INSTRUMENT DESIGN INSTALLATION & MAINTENANCE

DESCRIPTION

Control techniques are discussed, and interface methods between instrumentation and the control system is discussed. System design, including details of the various types of instrument related drawings, is covered extensively. Instrument Data Sheets are covered, including the reasons for each of the fields in the sheets. Important items to consider when developing contracts for design, installation, calibration and maintenance of instrumentation systems, are discussed. Recommendations, based on the instructor’s experiences, will be presented for discussion. Pre-Instruction Exercises, daily written exercises, and a Post-Instruction Exercise, will be used to monitor if the information is being presented effectively.

OUTLINE

Introduction of presenter and attendees
Pre instruction exercise
Outline of the course

1. Introduction of concepts, Definitions
2. Tank Example, Manual Control, Feedback, Deadtime
3. Involvement of Process Eng, Instrument Eng, Mech. Eng, Project Eng
4. Types of Process Measurements
5. Technologies of Measurement
6. Control Devices are also involved in instrumentation
7. Importance of Documentation, Design and As Built
8. Types of Documentation
9. Installation and Calibration of Instruments and Systems
10. Maintenance of Instrument and Control Systems
11. Control Systems, Safety Shutdown Systems, Fire and Gas Systems

Process Measurements for control – various process equipment considered
Technologies available for instrumentation, advantages and disadvantages
Isolation of instrument from process and environment – Standards
Communication between instrument (or valve) and Control System – Protocols
Advantages of Digital Communication – Asset Management
Distributed Control Systems and Control Rooms
Control Valves, Pressure Safety Valves, Shut Down Valves and monitoring them
The Design Process

1. Project Eng, Process Eng, Mgmt – Process Flow Drawing – Symbols
2. Process Eng, Instrument Eng, Mech. Eng – P&ID
3. Symbols Used
4. HAZOP
5. SIL Evaluation
6. Corporate Standards – Basis of Instrument Selection
7. Instrumentation Index
8. Instrument Data Sheets
9. Installation Drawings
10. Instrument Location Drawings
11. Wiring Drawings
12. Panel Layout and Connection Drawings
13. Loop Diagrams
14. Logic Diagrams
15. Squad Checks and Sign Offs

Document Control and Management of Change
Instrument Purchase and Receiving
Installation of Instruments
Calibration, Loop Checkout and Documentation

1. Co-ordination with Electrical Cable Installation
2. Co-ordination with delivery of DCS/SIS/Electric Power

DCS Factory Acceptance Tests, Site Acceptance Tests
SIS Factory Acceptance Tests, Site Acceptance Tests
System Integration Functional Tests
Maintenance schedules for control instrumentation
Maintenance schedules for Safety equipment
Documentation of Incidents – effects on maintenance
Design for maintenance, equipment selection, bypasses
Contract considerations for Installation, Calibration and Maintenance
Post-Instructional Exercise
Discussion and Questions

INSTRUCTOR

Ir. Iyus Rusmana, M.Eng & Team / Tugino, ST, MT & Team