Introduction
Documentation Plays a vital role for implementation, execution and maintenance of a plant.
What to document and how to document in most systematic and user friendly manner becomes a good engineering feature.
Automation engineers are responsible for design specifications and other detailed documentation of their creations.
Some important document required for automation project are as given below:
Types of documents
- Instrument Index
- I/O List
- Bill of material
- System architecture drawing
- Panel layout, power and module wiring drawing
- Sequence of operation and flow chart
- Functional design specification
- Operation & Maintenance Manuals
Instrument Index
Instrument index is a document containing list of instrument devices within a plant. Instrument index shall include tag number of all physical instruments (eg. Field instrument, physical alarm and indicator) and pseudo instruments which commonly named "soft tag" (eg DCS indicator, alarms, controller)
Instrument index shall be created at the beginning of the project and considered as a live document which should be kept updated even though the plant has been operated. Instrument index shall be revised if there is any plant or system modification which impact to additional \, removal or resetting of instrument.
In instrument index document, the following information should be stated but not limited to:
- Tag number
- Loop number
- Type of instrument
- Location
- Service description
- P&ID number
- Line number or equipment number
- I/O type
- Control system
- Range or set point along with engineering unit used
- Applicable reference document (Instrument data sheet number, Hook up drawing number, Instrument layout number, Loop drawing number)
- Package number
- Manufacturer
- Model number
Reference drawing: P&ID, HMB
- P&ID (Piping & Instrument Diagram)
- HMB (Heat and Material Balance)
Instrument index should include fire and gas related tag numbers.Fire and Gas devices usually do not appear in P&ID, they are stated in cause and effect instead.
The purpose of instrument index
From its self explanatory name, instrument index will be referred as an index for many purposes as follow:
- As a basis to prepare the I/O list by extracting only the tag number which has I/O point.
- Searching, Listing, Filtering a tag number.
I/O List
I/O list is a document containing list of instrumentation which serves as an input and output of control system. Therefore, only the tag number that physically has a cable which connects to the control system appears on I/O list.
When there are more than one control system in a plant the I/O list shall clearly indicates which instrument is assigned to which control system or may separate them to different section in the document.
In I/O list, the following information should be stated but not limited to:
- Software I/O address
- Tag number
- Description
- I/O module
- Channel address
- I/O rack
- Slot number
- Pin
- Panel TB number
- Range or set point
- Loop number
- P&ID number
- Signal type
- Location
- I/O type
- Control system
The information column in which I/O list contains may be as simple as above, however some project require I/O list to be detailed by having alarm list, controller action, logic "0"/"1" descriptor.
I/O List
The purpose of I/O list
I/O list is used to determine the size of control system required by project, by counting how many I/O exists within a plant by each control system.
Bill Of Material (BOM)
Bill Of Material is a list of automation components that are required to build a project. The BOM served a way to track a project changes and maintain an accurate list of required components.It serves as the primary reference file.
In BOM, the following information should be stated but not limited to:
- Part number
- Part name
- Description
- Quantity
- Unit of measure
- Manufacturer's name
The purpose of BOM
BOM is used to determine accurate quantity of control system required by project, listing there make and model no.
Control System Architecture
Control system architecture depicts the architecture of the plant control systems and the interface among the systems required for overall operation of the process plant.The required control system is determined by the level of functionality, complexity and safety of a plant. This may comprise of process control system, safety instrumented system, HIPPS, fire and gas system, package unit control system.
Control system architecture drawing shall also shows supervisory level equipment such as operators workstation, engineering workstation, HMI server, OPC server, historian server, control panel such as ESD panel (Push buttons and lamp), fire and gas matrix and also network equipment.
Control system architecture shall clearly define the locations, both main locations, remote I/O locations, indoor/outdoor location, control room and building limit.
The major control, Ethernet and communication cable are also shown and specified.
The control system architecture is conceptual in nature and is used for specifying the requirements of the control system to the DCS supplier. This drawing is provided as supporting documentation for the process control system requisition.
To help ensure that your software system or application meets your user needs, you can create models in Visual Studio Ultimate.
Panel layout, power and module wiring diagram
Panel layout, power and module wiring diagram are usually done on AutoCAD software. It is the layout drawing depicting electric panel board, power supply, module wiring and electronic terminal plans with components extracted from schematic diagram.The purpose of wiring diagram
The diagram is helpful while wiring control system channel's to panel board.
Sequence of operation and flow chart
The visual representation of the logical sequence of steps needed to perform a process.Each step in the sequence is noted within a diagram shape.Steps are linked by connecting lines and directional arrows.
The purpose of flow chart
This allows anyone to view the flowchart and logically follow the process from beginning to end.
It also helps in audit a process for inefficiencies and malfunctions, system design and process documentation.
Functional Design Specification (FDS)
This documents defines the functional requirement for the control system to be supplied for the project. For the supply, engineering, testing, commissioning, and final hand over of the SCADA system.This FDS incorporates, and expands upon, Technical information and corresponds received will be used to validate the control system functionality during Site Acceptance Testing (SAT)
In FDS, the following information should be stated but not limited to:
- Reference documentation (If Provided)
- System overview
- Scope of supply
- Hardware and software scope
- Project implementation
- Control system description
- Hardware configuration
- Operator station
- Acceptance criteria
- Installation, Commissioning and warrenty
- Training & Documentation
The purpose of FDS
The purpose of this document is not intended to address how functions will be designed and implemented but to address what functions are available.
Operation & Maintenance Manual (O&M)
An Operation & Maintenance manual should contain procedure, instructions and guidance for use by operational personnel in the execution of their duties.In O&M, the following information should be stated but not limited to:
- System description
- System topology
- SCADA application
- PLC programs
- List of product
- Product catalogue and CD's
- I/O list
- Spare parts
- As built drawing
- List of suppliers and manufacturers
The purpose of operation and maintenance
This document is a reference for the operator to control the plant through SCADA system and is also helpful for the maintenance engineer at the time of maintenance.
This document is a reference for the operator to control the plant through SCADA system and is also helpful for the maintenance engineer at the time of maintenance.
No comments:
Post a Comment