Whitt2003.

book Page 137 Thursday, July 10, 2003 4:05 PM

Introduction—Part III
As we have seen in Part I of this book, a project is a deliverable in its own right, from conceptual
design through scope development and on into the execution phase. A well-managed, well-exe-
cuted project is a wonderful thing to behold. However, the object of the engineering exercise is to
generate intellectual property, not to perfect the process of doing so.
In any case, a “perfect” design package is rarely the same from one project to the next, even
between two projects for the same customer. A perfect design package is one that gets the job done
within schedule and budget. That doesn’t sound difficult, but it can be very difficult to strike a bal-
ance between cost and schedule and between product quantity and quality.
The basic job of the design team is to assemble a mass of seemingly unrelated bits of informa-
tion into a cohesive design package. The package must convey information that is useful and timely
to the constructors, who may then use it to convert an existing process state (such as a green field)
into a desired state (such as a chemical plant), while being useful later for plant maintenance. Fur-
ther, the package must strike a balance between cost and utility. A package that is perfect for the con-
structor is likely to blow the engineering budget, while a minimized engineering package might
torpedo the project during construction or present problems for maintenance later. The key is to find
that specific mix of products and services that will get the job done without “gold-plating” it.
What is the difference between a product and a service? In short, a product is something physical
that may be handed over to the customer or to the construction team. An example of this would be a
bill of materials or a drawing. The entire set of such design products is called the engineering package.
A service is work that does not necessarily result in a physical deliverable. An example of an engi-
neering service is consulting (advising) or construction management, in which the deliverable is a
smoothly functioning construction process.
The engineering package consists of several distinct elements. Figure 1 shows the basic set of
individual products and services in a flow chart format. The three basic types of engineering prod-
uct are as follows:

• Engineering deliverables are needed by customers either for their records or for maintenance
and upkeep of their facility. Engineering deliverables may also be needed for construction.
Whether issued for construction or merely issued for record, engineering deliverables must
meet or exceed customers’ drafting standards and comply with their document control
guidelines.
• Construction deliverables are needed for the construction of the facility but are probably not
maintained afterward. An example of such a deliverable is an instrument location plan
drawing, which is a tremendous time-saver for the construction team but is not required
for the day-to-day operation of the plant. Many times, these and other construction deliver-
ables are issued in the form of sketches to bypass the sometimes rigorous drawing stan-
dards of the customer, thus saving time and money.
• Engineering services are tasks that do not lead directly to products.

This part of the book discusses the various types of documents that should be considered for
inclusion in the instrument design package and illuminates the function of each with respect to the
package as a whole. Methods of producing these documents are discussed, using a practical project
example as the basis for these discussions. The example project adds a feed tank, shown in Figure 2,
and its associated equipment and instrumentation to an existing facility.
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138 SUCCESSFUL INSTRUMENTATION AND CONTROL SYSTEMS DESIGN

Indicates products of others

PHASE ONE & TWO : ENGINEERING
A "Service" or Indirect Task
Indicates an Engineering Deliverable x
Part III Chapter Number
A Construction Deliverable

1 Piping & Instrumentation Diagram (P&ID)

Process Flow Diagram (PFD), and Heat & Material Balance (HMB)

3 2
2 Equip. Arrang. 3 2
DCS SELECTION / DETAILED PUMP SPECS EQUIP SPECS
Dwg List (Mech/Elec) (Mechanical)
(Civil/Mech) FAMILIARIZATION SCHEDULE &
ESTIMATE 5

4 5
2 Piping Systems 3 I/O Config. Database / I/O 6 Instrument Specifications
Orhographics Integration (Client & SI) List

7 Control/Termination Instrument Elementaries (Schematics)

Instrument Room Arrangements and/or Instrument Loop Sheets
Location Plans 7 8
(Locate Instr.)
Cabinet & Panel
Arrangements Installation Details
9 7

10 10
8 Wiring (Connection) Diagrams
Mech. COST GROUP
Mat'l Quotations
7
Instrument
Location Plans 1011 Electrical Bill of Material
Procurement
(Cable,Conduit)

11
Integrated Design Check & Issue for Construction

PHASE THREE : CONSTRUCTION

12 12 12
CONSTRUCTION ADJUST DESIGN DRAWINGS TO 12 PROJECT
SUPPORT ISSUE FOR RECORD
REFLECT RED-LINE MARKUPS WRAPUP

Figure 1. Instrumentation and controls engineering tasks

The various documents that make up the drawing package are presented in their usual order of
creation as indicated by the products and services flow chart in Figure 1. In each case, the standard
approach is discussed first, followed by one or more alternatives as appropriate. For example,
power distribution information has historically been conveyed using a drawing. However, a chart
could also serve depending on customer preference. Note that the word customer in this context
refers to the end user of the information, which could be the construction team or a vendor, not nec-
essarily the client.
The purpose of Part III is for you to become familiar with the instrumentation and controls
(I&C) design package. It is organized by products and services flow chart item number as listed in
Figure 1. Industry guidelines and/or standards are referenced where appropriate.
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INTRODUCTION—PART III 139

Figure 2. Typical feed tank configuration