Instrumentation and Control (I&C) Design

5/20/22, 8:39 AM Instrumentation and Control (I&C) Design - InstrumentationTools
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Instrumentation and Control (I&C) Design

by Editorial Staff
The purpose of Instrumentation and Control (I&C) Design document is to cover the project-specific
technical requirements which are to be followed throw-out the Feed or Detailed Engineering Phase while
preparation of engineering deliverables.
Table of contents
Instrumentation and Control Design
$ Inputs Required
a d k h J y %
https://instrumentationtools.com/instrumentation-and-control-design/ 1/38
Typical Structure of Design Basis

What is Inter Discipline Check (IDC)?
X of Instrumentation & Control Instrumentation and Control (I&C) General
X
Specifications… INSTRU MEN TATIO N DE SIGN

List of Codes, Standards, and Regulatory Requirements
I NS T R UM E NTAT I ON DE SI GN
General Specification is a deliverable prepared by
Inter Discipline Check (IDC) is an activity done by Design
Standards:
Engineers in Plant Design Companies. IDC is performed
Instrumentation and Control (I&C) Engineers to define
minimum requirements for designing Instru…
to ensure that the design and enginee…
Codes:
Statutory & Regulatory Requirements:
Statutory Requirement:
Regulatory Requirement:
Units of Measurement
Control System Philosophy
Mode of Plant Operation
Centralized
Dedicated
Type of Plant
Type of System Hardware Configuration
Simplex
Redundant
Remote I/O Requirement
The scan time requirement of the system
Type of Engineering Console Design
Package Control System Philosophy
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Package control by
X
Instrumentation and Control (I&C) General
X

Type of package configuration
Engineers in PlantType
Designof communication
Companies. between
IDC is performed DCS and package control panel
Power Supply & Instrument Air Supply Philosophy
Power Supply Requirements:
Instrument Air Requirements:
Basic Requirements Related to Field Instruments and Cables
Signal Types
Power supply
Ingress Protection
Painting & Coating Requirement
Flange Ratings
Basic Requirements Related to Installation & Related Items
Type of mounting style of transmitter
Instrument Cable Entry Type
Instrument cable tray spacing requirement
Spare Philosophy
2 Years Operation and Maintenance Spare
Startup and Commissioning Spare (As required)
Consumable Spare (for specified duration, e.g. 6 months or 12 months)
$ a d k h J y %
Mandatory Spare
X
X

Recommended Spare
Engineers in PlantSpares relatedIDC
Design Companies. toiscontrol
performed system
Design Basis is considered as a mother document for all the engineering activities or deliverables to be
carried out in a particular project.
Instrumentation and Control Design
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X X
What is Inter Discipline Check (IDC)? Instrumentation and Control (I&C) General
We will first understand the inputs required to prepare this document.
$ a d k h J y %
Inputs Required
X
X

Below
Inter listed
Discipline references
Check aredone
(IDC) is an activity thebyrequired
Design inputs for the preparation of the document
General Specification“Instrumentation &
is a deliverable prepared by
Control
to ensure thatDesign
the designBasis”.
and enginee…
Client’s Specification / Philosophy

Electrical Hazardous Area Layout – Process Package
Basic Engineering Design Data
Now let’s discuss the typical structure of the document.
Typical Structure of Design Basis of Instrumentation & Control
Instrumentation & Control Design Basis should cover below listed technical requirements as a minimum.
1. List of Codes, Standards, and Regulatory Requirements
2. Units of Measurements
3. Control System Philosophy
4. Package Control System Philosophy

$ a d k h J y %
5. Power Supply & Instrument Air Supply

X
Philosophy Instrumentation and Control (I&C) General
X

6. Hazardous Area Classification Requirements Instrumentation and Control (I&C) Engineers to define
7. Basic Requirements Related to Field Instruments and Cables
8. Basic Requirements Related to Installation & Related Items
9. Spare Philosophy
In this article, we shall talk about the first THREE points in detail.
List of Codes, Standards, and Regulatory Requirements

Standards:
Standard can define as a set of technical definitions and guidelines for designers and manufacturers. It
provides all the necessary information/requirements for the product, service, and operation.
Written by the public organization or by the government body.
Examples: ANSI, API, ASTM, ISO, IEC, ISA, etc.

$ a d k h J y %
Codes:
X
X

Code
Inter can Check
Discipline define
(IDC)as accepted
is an activity done general
by Design guidelines which use for design, fabrication, construction, and
installation
to of equipment/instruments.
ensure that the design and enginee…
Written by Government or Government approved body.
Examples: ASME Boiler and Pressure Vessel Code, BS, DIN, etc.
Statutory & Regulatory Requirements:

Statutory Requirement:
Laws passed by a state and/or central government.
Regulatory Requirement:
The rule issued by a regulatory body appointed by a state and/or central government.”
Units of Measurement
System for measuring unit either “Metric” or “Imperial” should be clearly identified in the I&C design basis
$with respect to the system follows in a country where plant to be build or asaper drequirement J y in %
k h specified
the client’s specification/philosophy. X

X

“Metric” system is generally preferred all over the world for units of measurement except
Instrumentation and Control the USA where
(I&C) Engineers to define
the “Imperial” system is being followed.
Below is a sample illustration of Units. Quantum of details is change subject to the type of process
variables to be measured.
$ a d k h J y %
X X
Control System Philosophy
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I&C design basis should cover the below-listed

X
details/requirements as applicable for the control
X
Specifications…
systems.
INSTRU MEN TATIO N DE SIGN

Mode of Plant Operation
Centralized
For all process units

For offsites
For utilities
Above all
Dedicated
For each process units

For offsites
For utilities
Above all
Type of Plant
Grassroot
$ a d k h J y %
Expansion / Revamping
X
X

Modification
Engineers inType of Control,
Companies.Monitoring
IDC is performedand Safety System Instrumentation and Control (I&C) Engineers to define
Plant Design
DCS (Distributed Control System)
SIS (Safety Instrument System) > SIL 3 system as per IEC 61511 or as per TUV AK6
FGS (Fire and Gas System) > SIL 3 system as per IEC 61511 or as per TUV AK6
MMS (Machine Monitoring System): For Rotating Package
PLC for mechanical packages/small-process units
Type of Controller Architecture (For Safety System – SIS and FGS)
DMR (Dual modular redundancy): Mostly preferred
TMR (Triple modular redundancy): Preferred for critical plants (Oil & Gas)
QMR (Quadruple Modular redundancy): Not preferred due to high cost
Type of System Hardware Configuration

Simplex
Single processor, Single Power Supply, Single I/O card
Redundant
$Redundant Processor, Redundant power supply and redundant I/O cards a d k h J y %
Remote I/O Requirement

X
X

Generally
Inter preferred
Discipline Check (IDC) is anfor MCC/VFD
activity signal interface,
done by Design where the distance between electrical sub-station
building
to ensure that or Instrument
the design and enginee…equipment room is more.
The scan time requirement of the system

As per the client’s specification/philosophy. Generally, scan time is specifically requested for SIS (SIL 3)
certified system which is less than 250 msec.
Type of Engineering Console Design
Ergonomic
Non-ergonomic
Auxiliary Console Requirement
Also Read: Instrumentation Guide
Package Control System Philosophy
I&C design basis should cover the below listed details/requirements as applicable for the package control
$system. a d k h J y %
Package control by
X
X

Plant
Inter Discipline Checkmain
(IDC) isDCS anddone
an activity SISby Design General Specification is a deliverable prepared by
PLC
to ensure that the /design
other andcontrol
enginee… system (Supplied by package vendor) minimum requirements for designing Instru…
Type of package configuration

Package skid with dedicated local control panel
Package skid with junction boxes and without dedicated local control panel
Package skid without junction box and local control panel
Type of communication between DCS and package control panel

Hardwired Interface
Serial communication (e.g. Modbus RS 485, 232, Modbus TCP/IP)
Power Supply & Instrument Air Supply Philosophy
Power Supply Requirements:

Below is a sample illustration to specify the power supply requirement for type of Instruments and control
system. Specific requirement if specified in client’s specification/philosophy then same to be covered in
I&C design basis.
$ a d k h J y %
X X
$Instrument Air Requirements: a d k h J y %

Requirements are generally specifiedX in input document “Process design

basis”. Which shall be
X

basis/reference
I NS T R UM E NTAT I ON DE SIfor
GN Instrument manufacturers (e.g. Control & On-off valve), Mechanical package supplier
and other
Engineers in Plantpneumatically
Design Companies. IDC operated
is performedfield Instruments. Instrumentation and Control (I&C) Engineers to define
Generally Instrument dry air of 5.0 kg/cm2(g) is source of pneumatic power to all the pneumatically
operated Instruments. However all pneumatic Instruments should be designed to worked at minimum
Instrument air pressure as specified in I&C design basis.
Instrument air quality should be in accordance with ANSI/ISA-7.0.01.
$ a d k h J y %
X X
Preferred method of Instrument to be specified either “Intrinsic safe (Ex ia)” or “Flameproof (Ex d)” as per
the requirements.
Generally 2 wire instruments are Intrinsically safe if required to be used in hazardous area. Preferred
method of protection for 4 wire instruments and solenoid valves are generally Flameproof (Ex ”d”).
$Basic Requirements Related to Field Instruments and Cables

a d k h J y %
Field Instruments: I&C design basis covers

X below listed technical detailsInstrumentation
as minimum, and Control (I&C) General
X

Standard for representation of
field Instruments and control in P&ID diagram
Instrumentation in accordance
and Control (I&C) Engineersto ISA
to define
S5.1, S5.2 and S5.3.
Accuracy for all measuring instruments should be specified clearly in design basis with reference to
requirement specified in client’s specification. If accuracy requirement are not specified in client’s
specification then same to be considered as per standard engineering practices.
Signal Types
Analog Signals (4 to 20 mA, HART)
Digital Signals
Digital input signals (either pot free or inductive proximity signal)
Digital output signals (either pot free or Voltage power signal)
Pot free contact shall always wired through relay
Frequency Signals (Speed monitoring)
Serial communication signals
Power supply
Generally all electronics instruments are 2 wire loop powered, which is powered by connecting
$ control system. a d k h J y %
Except 4 wire instruments andX in some cases solenoid valves, transmitters

which required separate
X
Specifications…
power supply arrangement.

Engineers inSome applications may use 3 wire instruments like HC and H2S gas detectors, etc. (I&C) Engineers to define
Instrumentation and Control
Plant Design Companies. IDC is performed
Ingress Protection
For outdoor application: Instruments, Junction box and local panel generally specified with
minimum Ingress protection of IP65 in accordance with IEC 60529 standard.
For Indoor application: System/Marshalling panels required minimum IP23 in accordance with IEC
60529 standard.
Wetted part material of field Instrument
General guideline to use common wetted part material for field instruments is specified in client’s
specification/philosophy.
Generally, minimum SS316 is specified as requirement.
Special requirement if any should be specified
NACE (For sour service)
IBR (For steam application)
Painting & Coating Requirement
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Instruments shall be suitable

X to use in project environmentalInstrumentation
condition specified in the project
and Control (I&C) General
X
Specifications…
specifications.

Engineers in PlantGenerally document
Design Companies. “Specification
IDC is performed for Painting & Coating” reference is and
Instrumentation mentioned
Control (I&C) in I&C design
Engineers to define
basis to cover the requirement. Which is prepared by piping engineering team.
Flange Ratings
Minimum Flange Rating
Requirement as specified in client’s specification regarding minimum flange rating for in-line
/on-line instruments should cover in the I&C design basis.
Orifice flange rating shall be minimum 300#. For above 300#, piping material specification
should be referred.
Control valve flange rating shall be minimum 300# for line size up to 6”. Above 6”, piping
material specification should be referred.
Electrical connection type
Metric Thread (e.g. M20, M25, etc)
NPT Thread (e.g. ½” NPT, 1” NPT, etc)
Basic Requirements Related to Installation & Related Items
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I&C Design basis should clearly specify

X the technical requirements related to Instrument, Junction box,
X

Local control
I NS T R UM panel,
E NTAT I ON DE SI GN Cable trays, Instrument cable as per guidelines provided in client’s specification /
philosophy.
Type of mounting style of transmitter

Remote mount
Direct mount
Close coupled assembly
Instrument manifold requirement (2 way, 3 way or 5 way)
Pneumatic tubing size & Material (Generally stainless steel tube and size of ¼” OD used. ¾” or ½”
may use for Pneumatically powered Instruments like, control valve / on-off valve.)
Cable routing philosophy
Under ground (duct / tranches)
Above ground (Perforated trays / Ladder Trays / Cable conduits)
Process connection for all In-line field instrument generally flanged type as per ANSI B16.5 and
B16.47 in accordance with the piping specifications.
Instrument Cable Entry Type
$ a d k h J y %
X X
Instrument cable tray spacing requirement
Generally 12” Spacing between Instrument signal cable and Power cable should be maintain or as
per guidelines specified in client’s specifications.
Spare Philosophy
Spares are to be classified as per their requirement and application as below,
2 Years Operation and Maintenance Spare

$ a d k h J y %
Type and quantity of spare always

X recommended by supplier. Instrumentation and Control (I&C) General
X

Startup and Commissioning Spare (As required)
Required to replace damaged parts/component cause during installation or commissioning phase

of project to avoid delay in activity.
Type and quantity of spare always recommended by supplier.
Consumable Spare (for specified duration, e.g. 6 months or 12 months)
Type and quantity of spare always recommended by supplier.
Mandatory Spare
Type and quantity of spare always recommended by supplier as per their past record.
These type of spares always procure by purchaser.
Recommended Spare
Type and quantity of spare always recommended by supplier as per their past record.
These type of spares may or may not procure by purchaser.
$ a d k h J y %
Spares related to control system

X
X

Installed
Inter Spare
Discipline Check (IDC) is an activity done by Design
System Cabinet: XX% of electronic modules (signal conditioning modules, signal distribution
modules, input / output modules etc.) relays, isolators mounted in each cabinet.
Marshalling Cabinet: XX% of terminals.
Multipair Cable: XX% of pairs in each Multipair cable.
Junction Box: XX% of terminals inside each Junction Box.
Spare Space
E.g. Spare space inside system/marshalling cabinet to install additional hardware in future.
Interest to add any further points? Share with us through below comments section.
Author: Kalpit Patel
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6 thoughts on “Instrumentation and Control (I&C) Design”
Suresh
June 16, 2020 at 7:20 am
$ a d k h J y %
X X
Hello inst tools, your team was sharing wonderful technical
I NS T R UM E NTAT I ON DE SI GN information for growing
Specifications… INSTRUengineer’s I’m
MEN TATIO N DE SIGN

really thankful to your team
Reply
Tapash khan
June 16, 2020 at 9:39 am
Thank you
Reply
Shanoob
June 16, 2020 at 3:19 pm
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X X
Thanks for sharing knowledge.
Reply
Pradeep
June 16, 2020 at 9:01 pm
What is the difference between using 110VAC and 230VAC for DCS panels?
Reply
Jatin
September 3, 2020 at 4:33 pm
$ a d k h J y %
X X
Practically no difference. Only the Power supply module model
I NS T R UM E NTAT I ON DE SI GN will Specifications…
differ like 110VAC toTATIO
INSTRU MEN 24VN DE
DC or
SIGN

230V AC to 24V DC.
Reply
Kennedy Mathekela
March 12, 2021 at 11:00 am
quiet informative
Reply
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5/20/22, 8:39 AM Instrumentation and Control (I&C) Design - InstrumentationTools

Inst Tools Menu

Instrumentation and Control Design

Typical Structure of Design Basis

Specifications… INSTRU MEN TATIO N DE SIGN

Specifications… INSTRU MEN TATIO N DE SIGN

Specifications… INSTRU MEN TATIO N DE SIGN

Instrumentation and Control Design

We will first understand the inputs required to prepare this document.

Specifications… INSTRU MEN TATIO N DE SIGN

Client’s Specification / Philosophy

Now let’s discuss the typical structure of the document.

Typical Structure of Design Basis of Instrumentation & Control

1. List of Codes, Standards, and Regulatory Requirements

3. Control System Philosophy

4. Package Control System Philosophy

5. Power Supply & Instrument Air Supply

Specifications… INSTRU MEN TATIO N DE SIGN

7. Basic Requirements Related to Field Instruments and Cables

8. Basic Requirements Related to Installation & Related Items

List of Codes, Standards, and Regulatory Requirements

Written by the public organization or by the government body.

Examples: ANSI, API, ASTM, ISO, IEC, ISA, etc.

Specifications… INSTRU MEN TATIO N DE SIGN

Written by Government or Government approved body.

Statutory & Regulatory Requirements:

Laws passed by a state and/or central government.

the client’s specification/philosophy. X

Specifications… INSTRU MEN TATIO N DE SIGN

Control System Philosophy

I&C design basis should cover the below-listed

General Specification is a deliverable prepared by

For all process units

For each process units

Specifications… INSTRU MEN TATIO N DE SIGN

Type of System Hardware Configuration

Single processor, Single Power Supply, Single I/O card

$Redundant Processor, Redundant power supply and redundant I/O cards a d k h J y %

Remote I/O Requirement

Specifications… INSTRU MEN TATIO N DE SIGN

The scan time requirement of the system

Type of Engineering Console Design

Auxiliary Console Requirement

Also Read: Instrumentation Guide

Package Control System Philosophy

Specifications… INSTRU MEN TATIO N DE SIGN

Type of package configuration

Type of communication between DCS and package control panel

Power Supply & Instrument Air Supply Philosophy

Power Supply Requirements:

$Instrument Air Requirements: a d k h J y %

Requirements are generally specifiedX in input document “Process design

Specifications… INSTRU MEN TATIO N DE SIGN

Instrument air quality should be in accordance with ANSI/ISA-7.0.01.

$Basic Requirements Related to Field Instruments and Cables

Field Instruments: I&C design basis covers

Specifications… INSTRU MEN TATIO N DE SIGN

Except 4 wire instruments andX in some cases solenoid valves, transmitters

General Specification is a deliverable prepared by

Painting & Coating Requirement

Instruments shall be suitable

General Specification is a deliverable prepared by

Basic Requirements Related to Installation & Related Items

Instrumentation and Control (I&C) Design - InstrumentationTools

Instrumentation and Control (I&C) Design - InstrumentationTools