HOW TO REDUCE

INSTRUMENTATION
AND CONTROL SYSTEM
DETAILED ENGINEERING COST
AND COMMISSIONING TIME
(When Package Units need to be Integrated)

Julin
J
li Sez
S
Positive Engineering

Twitter Conference Hashtag: #EMRex

Presenter
ese te

How to Reduce I&C Engineering

g
g Cost

Julin Sez

julian.saez@positiveengineering.com
www positiveengineering com
www.positiveengineering.com

Introduction

How to Reduce I&C Engineering

g
g Cost

Company presentation
P iti E
Positive
Engineering
i
i
Control & Instrumentation Solutions for Process Industry
Detailed Engineering for C&I International Projects
Integration of Package Units with the Rest of the Plant

Introduction

How to Reduce I&C Engineering

g
g Cost

Presenter short biography

Julin Sez (Control and Instrumentation Engineer)
BSc in Electrical Engineering
BSc in Computer Science
MSc in Electronics and Industrial Automation Engineering

General Electric Plastics (3 years)

years), Process Automation
Tcnicas Reunidas (7 years), Control & Instrumentation
CPC Engineering
g
g ((9 yyears),
), Control & Instrumentation
Positive Engineering (1 year), Control & Instrumentation
Lecturer at University of Murcia (7 years), Control Systems

Introduction

How to Reduce I&C Engineering

g
g Cost

Positive Engineering State of Business

Mid 1990s

Early
y 2000s

2011-2016

2005-2010

DCS Programming

DCS HW & SW Spec

Package Unit Integration

C&I Consulting

Loop Test

PLC

Construction Supervision

DCS & ESD Upgrade

Simulation for OTS

Commissioning

Instrumentation

ICSS

Presentation

How to Reduce I&C Engineering Cost

How to Reduce Instrumentation and Control System Detailed

Engineering Cost and Commissioning Time (When Several Package
Units need to be Integrated)
Abstract

This presentation will show tips to reduce Instrumentation and Control System Detailed Engineering cost
and commissioning time in projects where several package units need to be integrated.
One of the main challenges in the development of Detailed Engineering for Instrumentations and Control
Systems is the integration of the controls of different package units.
Typically package unit vendors only look at the controls inside of their battery limit and don
dontt take care or
sometimes overlook important details of the integration of their package units with other package units and
with the rest of the client plant. Also quite often they dont take enough care of the client specifications.
This leads to a lot of misunderstandings and endless hours for clarifications during the detailed
engineering phase.
phase
And typically not all aspects are considered during the detailed engineering phase, so they only appear
during commissioning, when the different package units and the rest of the plant need to work together.

Presentation

How to Reduce I&C Engineering Cost

How to Reduce
I t
Instrumentation
t ti and
dC
Control
t lS
System
t
D
Detailed
t il d E
Engineering
i
i C
Costt
and Commissioning Time
((When Several Package
g Units need to be Integrated)
g
)

Abstract

Agenda

How to Reduce I&C Engineering Cost

Typical Issues in C&I Detailed Engineering when

Package Units are Involved
Consequences of Poor Design
S
Some Best
B t Practices
P ti
for
f Control
C t l System
S t
and
d Field
Fi ld
Wiring Design and Commissioning
Business Results Achieved
Q&A

Typical Issues in C&I Detailed Engineering when Package Units Involved

Package Unit Vendor doesnt differentiate which signals need to

b wired
be
i d to DCS and
d which
hi h signals
i
l need
d to b
be wired
i d to ESD

Typical Issues in C&I Detailed Engineering when Package Units Involved

Correct:

10

Typical Issues in C&I Detailed Engineering when Package Units Involved

Package
P
k
U
Unit
i V
Vendor
d or client
li
d
doesnt
d
define
fi if ESD mushroom
h
is required

11

Typical Issues in C&I Detailed Engineering when Package Units Involved

DCS-ESD Interface: Signals hardwired between controllers

(mainly DCS-ESD) not defined

DCS

ESD

It is necessary to analyze which interlocks are to be programmed in DCS and

which in ESD and where are wired to (DCS or ESD) each of the signals involved
in the interlocks

12

Typical Issues in C&I Detailed Engineering when Package Units Involved

DCS-ESD Interface:
Signals hardwired between controllers
not defined

DCS

ESD

It is necessary to analyze which interlocks are to be programmed in DCS and

which in ESD and where are wired to (DCS or ESD) each of the signals involved
in the interlocks

13

Typical Issues in C&I Detailed Engineering when Package Units Involved

Hardwired signals between MCC and DCS or ESD defined too

late

P&ID 1st rev received from Vendor

P&ID marked by client with MCC signals

14

Typical Issues in C&I Detailed Engineering when Package Units Involved

Package Unit Vendor doesnt follow Client tagnaming criteria for

Control System Signals and wiring design (JBs, Multicables,
TBs...etc).
)

15

Typical Issues in C&I Detailed Engineering when Package Units Involved

Controls and Interlocks poorly represented on Package Unit

Vendor P&ID

Controls and Interlocks poorly defined in Package Unit Vendor

Control Narratives

P&ID 1st rev

received from
Vendor

16

Typical Issues in C&I Detailed Engineering when Package Units Involved

P&ID marked by client

17

Typical Issues in C&I Detailed Engineering when Package Units Involved

Integration of Package Unit Vendor Controls and Interlocks with

the rest of the plant poorly defined (quite often overlooked)

Definition by client of which controllers (DCS & ESD) will receive

Package Unit Vendor hardwired signals defined too late

18

Consequences
q
of Poor Design
g

Consequences of Poor Design:

Endless hours spent (email chains, telephone calls..etc)

Many revisions in (P&ID, Signal List, Logic Diagrams, Wiring

Design...etc)

Longer commissioning and start-up time

M
More
diffi
difficult
lt and
d expensive
i ffuture
t
maintenance
i t

19

Some
So e Best
est Practices
act ces for
o Control
Co t o System
Syste a
and
d Field
e d Wiring
g Design
es g a
and
d Co
Commissioning
ss o g

Some Best Practices

For Control System and Field Wiring
Design and Commissioning

20

Some
So e Best
est Practices
act ces for
o Control
Co t o System
Syste a
and
d Field
e d Wiring
g Design
es g a
and
d Co
Commissioning
ss o g

Send Client C&I Design Specs to Package Unit Vendor

Involve Client personnel in all phases of the project

Clarification meetings at Package Unit Vendor facilities

Dedicate a person to take care of the integration of Package

Unit Vendor design with rest of the plant

21

Some
So e Best
est Practices
act ces for
o Control
Co t o System
Syste a
and
d Field
e d Wiring
g Design
es g a
and
d Co
Commissioning
ss o g

Prepare Control System SW Functional Design Specification

Request ILDs (Instrument Loop Diagrams) for all signals

Homogenize PLCs in your plant

Use AMS (or similar tool) for loop test

Request FAT and SAT protocols before starting the tests

22

Business Results Achieved

How to Reduce I&C Engineering Cost

-Cost drastically reduced (many engineering hours saved)

- Commissioning and Start-up time reduced

23

Questions and Answers

How to Reduce I&C Engineering Cost

Thanks for your attention

Now: Questions and Answers

24

Lets Connect

Julin Sez
LinkedIn.com/in/juliansaezmateo
j
julian.saez@positiveengineering.com
@
g
g

25