Upload
dalver17
View
31
Download
10
Embed Size (px)
Citation preview
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
An Introduction to ISA Technical Training
Mini Course Series
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
An Introduction to Developing & Applying Standard Instrumentation & Control Documentation (FG15)
FG15WS, Version 1.0© 2011
Seminar Logistics
• Seminar materials– Downloadable presentation– Question and Answer session (audio and email)– Survey– Earn 1 Professional Development Hour (PDH)
• Seminar length– 60 minute presentation– Three 10-minute question and answer sessions
Introduction of Presenter
Alex Habib, PE
• Alex Habib, PE is a Licensed Professional Automation and Control Engineer with over 19 years of experience in automating and modernizing: specialty chemicals, food, flavors, pharmaceutical, biotech , Oil Refinery plants and research facilities.
• Alex worked on projects at: Hoffmann La Roche, Givaudan Flavors, IFF, Merck, Pfizer, Rhone-Poulenc (now Sanofi Aventis and Rhodia), Conoco-Phillips, and Olin Chemicals. Alex also worked for engineering consulting firms and system integrators such as Jacobs Engineering, and Invensys.
• Alex earned his Masters of Science in Electrical Engineering (MSEE) from Fairleigh Dickenson University in Teaneck, NJ.
Introduction of Presenter – Cont’d
Alex Habib, PE
ISA Roles, Offices and Responsibilities
Director of The Food and Pharmaceutical Division (FPID)
President and Web master of the Central NJ section
Chairman of ISA 5.6 “Control Software Functional Requirement Documentation”
Standards Committee
ISA Instructor
Alex Can be contacted at:
732-742-7913
Key Benefits of This Webinar
• This Webinar will present the requirements, methodology, and benefits for the developing, reading, and interpreting control systems documentation.
• The development of piping and instrument diagrams (P&IDs) and related ISAdrawings are emphasized.
• This Webinar covers the benefits of developing the Functional Requirement Specification (FRS) of control software for PLC’s, DCS’s & SCADA systems
• Attending this Webinar is beneficial to automation , process engineers, control software programmers, system integrators, and instrument technicians.
Conceptual Engineering
Detailed Design & Construction
Automation Software
ISA & Other related Standards
Documentation Requirements
Conceptual Engineering
Detailed Design & Construction
Automation Software
ISA & Other related Standards
Documentation Requirements
Conceptual Engineering Documentation
• PFD’s
• P&IDs
The Process Flow Diagram (PFD)
• The purpose of the PFD is to define the design of the
process
• It is a project scope definition tool.
• Conversion of raw materials into finished products
• It shows material and energy balances
• It Gives insight into the cost & long delivery Items
• The PFD should have enough information to start
development of the P&ID
Typical Process Flow Diagram (PFD)
STREAMNUMBER FLOW
10,000#/Hr
1000#/Hr
9,000#/Hr
DESCRIPTION
WET GAS
DEGASSED MATERIAL
LIGHT ENDS TO FLARE
PRESSURE
20 psi
50 psi
4 psi
SP GRAVITY
–
.9 AT 60 F
–
TEMP
90 -180 F
70 -170 F
80 -140 F
1
2
3
G-005
ISA COURSE FG15
PROCESS FLOW DIAGRAM
DRG# PFD-1
PLANT 001KNOCKOUT DRUM D-001
2
1
3
TO SEPARATOR
TO FLARE
D-001
P&ID Development
• Developed by many disciplines• An interactive process• Several revisions
Process EquipmentVessels
PipingElectrical InstrumentationHazardous Operations
Typical P&ID
P&ID Development (cont’d)
• The P&IDs “show the interconnection of process equipment and the instrumentation used to control the process.”
• P&ID is covered by ISA-5.1 which defines instrument symbolism
• In some states, P&IDs carry Professional Engineers’ stamps.
• Typical P&ID drawing issues may include:– A – Issue for scope definition– B – Issue for client approval– C – Issue for bid; bidding of major or “long lead” equipment– D – Issue for detailed design– 0, 1, 2, 3 etc. – Issue for construction
Review of Key Points – The Role of P&IDs in Project Success
• P&IDs symbolically depict and include information on all of the process equipment, piping, and automation components involved with the particular process.
• P&IDs, together with a written scope of work, define a project and form the basis for all subsequent detailed I&C design documents.
• P&IDs also form the basis for all subsequent detailed piping and process equipment design documents.
• P&IDs are the road map to explain the overall process and the control systems that are involved
Live Question and Answer Session
Conceptual Engineering
Detailed Design & Construction
Automation Software
ISA & Other related Standards
Documentation Requirements
Detailed Design & Construction Documentation
• Instrument Lists
• Instrument Specification forms
• Installation Details
• Location Plans
• Loop Diagrams
Instrument Indexes and Databases
• The instrument Index should include all the tag-marked devices from the P&ID
• If something has to be purchased and then mounted, wired, tubed or calibrated, then it should appear in the instrument index.
• Instrument Databases Boost Efficiency- were able to prepare and manipulate data with relative ease
• Instrument databases contain information to produce maintenance schedules, calibration records, Loop Diagrams, and configuration files for the process control computer.
Instrument Specification Forms
• Specification forms, or data sheets, define the tag-marked devices that make up a control system
• The form contains information necessary to secure vendor quotes and to purchase devices
• Provide application information for instrument, including:– Operating conditions, construction requirements, range of
measurement, calibration– Tagging/identification, manufacturer model and part numbers
Installation Details
• An installation detail depicts the installation of a single instrument
• Installation details show where the instrument connection will be made on the piping, tank, vessel, and the relative position to the process connection and to the floor
• Libraries of installation details are established and maintained by many plant owners
• Installation details typically include bills of material lists
• Exact tubing lengths are not normally provided, since the required lengths will vary.
Location Plans
• Location plans are orthographic drawings that show where control system components are to be installed
• Location plans show the field control system components—the transmitters, control valves, transducers, local panels, junction boxes, termination points for field I/O, etc.
• The plan shows the devices connecting to an instrument air supply
• The location plan uses the plant identification grid and rows and columns
Loop Diagrams
• A schematic representation of a complete hydraulic, electric, magnetic or pneumatic circuit.”
• Loop Diagrams will depict only one loop; measurement of a single process variable, a control action, and manipulation of the process, or some combination of the three.
• The Loop Diagram provides termination information including junction box identifiers, terminal strip numbers, terminal block numbers.
• Loop Diagrams are typically ASME B size (11" x 17) drawings.
Typical Loop Diagram
Review of Key Points : Detailed Design Documentation
• Instrument Lists
• Instrument Specification forms
• Installation Details
• Location Plans
• Loop Diagrams
Live Question and Answer Session
Conceptual Engineering
Detailed Design & Construction
Automation Software
ISA & Other related Standards
Documentation Requirements
G A M P (Good Automated Manufacturing Practice)
FUNCTIONALREQUIREMENTSPECIFICATION
( FRS)
DETAILEDDESIGN
SPECIFICATION(DDS)
BUILD SYSTEMAND FACTORY ACCEPTANCE
TESTING (FAT)
CONTINUITY &LOOP CHECK-OUT
OPERATIONALTESTING &SITEACCEPTANCE
(SAT)
USERREQUIREMENTSPECIFICATION
(URS)
SYSTEM START-UPAND COMMISSIONING
RELATED TO
RELATED TO
RELATED TO
Process & InstrumentationDiagram (P&ID)
Database
InterlockMatrix H M ISequence
Matrix
Application Program(Source Code)
User Requirement
PlantAutomation Model
Instrument Index
ISA- 5.6
validation
ProcessNarrative I/O list
Control System Documentation Life Cycle
Data Base
Interlock Matrix
Sequence Matrix
Human Machine Interface
Software Definition Components
STORAGE
UTILITIES
STORAGE
PACKAGING
Gas Waste Treatment
Liquid & Solids Waste Treatment
A B C D ETrainProcess Unit Classes
Discharge
Discharge
RawMaterial
ProductShipping
Drying
Drying
Drying
Drying
Distillation
Distillation
Distillation
Centrifuging
Centrifuging
Reaction
Reaction
Reaction
Reaction
Blending
Blending
Data BaseInterlock MatrixSequence MatrixH M I
Data BaseInterlock MatrixSequence MatrixH M I
Data BaseInterlock MatrixSequence MatrixH M I
Data BaseInterlock MatrixSequence MatrixH M I
1
2
3
4
Blending
Centrifuging
Centrifuging
5
Plant Automation Model (Example)
Basic Point DataTag Location
Man / Machine Interface DataScales Descriptor Keywords
Operating Data DataAlarm Type Controllers
Change ControlDescription Date By
I/O Interface DataPoint Type Signal Type I/O Address
Data Logging & Archival
P & I D
Device Type I/O Type
Eng. Units
SetpointFunctionPriority
OutputDirection Type Modes Action
Data Base
Interlock Matrix (Example)
Interlock Matrix (Example)
OPERATIONS PREPARATION REACTION TRANSFER SHUT CHANGE CONTROL PHASES INITIAL FILL HEAT CURE DUMP DOWN
CONTROL DEVICE (1) (2) (3) (4) (5) (6) DESCRIPTION DATE BYTAGS DESCRIPTION
DISCRETE XV-1 INLET VALVE CLOSED OPEN (3) CLOSE CLOSE CLOSE (2) CLOSEN CONTROL XV-2 OUTLET VALVE CLOSED CLOSE (2) CLOSE CLOSE OPEN (3) CLOSEO DEVICES HS-1 AGITATOR STOPPED STOP (1) RUN RUN STOP (1) STOPR ANALOG TIC-1 BATCH TEMP. RAMP SP: SP= 60 FM DEVICES 2 Deg/min
A START OF PHASE CONDITIONS PV OFL TIC-1 = RP1
IF LI-1 < 1% PV OF WAITAND TIC-1 = RP1 TIME=RP2
END OF PHASE CONDIT IONS OPERATOR LI-1=>90% (SEE RECIPE HOURS LI-1=<1%S START M ATRIX) (SEE RECIPE
E BATCH M ATRIX)
Q ALLOWABLE PHASE TRANSITIONS TO PHASE 2 TO PHASE 1 &3 TO PHASE 4 TO PHASE 5 & 3 TO PHASE 1 TO PAHSE 1U OPERATOR START ENTER ENTER PHASEE MESSAGES NEW SP. OF DURATIONN BATCH ?? TIC-1 TIMEC PHASE PHASE TEMP. PHASEE BATCH REPORT DURATION DURATION AT END DURATION
VARIABLES OF PHASE
F A I L U R E S E Q U E N C E
R E C I P E S
Sequence Example (Normal Sequence)
N O R M A L S E Q U E N C E
OPERATIONS PREPARATION REACTION TRANSFER SHUT CHANGE CONTROL PHASES INITIAL FILL HEAT CURE DUMP DOWN
CONTROL DEVICE (1) (2) (3) (4) (5) (6) DESCRIPTION DATE BYTAGS DESCRIPTION
XV-1F C DISCRETE XV-2 OPEN OPENA O CONTROL HS-1 STOPI N DEVICESL DU I ANALOG TIC-1 IF >140 FR T DEVICESE I
O LI-1 > 1%S NE S ELAPSED IF >30 min IF >1 hr IF >30 minQ TIME FAIL PHASE FAIL PHASE FAIL PHASEU DO NOT STOP HS-1E PROCEED CLOSE XV-1 AND CLOSE XV-2N FAILURE ACTIONS TO FILLING SET TIC=60F SET TIC=60FC PHASEE OPERATOR MESSAGES EMPTY REACTOR CHECK XV-2 CHECK HS-1 RECOVERY AFTER RESTART RESUME GO TO RESTART RESUME
FAILURE PHASE PHASE SHUT-DOWN PHASE PHASE
R E C I P E S
Batch Sequence Example(Failure Sequence / Exception Handling)
Control Valve
Motor
M
MI/B
XM-601
M
I/B O/C
RS
XV-501
Auto / Manual
Auto / Manual
Interlock/Bypass
Interlock/Bypass
Show only on failure
Green Red Yellow BlinkingYellow
Open Close Travel Failure
Green Red BlinkingYellow
Run Stop Failure
Graphic Elements (Example)
I #
1
32
4
5
6
7
AgitatorAg-1
OutletpumpXM-1
SteamValveTV-1
Initiating Devices
Low Rx level ( <15%)
High Rx Temp.( > 200F)
AR AR
R
AR = AUTOMATIC RESETR= MANUAL RESET Common Alarm
Interlock Diagnostic Display (Example)
Operator Message
InitialFillHeatCureDumpShutdown
Parameter Actual Target
Recipe # A
Modes of operationAutomaticSemi-automaticManual
Start PhaseStop Phase
Phases:
Phase Progress
Start SequenceStop Sequence
Catalyst Volume 450 Gal. 500 Gal.
Operation: Reaction
Common Alarm
Sequence Display (Example)
Review of Key Points
The documentation resulting from use of ISA-5.6 Standard:
• Can be used for control software definition, design, testing and validation.
• Is not intended to require specialized knowledge of any particular engineering or computer science discipline to develop or understand.
Conceptual Engineering
Detailed Design & Construction
Automation Software
ISA & Other related Standards
Documentation Requirements
ISA Standards Referenced in this Webinar
• ANSI/ISA5.1-2009, Instrumentation Symbols and Identification
• ANSI/ISA5.4-1991, Instrument Loop Diagrams
• ISA-5.6-2009, Software Documentation for Control Systems
• ANSI/ISA20-1981, Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves
• ISA-dRP5.07.01 Piping and Instrumentation Diagram Documentation Criteria (in development)
The Role of Standards and Regulations
• Mandatory Standards:
– Food and Drug Administration (FDA)– National Fire Protection Association (NFPA)– Occupational Safety and Health Administration (OSHA)
• Consensus Standards:
– The International Society of Automation (ISA)– Process Industry Practices (PIP)
Summary
• Conceptual Engineering
• Detailed Design & Construction
• Automation Software Requirement
• ISA & Other related Standards
Live Question and Answer Session
Related Courses from ISA
• Developing & Applying Standard Instrumentation & Control Documentation– Course No.: FG15– Length: 2 days– CEU Credits: 1.4
• Introduction to Industrial Automation and Control (FG07)
All ISA courses are available any time as on-site trainingFor more information: www.isa.org/training or (919) 549-8411
Upcoming offerings for this course (FG-15)
02/07/2012 Pickwick Gardens Conference Center By SodexhoBurbank, CA US
03/29/2012MAVERICK TechnologiesColumbia, IL US
05/16/2012County College of Morris At Headquarters PlazaMorristown, NJ US
ISA Membership
• ISA Membership is just $100 per year, which includes free membership in two Technical Divisions (a $20 value) - one from each Department: Automation and Technology and Industries and Sciences.
• Plus, member discounts on training !
– For more information: http://www.isa.org/membership/meminfo or (919) 549-8411
Zoomerang Web Seminar Survey
Please do not forget to complete this program survey,which will be sent to you following the seminar.
Contacts
• Alex Habib, PE732-742-7913
• International Society of Automation (ISA):PO Box 12277, 67 Alexander DriveResearch Triangle Park, NC 27709HQ: 919-549-8411919-549-8411 Faxhttp://www.isa.org