Herve Baron - Engineering Training - Instrument - Control

HERVE Engineering Training
BARON
Welcome to this presentation.
It is part of a suite of Engineering training modules.
It shows the activities and deliverables of the

Instrumentation & Control discipline.
Comments are most welcome (herve.baron@gmail.com),

which I will incorporate for the benefit of all.
Please download this file so that you can see my trainer’s

notes in the top left corner – latest Acrobat Pro feature.
© 2015 – Hervé Baron

Hervé
HERVE Engineering Training
BARON
 PROCESS
 PLANT LAYOUT
 EQUIPMENT
 SAFETY & ENVIRONMENT
 CIVIL
 PIPING
 PIPELINE

 INSTRUMENTATION
 ELECTRICAL
HERVE
BARON
Process design
PFDs P&IDs We are

here
H&M balance
Piping
Instrumentation
Equipment specification
Process
data sheet Vendor
Rotating drawings Layout
Pressure vessels
Fired equipment Civil

Heat exchangers
Electrical
Packages etc.
HERVE Engineering disciplines: activities and deliverables
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 PROCESS
 PLANT LAYOUT
 EQUIPMENT
 CIVIL
 PIPING
The discipline is commonly split in 3
 PIPELINE specialties. Which ones?

 INSTRUMENTATION
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 PROCESS
 PLANT LAYOUT
 EQUIPMENT
 CIVIL
 PLANT LAYOUT & PIPING
 PIPELINE
 INSTRUMENTATION

• Field instrumentation
• Systems
• Installation
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 PROCESS
 PLANT LAYOUT
 EQUIPMENT
 CIVIL
 PIPING
 PIPELINE
INSTRUMENTATION


• Systems
• Installation
HERVE Piping & Instrumentation Diagram (P&ID)
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HERVE Piping & Instrumentation Diagram (P&ID)
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HERVE Instrument list
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HERVE Instrument data sheet
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HERVE Level sketch
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 PROCESS
 PLANT LAYOUT
 EQUIPMENT
 CIVIL
 PLANT LAYOUT & PIPING
 PIPELINE
 INSTRUMENTATION

• Systems
• Installation
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 INSTRUMENTATION
• Systems:
 Process Control System
 Unit Control System
 Emergency Shutdown System
 Fire & Gas System
 Other systems
• Installation

HERVE PCS (Process Control System)
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HERVE System requisition
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HERVE System architecture drawing
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HERVE Control narrative
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Gas inlet
93-E161
Gas outlet

HERVE Functional diagram
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HERVE Mimic display drawings
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HERVE Process automations & Process Shut Down (PSD)
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 INSTRUMENTATION
• Systems:
 Other systems
• Installation

HERVE Package instrumentation & control
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HERVE Package instrumentation & control
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HERVE Package control
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Package controlled
by Central Process
Control System

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Package controlled
by Central Process
Control System

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Package
controlled by

own Unit
Control
System
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Package controlled by own Unit Control System

What documents from the
package Vendor are needed by
the DCS Vendor in this case?
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Package controlled
by Central Process
Control System
What documents from

the package Vendor are
needed by the DCS

Vendor in this case?
HERVE Process Control System
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Process Control System

Engineering by Vendor
The Process Control Hardware Software
System is engineered by
the Vendor based on
information supplied by
Engineer.

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the Vendor based on
Engineer.

Which documents are
needed by the Vendor?
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Engineering documents
Vendor documents

the Vendor based on
Engineer.

Which documents are
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P&IDs
Control Narratives
Cause & Effects
Vendor documents

the Vendor based on
Engineer.

Which documents are
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P&IDs
Control Narratives
Cause & Effects
Packages with Unit Control

System:
Exchange table with Process Control System
PCS Engineering by Vendor
Packages controlled by Central
Control System:
the Vendor based on
P&IDs information supplied by
Engineer.
Control Narratives

Cause & Effects
Control & logic

diagrams
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 INSTRUMENTATION
• Systems:
 Other systems
• Installation

HERVE Emergency Shutdown (ESD) System
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HERVE Emergency shutdown (ESD)
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SIL study
Have you heard about SIL studies? What does it mean?
What does SIL, SIF and SIS mean?
Terms defined in ANSI/ISA-84.00.01-2004 (IEC 61511-1) Functional

Safety: Safety Instrumented Systems for the Process Industry Sector
SIF: Safety Instrumented Function
SIS: Safety Instrumented System: Sensor + logic solver + final element
SIL: Safety Integrity Level: Level used for specifying the safety integrity
requirement of SIFs. There are 4 levels:

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SIL study


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SIL study

ANSI/ISA-84.00.01-2004 (IEC 61511-1)
Functional Safety: Safety Instrumented Systems for the Process Industry Sector
 SIF: Safety Instrumented Function
 SIS: Safety Instrumented System: Sensor + logic solver + final element
 SIL: Safety Integrity Level: Level used for specifying the safety integrity

BARON
SIL study

ANSI/ISA-84.00.01-2004 (IEC 61511-1)
Functional Safety: Safety Instrumented Systems for the Process Industry Sector
 SIF: Safety Instrumented Function
 SIS: Safety Instrumented System: Sensor + logic solver + final element
 SIL: Safety Integrity Level: Level used for specifying the safety integrity

BARON
SIL study
Step 1: SIL Determination, “assignment workshop”
 Identification of Instrumented Interlocks on the P&IDs =

inventory of Safety Instrumented Function (SIF)
 For each SIF:

• Qualitative evaluation of consequences if the event the SIF is
designed to safeguard from
• Qualitative evaluation of the likelihood of the event
• Determination of risk level (likelihood * consequence) and
resulting SIF required performance (SIL level)

 Deliverable: SIL assignment logsheet / worksheets
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SIL study
LIKELIHOOD
DEFINITION POTENTIAL FREQUENCY
CATEGORY
A Possibility of repeated incidents 20 or more times per Facility life
B Possibility of isolated incidents 5 times per Facility life
C Possibility of occurring sometime Once in Facility life
D Not likely to occur Once every 10 Facility lives
E Practically impossible Once every 100 Facility lives
CONSEQUENCE CONSIDERATIONS
CATEGORY Health/Safety Public Disruption Environmental Impact Financial Impact
Abbreviation S – Safety P – Public E – Environmental F – Financial
Large Major/Extended Major Impact to
Fatalities/ Serious
I Impact on Public
Community Duration/ Full Scale Company
(10,000+) Response (>$50 million)
Significant
Small
Serious Injury to Serious/Significant Impact To
Community
II Personnel/ Limited
(1,000 to
Resource Company
Impact on Public Commitment ($2 - $50
10,000)
million)
Moderate
Medical Treatment for Moderate/Limited Impact To
Minor
III Personnel/ No Impact Response of Short Company

(10 to 100)
on Public Duration ($500M - $2
million)
Minimal to Minor Impact
Minor Impact on Minor/Little or No
IV Personnel
None
Response Needed
To Company
(1 or 2) ($50M-$500M)
HERVE SIL Study
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Step 1: SIL Determination, “assignment workshop”
 Deliverable: SIL assignment logsheet / worksheets
 Summary:

What is the second step of the SIL?
HERVE SIL Study
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Step 2: calculations and recommendation
SIS Performance Verification
 Evaluate the performance of each SIF, based on device

selection, architecture, voting, testing etc.
 Compare to required SIL level and specify modifications to

the SIF design (device selection, component redundancy) or
testing intervals
 Deliverable: SIS Performance Verification Results and

recommendations
HERVE SIL Study
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Step 2 – SIS Performance verification Results

HERVE SIL Study
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Step 2: calculations and recommendation - Summary

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 INSTRUMENTATION
• Systems:
 Other systems
• Installation

HERVE Fire & Gas system
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HERVE Fire & Gas system
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 INSTRUMENTATION
• Systems:
 Other systems
• Installation

HERVE Systems
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The main systems are:

 the Process Control System (DCS), and Emergency Shutdown System (ESD),
usually integrated: ICSS (Integrated Control and Safety System)
 the Fire & Gas system (F&G)?
What other systems do we find?


HERVE Systems
BARON
The main systems are:

 the Process Control System (DCS), and Emergency Shutdown System (ESD),
usually integrated: ICSS (Integrated Control and Safety System)
 the Fire & Gas system (F&G)?
What other systems do we find?

 Packaged equipment Control systems
 Machinery Monitoring System (MMS) for vibration & temperature monitoring
 Burner Management System (BMS)
 Compressor Anti-Surge System (CCC)
 Analyzers Data Acquisition system
 Fiscal Metering Systems afor Custody transfer and allocation
 Storage tank data acquisition (gauging) system
 Continuous Emissions Monitoring System (CEMS)
 Process Operator and Information System (POIS) / SCADA

 Advance Process Control (APC)
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 PROCESS
 PLANT LAYOUT
 EQUIPMENT
 CIVIL
 PIPING
 PIPELINE
 INSTRUMENTATION

• Systems
• Installation
HERVE Field Instrumentation
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Equipment room Control room
Field Marshalling System

cabinet cabinet
Operator
station
PT JB
Process
line
Secondary cable
Multi cable

HERVE Main cable routings and Junction Box (JB) location drawing
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HERVE Instrument location & secondary cable routing drawings
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HERVE Telecommunication equipment layout drawing
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HERVE Typical installation drawings
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HERVE Junction box wiring
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HERVE Instrument location & secondary cable routing drawings
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Cable list

HERVE Cable routing / section
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HERVE Instrumentation installation standards
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HERVE Instrument bulk material take-off
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ITEM QUANTITY DESIGNATION
1 195 Gauge adapter – ½” x ½”
2 37 Block manifold 2 valves (Gas) – ½”
3 23 Block manifold 5 valves (Gas) –½”
4 0 Ball valve ½” – 12mm
5 300m Tubing – 12mm OD x 1mm
6 200 Reducer – 12mm x ¼”
7 50 Union tee – 12 x 12 x 12mm

8 50 Female connector – 12mm x ½”
9 350 Male connector – 12mm x ½”
10 9 Plug – ½” NPTF
11 8 Plug – ½” NPTM
HERVE Equipment layout drawings
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HERVE Instrument loop diagram
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HERVE Main schedule Milestone for Instrumentation
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The main schedule Milestones are the commitments to the Control System Contractor.
There are 2 commitments:
- Hardware freeze, for the manufacturing of the marshalling and I/O cabinets,
- Software freeze, for the configuration of the DCS
Marshalling System
Cabinet Cabinet
Operator
station
PT JB
Process

line
Secondary cable
Multi cable
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In your opinion, which Milestone is required to be reached first?

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What are the Engineering documents required to reach each Milestone?

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What are the Engineering documents required to reach each Milestone?
What is challenging to meet the schedule?

HERVE The Oil & Gas Engineering Guide
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2nd edition
Do you want to know more... Much more?

HERVE The Oil & Gas Engineering Guide - 2nd edition
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Table of Contents

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Table of Contents
This suite of training modules

covered the discipline
chapters of the book...

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Table of Contents
The Guide contains much more:
The overall picture, interfaces,

methods & tools, etc.

HERVE The Oil & Gas Engineering Guide
BARON
2nd edition
Order direct from the publisher:
http://www.editionstechnip.com/en/catalogu
e-detail/1111/oil-gas-engineering-guide-
the.html

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HERVE Engineering Training

Welcome to this presentation.

It is part of a suite of Engineering training modules.

It shows the activities and deliverables of the

Comments are most welcome (herve.baron@gmail.com),

Please download this file so that you can see my trainer’s

© 2015 – Hervé Baron

 SAFETY & ENVIRONMENT

© 2015 – Hervé Baron

PFDs P&IDs We are

© 2015 – Hervé Baron

 SAFETY & ENVIRONMENT

© 2015 – Hervé Baron

 SAFETY & ENVIRONMENT

 PLANT LAYOUT & PIPING

© 2015 – Hervé Baron

 SAFETY & ENVIRONMENT

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

 SAFETY & ENVIRONMENT

 PLANT LAYOUT & PIPING

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

What documents from

© 2015 – Hervé Baron

Process Control System

© 2015 – Hervé Baron

Process Control System

© 2015 – Hervé Baron

Process Control System

© 2015 – Hervé Baron

Cause & Effects

Process Control System

© 2015 – Hervé Baron

Cause & Effects

Packages with Unit Control

© 2015 – Hervé Baron

Control & logic

© 2015 – Hervé Baron

© 2015 – Hervé Baron

© 2015 – Hervé Baron

What does SIL, SIF and SIS mean?

Terms defined in ANSI/ISA-84.00.01-2004 (IEC 61511-1) Functional

SIF: Safety Instrumented Function

SIS: Safety Instrumented System: Sensor + logic solver + final element