2011/6/26

Successful Instrument and Control

System Design

Part III (3/3) Ch 15 to 18

8th-Jul-2011

Agenda
Chapter 15 Panel Arrangement
Chapter 16 Procurement
Chapter 17 Quality Control
The Integrated Design Check
Chapter 18 Phase Three
Construction Support

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Chapter 15 Panel 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 Sample

Graphic detail should be minimized, and no wiring detail need

to be included.

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Arrange 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 Drawing

Generate a Bill of Materials

For each item, place at least one bubble and leader. And
generate a bill of materials on the left side of graphic.

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Field 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.

Summary

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Chapter 16 Procurement
A design package is built from the conceptual
to the actual and procurement is 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 specified
by the I&C design team:

Electrical material

Mechanical material

Bulk 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 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 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 Classification

Bulk materials can be stored in bulk or 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 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 Takeoff

Summary

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Chapter 17 Quality Control

The 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 they
are 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.

Checkpoints

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 content Individual 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 content Squad 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 content Squad 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 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 a
couple 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 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 and
maximizes the effectiveness of the time spent
in its execution.

summary

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Chapter 18 Phase Three

Construction 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 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 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 Phase Periods

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 the
project, 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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Construction Phase Periods

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.

Construction Phase Periods

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 training
from 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 Reflect

Construction 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, the
drawings 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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