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Icm 100
Icm 100
Abstract
This section discusses the major phases of the design of instrumentation and control
systems. It references other sections of the manual for detailed information on
each aspect of the design process. It presents the overall picture of how the many
components of an instrumentation design develop, from job scope to turnover to
Operations.
Chevron Corporation
Contents
Page
110
Introduction
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120
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121
122
123
124
125
130
131
132
Design Specifications
133
Specification of Instrumentation
134
Documentation
135
Instrumentation Database
140
141
142
Commissioning
143
System Startup
144
Closing Documentation
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110 Introduction
The Instrumentation and Control Manual is intended to help engineers and
designers design, construct, start up, and maintain typical Company instrumentation
systems. It is intended to be used as a guide, with the understanding that no guide
can replace sound engineering judgement.
This section introduces the many aspects and procedures involved in designing an
instrumentation system. Whether designing a small field job or a large facility, the
elements of system design are similar.
Protecting People and the Environment is a cornerstone of how Chevron does business, and must become an integral part of the design of any Chevron facility.
With this commitment firmly in mind, a structured approach to defining, designing,
and implementing a control system must be used to ensure success.
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Chevron Corporation
Chevron Corporation
System Architecture - what will be the defined and potential data transfer links
to other control systems? To control and/or monitoring computers? To a
Management Information system?
Control Architecture - how much of the control will be done by the systems
front end? Will there be advanced control such as DMC? Will there be a separate computer for advanced control?
Environmental - what is the Area Classification for the plant and for field sites
where controls will be located? For the area where operator interfaces will be
located? What are the measurable airborne contaminants for these locations?
Operator Interface - does the operator see the process via a CRT, an array of
controller faceplates, or field indicating controllers? Or via a combination of
two or three of these methods?
Operability - can the process be manually controlled in the field using a manual
bypass around the regulating valve? Will there be field operators to perform
this function when required?
Reliability - what is the minimum acceptable operating factor for the control
system? What is the economic incentive for increasing reliability by a defined
percentage?
Failure Modes - what will be the status of the control system if individual
instruments fail? Do all failures result in the control system going to (or tending
to) the defined Fail-Safe condition of control valves and drives?
Cutover Plans - for reinstrumentation projects, the plan for cutting over from
existing to new instrumentation should be a part of the control design process.
Hot cutovers are typically more labor intensive than conversion en masse
during a planned shutdown; however, most plants opt for the hot cutover, since
it allows a more gradual conversion, and results in one less unknown during a
plant startup.
Urban Renewal - the amount of re-engineering of existing facilities (reverification of the suitability of reused field instrumentation such as orifice plates
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and control valves) needs to be determined at the initial design phase. This
process is labor intensive if done properly - process conditions need to be field
verified.
Transmitters
Smart process variable transmitters should also be considered as the default standard. These instruments offer higher accuracy and reliability than their electronic or
pneumatic analog counterparts, and add the bonus of remote diagnostic data acquisition and calibration checking.
Control Valves
Smart control valves are an emerging technology which offers extensive valve and
process diagnostics, using the valve positioner - actuator as a sensor, or using pressure and temperature sensors embedded in the control valve body, or a combination
of both. This technology should be considered on installations where maintenance
access to control valves and drives is restricted.
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Chevron Corporation
Field Communications
Communications between Smart field instrumentation (transmitters and/or valves)
and the control room are typically done over the same twisted pair of wires carrying
the transmitter output or valve positioner input signal. Communications protocols
range from vendor proprietary systems such as Honeywell DE- 6 Byte to multivendor open systems such as HART.
The Fieldbus communications protocol, which is being developed by an international consortium of instrument manufacturers, will offer the ability to link field
instrumentation (transmitters, controllers, field indicators, valve positioners, and
auxiliaries) on a multidrop power - communications wire pair. Control functions
(algorithm execution) will be downloaded to the lowest possible tier of the system
architecture, freeing up higher level computation capacity for running advanced
control strategies.
Intrinsic Safety
Intrinsically Safe (I. S.) construction is intended to prevent sources of ignition (electric sparks) in Hazardous Areas by limiting the transmission of power from nonHazardous areas and by limiting the storage of energy in field devices.
Use of I.S. construction permits opening field enclosures (including transmitter and
valve positioner housings) without first powering down circuits or sniffing the area
to verify the absence of flammable mixtures.
There is no necessary correlation between I. S. construction and Hazardous Area
Classification ratings nor between I. S. construction and Explosion-proof housing
construction.
Because Intrinsically Safe construction severely limits the voltage and current
which can be transmitted into Hazardous Areas, special attention must be given to
limiting the number and type of field devices which cause voltage drops, and to the
quality of field terminations. (Corrosion on field terminals can cause indeterminate
voltage drops on current loops.)
Final determination of whether this level of protection is appropriate for an installation should be made only after an extensive review of local Electrical and Safety
Codes.
The use of Smart field instrumentation, which permits communications from a
non-Hazardous area, has diminished the use of Intrinsically Safe instrumentation
systems in domestic petrochemical installations.
Chevron Corporation
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System Maturity - reject sunset technology unless youre fitting in the last
piece of a multi-phase control replacement project. Recognize that even though
a manufacturer is legally bound to provide spare parts support for a limited
period of time following obsolescence of a product, he has limited control over
keeping competent engineers in a support function on an obsolete system.
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Chevron Corporation
System Engineering - include an estimate of the cost of documentation, configuration, and commissioning services.
Systems Integrators
In a similar fashion, systems integrators and packaged systems suppliers must be
provided with Chevron or plant specifications stating minimum requirements for
controls which they provide, integration with other systems, documentation and all
other information normally supplied by vendors of non-packaged instrumentation.
Chevron Corporation
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134 Documentation
A system designed in-house by Chevron, or designed by an engineering contractor,
or designed and built by a system integrator/packaged systems supplier generally
includes complete documentation for design, construction, operation and maintenance. These documents will usually satisfy the Federal and/or local safety and
health legal compliance requirements for critical instrumentation.
The following should be considered as minimum documentation requirements for
control systems installations:
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Plot Plans & Elevations, showing location of and access to major equipment
and critical instrumentation.
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Chevron Corporation
Process Flow Diagrams, showing flow rates and conditions of pressure, temperature and chemical composition for all streams in the plant.
Process Control Diagrams, showing the configuration of front-end control strategies, as determined by the Control Objectives Analysis (COA), and verified by
the Control Designs Analysis (CDA).
Vessel Drawings, showing the elevation and orientation of nozzles and the
maximum, normal, and minimum levels of product and/or interfaces within the
vessel. (These are required for designing instrumentation bridles and ordering
level instruments.)
The vessel drawing shall also tabulate the following data for each level instrument connected to the vessel.
Type of instrument
Alarm setpoints
Specific gravity of process fluid(s)
Specific gravity of seal or capillary fluid
Instrument span with calculations
Zero suppression or elevation
Chevron Corporation
Orifice Data Sheets, detailing flowing conditions for all orifice flowmeters.
These data should be supplied by Process Engineers familiar with the plant of
similar processes. Inaccurate process data will come back to haunt ALL engineering disciplines.
Junction Box Wiring Diagrams, showing the layout of termination strips and
their connection to Main or Branch cables or to field wiring.
Cable Schedules, listing the cables and pairs (or conductors) used for interconnection of instrumentation components. (In some cases, these may be combined
with Junction Box drawings described above.)
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Configuration Forms, describing the software or firmware (or both) used for
creating Control Strategies, Operator Displays, and Reports.
Design Reviews
Periodic reviews of project design documentation ensures that costly rework or reordering of material is eliminated. The frequency of these design reviews is best determined by the Project Management team, to which the Control Engineer reports.
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Chevron Corporation
142 Commissioning
The commissioning process consists of verifying the proper installation, connection, and calibration of all instrumentation items on the Project.
Specification ICM-MS-1586, Instrument Commissioning, is a guide for preparing
newly installed instrumentation prior to plant startup. It describes the contractors
responsibility for inspecting, checking, adjusting, and calibrating the instrumentation and documenting all of the work for approval by the Company.
Recent trends in instrumentation have eased the burden of the Commissioning
process:
Most Smart process transmitters can be interrogated from the control console
or from termination panels in the rack room, to verify that the right transmitter is connected to the right terminations. (Forcing the transmitter to identify itself by Tag Number is a technique for electronically ringing out a
transmitter installation.)
The accuracy of digital electronic transmitters far exceeds that of field test
equipment, and digital transmitters show no tendency to drift. Therefore, shop
or field calibration of transmitters becomes superfluous. Instruments can move
directly from the Tally Room to the installation site.
All instrument installations should be signed off by the installer, the instrument
inspector, and an Operator. OSHA regulations (29 CFR 1910) require that Critical
instrumentation be installed and inspected by qualified workers.
Chevron Corporation
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Chevron Corporation