRESSURE; INSTRUMENTS
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Engineers - Contractors CLIENT AI 13, C. ~. I SPEC, NO.
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Box 34451 Phone 946-9040 LOCATION UNlrel2. ~'11ES
HOUSTON, TEXAS 77034 BY DATE ITEM SHT.
CLIENT NO. ~,-DA lO2- J of}

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2 Function Record 0 Indicate 0 Control 0 Blind 0 Irllns)(.
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7 Chart Strip:O Roll 0 Fold 0 Circular __ ~ lime Marks ___
Range Number __
8 Chart Drive Speed Power
9 Scales Type --- --_- --
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XMTR 1U T fa nsmi tte r 4·20 mA~ 10-50 mA 0 21·103 kPa (3-15 psigf 0 Other
Output For Receiver See Spec Sheet JI:. R-3
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15 Manual Reg, None 0 MFR STO 0 Other
16 Output 4·20mA 0 10-50mA 0 21-103 kPa (3-15 psigl 0 Other
17 Service Gage Press. ~ Vacuum 0 . Absolute 0 Compound 0
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22 Process Conn. Y. in. NPT 0 % in. NPT ~ Other
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Figure 1.4. This pressure instrument specification sheet is typical of 27 instrument specification sheets available from Ihe ISA.

instrument Project Controi 9

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10 Applied Instrumentation

The choice of the form to be used depends on several factors-the needs of the builder, the records required and the extent of information given on other drawings. Loops may be drawn on 8 Y2 x l l-inch sheets, 11 x 17 -inch or larger if preferred. Loops similar to that shown in Figure l.5 are often drawn on "D" size sheets (24 x 32 inches). One to four loops may be shown on a "D" size drawing, depending on the complexity of the loop.

The preparation of loop wiring diagrams normally is needed, prior to the purchase of the central control panels to furnish wiring information to the panel fabricator. Complete field wiring identification may not be available at this stage of the jobcbut the essential facts pertinent to the panel fabricator will be known.

On jobs using pneumatic instruments, loops may also be drawn showing all instruments and their hookup. Figure 1.6 shows a typical loop.

Panel Drawings and Specifications

Another chapter of this volume discusses in detail various panel arrangements and layouts as well as panel specifications. This section does not duplicate these discussions but assumes that panel arrangement and layout philosophy are already determined and work execution only is needed. Panel specifications and instrument specifications for all panel instruments must be prepared.

Early in the job a decision shou ld be made concerning the extent of engineering to be done by the panel fabricator. This decision is based on four primary factors.

I. Cost

2. Time

3. Available manpower

4. Capability

The factors are so interrelated that they need not be listed in a definite order of importance. Fabrication cost is always im portant, but other factors such as installation schedule, startup time, etc., can minimize initial fabrication cost. Timing and cost, then, must be considered together.

I f the timing or schedule is critical, panel fabrication may be started before engineering is complete with a gain of several weeks in panel delivery. The added cost of such an action may be small compared to the advantage of earlier onstrearn commitments or other factors.

Capability and availability of manpower are also closely related. In most cases (he buyer knows the panel fabricator well enough to judge his engineering capabilities. The buyer also knows his own department's workload and capabilities. From these factors, he then must determine the amount of engineering to be done by each. in some cases the panel fabricator will do little or none of it; in other cases, he may do all of it.

Having decided which route to take, the engineer must schedule the work accordingly. If the detailed engineering is left to the panel fabricator, the contract must be let at an earlier date to allow time for engineering by the fabricator. The quality of the written panel specifications must be better for this option than for one on which detailed engineer-

ing is complete, because the written specifications must convey in word description what detailed drawings normally show pictorially.

If detailed engineering is done by the specifying engineer, the written specifications can often be simplified, and the purchase date of the panel can occur later in the course of the project. For either option, scheduling and planning of the work associated with the panel must be coordinated with other events of the job. In either case, the purchase and delivery of instruments to be installed by the panel fabricator must be made with sufficient lead time to prevent delay of panel completion. Some or all of the panel instruments may be purchased by the fabricator, Normally the fabricator buys only a small percentage of the installed instrument items.

Plot Plans

Instrument location plans (plot plans) include all instrument items that interconnect with other instruments. They usually do not show single items (such as level or pressure gauges and in-line rotameters) that connect only to process lines or vessels because those items normally appear on piping and/or equipment drawings and on mechanical flow sheets.

Many instrument items are shown on two sets of plan drawings because their installation involves two different crafts-pipefitters and electricians. Electrical plot plans normally show all items that have electrical connections. Instrument plot plans show items that have both electrical and piping connections. The drawing scale normally used is It:i or Va inch per foot. An advantage of the J/8·inch scale is that it duplicates the scale normally used by the piping department. Background layouts may then be traced or duplicated with little effort and cost. The location of instrument items also is easy since many of them are shown on piping drawings.

Location of all instrument junction boxes should be shown on the instrument plans. Instrument cable and tubing trays, if not shown on electrical drawings, may also be shown on the instrument plans.

Underground cable and tubing runs must be carefully routed. Preliminary locations and routing should be reviewed by piping, electrical and civil engineering design disciplines to avoid conflicts during construction with new design and also existing pipes, conduits, electrical grounding systems, foundations, drains, and sewers.

Installation Details

Installation details or sketches are needed to show mounting and piping methods and preferences. They show the size, pressure rating and type of materials required Ior the installation: Sufficient information is given to allow correct installation even if the craftsman is not familiar with the instrument. Figure 1.7 shows a typical installation detail for a dip cell.