CONTROL SYSTEMS

TECHNICAL TRAINING

DESIGN ASPECTS
E18
Revision 2.0
DESIGN ASPECTS

Instrument air

Instrument tubing & fittings

Instrument Installation
− Mounting
− Locations

Wiring
− Wiring arrangements
− Loops

Instrument freeze protection

Control Panels

3D Model

Design deliverables

Page 2
DESIGN ASPECTS
INSTRUMENT INSTALLATION TERMS

Instrument taps
− The instrument connection to a pipe provided by
piping design

Impulse Lines
− The tubing that runs from the instrument tap to the
instrument

Air Sets
− An air pressure regulator plus a air filter

Page 3
DESIGN ASPECTS

Instrument Stands

Taps

Impulse Lines

Tubing

Tube Fittings

Air Sets

Page 4
DESIGN ASPECTS
INSTRUMENT AIR

Pressure
− 40 psig to 120 psig

Dry
− Dew point of -20 degrees

Individual instrument applications
− Airsets
− Air filters
− Filter-regulators

Page 5
DESIGN ASPECTS

Airsets

Air filters

Filter-regulators

Page 6
DESIGN ASPECTS
TUBING

Materials
− Stainless Steel (Typically 316/316L)
− Copper

Sizes
− ¼ in
− 3/8 in
− ½ in

Wall Thickness
− 0.035 in
− 0.049 in
− 0.065 in

Types
− Seamless
− Welded

Coated
− PVC

Bundles
− Jacketed
− Insulated
− Steam Traced
− Electrical Traced

Physical
− Stalks
− Coils

Page 7
DESIGN ASPECTS
TUBE FITTINGS

Plugs

Caps

Male Connectors

Elbows/45s

Tees

Crosses

Page 8
DESIGN ASPECTS
INSTRUMENT MOUNTING – 2” PIPE STANDS

Page 9
DESIGN ASPECTS
FLUID RELATIVE INSTRUMENT LOCATIONS

Process connected transmitters

− Liquid service

Install transmitter below the instrument tap
− Gas & Vapor service

Install transmitter above the instrument tap
− Steam service

Install transmitter below the instrument tap

Page 10
DESIGN ASPECTS
INSTRUMENT LOCATIONS

Locate instruments for

− Visibility
− Maintenance access

Do not locate or mount instruments
− On handrails
− In walk ways

Page 11
DESIGN ASPECTS
WIRING

Individual instruments
− Conduit entry
− Terminals

Field junction boxes
− Terminal strips
− Cable entry

Never from top

Homerun cables
− Multi-pair
− Multi-conductor
Page 12
DESIGN ASPECTS
WIRING

Marshalling panels
− Terminal strips
− Single marshalling
− Double marshalling

System field termination assemblies (FTAs)

System umbilical cables

Page 13
DESIGN ASPECTS
WIRING

INSTRUMENT MARSHALLING PANEL I/O MODULE

INDIVIDUAL PAIR HOMERUN CABLE

FTA
FIELD JUNCTION BOX

Page 14
DESIGN ASPECTS
WIRING

Loop
− System termination thru wire arrangement to
instrument then back thru wire arrangement to
system termination
− Power

Loop powered instrument (2-wire)

Field powered instrument (4-wire)
− Isolation
− Loop range resistor (250 ohms)
− Transmitter load limit

Typically 500 to 750 ohms for a 24 vdc supply
Page 15
DESIGN ASPECTS
WIRING

Barrier Type Screwed Terminals

Din Rail Mounted

Compression Terminals

Crimping Tool

Wire Stripping Tool

Butt Splice
Wire Nut
DO NOT USE
Page 16
DO NOT USE
DESIGN ASPECTS
JUNCTION BOX

Junction Box Terminal Strips

Page 17
DESIGN ASPECTS
WIRING (2-WIRE)

TRANSMITTER FTA

24 VDC

250 ohm RESISTOR

COMMON

Page 18
DESIGN ASPECTS
WIRING (4-WIRE)

FTA

24 VDC

TRANSMITTER
(120 VAC)

250 ohm RESISTOR

COMMON

Page 19
DESIGN ASPECTS
FREEZE PROTECTION

Instruments
− Enclosures

Insulated only

Insulted and heated

Tubing
− Tube bundles

Insulated only

Insulted and heated

Heat trace
− Self limiting
− Thermostat controlled
Page 20
DESIGN ASPECTS
FREEZE PROTECTION

Instrument Environmental
Enclosures

Instrument Environmental
Enclosure

Pre-traced Tube Bundle

Page 21
DESIGN ASPECTS
CONTROL PANELS

Main panels

Local panels

Panel front layouts

Back of panels

Page 22
DESIGN ASPECTS
3D Model

Inline instruments
− Control valves
− On-Off valves
− Safety valves
− Flow meters
− Level instruments

Offline instruments
− Transmitters
− Solenoid valves
− Junction boxes
− Panels
− Analyzer Shelters
Page 23
DESIGN ASPECTS
DESIGN DELIVERABLES

Review examples of

Installation details

Location plans

Wiring diagrams

Logic diagrams

Control panels

Loop diagrams

Page 24
DESIGN ASPECTS
DESIGN DELIVERABLES

Installation Details

Page 25
Page 26
Page 27
Page 28
Page 29
Page 30
Page 31
DESIGN ASPECTS
DESIGN DELIVERABLES

Location Plans

Page 32
DESIGN ASPECTS
INSTRUMENT LOCATIONS

Page 33
Page 34
DESIGN ASPECTS
DESIGN DELIVERABLES

Loop Diagrams

Page 35
Page 36
DESIGN ASPECTS
DESIGN DELIVERABLES

Control Panels

Page 37
Page 38
Page 39
DESIGN ASPECTS
DESIGN DELIVERABLES

Wiring Diagrams

Page 40
Page 41
Page 42
DESIGN ASPECTS
DESIGN DELIVERABLES

System Block Diagram

Page 43
Page 44
DESIGN ASPECTS
DESIGN DELIVERABLES

Dimensional Data

Page 45
Page 46