1、Instrumentation andControl SystemsDocumentationSecond EditionNotice The information presented in this publication is for the general education of the reader. Becauseneither the author nor the publisher has any control over the use of the information by the reader,both the author and the publisher di
2、sclaim any and all liability of any kind arising out of such use.The reader is expected to exercise sound professional judgment in using any of the information pre-sented in a particular application.Additionally, neither the author nor the publisher has investigated or considered the affect of anypa
3、tents on the ability of the reader to use any of the information in a particular application. Thereader is responsible for reviewing any possible patents that may affect any particular use of the infor-mation presented.Any references to commercial products in the work are cited as examples only. Nei
4、ther the authornor the publisher endorses any referenced commercial product. Any trademarks or trade names ref-erenced belong to the respective owner of the mark or name. Neither the author nor the publishermakes any representation regarding the availability of any referenced commercial product at a
5、nytime. The manufacturers instructions on use of any commercial product must be followed at alltimes, even if in conflict with the information in this publication.Copyright 2011 International Society of AutomationAll rights reserved. Printed in the United States of America. 10 9 8 7 6 5 4 3 2ISBN 97
6、8-1-936007-51-6No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or byany means, electronic, mechanical, photocopying, recording or otherwise, without the prior writtenpermission of the publisher. ISA 67 Alexander Drive P.O. Box 12277 Research Triangle
7、Park, NC 27709 Library of Congress Cataloging-in-Publication Data is in process. DEDICATIONThis book is dedicated to Cris and Jean,without whose assistance and encouragementthis book would not have been started, let alone finished.VIIAcknowledgementsACKNOWLEDGMENTSWe wish to thank all those who assi
8、sted in the development of this book, especially Dave Fusaro of Control, a Putman Media Co. publication;Ken Brabham of Industrial Design Corporation; co-workers at Harris Group Inc.;and to the Technical and Education Services Departments of ISA, especially Lois Ferson, Alice Heaney andLinda Wolffe;
9、designer, Vanessa F. Harris; and our copyeditor, Jim Strothman.Cliff would like to especially thank the lads in Dublin, for making it fun, and in particular to Tony Riordan,whose encouragement to have that ceremonial first scoop with “me Da“ eventually led to the idea of writing this book.For the Se
10、cond Edition, we wish to thank the ISA Staff for all of their help, especially Susan Colwell,Eugenia Bell and Charles Robinson. IXContentsContentsList of Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XIAbout the Authors . . . . . . . . . . . .
11、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .XVIntroductionInstrumentation and Control Systems Documentation . . .1Chapter 1The Process Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . .15Chapter 2P the Edmonton, Alberta, Section; and the Tar Heel (North Carolina
12、) Capital Area Section. He wasawarded the ISA District II Golden Eagle Award in 2000 and ISAs Golden Achievement Award in 2005.Fred presented two papers at ISA 1982, “Why Not Be an Adaptive Manager?” and, jointly with co-worker Trevor Haines, “Contractor Handling of Engineering for Distributed Contr
13、ol Systems”. Heauthored the cover article for CHEMICAL ENGINEERING, Feb. 22, 1982, “Is your control systemready to start up?” Fred and son Cliff (this books co-author) presented a joint paper at ISA 1999, “AStandard P after his “second” retirement, asan ISA Instructor and Consultant; and, since his
14、“third” retirement, as co-author of this book. Fredand Jean have been married for 62 years and are the proud parents of four children, four grand-children, and two great granddaughters, all scattered across the United States and Canada. Theycurrently live in Carolina Meadows, a retirement community
15、near Chapel Hill, North Carolina.ABOUT CLIFF MEIER Cliff Meiers engineering experience started back in the 70s with a Bachelor of Science degree inMechanical Engineering from Northeastern University. His attraction to the widgets and intricacies ofInstrumentation and Controls has taken him to three
16、continents and involvement in nuclear andfossil fuel power generation, oil and gas production, chemical, pulp and paper processes, microelec-tronics factories and even wastewater treatment. Cliff has worked on projects ranging in complexityfrom a few control diagrams to complex modernization project
17、s and green-field installations entailingthousands of loops and hundreds of schematics. His career started with manual drafting on Mylarsheets and has transitioned to computer-aided design (CAD) where efficient data handling has almosteclipsed the importance of the physical drawings. While he enjoys
18、 the team relationships of design projects, he finds construction, commissioning andteamwork with skilled maintenance technicians, especially the ones with fists of ham, to be almost asrewarding as writing with his Dad.Cliff is a member of ISA and holds a professional engineering license for Control
19、 Systems in Oregon.He and his wife, Cris, have been married more than 32 years and are the parents of the two finest kidson earth - Will and Helen. They live in Beaverton, Oregon, where they can gaze at snow-cappedmountains when it isnt raining, which, come to think of it, is not that often.Instrume
20、ntation and Control Systems DocumentationXVI1INTRODUCTIONIntroductionThis book is written to be easy to read, with many illustrations and little or no mathematics (andabsolutely no calculus!). It will be of interest to engineers and technicians, not only in the controlsystems field, but in many othe
21、r technical disciplines as well. Control system groups are unique inthat they have to coordinate among all the other work groups in a plant, mill, or factory duringdesign, construction, commissioning and operation. This book explains their varied, all-encom-passing language. It will also be of value
22、 to plant operating, maintenance, and support personnelwho are interested in plant design deliverables (the documentation that a design group usuallydevelops).The engineering design phase of a typical process plant may last from perhaps a few weeks to sev-eral years. Once the plant is built it may o
23、perate for thirty or more years. Common sense dictatesthat the documents developed during the engineering phase should have lasting value throughouta plants operating life. The purpose of this book is to provide you, the reader, with enough information to be able tounderstand the documents and the i
24、nformation on them and to use that understanding effectively.It is hoped this knowledge will be useful, not only in existing plants, but also as a basis for a reviewand reality check on future engineering design packages. Alsodare we say itthe authors hopeto encourage effective discussions among the
25、 design team, the construction contractor, and themaintenance team that will lead them to agree on the document set that will most effectivelymeet all their requirements. Significant material has been sourced from ANSI/ISA-5.1-2009 Instrumentation Symbols and Iden-tification (hereafter referred to a
26、s ISA-5.1). Material has also been sourced from ISA-5.2-1976(R1992) Binary Logic Diagrams for Process Operations (hereafter referred to as ISA-5.2). Explanatory material has also been used from ISA publication, The Automation, Systems andInstrumentation Dictionary, Fourth Edition, Research Triangle
27、Park, NC: ISA, 2006) (hereafterreferred to as ISA Dictionary). Instrumentation and ControlSystems DocumentationFirst, we need to understand some terms. Instrument - as defined in ISA-5.1, is a device used for direct or indirect meas-urement, monitoring, and/or control of a variable, including primar
28、y elements,indicators, controllers, final control elements, computing devices and electricaldevices such as annunciators, switches and push buttons.Instrumentation - as defined in ISA-5.2, is a collection of instruments, devices,hardware or functions or their applications for the purpose of measurin
29、g, monitoring or controlling an industrial process or machine or any combinationof these.Process Control as defined in the ISA Dictionary, is the regulation or manip-ulation of the variables that influence the conduct of a process in such a way asto obtain a product of desired quality and quantity i
30、n an efficient manner.System - from the ISA Dictionary definition 4, is the complex of hardware andsoftware that is used to affect the control of a process.This book is about instrumentation and control systems documentation. Thebook can best be used in an advisory mode. Sometimes the advice is aime
31、d at thecontrol system personnel who are directing the implementation effort and some-times aimed at the process control personnel who define what is to happen.The documents we will look at in this book have been developed by industryover many years to efficiently meet the needs of plant design, con
32、struction, oper-ation and maintenance. We will look at process control system documents intwo ways. First, we will describe them with enough detail to help the readerunderstand their form and function. For some of these documents, no pub-lished industry standard is available to guide the user about
33、their content. Thebook will therefore describe what the authors believe is a middle pathone thatmany will accept but, realistically, one that may not be accepted by everyone orin every detail, but what we believe will yield a typical document set. You may have heard developers of documentation stand
34、ards say, “My way orthe highway” or “There are two ways to do anything, my way and the wrongway.” They take this approach from necessity, since a wishy-washy plant stan-dard is not much of a “standard”; it has little value. The authors will not be asdogmatic, since we want you to develop a document
35、set that works for yourfacilityone that meets your specific requirements. We believe it is appropriateto approach the development of plant documentation standards for your facilitydemocraticallywith input from all the parties that have a stake in theproduct. However, there is a need at some point fo
36、r autocracy or maybe a“benevolent dictatorship.” Once the standards are setdemocraticallytheyInstrumentation and Control Systems Documentation2must be consistently and properly used. Someone needs to monitor that useand educate users in the acceptable application of the standards. The plant alsoneed
37、s to establish a mechanism for change that controls standards revisions toensure that all stakeholders review potential changes. The authors urge you,based on painful experience, to control modifications to the plant standardsvery carefully once a majority of users have defined the plants documentat
38、ionrequirements. People lose interest in working with a standard that isnt. Rigidcontrol is critical for an effective system. Develop freely; operate rigidly.The second way we will look at a typical document set is to use a very simplesimulated project to follow the sequence by which the documents a
39、re devel-oped. There is a logical, time tested sequence to their preparation. Often thedevelopment of one type of document must be essentially complete before thedevelopment of the next type of document can be started. If the documents arenot developed in the right sequence, work-hours will be waste
40、d, since you willhave to revisit the documents later to incorporate missing information. While the sequence is of more importance to those interested in the designprocess, it is useful for operating personnel to understand how document setsare developed. If for no other reason, this understanding wi
41、ll help ensure thatoperating personnel modify all the information in all the affected documents asthey make changes. In the authors experience, there are many different ways to define and docu-ment instrumentation and control systems. All the plants that we have seenwhich used markedly different doc
42、ument sets from the typical set described inthis book were eventually built and operated. Of course, some projects ransmoothly, while others seemed to develop a crisis a minute. Some plants wereeasier to build, and some took longer, but eventually all the plants were com-pleted. Sometimes, the docum
43、ent sets content had a direct influence on howwell the project ran, and a smoothly run project is a less expensive project. Inour experience, the quality of the document set has a DIRECT impact on theease of construction, commissioning, start-up and operations. The use of computers in engineering de
44、sign now offers many options to betterdefine the work to be performed. Indeed, the new ways available now withlinked documents offer attractive efficiency and accuracy that may compelsome to revisit the content of the standard design package document set. You will see that the drawings, specificatio
45、ns and other documents generated insupport of process control are unique in many ways. Most control system draw-ings are schematic in nature, showing how things are connected but not howfar apart they are. They are not much concerned with orthographic dimen-sions; instead they concentrate on the rel
46、ationships between elements. Unlike3Introductionwith piping plans or structural drawings, the creators of control system draw-ings are less concerned that elements are X inches from each other and morethat the documentation shows the interrelation between field measurementelements and final control
47、elements.The devices we deal with are becoming infinitely configurable, so our draw-ings and documents have evolved to capture each devices configuration forreference so the people working with the devices can understand why theywere set up the way they are and how they will react to signals. We use
48、 our documents to coordinate with the disciplines that install our con-trol valves. The electrical designers provide power to them, and the mechan-ical designers provide pressurized air to drive the valves. The control valvespecification form is developed by the control systems design group. Itdescr
49、ibes the flanges on the control valves. The piping group installsmatching flanges as part of the piping design and construction. Our designs must address device failure due to the impact that failure willhave on the process, so our documents must state failure action and responseparameters for record. Some instruments require power. This information is defined by the controlsystems design group but supplied and installed by electrical design and con-struction.We generate a lot of documents; it is not uncommon for a set of loop dia-grams on a project to be far thicker t
