Whitt2003.

book Page 135 Thursday, July 10, 2003 4:05 PM

Part III
Table of Contents
IntroductionPart III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Chapter 7: Piping and Instrumentation Diagrams (P&IDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
A. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Practical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. P&ID Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

141
141
142
144
146

Chapter 8: Links to Mechanical and Civil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

A. Equipment Arrangement Drawing (Civil and Mechanical). . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Piping Drawing (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Pump and Equipment Specifications (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Links Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

147
149
149
150

Chapter 9: Preliminary Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

A. Development of a Detailed Scope of Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Control System Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Project Database Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Estimate and Schedule Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Preliminary Engineering Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151
151
154
166
181

Chapter 10: Systems Integration (Control System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

A. Division of Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Review. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Develop a Control Logic Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Operator Interface Specification DevelopmentHMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Network Single-Line Diagram Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F. Other Systems Integration Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Systems Integration Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

183
185
186
216
228
228
235

Chapter 11: Project Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

A. Document Control Table with Related Queries and Reports. . . . . . . . . . . . . . . . . . . . . . . . . . 237
B. Instrument and I/O List Table with Related Queries and Reports . . . . . . . . . . . . . . . . . . . . . 240

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SUCCESSFUL INSTRUMENTATION AND CONTROL SYSTEMS DESIGN

Chapter 12: Instrument Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

A. Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

248
250
250
254

Chapter 13: Physical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

A. Control Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Termination Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Process Area (Instrument Location Plan) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Instrument Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

255
256
258
277
282

Chapter 14: Instrument and Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

A. Instrument Elementary (Ladder) Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Loop Sheet (Ref: ANSI/ISA-5.4-1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Connection Diagrams (Ref: NFPA79) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Wiring Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

285
298
301
314

Chapter 15: Panel Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

A. Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
B. Junction Box JB-TK10-01 Arrangement Drawing ARR-002 . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
C. Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Chapter 16: Procurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
A. Typical Purchasing Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Material Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Bulk Electrical Bill of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Bulk Mechanical Bill of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E. Procurement Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

331
333
333
337
343

Chapter 17: Quality ControlThe Integrated Design Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

A. Administrative ContentIndividual Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Technical ContentSquad Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C. Squad-Check Roster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Design Check Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

345
345
346
346

Chapter 18: Phase ThreeConstruction Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

A. Construction Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Adjustment of Document Package to Reflect Construction Modifications . . . . . . . . . . . . . .
C. Issue for Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D. Phase III Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

349
351
351
351

ReferencesPart III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

Whitt2003.book Page 355 Thursday, July 10, 2003 4:05 PM

Additional Resources
Software Tools for Successful
Instrumentation and Control Systems Design
For additional tools that can help you with successful instrumentation
and control systems design, consider purchasing Software Tools for
Successful Instrumentation and Control Systems Design by
Michael D. Whitt available from ISA at www.isa.org/whittCD or
919-549-8411.
This CD-ROM contains files for use in designing a project as
well as the figures, charts, and forms presented in this book for use
as training or presentation aids. The files can be placed into two
categories.

ESTIMATE & SCHEDULE

The Estimate & Schedule PDF file in this category describes a method for generating a comprehensive, cross-referenced project estimate and execution schedule using Microsoft Excel. Microsoft
Excel is used due to its flexibility and usefulness, and to its almost universal availability. This
narrative provides instruction for building the material and labor estimates, and a subsequent
project schedule.
Two Microsoft Excel files are also includedthe first being fully implemented per the imaginary scenario described in the narrative. The second file is a blank file that may be used as a template for a new project. There are a total of three files:

File_1A_Estimate&Schedule (the narrative text in Adobe format)

File_1B_AddisonPlasticsEstimate&Schedule (the sample Microsoft Excel workbook)
File_1C_BlankEstimate&Schedule (the blank Microsoft Excel workbook)

In this approach, teaching occurs through interactive involvement. You are forced to open
Microsoft Excel, for example, in order to follow the authors reasoning in building the estimate.
New skills in the use of Microsoft Excel are likely to be gained, as is a new understanding of the
proper relationship that should exist between the project estimate and schedule. All too often the
link between the two is lost, thus making budget difficult to manage. Here, the estimating process is
tied to the Work Breakdown Structure (WBS), which is then used to generate the schedule. And,
once the schedule is generated, a project planning and tracking tool facilitates labor management.

FORMS, FIGURES, AND DATABASE

The files in this category provide the figures, charts and forms discussed in each Part of the Book.
The first four items (File 2A through 2D) are the Figures that are in the Book presented in their original Microsoft Excel format. Having them available in their native format makes them suitable
for use as training aids since they can be tailored to individual needs. File 2E is the Instrument Database (Microsoft Access) developed in Part III. And finally, File 2F is a Microsoft Visio file with
the final deliverable drawings that are shown in the book.

File_2A_Part1Figures (Book Part I charts and forms Microsoft Excel file)

File_2B_Part2Figures (Book Part II charts and forms Microsoft Excel file)

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SUCCESSFUL INSTRUMENTATION AND CONTROL SYSTEMS DESIGN

File_2C_Part3Figures_1-99 (Book Part III charts and forms Microsoft Excel file)
File_2D_Part3Figures_100-213 (Book Part III charts and forms Microsoft Excel file)
File_2E_Instrument Database (Microsoft Access file)
File_2F_Deliverables (Microsoft Visio file)

If you wish to use a form that is provided, you must first copy the sheet from the Microsoft
Excel workbook and clear it of existing sample data. Then the form may be adapted to your purposes.