BECHTEL CORPORATION

ENGINEERING — CONTROL SYSTEMS

ENGINEERING DESIGN GUIDE
INSTRUMENTATION AND CONTROLS FOR PACKAGED SYSTEMS
3DG-J21-00012, Revision 000, 2002 August 15
Reason for Revision: Supersedes 3GS-JP0G-00002, Rev. 001
Prepared by: T.L. Webb
Checked by: E. P. Mercado
Approved by: A. P. DiMartino

INTRODUCTION

This design guide addresses the development of a general specification for instrumentation and
control components to be provided as part of packaged equipment systems, e.g. cooling towers,
air compressors, grinding mills, etc.

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3DG-J21-00012-000 Page 1 of 11
TABLE OF CONTENTS

INTRODUCTION 1

1.0 PURPOSE 3

2.0 DEFINITIONS 3

3.0 GENERAL 3

3.1 SCOPE OF SUPPLY ISSUES 4

3.2 PACKAGE CONTROL AND INTEGRATION ISSUES 5

4.0 CONTENT 6

4.1 GENERAL 6

4.2 REFERENCE DOCUMENTS 7

4.3 INSTRUMENT IDENTIFICATION 7

4.4 INSTRUMENT SELECTION AND DESIGN CRITERIA 8

4.5 CONTROL SYSTEM DESIGN REQUIREMENTS 8

4.6 INSTRUMENT CONNECTION AND INSTALLATION CRITERIA 9

4.7 SUBMITALL REQUIREMENTS 9

4.8 SPECIAL PACKING AND SHIPPING INSTRUCTIONS 11

5.0 REFERENCES 11

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1.0 PURPOSE

This design guide discusses the development of a general specification for instrumentation and
controls provided with packaged equipment systems (Packaged Equipment Spec). Usually,
these specifications are used to establish a set of minimum general requirements applicable to
all packaged systems. Additional requirements and constraints applying to specific packages
are included in the specifications for the individual equipment system packages.

Note that in some cases, relatively small or simple, self-contained packaged systems, such as
small air compressors, may be purchased as essentially "off-the-shelf" units, though they may
require some engineered features. It is generally better to not use the Packaged Equipment
Spec in these cases; the requirements specific to that package should be defined in the
equipment package specification.

2.0 DEFINITIONS

The following terms are used in this guide with the indicated meanings:

Packaged Equipment Spec Refers to the subject of this design guide,

or "the Spec" properly entitled "Specification for
Instrumentation and Controls for Packaged
Equipment Systems"

Specification for Instrumentation The subject of this design guide, a project

and Controls for Packaged specification defining requirements for
Equipment Systems instruments and controls to be provided by the
suppliers of packaged equipment systems.

Packaged Equipment System A system of equipment, piping, instruments,

electrical devices, panels and other components,
provided by a single supplier to fulfill a specific
role on the project, e.g. an instrument air
compressor, a SAG mill, steam turbine, etc.

System Specification The specification defining the overall

requirements for the packaged equipment system

3.0 GENERAL

The Packaged Equipment Spec should be prepared, coordinated, issued and maintained in
accordance with EDP 3DG-G04-00049, "Engineering Specifications" and any applicable GBU,
office, or project specific procedures and instructions.

There are basically two reasons to utilize custom engineered or "off-the-shelf" packaged
equipment systems: 1) for economy or convenience, and 2) to utilize the supplier's expertise or
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proprietary technology. Both of these are usually best accomplished with a minimum of additional
requirements. However, some minimum standards and constraints must be imposed to insure
that the systems provided meet regulatory, client and Bechtel requirements for safety, quality,
performance, maintainability, etc. Since most equipment packages will have at least some
instrumentation and at least some interface to the plant control system, the Control Systems group
is responsible for ensuring that all project requirements regarding these components are met to
the extent required by the contract. The goal is to develop a specification that captures the
essential requirements without overly constraining the suppliers. Differing, unique and more
stringent requirements applying to only one or a few packages are better omitted from the
Packaged Equipment Spec and defined in the applicable System Specifications.

The first step in producing the Packaged Equipment Spec is to review the project design criteria.
These criteria establish the basic requirements.

Next, the plant operation and control philosophies must be considered. These will generally
determine the degree of interface and level of integration with the plant process control system.

Finally, consideration must be given to other project documents generated to support the
specification of packaged systems, such as general project specifications, client specifications
required to be included, Packaged Equipment Specs from other disciplines, etc. The Packaged
Equipment Spec should repeat a minimum of information and requirements contained in other
documents, especially those not specifically the responsibility of the Control Systems group.
This helps to eliminate or minimize the instances of conflicting requirements and simplifies
situations where information or requirements change.

In preparing the specification, it is important to differentiate between "requirements" and

"preferences". Though specification format is beyond the scope of this guide, this is usually
accomplished with the use of the words "shall" (requirements) and "should" (preferences).
Regardless of the means, the distinction must be made. A key point is that many equipment
suppliers do not specialize in instrumentation and control systems. Precision and clarity in
defining project requirements are essential elements of any well written specification.

3.1 SCOPE OF SUPPLY ISSUES

Frequently, the basic requirements derived from the design criteria will determine the equipment
suppliers' scope of supply for instrumentation and the extent to which their selection criteria are
constrained. For example, many clients require the use of specific types of instruments in
certain services and may actually dictate a specific manufacturer. In other cases, the client will
require only that all instrumentation of each type on the project be from the same manufacturer
to reduce spare parts inventories, maintenance training, and repair / replacement costs. Other
approaches include the "approved suppliers" list, wherein multiple suppliers' products are
acceptable, and the list of "acceptable suppliers and products" which are merely intended to
illustrate type and quality expectations without actually constraining the supplier or even
expressing a preference. In other cases, the client will have no specific requirements or
preferences. Each of these situations demands a slightly different approach when developing
the Packaged Equipment Spec.
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In a few cases, equipment suppliers have been instructed to provide only instrument data
sheets to specify the major instrumentation for their packages. The suppliers were required to
furnish any custom instruments, those with special connections or other special features not
available on the open market, and those which were part of the internal design of the
equipment, such as bearing RTDs, vibration monitoring probes or sealed systems with parts
integral to the equipment. The packaged equipment suppliers' data sheets were then included in
the project requisitions. While there are benefits to this approach in some situations, it is not
generally recommended due to potential problems with the supplier accepting responsibility for
the operation and performance of the system and other possible warrantee issues. So that
leaves us with passing down such requirements to the suppliers.

If the client has imposed straightforward, specific "requirements" for the types and
manufacturers of instrumentation, the engineer must include them in the Packaged Equipment
Spec. Suppliers may be permitted, or perhaps even encouraged, to propose separately priced
alternatives, i.e. their "standard" design, or they may take exception to the requirements. In
either case, there will be a cost comparison or technical basis upon which to formulate a
cost/benefit or technical design analysis during the proposal evaluation. Then the client can
decide whether to waive the requirement or demand compliance.

Likewise, "preferences" for types, and even manufacturers, are easily accommodated.

Difficulties do arise, however, in instances where the underlying requirement is that the types or
manufacturers be the same or consistent across the project. This poses a dilemma for the
Packaged Equipment Spec engineer. Since the Packaged Equipment Spec is usually
developed early in the project, most of the instruments for the project will not have been
specified, much less into the procurement cycle, so the instrument suppliers are not yet
determined. It is entirely possible that the packaged system will have been purchased and
perhaps well into fabrication before all of the instrumentation suppliers have been identified.
There is no single correct solution to this problem. Fortunately, this particular situation does not
arise frequently. The usual approach is to include the requirement in the Packaged Equipment
Spec with the actual information shown as "LATER" or some similar mechanism. The actual
resolution is then addressed on a package-by-package basis as the project progresses.

3.2 PACKAGE CONTROL AND INTEGRATION ISSUES

The project operations and control philosophies apply in general to all control designs on the
project. They may also deal more explicitly with certain types or classes of equipment
packages. Typically, however, somewhat different factors are considered for each equipment
package depending on its size, physical location, function in the process, criticality, etc. Any, all
or variations of the following levels of control and integration may be used on a particular
project.
(a) Standalone, locally operated
(b) Standalone, with hardwired alarms to the plant control system (PCS). Usually the
number of alarms is limited to summary "trouble", "alarm" and "shutdown" outputs with
more detailed local annunciation and perhaps a few critical "process" type alarms.
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 (c) Standalone, signals and alarms hardwired to the PCS. Similar to the above, except with
a greater level of PCS surveillance, including perhaps more alarms, other "status"
monitoring signals, and analog "process" monitoring signals
(d) Standalone/Partially Integrated, with a "read-only" digital data link to the PCS for
monitoring rather than hardwired signals.
(e) Partially Integrated, with a "read/write" digital data link to the PCS permitting monitoring
and "supervisory" (start/stop, shutdown) control capabilities
(f) Integrated, with a "read/write" data link to the PCS permitting monitoring and full remote
control capabilities (start/stop, shutdown, controller mode selection, controller setpoint
changes, etc)
(g) Fully Integrated by Supplier. The supplier provides all instruments and controls,
including a "node" of the PCS dedicated to control of the packaged system.
(h) Fully Integrated by Implementer. The supplier provides the instruments, local controls,
analog, discrete and sequence control logic, and perhaps remote PCS I/O, but actual
control is performed in the PCS based on the supplier's control schemes
(i) Fully Integrated by Engineering (equipment only), where the supplier provides the
equipment, piping and instruments, and perhaps "suggested" or "typical" control
schemes, but engineering provides all control hardware and designs the analog,
discrete and sequence control logic.

Variations of these basic categories are required if the equipment package contains or is
involved in broader emergency or safety shutdown systems.

The engineer developing the Packaged Equipment Spec must review the operating and control
philosophies, assess to the extent possible what levels of control and integration are required,
and include requirements for enclosures, wiring, controller hardware and software (e.g. PLCs),
data communication interfaces etc., consistent with the most stringent, with the qualification "if
required by the System Specification" or something similar. The various parts "required" are
defined in the System Specification for each package.

4.0 CONTENT

This guide will not attempt to recommend a document structure nor specific content. The
following are generic areas that should be addressed if applicable to the individual project. This
should in no way be construed to be an all inclusive list.

4.1 GENERAL

The specification should have a section defining its purpose and application. Usually it contains
a statement to the effect that the control functions and extent of instrumentation required are
defined in the System Specification. It also should contain a brief description of the work NOT
included as well as the work that is included, as it is often just as important to clarify what is not
expected of the supplier as what is.

This section may also contain definitions of the terms used, e.g. Seller, Buyer, Owner, Shall,
Should, Will, etc. On an ideal project, these terms would be used consistently throughout all
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project documents and defined once, in a General Specification, the MR boilerplate, or
elsewhere. Since most projects tend to be less than ideal, it seldom hurts to define the usage of
such terms as used in this particular specification. However they are defined, it is crucial that
they be used consistently throughout the specification.

This section occasionally contains a statement regarding the precedence of documents. Since
the Packaged Equipment Spec is itself a supporting document, this is generally not the best
approach — the precedence for each package should be established in the System
Specification or in the Material Requisition. An exception to this may be the situation where
data sheets or other attachments to the Packaged Equipment Spec itself may be used to
provide some required information or clarification: in these cases it can be beneficial to define
the precedence of such attachments in relation to the specification and to each other.

This section may also contain general project information, such as a project description, site
data, design conditions, utilities to be provided, etc. Again, since this is a supporting document,
these are better defined elsewhere.

The Packaged Equipment Spec should define the units of measure to be used for instruments,
charts, indicators, etc.

4.2 REFERENCE DOCUMENTS

This section should list other documents defining requirements or providing guidance for the
design, installation and supply of the instrumentation and controls for the package, especially
any specifically referenced in the specification itself. This may include other project
specifications, client specifications, and international, national, and local codes and standards.

One common approach for codes and standards is to simply list the applicable governing or
standards organizations, such as ISO, IEC, ANSI, ASME, ISA, IEEE etc., with a statement that
the materials and work should be in compliance with all that are applicable. This is generally
less than satisfactory, especially with the increasing usage of international standards. Though
significant effort is required to define which specific regulations, codes and standards apply, it is
subsequently much easier to verify that the design is in compliance.

4.3 INSTRUMENT IDENTIFICATION

The Spec should define requirements for instrument identification and tagging. Depending on
the project, different approaches may be adopted, ranging from the requirement that all supplier
instruments be assigned instrument tag numbers in accordance with project procedures to
requiring no other identification than the supplier's standard. Generally, the approach taken is
somewhere between these two extremes, and is tied to the representation of the supplier's
instrumentation on the P&IDs. Refer to design guide 3DG-J21-00003, "Instrument
Identification" for additional guidance. Usually this involves assigning project tag numbers to
instruments mounted in or on the piping, instruments requiring field wiring, instruments in major
control loops or instruments shipped separately that must be installed in the field. Another
approach is to require tag numbers only for instruments connected to or monitored by the PCS.
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 Tag numbers may be assigned by the Control Systems group or by the supplier from a "block"
of numbers allocated to them for that purpose. Usually suppliers will be permitted to use their
standard identifications on documents and drawings as well as the project assigned tag
numbers. The need to apply project tag numbers for tracking, identification, etc should be
weighed against the potential cost impact for the supplier to revise parts lists, drawings,
manuals and other documentation to include them.

Usually, permanent, durable tagging of all supplier furnished instruments is required, whether
assigned project tag numbers or not, to facilitate troubleshooting and maintenance.
Occasionally, the project will issue a specification dealing specifically with equipment and
instrument physical tagging requirements, i.e. tag material and configuration, lettering sizes,
information shown, manner of attachment, etc. Should this be the case, the Packaged
Equipment Spec should reference this specification. In the absence of this type of specification,
the Packaged Equipment Spec should specify these requirements.

4.4 INSTRUMENT SELECTION AND DESIGN CRITERIA

The Spec usually contains information defining requirements and preferences for the
application, sizing and selection of the instrumentation for process measurement and control.
This generally includes definition of the signal levels (4-20 mA for analog, 24 VDC for discrete,
etc.) to be used, guidelines for use and design of field bus networks (if used), and acceptable
digital interfaces. It should include any design requirements, such as contact configuration and
minimum rating requirements for process switches (DPDT, SPDT), failure modes, use of
explosion proof or intrinsically safe devices in hazardous areas, etc. It should include any other
selection criteria, e.g. requirements for transmitters rather than switches in monitoring
applications, from the Design Criteria that may apply. As previously discussed, it also includes
requirements related to permitted types of transmitters, control and relief valves, motor speed
controllers, etc.

4.5 CONTROL SYSTEM DESIGN REQUIREMENTS

The Packaged Equipment Spec should address the requirements and preferences for any
control equipment to be provided, be this single loop controllers, Programmable Logic
Controllers (PLCs), other types of embedded controllers, or portions of the overall plant control
system. It should address I/O selection, redundancy requirements, shielding, and surge
protection requirements. Such requirements may include restrictions to specific systems or may
be more general. It should define any requirements for local CRT operator stations if this could
be an issue, including any requirements relating to required displays, use of graphics, etc. Any
general requirements regarding interfaces, software design or other issues resulting from
integration issues as discussed in section 3.2 should be defined.

Occasionally, basic requirements for software design, such as program structure, data table
layout, point naming and in-line documentation requirements are included, but since these are
generally imposed only on major equipment packages and in cases of significant integration,
they are usually issued as a separate specification attached only to the applicable packages.

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The requirements and preferences for design and fabrication of instrument panels and control
cabinets should also be addressed, as should any relating to junction boxes if these are not
defined in an Electrical Packaged Equipment Spec. This may include requirements such as
space heaters for outdoor enclosures, internal lighting, air conditioning / filtration, etc.

4.6 INSTRUMENT CONNECTION AND INSTALLATION CRITERIA

The Spec usually contains a section defining the requirements and preferences for mounting,
installing and connecting the instruments and control devices to the process and each other.
This may include
(a) Establishing standard or minimum process connection sizes and pressure ratings
(b) Defining requirements for isolation (or root) valves, if not addressed in a piping spec
(c) Other process sensing line requirements, e.g. vents, drains, test connections, etc.
(d) Installation materials specifications, e.g. process tubing, valves and fittings, instrument
air supply tubing, valves and fittings, calibration manifolds, etc.
(e) Instrument electrical requirements (if not addressed in an Electrical Packaged
Equipment Spec), such as
(1) signal connection junction boxes, including minimum NEMA/IP ratings, terminal
blocks, wiring, tagging, spares, etc.
(2) use of conduit vs. cable connections, including types, materials, fittings and
supports
(3) instrument power and signal wiring
(4) signal separation
(5) surge protection and lightning protection
(6) redundant/backup power supply switching
(7) design for hazardous locations
(8) lighting
(f) Accessibility, visibility and maintainability requirements
(g) Winterization, tropicalization, sun shielding, weather or other environmental protection
requirements
(h) Required compliance with any specific instrument installation details

4.7 SUBMITALL REQUIREMENTS

Though the actual requirements for what engineering and quality documentation must be
submitted and the quantities, form, and schedule of their submittal are defined in the Material
Requisition or Subcontract, the Packaged Equipment Spec may contain descriptions of the
various classes of documents defining the minimum and preferred content. If electronic
submittals are required, the format and data structures should also be defined.

When determining what types of documents to request, the engineer should consider the
purpose and need. Suppliers providing customized designs of relatively standard packages
may include significant charges for extensive documentation beyond their standard offering.
Even suppliers of unique custom packages may add significant costs for drawings and data that
require changes to their standard work processes. Sufficient documentation must be requested

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to fulfill client requirements, facilitate evaluation of the proposal, and install and maintain the
equipment, but excessive requirements can have significant impact on the overall costs.

The following types of information are frequently requested.

(a) Instrument Index or Lists of instrument data, including
(1) Tag number (Suppliers identification and project assigned tag number, if different)
(2) Service description
(3) Drawing references (e.g. P&ID, Logic Diagram, Schematic, Location Drawing,
Installation Detail, etc.)
(4) Manufacturer
(5) Model number
(6) Calibrated range
(7) Setpoints and control action
(b) Control Panel, cabinet and junction box arrangement drawings (including weight,
mounting or hold down requirements, etc)
(c) Panel, cabinet and junction box wiring diagrams
(d) Wiring, tubing and piping diagrams for all external connections to the package
(e) Location drawings showing the instruments and their process connections
(f) Installation details for items shipped separately for field installation
(g) Piping and Instrument Diagrams showing the full extent of the supplier's system
(h) Logic Diagrams, Cause and Effect Diagrams, Functional Block Diagrams, Sequential
Function Charts, descriptive narratives, or other documentation describing the supplier's
control schemes
(i) Alarm and trip schedules
(j) Instrument loop diagrams
(k) Cable block diagrams
(l) Control system (e.g. PLC) block diagrams
(m) Fully annotated program or configuration listings for supplier furnished controllers
(n) Configuration software and manuals for any digital control systems provided
(o) Details of any digital communication links, including type of link, media, protocols, data
descriptions and format, etc.
(p) Instruction manuals for operation, adjustment, maintenance, troubleshooting, and
repair, including lists of any special tools, test or calibration equipment, etc.
(q) Instructions for site storage, installation and start-up
(r) Instrument data sheets (supplier standard, ISA or project forms) with supporting
calculations
(s) Calibration records
(t) Flushing/cleaning records.
(u) Peak and continuous electrical load requirements
(v) Grounding requirements
(w) Peak and continuous Instrument / Plant Air usage requirements
(x) Calculated heat loads for control panels and cabinets.
(y) Inspection, Test and Validation plans, procedures, records and reports, including any
required certification records
(z) Recommended spare parts lists
(aa) Hazardous Area Classification drawings
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4.8 SPECIAL PACKING AND SHIPPING INSTRUCTIONS

Usually, a project specification or standard part of the Material Requisition / Subcontract

package will define basic requirements for packing and shipping. If not adequately addressed,
the Packaged Equipment Spec should define any special requirements pertaining specifically to
the instrumentation and control equipment provided. For example, suppliers are usually
instructed to remove sensitive instruments after testing, and suitably pack them for separate
shipment and reinstallation in the field to prevent damage during transit.

5.0 REFERENCES

3DP-G04-00049 Engineering Specifications

3DG-J21-00003 Instrument Identification

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Refer to the electronic documents in BecRef for current revisions.
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