554 P3 e1 fm Process Control Systems— Project Execution and Process Control System Ownership API RECOMMENDED PRACTICE 554, PART 3 FIRST EDITION, OCTOBER 2008 Process Control Systems— Project Execution[.]
Document Organization
This document is organized to follow the sequence of activities associated with the typical life cycle of a process control system as summarized in Table 1
The life cycle phases as they apply to process control systems are as follows.
— Appraise Develop business goals and requirements and identify basic functions required This step is often also referred to as the Conceptual Stage.
— Select Further develop business goals and functions into a process control systems scope definition This step often is part of the early portion of front end engineering design (FEED).
The process control systems scope definition is crucial, involving the selection of appropriate hardware and software, as well as the preparation of necessary design drawings and specifications This phase also includes the procurement of additional hardware and equipment, often constituting the majority of the Front-End Engineering Design (FEED) process.
— Execute Detailed design and procurement, construction/installation, checkout, commissioning.
— Operate Commission operate and maintain.
API 554 has been divided into three parts, each focusing on a major aspect of process control systems The three parts and the areas that they cover are as follows.
A process control system is essential for managing various functions within industrial applications This article outlines the fundamental capabilities required of such systems and offers guidance on effective methodologies for identifying specific functional and integration needs tailored to individual applications.
Part 2 of the article focuses on the design of process control systems, detailing the essential hardware and software components involved It offers practical recommendations for effective implementation and highlights key design considerations Additionally, the section includes references to best practices for control centers and various control system buildings and enclosures.
Part 3 focuses on the execution and ownership of process control system projects, detailing the necessary project organization, skills, and work processes essential for successfully implementing and managing a process control system Table 1 highlights the relevant sections of API 554 that correspond to each phase of the project life cycle.
Part 1, Part 2, and Part 3 of API 554 reference several publications that form the foundation of process control systems Users must determine the relevance of these references to their specific installations, as local jurisdiction requirements may modify or take precedence over the information provided in these publications.
API Recommended Practice 551, Process Measurement Instrumentation
API Recommended Practice 552, Transmission Systems
Table 1—Process Control Systems Life Cycle Overview
Number Phase Objectives Major Inputs Major Outputs
To ensure project success, it is essential to document the business goals and foundational elements, including process design, PFDs, and an equipment list Additionally, assessing existing systems and infrastructure, along with layout considerations, is crucial Aligning these factors with business objectives, developing an operations staffing plan, and adhering to the corporate master plan and control system standards will facilitate effective project execution.
Process control system conceptual design basis
Sec 3, 4 Select/FEED Develop a functional specification describing the scope of the project, functional requirements and overall implementation responsibilities
Design basis, P&IDs, equipment lists, process hazard analysis
Process control system conceptual design basis
Process control system functional specification
Prepare request for quote, issue, and select a vendor
Specify hardware, I/O layouts and communications
Design control centers, field devices, interconnecting wiring, instrument power
Define control systems interfaces to other systems and hardware
Process control system functional specification
Hardware and software selection Detailed specifications and installation/construction drawings
Part 3 Execute—project execution and management
Execute designs to meet cost, schedule and technical requirements
Project objectives, cost and schedule Complete design drawings and specifications
Procurement of all materials and equipment Implementation and testing of all software based functions
Parts 2, 3 Execute— construction and installation
Install, calibrate, and loop test instrumentation and control systems
Configuration and programming Equipment and systems manuals
Process control systems ready for operation
Part 3 Operate—commission Prepare process controls system for operation Performance requirements Process control systems in operation All deficiencies identified and corrected
Part 3 Operate—operation Operate process control system to best operational effectiveness
Performance requirements Business revenue and minimal costs
Part 3 Operate—maintain Maintain, preventative maintenance (PM) and repair process control systems
As-built documentation and training Maximum unit performance and availability
API Recommended Practice 553, Refinery Control Valves
API Recommended Practice 555, Process Analyzers
API Recommended Practice 556, Fired Heaters and Steam Generators
API Recommended Practice 557, Guide to Advanced Control Systems
API Recommended Practice 750, Management of Process Hazards
AICHE G-12 1 , Guidelines for Safe Automation of Chemical Processes
AICHE G-66, Layer of Protection Analysis: Simplified Process Risk Assessment
AICHE Guidelines for Safe and Reliable Instrumented Protective Systems
EEMUA 191 2 , Alarm Systems—A Guide to Design, Management and Procurement
EEMUA 201, Process Plant Control Desks Utilising Human-Computer Interfaces
IEC 61131-3 3 , Programmable Controllers, Part 3, Programming Languages
IEC 61158 Parts 1 – 7, Digital Data Communications for Measurement and Control—Fieldbus for Use in Industrial
IEC 61508 Parts 1 – 7, Functional Safety of Electrical/Electronic/Programmable Electronic Safety Related Systems IEC 61511 Parts 1 – 3, Functional Safety Instrumented Systems for the Process Industry Sector
ISA 5.1–1984 (Reaffirmed 1992) 4 , Instrumentation Symbols and Identification
ISA 5.2–1976 (Reaffirmed 1992), Binary Logic Diagrams for Process Operations
ISA 5.3–1983, Graphic Symbols for Distributed Control/Shared Display Instrumentation, Logic and Computer
ISA 5.5–1985, Graphic Symbols for Process Displays
ISA 18.1, Annunciator Sequences and Specifications
ISA 84.00.01 (IEC 61511 Mod), Functional Safety: Safety Instrumented Systems for the Process Industry Sector
1 American Institute of Chemical Engineers, Center for Chemical Process Safety, 3 Park Ave, New York, New York, 10016-5991, www.aiche.org/ccps/.
2 Engineering Equipment and Materials Users’ Association, 10-12 Lovat Lane, London, EC3R8DN, United Kingdom, www.eemua.org.
3 International Electrotechnical Commission, 3, rue de Varembe, P.O Box 131, CH-121 Geneva 20, Switzerland, www.iec.ch.
4 The Instrumentation, Systems, and Automation Society, 67 Alexander Drive, Research Triangle Park, North Carolina 27709, www.isa.org.
ISA TR84.00.03-2002, Guidance for Testing of Process Sector Safety Instrumented Functions (SIF) Implemented as or Within Safety Instrumented Systems (SIS)
ISA 88.01, Batch Control—Part 1: Models and Terms
ISA 91.00.01, Identification of Emergency Shutdown Systems and Controls That Are Critical to Maintaining Safety in
ISA 95.00.01, Enterprise-Control System Integration—Part 1: Models and Terminology
ISA 98.00.01-2002, Qualifications and Certification of Control System Technicians
ISA TR98.00.02-2006, Skill Standards for Control System Technicians
ISA 99.00.01, Security for Industrial Automation and Control Systems, Part 1: Terminology, Concepts, and Models ISA TR99.00.02, Integrating Electronic Security into the Manufacturing and Control Systems Environment
ISA 99.00.03, Operating a Manufacturing and Control Systems Security Program
ISA 99.00.04, Specific Security Requirements for Manufacturing and Control Systems
OSHA 29 CFR 1910 5 , Code of Federal Regulations Title 29—Occupational Safety and Health Standards
PIP PCESS001 6 , Safety Instrumented Systems Guidelines
PIP PCED001, Guideline for Control System Documentation
PIP PICO001, Piping and Instrument Diagram Documentation Criteria
The following terms and definitions are used in API 554.
Refers to control functions that occur in a series of complex steps or phases that may combine continuous control, sequence control and discrete control to execute a processing scheme
A digital communications network is essential for general business applications, including desktop computing and non-process control database tasks These networks commonly utilize industry-standard communication methods, such as Ethernet, to ensure efficient connectivity and data exchange.
Refers to the process of preparing a process control system and all of its components and field instrumentation for operation after all loop testing and validation testing has been completed
5 Occupational Safety and Health Administration, U.S Department of Labor, 200 Constitution Avenue, NW, Washington, D.C
6 Process Industry Practices, 3925 West Braker Lane (R4500), Austin, Texas 78759, www.pip.org.
Control functions are essential for continuously and repetitively managing process variables like pressure, temperature, and flow These functions play a crucial role in continuous processes, such as refining, as well as in specific segments of batch control systems.
The instrument control system encompasses the input sensor, transmitter, communication path, control algorithm, and final control element The control algorithm can operate as one of several algorithms within a process control system or be executed by independent electronic, pneumatic, or mechanical devices.
A Demilitarized Zone (DMZ) is an additional digital communications network positioned between an internet-exposed network and a protected network In practical terms, the DMZ serves as a buffer zone between a business Local Area Network (LAN) and the process control network, enhancing security by isolating sensitive systems from public access.
Discrete control functions manage on-off operations and interlocks, utilizing control variables linked to specific thresholds When these thresholds are crossed, a control action is triggered, which typically involves discrete functions like opening or closing a valve or starting or stopping a motor.
Data transmission involves coding and decoding information through algorithms and encryption keys that are exclusive to the sending and receiving devices Numerous encryption techniques and algorithms exist, each offering different levels of security.
Refers to systems that are used to identify and coordinate supplies of raw materials, intermediate materials, finished products, consumables and other material or resources required to operate a manufacturing business.
Ethernet is a networking standard that connects multiple computing devices using a single cable with four pairs of wires, enabling communication without the devices needing to recognize each other This asynchronous communication method allows for message collisions and incorporates collision detection, along with a random pause and retry mechanism for effective communication among devices The Ethernet standards are outlined in the IEEE 1802.x series.
A meta-language written to allow for the easy interchange of documents on the world wide web or among computers using web based software tools.
Testing is conducted on a process control system at the manufacturer's or designated facility to ensure it is complete and operational Engineers or owners carry out all necessary tests to confirm the system's readiness for shipment to the site.
A fieldbus network is a digital communication system that links field sensors, transmitters, and control actuators to a controller or control network This network enables devices to exchange messages over a common pathway, allowing them to transmit current measurements and diagnostic information while receiving commands and configuration data.
Define/Execute Project Scope
In the early stages of a project, it is essential to develop a functional specification for the process control system, which serves as the foundation for initial estimates and further scope development The project scope development process must encompass the selection of hardware and software, along with a thorough analysis of the execution plan and schedule The following points emphasize key aspects that should be considered during these scope development activities.
Scope and planning activities must consider the type of project involved and the limitations that may be placed upon schedule and execution of work
Planning projects for new installations on new units is relatively simple The process includes completing design specifications and drawings, delivering materials, and conducting installation, loop checks, and commissioning These steps follow established practices and can typically be scheduled to enhance efficiency.
Modifying existing facilities presents significant scheduling and execution challenges It is essential to consider the constraints imposed by ongoing operations and infrastructure during the scope and planning phases of a project.
Upgrading existing process control systems requires less equipment than process modifications, yet these projects typically allocate a larger portion of the total budget to engineering Additionally, they often necessitate a hot cut-over of the control system, which demands meticulous planning, scheduling, and execution.
Installation and commissioning schedules will often be governed by expected unit turnarounds
Installation and commissioning periods can be constrained and influenced by concurrent turnaround activities Therefore, scheduling during a turnaround must be precise and well-coordinated with other maintenance tasks.
To optimize the turnaround schedule, it is essential to maximize pre-installation, pre-testing, and pre-commissioning activities Performing work while a unit is operational can lead to inefficiencies and may necessitate special permits and adherence to specific work rules In certain situations, on-stream transfers of control functions will be required, demanding meticulous planning and coordination with operations and maintenance teams This ensures the safe isolation of systems and the effective testing and commissioning of modifications, typically involving the preparation of detailed step-by-step isolation, tie-in, and commissioning procedures.
5.1.2 Process Control System Life Cycle
Table 1 outlines the typical project life cycle, highlighting key inputs and outputs for each phase It is essential to make all process control system decisions with this life cycle in focus Additionally, all components should align with the project's overarching business objectives while ensuring the required reliability and maintainability to achieve those goals.
While simplification or scope reduction might seem advantageous for a project, any proposals should be thoroughly evaluated in light of long-term business implications Altering the process control system design to cut costs or shorten timelines can significantly affect the overall business strategy, potentially leading to costly and disruptive remedial actions later in the project.
5.1.3 Process Control System Functional Development
The development of process control systems encompasses both physical design, including the identification and installation of hardware, and non-physical design, which involves system configuration, programming, and the implementation of software functions like historians, advanced control schemes, complex logic, sequences, and protective shutdowns A comprehensive project execution plan and schedule should clearly outline the non-physical project scope, tasks, and ensure the allocation of sufficient resources, costs, and timelines.
The project execution plan should effectively address both physical and non-physical design and implementation needs Control system designs depicted in P&IDs may often be indicative rather than fully complete, even when other mechanical and piping elements are largely finalized Design engineers must adapt the control system P&ID representations to accommodate advancements in control system details, despite the established state of the piping and mechanical information in the drawings.
Design organizations must ensure that P&ID representations of control systems are thorough and distinguish between design intent and actual scope changes Artificially freezing incomplete designs for scope control is rarely cost-effective Incomplete work in the design phase often leads to substantial modifications during construction, checkout, and commissioning, ultimately impacting the overall design quality and increasing operating and maintenance costs.
Choosing a process control system for a project involves more than just considering cost and performance; it must align with the existing operational culture of the facility Typically, when a new system is introduced, it is selected to be compatible with the current systems in place Any decision to change requires significant justification based on life cycle costs and functional requirements.
Selecting a process control system for a project requires the involvement and support of facility personnel across various job functions It is essential to consider the long-term automation and information systems plans for the facility during this selection process.
The following are some of the life-cycle issues that must be considered when selecting a process control system.
— Is there an existing process control system that the project must expand or modify?
— If a new process control system is required for the project, does the facility have existing systems with which the new system must be compatible?
When upgrading or replacing a process control system, it is essential to thoroughly evaluate how the enhanced capabilities of the new system can be leveraged to optimize process performance.
Training costs for engineering, operations, and maintenance personnel to support a process control system can be significant Prior experience and training with an existing system may outweigh any potential cost savings from switching to a new process control system.
— What are the costs associated with maintaining an inventory of spare parts?
— What is the scope and costs associated with interfacing functions such as historians and advanced process control systems?
Overview
Effective implementation of process control systems necessitates a diverse range of skills and experience to ensure safety, reliability, and ease of maintenance Project staffing plans must align project requirements with available resources and expertise It is often beneficial to engage specialized personnel for specific functions and to coordinate their efforts with the overall project activities.
Resources and Staffing
6.2.1 Traditional Engineer-procure-construct (EPC)
Traditional engineering contractors excel in project management and organization, offering essential procurement and design services However, they often lack the specialized skills required to specify, engineer, test, and commission the increasingly complex process control systems available today, which are typically not found within general EPC organizations.
6.2.2 Specialty Resources—Main Automation Contractor
For projects involving new process control systems and less commonly used software, choosing a specialized organization for design, configuration, testing, and commissioning can be beneficial These organizations possess expertise in specific systems, leading to cost savings, enhanced application skills, and improved reliability and performance.
A main automation contractor typically specializes in specific functions within a larger design organization and may lack the capability to offer additional services like physical designs, building design, and electrical distribution It is crucial to coordinate third-party participation when selecting these organizations to avoid gaps in service and ensure that all deliverables align with the end user's requirements.
Owner’s staff can significantly enhance project designs by ensuring they align with established practices and maintain quality standards, although their availability is often quite limited.
A project scope may involve the integration of new technologies, which often requires specialized assistance for implementation and personnel training Additionally, it is essential to ensure support is available during the testing, commissioning, and initial operation phases.
6.2.5 Third Party Engineering and Package Systems Suppliers
Assigning the scope of work to third-party suppliers, especially for major equipment, can be beneficial; however, when it comes to process control systems, the overall value must be thoroughly assessed The effectiveness of a process control system heavily relies on the quality and consistency of the work performed Therefore, it is often more prudent to restrict package suppliers to mechanical equipment and basic instrumentation, while ensuring that any advanced controls are implemented or coordinated by the main contractor responsible for all process control system tasks.
Standards and Practices
All instrument and control system projects must adhere to established engineering and design standards, which can include a mix of owner, contractor, and industry standards It is crucial to identify and prepare these standards early in the project timeline If new standards need to be developed for a specific project, adequate time must be allocated in the project schedule to accommodate this task.
The standards set should address the following major areas:
— general control system engineering and design practice including identification of local regulations that apply, device and tagging naming practices;
— the required review and approval process for the project;
— functional and physical requirements for various common devices found in instrument and control systems;
— applicable local codes and regulatory requirements;
— process control system design, configuration practices and standards, including graphics standards and practices;
— safety Instrumented system design, documentation and test practices;
— standard Instrument installation details and installation material specifications;
— calibration and loop check practices;
— safety and protective system testing, validation and acceptance practices; and
6.3.1 Documentation and Design Drawing Standards
Facilities typically have established guidelines for the types and formats of design drawings, which are crucial to understand along with the associated documentation procedures When projects relate to existing processes, there may be strict protocols for accessing current drawings and returning as-built versions to permanent files Additionally, in environments with multiple concurrent projects, it is essential to ensure that the as-built drawings of one project do not interfere with those of another.
In many projects, the focus of design efforts is on creating piping and instrument diagrams (P&IDs), which illustrate all piping components, physical instruments, and the control functions implemented in programmable control systems P&ID practices differ significantly across organizations, with standards organizations like ISA and PIP establishing guidelines for P&ID representations.
Regardless of the P&ID standard applied, it is crucial to thoroughly develop control system functions Often, the details of control systems may not keep pace with those of piping and equipment To manage scope and costs, it is common to "freeze" P&IDs during the design process Understanding the status of the process control system design at the time of this freeze is essential.
Documents related to process units often hold significant process safety management (PSM) importance, necessitating the inclusion of specific information and adherence to approval processes beyond standard project documentation Additionally, these drawings may be subject to handling restrictions and limitations on who is authorized to make changes.
Design Data Management
Many facilities utilize electronic documentation systems, and projects often plan to implement specific applications such as P&ID, drafting tools, electronic instrument databases, and process control data storage systems It is essential for the project plan to outline these requirements and ensure compliance with the final documentation format and existing procedures for these applications.
Many process control system manufacturers offer tools that enable offline system configuration, eliminating the need for hardware during setup In certain applications, like fieldbus, these tools can also facilitate the configuration of most or all field devices.
An electronic documentation system can generate configurations for process control systems, offering potential benefits However, it is crucial to integrate these capabilities with the plant's data management practices Before deciding on how to complete configuration tasks, it is essential to evaluate the electronic documentation system's features in comparison to other available tools.
Many facilities utilize a centralized maintenance management system to store essential engineering specifications, manufacturer data, and equipment numbers This system is primarily employed to schedule and monitor maintenance activities while also documenting maintenance and repair records The specific applications and their usage can differ significantly across various companies and locations.
The project must identify requirements in this area and establish how these data bases will be populated with new or revised data.
Procurement
Procurement activities involve soliciting proposals and selecting suppliers for all engineered and bulk materials needed for a project These activities encompass several essential functions.
Engineered equipment necessitates the clear definition of functional and mechanical requirements for instrumentation or process control systems through data sheets, narrative specifications, drawings, or a combination thereof To ensure accurate proposals, it is essential that all requests for proposals include comprehensive specifications as the foundation for the proposal.
When engineered equipment includes process control system components, it is essential for the supplier to comply with the plant's accepted supply and design requirements Except for specialty or proprietary designs, the components supplied should be limited to those commonly used by the plant or identical to those used in other project areas.
Many owners and operators maintain a list of preferred suppliers for equipment and materials, typically influenced by prior installations, familiarity with the plant, and established procurement agreements that are not specific to any single project.
For a project, it is essential to compile a list of acceptable or required suppliers Procurement must follow this list unless directed otherwise In certain situations, the list may necessitate sole source awards due to the commercial agreements of the owner or operator.
6.5.3 Solicitation of Proposals and Supplier Selection
When evaluating proposals from potential suppliers, it is essential to condition these proposals to accurately assess their technical compliance and commercial value This process should take into account the owner or operator's current installations and commercial agreements A low bid may not always be the best option, as it could come from a supplier without an established presence or significant installed base, leading to additional costs for training, spare parts, and support that diminish the overall value of the proposal.
6.5.4 Review of Supplier Drawings and Specifications
After an award is granted, the supplier must submit comprehensive drawings and specifications for the equipment or materials These submissions are essential for reviewing and ensuring that the design aligns with the specified requirements, that the equipment adheres to the approved list of suppliers and models, and that adequate data is provided for designing interfaces with the equipment.
6.5.5 Integration of Supplier Information into Design Drawings
Integrating supplier data with a plant's essential design drawings is crucial for maintaining accurate and up-to-date information Owner operators typically establish standards and practices that dictate the vendor-supplied data to be included in the core drawing set Examples of these standards help ensure consistency and reliability in the documentation process.
Instrumentation datasheets often need to be submitted in the standard format required by the owner or operator This process frequently involves either importing data or manually entering information into the plant databases.
— P&IDs may need to be modified to include vendor equipment details.
— Documentation of logic systems may need to be presented in site standard format This includes logic diagrams, descriptions and routine testing procedures.
— Schematics or interconnecting wiring drawings may need to be presented in a standard format.
When preparing specifications and selecting suppliers, it is essential to consider the integration of supplier drawings into the owner or operator's drawing practices, as this will impact project closeout planning.
Engineered equipment necessitates source inspection or testing, which must be explicitly outlined in technical specifications and requests for proposal The inspection or testing scope often involves oversight by design engineers or owner representatives, serving as a critical hold point for equipment delivery In process control systems, employing inspectors without direct engineering involvement is typically unsuitable due to the specialized knowledge required for the application and equipment.
Physical Design
Physical design involves essential activities for the installation of process control system equipment, including equipment placement, wiring routing, conduit installation, and instrument mounting While this document does not delve into these practices, references such as API 551 and API 553 provide valuable guidelines on physical installation methods.
Construction
Construction planning and scheduling must recognize activities associated with installing, testing and commissioning process control systems This process needs to address the following:
— installation of field instrumentation and associated wiring and communications systems;
— installation of process control system control modules or other support systems such as historians, advanced control systems, etc and the thorough testing of these systems;
— control centers and other buildings such as analyzer shelters, satellite equipment rooms or shelters;
— other complex systems such as machinery monitoring, process sequence controls etc.;
— power supply and distribution systems;
— hot cut-over and tie-ins;
— testing and commissioning of control, indication and alarm loops;
— testing and validation of protective systems such as SIS; and
— testing and commissioning of advanced control systems.
Incorporating the necessary time and resources for all activities into the overall construction schedule is essential, with detailed identification of each task It is crucial to schedule mechanical installations and other activities to allow sufficient time for work related to the process control system, ensuring alignment with the expected completion date For further details, refer to Section 7.
Training
Integrating training for plant engineering, operations, and maintenance personnel into project planning is essential Each project should develop a comprehensive training plan that encompasses all necessary training for designing, testing, operating, and maintaining the process control system This plan must involve both the owner's personnel and project team members Additionally, training requirements may influence construction and checkout schedule milestones, as significant portions of the training can only occur once construction and checkout are largely completed.
Engineering training is often the initial training provided, with process and control engineers playing a crucial role in the project from its inception Their involvement in configuring the control application is essential, as a deep understanding of the system is necessary for effective contributions to the project team during the development of the control application.
To optimize operator training, it should be scheduled well in advance of system installation, allowing operators to familiarize themselves with the system Conducting training just before installation keeps the information fresh in their minds Additionally, early training sessions can provide valuable feedback from operators, which can be used to enhance system features such as graphic layouts and alarms.
To effectively support operator training, it is essential that the process control system is accessible, or alternatively, a dedicated training system should be implemented Full simulators are crucial for adequately training operators in both the fundamental operations of the process control system and in managing abnormal situations For further insights on determining the necessity of training simulators, refer to API 554, Part 1.
Before installation, it is essential for maintenance training to be completed, and the personnel responsible for instrument maintenance should be involved in the installation process This training should ideally occur right before the equipment is installed and commissioned, unless certain individuals need it to support the project effectively.
Testing, Validation and Commissioning
In the design of logic and sequence systems, it is essential to create a comprehensive plan that outlines the necessary testing, validation, and commissioning activities required before the system can be operational For critical systems, particularly those related to safety and protection, it is important to develop detailed testing procedures For further insights into the recommended testing and validation practices, refer to Section 7.
Project Close Out
During loop checking and startup activities, it is essential to update key process control system documentation to reflect as-built status Process safety management mandates that operations and maintenance personnel have access to a complete set of current documentation Consequently, until the as-built documentation is finalized, maintaining a set of current mark-ups of construction drawings and data in the control center or another accessible location may be necessary.
It is recommended that at a minimum the following drawings be updated to as built status and maintained in an as- built condition for the life of a plant:
— instrument terminal box and control panel interconnecting wiring drawings; and
— control system configuration including process control system or PLC programs.
Planning
In construction planning, it is essential to define the scope and schedule for loop testing, safety and protective system testing, validation, and cut-over for each project individually This planning process must encompass specific considerations to ensure effective execution.
The testing schedule and requirements for the main control system equipment and software encompass both factory and site acceptance testing (SAT) The duration of SAT may be prolonged based on the efficiency of factory acceptance testing and the complexity of interactions with other systems Often, interfaces with existing systems can only be evaluated once the process control system is fully installed and operational For more details, refer to section 7.2.
The inspection, calibration, and loop checking schedule must account for the time required after mechanical installation is finished Often, construction timelines overlook the actual duration needed for thorough loop testing and the validation of protective and safety systems, leading to potential delays in project completion.
During construction, it is essential to determine the scope of bench calibration and the calibration required in the field during loop testing Typically, modern digital instruments do not undergo bench calibration; however, it is important to perform configuration data checks as needed.
— Define the procedure that loop testing will follow for each major type of loop See loop testing procedures below.
To ensure effective loop testing, it is essential to identify all necessary personnel, including adequate resources at the process control system console, instrument supplier representatives for specialized instruments, and maintenance and operations staff who may need to witness and approve the loop testing process.
— Identify all complex instrumentation, analyzer systems, etc that require more than the routine amount of configuration, testing, commissioning and validation and show required support and time requirements.
Identify all logic and interlock systems that necessitate formal testing beyond basic loop testing Determine the personnel and time needed for this testing, and specify which systems require formal written test procedures.
Main Process Control System
The planning and execution of instrumentation and control systems in construction vary significantly based on project size and complexity Small projects typically need minimal formal planning, focusing mainly on workforce and schedule allocation In contrast, larger projects, especially those interfacing with existing systems or involving substantial process control equipment and safety instrumented systems, necessitate comprehensive planning to ensure successful implementation.
— loop cutover/system validation; and
Before system testing and commissioning, it is essential for technical staff to undergo training on the new system The manufacturer of the process control system provides various training courses, with a minimum requirement for process and control engineering staff to receive training in application configuration and graphic building Additionally, instrument personnel need training in hardware maintenance, while all operators and supervisors must be trained in the system's usage.
Once an instrumentation and control project has been scoped, an overall construction plan should be developed The plan should address:
— overall construction schedule with time lines for all activities identified;
— approved plans for system installation;
— approved procedures for hardware testing, factory acceptance, site acceptance and cutover;
— pre-start up safety review (PSSR); and
— management of change (MOC) procedures.
Before starting the Factory Acceptance Test (FAT), the manufacturer of the process control system must perform an internal Factory Hardware Test (FHT) This test includes a thorough inspection of all components listed in the bill of materials (BOM) and a complete check of the system's input/output (I/O) functionality.
NOTE The I/O check may not be possible in some cases; i.e fieldbus I/O or remote I/O provided by others or shipped early The FHT records are reference material for the FAT.
The Factory Acceptance Test (FAT) typically evaluates the system based on the specifications outlined in the functional design document, detailed design document, and system architecture drawings This testing process generally encompasses hardware functionality, application functionality, and integration with other systems.
The FAT will typically include testing of:
— process control system communication network(s);
— integration with other systems (safety systems, compressor controls, etc.).
Before initiating the Factory Acceptance Test (FAT), it is essential to develop and obtain approval for a comprehensive FAT manual from both the vendor and the end user This manual should outline the testing scope, schedule, and a detailed list of tests along with their acceptable results It must also include sections for documenting test outcomes, acceptance signatures, and dates Additionally, a "punch list" of non-conformances will be generated during testing, with each item requiring correction and demonstration before proceeding with the loop cutovers.
The FAT procedures aim to outline the detailed steps for conducting each test and documenting the results Each test procedure must include specific sections to ensure clarity and consistency.
— results check sheet/comments/test record sign-off sheet.
The FAT manual contains design information that was used to configure the process control system, and records any exceptions (variations) that may be discovered during testing.
The intent of the hardware testing is to ensure that the particular hardware components are correctly manufactured, integrated and configured as per the approved system specification.
This part of the FAT provides structured and step-by-step procedures to demonstrate that the hardware operates without any performance or communication errors Testing activities include:
— system hardware inspection (appearance, construction and size);
— visual and mechanical examinations of system connectivity;
— inspect and verify all component and cable labeling or other identification;
— system redundancy, including testing of back up control, I/O, communications and power redundancy functions;
— power on and off sequences;
— peripheral connection and functionality, etc.; and
— random I/O check from field side of marshalling cabinet.
Configuration testing is essential for verifying the functionality of process control system software and application programming The extent of this testing can differ based on the process control system's scope, but it generally encompasses specific activities included in the factory acceptance testing (FAT).
— historian and sequence of events recording (SER);
This section addresses the need to test integration and communications links between the process control system and other auxiliary systems See 7.5 for discussion of testing for these separate systems.
In various applications, process control systems are often assembled and tested as distinct systems, including safety systems, compressor control systems, logic systems, PLCs, and analyzers Each of these systems may follow its own acceptance testing procedures For safety systems, additional guidance on testing procedures is provided by organizations, with references to ISA 84.0.01 and IEC 61511 for safety requirements specifications.
Effective communication between the process control system and other systems is essential, as outlined in the functional specification (API 554, Part 1) This interface must be tested during the Factory Acceptance Test (FAT) For smaller systems like PLCs, integration and testing can occur directly on the factory floor However, for larger systems, only parts of the process control system may be tested on-site, necessitating a comprehensive plan for field testing all communication functions after installation It is crucial to incorporate these testing provisions into the overall construction and testing schedule.
This activity, distinct from testing, occurs between the Factory Acceptance Test (FAT) and the Site Acceptance Test (SAT) It involves the physical installation of process control system cabinets and consoles, as well as the wiring of I/O to marshalling panels and junction boxes However, it does not include the physical connection to instrumentation and final control elements.
In project planning for process control system installation, it is crucial to identify the responsible organization For larger systems, this role is typically filled by the main automation contractor, while smaller systems may see the end user taking on this responsibility Regardless of the size, several key issues must be meticulously addressed.
Before installing the process control system equipment, it is essential that control centers, satellite buildings, and other enclosures are fully completed with all necessary utilities, including power, HVAC, and lighting This completion may involve a separate testing and acceptance process, as well as inspections and permits from local authorities If the final facilities are not ready when the equipment arrives, alternative protected and climate-controlled storage solutions must be arranged.
Power and grounding specifications are essential components of the functional design for process control systems It is crucial to adhere to these requirements, which may include a primary power source, a backup power source, and/or an uninterruptible power supply (UPS) For detailed guidance on power system and grounding design, refer to API 554, Part 2.
The SAT is typically shorter and less comprehensive than the FAT, but this can vary based on the FAT's scope and thoroughness The FAT should include detailed testing and documentation of all system components and their interfaces Generally, the SAT serves as a subset of the FAT, with testing often concluding at the process control system I/O terminations, as each loop is thoroughly tested during commissioning.
The SAT serves as the initial testing phase for all network and communications interconnections While factory tests may have been conducted, it is crucial to fully validate communications with equipment installed in the field to uncover any unforeseen issues arising from installation or unrecognized interactions.