2016 emerson exchange ppt reduce c&i cost rev0b js 11apr16
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8/17/2019 2016 Emerson Exchange PPT Reduce C&I Cost Rev0b JS 11Apr16
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HOW TO REDUCE
AND CONTROL SYSTEM
DETAILED ENGINEERING COST
(When Package Units need to be Integrated)
u n ezPositive Engineering
Twitter Conference Hashtag: #EMRex
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Presenter How to Reduce I&C En ineerin CostPresenter How to Reduce I&C En ineerin Cost
Julián Sáez
julian.saez@positiveengineering.com
. .
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Introduction How to Reduce I&C Engineering CostIntroduction How to Reduce I&C Engineering Cost
Company presentation
os ve ng neer ng
Control & Instrumentation Solutions for Process Industry
Detailed Engineering for C&I International Projects
Inte ration of Packa e Units with the Rest of the Plant
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Introduction How to Reduce I&C Engineering CostIntroduction How to Reduce I&C Engineering Cost
Presenter short biography
Julián Sáez (Control and Instrumentation Engineer)
BSc in Electrical Engineering
BSc in Computer Science
MSc in Electronics and Industrial Automation Engineering
,
Técnicas Reunidas (7 years), Control & Instrumentation
CPC En ineerin 9 ears Control & Instrumentation
Positive Engineering (1 year), Control & Instrumentation
Lecturer at University of Murcia (7 years), Control Systems
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Introduction How to Reduce I&C Engineering CostIntroduction How to Reduce I&C Engineering Cost
Positive Engineering State of Business
Mid 1990s Early 2000s 2005-2010 2011-2016
DCS Programming
Loop Test
DCS HW & SW Spec
PLC
Package Unit Integration
Construction Supervision
C&I Consulting
DCS & ESD Upgrade
Simulation for OTS Commissioning Instrumentation ICSS
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Presentation How to Reduce I&C Engineering CostPresentation How to Reduce I&C Engineering Cost
How to Reduce Instrumentation and Control System Detailed
Units need to be Integrated)
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 ControlSystems is the integration of the controls of different package units.
’
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 don’t take enough care of the client specifications.
This leads to a lot of misunderstandings and endless hours for clarifications during the detailed.
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.
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Presentation How to Reduce I&C Engineering CostPresentation How to Reduce I&C Engineering Cost
How to Reduce
ns rumen a on an on ro ys em e a e ng neer ng os
and Commissioning Time
When Several Packa e Units need to be Inte rated
Abstract
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Agenda How to Reduce I&C Engineering CostAgenda How to Reduce I&C Engineering Cost
– Typical Issues in C&I Detailed Engineering when
Package Units are Involved
– Consequences of Poor Design
– ome es rac ces or on ro ys em an eWiring Design and Commissioning
– Business Results Achieved
–
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical Issues in C&I Detailed Engineering when Package Units Involved
Package Unit Vendor doesn’t differentiate which signals need to
e w re to an w c s gna s nee to e w re to
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical Issues in C&I Detailed Engineering when Package Units Involved
Correct:
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical Issues in C&I Detailed Engineering when Package Units Involved
ac age n t en or or c ent oesn t e ne mus room
is required
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical 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
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical Issues in C&I Detailed Engineering when Package Units Involved
DCS-ESD Interface:
Signals hardwired between controllers
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
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical 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
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical Issues in C&I Detailed Engineering when Package Units Involved
Package Unit Vendor doesn’t follow Client tagnaming criteria for
Control System Signals and wiring design (JBs, Multicables,
TBs...etc .
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical Issues in C&I Detailed Engineering when Package Units Involved
Controls and Interlocks oorl re resented on Packa e Unit
Vendor P&ID
Controls and Interlocks oorl defined in Packa e Unit Vendor
Control Narratives
P&ID 1st rev
received from
Vendor
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical Issues in C&I Detailed Engineering when Package Units Involved
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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical Issues in C&I Detailed Engineering when Package Units Involved
Inte ration of Packa e 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
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Consequences of Poor DesignConsequences of Poor Design
Consequences of Poor Design: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
ore cu an expens ve u ure ma n enance
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Some Best Practices for Control S stem and Field Wirin Desi n and CommissioninSome Best Practices for Control S stem and Field Wirin Desi n and Commissionin
Some Best PracticesSome Best Practices
For Control System and Field WiringFor Control System and Field Wiring
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Some Best Practices for Control S stem and Field Wirin Desi n and CommissioninSome Best Practices for Control S stem and Field Wirin Desi n and Commissionin
Send Client C&I Desi n S ecs to Packa e 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
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Some Best Practices for Control S stem and Field Wirin Desi n and CommissioninSome Best Practices for Control S stem and Field Wirin Desi n and Commissionin
Pre are Control S stem SW Functional Desi n S ecification
Request ILDs (Instrument Loop Diagrams) for all signals
Homogenize PLCs in your plant
Use AMS (or similar tool) for loop test
Re uest FAT and SAT rotocols before startin the tests
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Business Results Achieved How to Reduce I&C En ineerin CostBusiness Results Achieved How to Reduce I&C En ineerin Cost
-Cost drastically reduced (many engineering hours saved)
- Commissioning and Start-up time reduced
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uestions and Answers How to Reduce I&C En ineerin Costuestions and Answers How to Reduce I&C En ineerin Cost
Thanks for your attentionThanks for your attention
Now: Questions and Answers
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