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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

[email protected]

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 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



Automation Software



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



Automation Software



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




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)

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.



Automation Software



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

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

http://www.isa.org/membership/meminfo

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

[email protected]

• International Society of Automation (ISA):PO Box 12277, 67 Alexander DriveResearch Triangle Park, NC 27709HQ: 919-549-8411919-549-8411 Faxhttp://www.isa.org

mailto:[email protected]

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