2016 Emerson Exchange PPT Reduce C&I Cost Rev0b JS 11Apr16

8/17/2019 2016 Emerson Exchange PPT Reduce C&I Cost Rev0b JS 11Apr16

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HOW TO REDUCE

AND CONTROL SYSTEM

DETAILED ENGINEERING COST

(When Package Units need to be Integrated)

u n ezPositive Engineering

Twitter Conference Hashtag: #EMRex



Presenter How to Reduce I&C En ineerin CostPresenter How to Reduce I&C En ineerin Cost

Julián Sáez

[email protected]

. .



Introduction How to Reduce I&C Engineering CostIntroduction How to Reduce I&C Engineering Cost

Company presentation

os ve ng neer ng

Control & Instrumentation Solutions for Process Industry

Detailed Engineering for C&I International Projects

Inte ration of Packa e Units with the Rest of the Plant




Presenter short biography

Julián Sáez (Control and Instrumentation Engineer)

BSc in Electrical Engineering

BSc in Computer Science

MSc in Electronics and Industrial Automation Engineering

,

Técnicas Reunidas (7 years), Control & Instrumentation

CPC En ineerin 9 ears Control & Instrumentation

Positive Engineering (1 year), Control & Instrumentation

Lecturer at University of Murcia (7 years), Control Systems




Positive Engineering State of Business

Mid 1990s Early 2000s 2005-2010 2011-2016

DCS Programming

Loop Test

DCS HW & SW Spec

PLC

Package Unit Integration

Construction Supervision

C&I Consulting

DCS & ESD Upgrade

Simulation for OTS Commissioning Instrumentation ICSS



Presentation How to Reduce I&C Engineering CostPresentation How to Reduce I&C Engineering Cost

How to Reduce Instrumentation and Control System Detailed

Units need to be Integrated)

This presentation will show tips to reduce Instrumentation and Control System Detailed Engineering cost

and commissioning time in projects where several package units need to be integrated.

One of the main challenges in the development of Detailed Engineering for Instrumentations and ControlSystems is the integration of the controls of different package units.

’

sometimes overlook important details of the integration of their package units with other package units and

with the rest of the client plant. Also quite often they don’t take enough care of the client specifications.

This leads to a lot of misunderstandings and endless hours for clarifications during the detailed.

And typically not all aspects are considered during the detailed engineering phase, so they only appear

during commissioning, when the different package units and the rest of the plant need to work together.

6



Presentation How to Reduce I&C Engineering CostPresentation How to Reduce I&C Engineering Cost

How to Reduce

ns rumen a on an on ro ys em e a e ng neer ng os

and Commissioning Time

When Several Packa e Units need to be Inte rated

Abstract

7



Agenda How to Reduce I&C Engineering CostAgenda How to Reduce I&C Engineering Cost

– Typical Issues in C&I Detailed Engineering when

Package Units are Involved

– Consequences of Poor Design

– ome es rac ces or on ro ys em an eWiring Design and Commissioning

– Business Results Achieved

–

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Typical Issues in C&I Detailed Engineering when Package Units InvolvedTypical Issues in C&I Detailed Engineering when Package Units Involved

Package Unit Vendor doesn’t differentiate which signals need to

e w re to an w c s gna s nee to e w re to

9




Correct:

10




ac age n t en or or c ent oesn t e ne mus room

is required

11




DCS-ESD Interface: Signals hardwired between controllers

(mainly DCS-ESD) not defined

DCS ESD

It is necessary to analyze which interlocks are to be programmed in DCS and

which in ESD and where are wired to (DCS or ESD) each of the signals involved

in the interlocks

12




DCS-ESD Interface:

Signals hardwired between controllers

DCS ESD

It is necessary to analyze which interlocks are to be programmed in DCS and

which in ESD and where are wired to (DCS or ESD) each of the signals involved

in the interlocks

13




Hardwired signals between MCC and DCS or ESD defined too

late

P&ID 1st rev received from Vendor P&ID marked by client with MCC signals

14




Package Unit Vendor doesn’t follow Client tagnaming criteria for

Control System Signals and wiring design (JBs, Multicables,

TBs...etc .

15




Controls and Interlocks oorl re resented on Packa e Unit

Vendor P&ID

Controls and Interlocks oorl defined in Packa e Unit Vendor

Control Narratives

P&ID 1st rev

received from

Vendor

16




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Inte ration of Packa e Unit Vendor Controls and Interlocks with

the rest of the plant poorly defined (quite often overlooked)

Definition by client of which controllers (DCS & ESD) will receive

Package Unit Vendor hardwired signals defined too late

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Consequences of Poor DesignConsequences of Poor Design

Consequences of Poor Design:Consequences of Poor Design:

Endless hours spent (email chains, telephone calls..etc)

Many revisions in (P&ID, Signal List, Logic Diagrams, Wiring

Design...etc)

Longer commissioning and start-up time

ore cu an expens ve u ure ma n enance

19



Some Best Practices for Control S stem and Field Wirin Desi n and CommissioninSome Best Practices for Control S stem and Field Wirin Desi n and Commissionin

Some Best PracticesSome Best Practices

For Control System and Field WiringFor Control System and Field Wiring

20




Send Client C&I Desi n S ecs to Packa e Unit Vendor

Involve Client personnel in all phases of the project

Clarification meetings at Package Unit Vendor facilities

Dedicate a person to take care of the integration of Package

Unit Vendor design with rest of the plant

21




Pre are Control S stem SW Functional Desi n S ecification

Request ILDs (Instrument Loop Diagrams) for all signals

Homogenize PLCs in your plant

Use AMS (or similar tool) for loop test

Re uest FAT and SAT rotocols before startin the tests

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Business Results Achieved How to Reduce I&C En ineerin CostBusiness Results Achieved How to Reduce I&C En ineerin Cost

-Cost drastically reduced (many engineering hours saved)

- Commissioning and Start-up time reduced

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uestions and Answers How to Reduce I&C En ineerin Costuestions and Answers How to Reduce I&C En ineerin Cost

Thanks for your attentionThanks for your attention

Now: Questions and Answers

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Let’s ConnectLet’s Connect

LinkedIn.com/in/juliansaezmateo

[email protected]

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Documents

2016 Emerson Exchange PPT Reduce C&I Cost Rev0b JS 11Apr16