VEPA INTEC

TRAINING COURSE

INDUSTRIAL
INSTRUMENTATIO
N AND DETAILED
ENGINEERING
MODULE B
Module B: Detailed Engineering and Documentation VEPA INTEC
 ABOUT VEPA INTEC.

Controlsoft
Engineering is in
Our Training
the field of
facility equipped Our main objective
Industrial VEPA INTEC
with modern tools, is to develop the
Automation and Training facility is
software and professional
Group company of detailed located in the
engineering lab for competence of the
Controlsoft engineering for the heart of Chennai,
training the aspirant through
Engineering. past 14 years and well connected
aspirants on all sharing of our
had executed with public
practical aspects knowledge and
many domestic transport.
of Instrumentation experience.
and overseas
and automation.
projects
successfully.
EXCELLENCE IN INSTRUMENTATION ENGINEERING AND AUTOMATIOIN TRAINING

Module B: Detailed Engineering and Documentation VEPA INTEC

 Course Sessions
Session No Course Contents

Session 1 Industrial Instrumentation Basics

Session 2 Project Life Cycle and Implementation Concepts

Session 3 Process Diagrams

Session 4 Exercises on Reading P and I Ds

Session 5 Instrumentation Project Deliverable & Design Basis

Session 6 Instrument Index and IO Schedule

Session 7 Exercises on Instrument Index Preparation

Module B: Detailed Engineering and Documentation VEPA INTEC

 Course Sessions
Session No Course Contents

Session 8 Exercises on Input / Output Schedule preparation

Session 9 Instrument Specifications - Overview

Session 10 PLC/DCS/SCADA Specification & System Architecture Concepts

Session 11 Datasheet Preparation Concept and Overview

Session 12 Exercises on Preparation of Datasheets

Session 13 Instrumentation Calculations and reports

Session 14 Control Philosophy and Logic Write up

Module B: Detailed Engineering and Documentation VEPA INTEC

 Course Sessions
Session No Course Contents

Session 15 Instrument and JB Location Plan, Tray Layouts

Session 16 Instrument Cable Block Diagrams and Cable Schedules

Session 17 Instrumentation Hook up and Installation Drawings

Session 18 Instrumentation Bulk Material Take of

Session 19 Instrumentation Termination Drawings and Loop Schematics

Session 20 Installation & Commissioning Concepts

Session 21 Review and Tests

Module B: Detailed Engineering and Documentation VEPA INTEC

 Course Sessions
Session No Course Contents
Demo Project Design and engineering of a demo project creating all the
deliverables required for the project 50 hours
Hands on Projects Deputation to Controlsoft Engineering to carry out part of an
ongoing project 50 hours

Module B: Detailed Engineering and Documentation VEPA INTEC

 Session 1 - Industrial Instrumentation - Basics

What is a plant/industry?

Types of Manufacturing and example of manufacturing industries

What is a chemical process and what are diferent types of it?

What do measurement and Instrumentation mean?

What are diferent type of Measurement/Instruments?

What are diferent type of measurement/instrument function?

Instrumentation Signal Levels

What does Process Control Mean?

Process Control Implementation

Complete Plant Control Solution

Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 2 Project Life Cycle, Engineering Phases
& Implementation Concepts

Multidisciplin Instrumentati
e on Design Drawing and DOs and
Project Life Engineering Project Kick Filing and
Responsibiliti Phases and Documentati DONTss of
Cycle Phases of Meeting Retrievals
es and their on Controls
Deliverables deliverable

Module B: Detailed Engineering and Documentation VEPA INTEC

Session 3 Process Diagrams
What are the
Process
Diagrams and
their
importance?
Study of What a P and I
Sample P and I Diagram
Diagrams Contains?

How a P and I
P and I Drawing Diagram is
Index and used by
Legend Sheets various
discipline?

P and I Diagram
How to read a P
Symbols and
and I Diagram?
legends
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 4 P and I Diagram Reading Exercise-1
List the process equipment (Tag and description) that you
observe in the given P and I Diagram
How many P and I D loops you observer in the P and I D?
List all the signal flow representation that you observe in the P
and I Diagram.
How many field instruments you can count from the P and I D?
List the PSVs shown in the P and I D along with the set points.
Describe the main process function of the P and I D.
Describe how the pipe lines are identified?
How many on-of valves you can count from the P and I D?
List the interconnections of the P and I D.
List the control valves shown in the P and I D along with its fail
safe position.
Count the manual valves shown in the P and I D as per their
type.
List all the utility services used in the P and I D.
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 4 P and I Diagram Reading Exercise-2

Draw a P and I D in an A3 Sheet (using pencil/pen) with the

following guidelines:
Batch Reactor R101 with Agitator
Two raw materials are getting added to the reactor through 2 Nozzles
The raw material lines have got a flow transmitter for remote indication
and totalization in DCS and a remotely operated on-of valve.
A temperature transmitter is provided on the reactor for controlling the
temperature in the reactor by adjusting the steam input to the reactor
through a steam coil.
The reactor contents are transferred to another vessel V-102 through a
pump. The nozzle connection for this will be 4. The transfer flows
through a cooler to reduce the temperature of the reactor contents to
40 deg C, using cooling water. The cooling water outlet temperature is
measured and indicated in DCS.
V102 is provided with a level Transmitter for remote indication purpose
The agitator and pump will be started and stopped remotely from the
DCS.

Module B: Detailed Engineering and Documentation VEPA INTEC

Session 5 Instrumentation Project Deliverable & Design
Basis

What are the Instrumentation project

deliverables - recap

What is the sequence of completion of these

deliverable?

What is a Instrumentation & Control Design

Basis document?

Understanding a design basis document in

detail.
Module B: Detailed Engineering and Documentation VEPA INTEC
Session 6 Instrument Index & IO Schedule
How to prepare an Instrument Index from a P
and I D?
What are the various fields(columns) in an
Instrument Index and their purpose?
Who uses the Instrument Index?
Going through a typical Instrument Index
document
How to prepare an Input/Output schedule from
Instrument Index and P and I D?
What are the various fields (columns) in an IO
Schedule and their purpose?
Who needs the IO schedule?
Going through a typical IO schedule document
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 7 Exercise on preparing the Instrument Index

Prepare an Instrument Index from the

given set of P and I Diagrams using
excel. The Instrument Index should have
the following columns as minimal:

Area No, Tag No, Description of Tag ,

Instrument Type,
Measurement Principle, Cal Range Low, Cal
Range High, Units,
Location, Status,
Datasheet Ref, Hook up Ref, Termination Dwg
Ref, Loop Dwg Ref, Manufacturer, Model No,
Revision No, Remarks
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 8 Exercise on preparing the Input / Output
Schedule
Prepare an IO Schedule from the given set of
P and I Ds and the instrument index prepared
earlier using excel. The IO schedule should
have the following columns as minimal:

Area No, Tag No, Description of Tag , Loop No,

Instrument Type ,
IO Type, Display Range Low, Display Range High,
Units,
Location, Status, IS/Non IS, Wiring Type, Signal
Level, Voltage Level,
High Alarm, Hi Hi Alarm, Lo Alarm, Lo Lo Alarm,
Control Panel No, Node No, Rack No, Module No,
Channel No,
Revision No, Remarksions of
Module B: Detailed Engineering and Documentation VEPA INTEC
Session 9 Instrument Specifications - Overview

What are Instrument Specifications and why do we need

them?
What is RFQ?
What a typical Instrument Specification contains?
What is Vendor Document Requirement List (VDRL)?
Going through few instrument specifications:
Pressure Instruments
Flow Instruments
Control Valves
Shutdown Valves
Level Instruments
Temperature Instruments
Module B: Detailed Engineering and Documentation VEPA INTEC
Session 10 Control System Specifications
Need for Control system (DCS/PLC/SCADA)
specifications
What a typical control system specification contains?
What is a System architecture drawing?
Going through a typical System architecture drawing
Going through a typical Control system specification
document
IO list Summary
Associated documents to go along with Control
system RFQ
Module B: Detailed Engineering and Documentation VEPA INTEC
Session 11 Datasheets
What is a Datasheet and why do we need it?
How to prepare a Datasheet?
What are the contents of a Datasheet?
Where and how to get data for the datasheets?
Going through typical datasheets for the following
instruments:
Pressure Gauge
Pressure Transmitter
Level Switch
Level Transmitter ( Radar, DP)
Orifice Plate
Flow Transmitter ( DP, Magflow, Coriolis, Vortex)
Control Valve
Shutdown (on-of) valve
Temperature elements ( RTD)
Module B: Detailed Engineering and Documentation VEPA INTEC
Session 12 Exercises on preparing Datasheets

Refer the exercise for creating the Instrument

index. Prepare the datasheets for all the field
instruments listed in the Instrument Index. Use the
standard datasheets in excel format for the above
purpose.

Module B: Detailed Engineering and Documentation VEPA INTEC

Session 13 Instrumentation Calculations
What are the typical calculations need to be done during
detailed engineering of Instrumentation projects?
How do we estimate the power requirements for the
Instrumentation and control system?
How do we estimate the requirement of instrument air for
the instrumentation items?
What do you mean by Control Valve sizing? How to size or
check a control valve sizing?
How do we size an Orifice Plate for flow measurement?
How do we size a pressure safety valve?
What is wake frequency of a thermowell and why is it so
important? How do we calculate the same?
Module B: Detailed Engineering and Documentation VEPA INTEC
Session 14 Control Philosophy & Logic Write up

Why do we need a control philosophy & logic write

up document?
What a typical control philosophy document
contain?
What is Block Logic Diagram?
What is Cause and Efect Diagram?
What is sequential flow chart?
Electrical Interface description
Emergency Shutdown philosophy
Fire and Gas detection philosophyof
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 15 Instrument/JB Location Plan & Tray Layout

What is an Instrument and JB Location plan?

Why do we need the location plan?
How do we prepare the location plan?
How do we group the instruments to a JB ie what is
the grouping philosophy?
How to size a Junction Box?
What are the various enclosure types for a Junction
Box?
What is Ingress Protection and Hazardous area
Classification?
How do we determine the cable requirement for
the JB and the instrument?
How to select suitable cable for the devices and
JB?
Module B: Detailed Engineering and Documentation VEPA INTEC
Session 16 Cable Block Diagram & Cable Schedule

What is a cable block diagram and why do we need

it?
Going through typical Cable block diagrams?
What is a cable schedule and why do we need it?
What are the typical fields (columns) in a cable
schedule?
What are the diferent cable types?
What are cable glands and their types?
How do we estimate the cable length requirement?
Cables for electrical interface
Cables for vendor supplied equipments?
Cable Trays and their selection procedures?
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 17 Instrumentation Hook-up and Installation
Drawings
What is a Hook-up drawing and why do we need it?
For which instruments hook up drawings are required?
What are instrumentation piping, tubing and fittings?
Going through standard hook-up drawings for:
Pressure gauges and pressure switches
Pressure and DP transmitters
DP Level Transmitters
Orifice Plates and DP Flow Transmitters
Level Gauges and other level instruments
Temp elements and temperature transmitters
Control Valves and shutdown valves
What are installation drawings and why do we need
them?
Going through typical installation drawings
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 18 Instrumentation Bulk Material Take of
(MTO)
What is Bulk Material Take of (MTO) and why do we
need it?
What a MTO contains?
How to do the estimation for cable and glands?
How to estimate the hook up components?
How to estimate the structural requirement from
the installation drawings?
How to estimate the requirement of Cables trays
and their supports?
Other consumables required for construction
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 19 Termination and Loop Drawings
What are termination drawings and why do
we need them?
JB Termination Drawings
Control Panel/Marshalling panel termination
drawings
Electrical and other inter panel termination
drawings
Going through typical termination drawings
What is a Loop Diagram and why do we need
it?
Typical loop diagrams for Open Loop, Closed
Loop, Motor and On-of valve operations
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 20 Installation and Commissioning
Installation of instruments is very crucial for
their better performance.
Precautions to be taken while installation
Checklist for auditing an installation
Going through a typical checklists
What is a punch list?
What is calibration?
What is loop checking and how to conduct the
same?
Loop checking records
What is cold commissioning and what is hot
commissioning?
What do you mean by handing over?
What is an As built drawing?
Module B: Detailed Engineering and Documentation VEPA INTEC
 Session 21 Review and Test
Review Questions and answers on various topics
covered thus for
Objective and fill in the blank type of Test papers to
determine the efectiveness of Training on the
participants
Feedback forms

Module B: Detailed Engineering and Documentation VEPA INTEC

 DEMO Project
Given a set of P and I Ds and a layout of a mock project, the participants shall
prepare the following deliverable required for the project:

Mock KOM and preparation of KOM

minutes
Submit a Design Basis document for
approval
Prepare and submit Instrument Prepare Instrument/JB location plan

Index Prepare cable block diagram

Prepare and submit IO Schedule Prepare Cable schedule
Prepare Instrument Tray Layout drawings
Prepare Specification for a
Prepare Hook up and Instrument Installation drawings
PLC/SCADA system
Prepare JB and control panel termination drawings
Prepare datasheets for field Prepare Loop schematics
instruments
Submit calculation reports for power
and instrument air requirements
Prepare the Control logic write up
 WILL GIVE OUR BEST

Module B: Detailed Engineering and Documentation VEPA INTEC