April 1997

Process Industry Practices Process Control

PIP PCEDO001 Guideline For Control Systems Documentation

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice.

Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3208 Red River Street, Suite 300, Austin, Texas 78705. PIP member companies may copy this practice for their internal use.

Not printed with state funds

April 1997

Process Industry Practices Process Control

PIP PCEDO001 Guideline For Control Systems Documentation

Table of Contents 1. Introduction ..................................2
1.1 Purpose..............................................2 1.2 Scope.................................................2 Level Instrument Documents.................... 5 Control Valve Calculations ....................... 5 Flow Instrument Calculations.................... 5 Computing Device Calculations and Calibration...................................... 6 Logic Documents...................................... 6 PLC Programming Guidelines .................. 6 Distributed Control System (DCS) Guidelines............................................. 7 Alarm Setpoint Listing .............................. 7 Layout Drawings....................................... 7 Instrument Location Drawings .................. 8 Instrument Installation Drawings............... 8 Instrument Loop Diagrams ....................... 8 Complex Loop Descriptions...................... 9 Instrument Wiring Documents .................. 9 Grounding System Drawings .................. 10 Instrument Installation Checkout and Calibration/Configuration Procedure.... 10 Decommissioning Documents ................ 10

2. References....................................2
2.1 Process Industry Practices (PIP).........2 2.2 Industry Codes, And Standards ..........2

3. Definitions.....................................2 4. Requirements ...............................3

General ....................................................3 Process Control Diagrams (PCDs) ............3 Piping and Instrument Diagrams (P&IDs)..3 Standards and Practices ...........................4 System Block (Architect) Diagrams...........4 Master Instrument Index ...........................4 Narrative Specifications............................5 Instrument Data Sheets (Specification Forms) ............................5

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1.

Introduction
1.1 Purpose The purpose of this Practice is to provide control systems design personnel with recommended basic criteria for creation of control systems documentation for use in the process industry. 1.2 Scope This Practice defines the general guidelines for control systems documentation for design, supply, installation, checkout or commissioning, and maintenance of instrumentation and control systems. The practice is primarily used for the process type industries such as chemical, and petroleum refining.

2.

References
When adopted in this engineering guide or in the Contract Documents, the latest edition of the following codes, standards, specifications, and references in effect on the date of contract award shall be used, except as otherwise specified. Short titles will be used herein when appropriate. 2.1 Process Industry Practices (PIP) 2.2 PIP PCCGN001 - Process Control General Design Specification

Industry Codes, And Standards The International Society for Measurement and Control (ISA) ISA S5.1 - Instrumentation Symbols and Identification ISA S5.2 - Binary Logic Diagrams for Process Operations ISA S5.4 - Instrument Loop Diagrams ISA S20 - Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves ISA S91.01 - Identification of Emergency Shutdown Systems and Controls that are Critical to Maintaining Safety in Process Industries

3.

Definitions
For the purposes of this engineering guide, the following definitions apply: Owner: The entity with final responsibility for the complete operation of the facility. Contractor: The owners hired representative, providing any combination of engineering, procurement and construction services.

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PIP PCEDO001 Guideline for Control Systems Documentation

4.

Requirements
General Prior to the project initiation, the Owner should provide the engineering contractor an example of the Owner's standard documentation package. Comment: It is recommended that the owner should complete, with input from the Contractor as required, PIP PCCGN001. Prior to project initiation, the Owner should convey to the Contractor, in writing, all necessary changes and/or modifications related to this guideline. The Owner may use the engineering contractors standard documentation as an alternate. On retrofit projects the Owner may require that changes be made to existing drawings or documents in lieu of generating new drawings or documents. Basic criteria for each type document are described one by one below. The Owner should specify which documents are to be used for the project. Comment: The use of a system of data bases and/or drawing tools, which are tied to the Piping and Instrument Diagrams (P&IDs) electronically, is encouraged to generate instrument index, instrument data sheets, instrument loop diagrams, installation details, and other applicable documents. Owner/Contractor should jointly identify the critical instruments and controls to be implemented in this project as described in ISA S91.01. Process Control Diagrams (PCDs) A PCD is a schematic representation of basic control philosophy, showing the main control scheme for the process. A PCD is normally developed prior to development of the Piping and Instrument Diagrams and is a useful tool for the control strategy discussion. Piping and Instrument Diagrams (P&IDs) A P&ID is a schematic representation of the piping, process control and instrumentation for a specific process/system, showing the functional relationship among the various components. A P&ID, as a key document conveying the great amount of system design information, provides a means for communicating with the project design groups, owners, regulatory agencies, and others to establish thorough understanding of systems. In general, ISA S5.1, Instrumentation Symbols and Identification, should be used as the guiding document for instrument symbology.

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Standards and Practices The accepted standards and/or practices that establish the basic design criteria for the project should be listed and developed at the beginning of the project. Unless otherwise stated in writing, PIP practices should be used. Standard Symbologies for Computer Aided Drafting (CAD) drawings should be defined by Owner and/or Contractor. System Block (Architect) Diagrams System Block (Architect) Diagrams will show in a block diagram format all major control systems components and the overall cable/wiring connection philosophy. Master Instrument Index The index database contains information on all the instruments in the project and is effective for determining current work completion status and for ascertaining that required work has been performed and documents have been issued. The master instrument index should be the key reference document for the control systems work and is generated as a product of the data base. The document should contain a record for every instrument tag number used in the project. Instrument index should have the following fields: a. Instrument Tag Number Comment: The instrument tag number may be divided into multiple fields such as Unit (or Plant, Train) Number, Function Identifier, Equipment (or P&ID) Number, and Loop Sequence Number. b. Service Description c. Reference Drawing Number such as P&ID (or Mechanical Flowsheet) Number d. Instrument Type e. Signal Type f. Instrument Location (field, local panel, control room, etc.)

g. Line Number (mainly for in-line devices) h. Pipe Specification (may be combined with Line Number) i. j. Data Sheet Number Critical Status

k. Material Requisition or Purchase Order Number l. Design Drawings such as: Location Plan Loop Diagram Installation Details

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PIP PCEDO001 Guideline for Control Systems Documentation

Logic Diagram Electrical Wire Diagram or Schedule Vendor Print Other useful fields can be added per project specific requirements. Narrative Specifications A written technical specification should be prepared for a complicated system such as distributed control system, programmable logic controller, complex analyzer system, burner management system, etc. Narrative specifications supplement the instrument data sheets when data sheets do not adequately define the general requirements for a category of instruments. Instrument Data Sheets (Specification Forms) Instrument data sheets are prepared to present the basic information for the instrument requisition. When completed, they provide a readily accessible, concise summary of information about installed instrumentation. ISA S20 or equal should be used. The instrument data sheet should define the instrument in sufficient detail as to allow a vendor to select the appropriate instrument. Level Instrument Documents Level Instrument Documents are provided to depict level instrument connection requirements, standpipe requirements, and level operating ranges and setpoints. Beginning in preliminary form, the Level Instrument Documents will communicate the level instrument connection requirements to Vessel and Piping groups and assist a control systems engineer in selecting the types and ranges of level instruments including providing data for the range calculations. Control Valve Calculations Preliminary control valve calculation methods should be defined at the beginning of the project. The final control valve calculation should be representative of the selected valve and documented accordingly, using the vendor sizing method. The final control valve data should include, as a minimum, instrument tag, sizing data, (such as flow rates, pressure drops, etc.) calculated and selected Cv, and sound level prediction. Flow Instrument Calculations All flow sizing methods should be defined at the beginning of the project as the owner's, vendor's, or engineering contractor's methods. Each flow instrument calculation sheet should have, as a minimum, the instrument tag, sizing data, and calculation results.

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Computing Device Calculations and Calibration Requirements described herewith apply to all computing devices. For DCS and other digital systems, a configuration block is normally self documented in the system. Comment: The instrument vendor's standard calculation/calibration form should satisfy this documentation requirement. The engineering contractor should provide the basis for all calculations, including: a. Final calculations including determination of constants. b. Limitations of the computing device constants. Logic Documents A number of different documents may be used to define the logic functions: Logic Narratives Logic narratives in plain language can be used to define the logic functions. Logic Diagrams a. ISA S5.2 may be used as a guide to develop logic diagrams. ISA S5.2 is intended to symbolize the binary operating functions of a system in a manner that can be applied to any class of hardware. b. Logic diagrams are typically used to transfer operational information from the Owner to the party responsible for generating the application program. Ladder Diagrams a. Logic programmed in ladder diagram form is common for the programmable logic controller (PLC). The party implementing PLC based logic systems should be required to supply ladder diagrams that satisfy the requirements of the logic diagrams and/or logic narratives. b. Ladder diagrams preferably are generated by the program development workstation software tools, and should be transmitted to Owner in hard (printout) and soft (diskette) format. c. Register listing and necessary annotation for PLC should be provided for explanation of the program. Cause and Effect Diagrams Cause and effect diagrams show the initiating events and required results for the logic functions. Batch Sequence Diagrams Batch sequence diagrams identify the required batch sequence operations. PLC Programming Guidelines Prior to the PLC programming, rules governing the PLC programming should be established.

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PIP PCEDO001 Guideline for Control Systems Documentation

As needed, notes should be added to the rung of the logic or ladder to explain each function. The Input/Output (I/O) and the register listing should be provided. A backup for electronic files in addition to the master is required. Distributed Control System (DCS) Guidelines Prior to the DCS configuration, a DCS hardware and software design guide should be established. Typical issues to be defined in this guide are: a. Nametag convention b. Alarm presentation philosophy c. Input/Output segregation philosophy d. Redundancy/System Security philosophy e. Configuration guidelines f. Graphics development guidelines

g. Interface guidelines (interface with the third party devices such as computer, PLC, analyzer system, tank gauging system, etc.) h. Spare capacity guidelines In most cases, the selected DCS will provide self documentation of the configuration that is installed. The DCS documentation should include the I/O listings for the various types of signals. If the DCS configuration software does not provide for self documentation, some other means such as documenting the configuration data on a database should be provided. A backup electronic file for the configuration data base is required. Alarm Setpoint Listing Alarm setpoint listing (both soft and hardwired alarms) should be available to cover shutdown alarm and pre-shutdown or critical set points. Alarm settings should include the process value and the signal value. The form of the documentation for this information should be determined at the beginning of the project. Using the loop folder or master instrument index for this purpose is an example of many available options. Layout Drawings Control Room Control room layout drawings should show in plan view the location of consoles, panels, control racks, computer racks and peripherals, logic racks, barrier cubicles, termination racks and boxes.

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Control Panel Control panel layout drawings should show the position of panel mounted instruments, panel dimensions, method of support, filler plates and major construction details for control panels. Control Console Control console layout drawings should show the console bay arrangements with function identification for each process area video system. Remote Building Remote building (DCS Satellite Building, Analyzer House, etc.) layout drawings should show the position of each item of major equipment. System Cabinet System cabinet layout drawings should show the location of all pieces of equipment, cabinet dimensions, terminal boxes, filler plates, and major construction details. Instrument Location Drawings Instrument location drawings should show the appropriate location coordinate of each field instrument. The Instrument Location Drawing is a plot plan with buildings, vessels, and other major equipment shown in outline. The Instrument Location Drawings may also show routings for tubing bundles, cables, air supplies, or electrical supplies as appropriate. Instrument Installation Drawings Instrument installation drawings should show the required method of installation of the instruments and shall list the needed piping, tubing and fitting materials, etc. Refer to PIP instrument installation details. Instrument Loop Diagrams In general, ISA S5.4 should be used to develop instrument loop diagrams. Instrument loop diagrams may include the following information: a. All devices or items with clear labeling and identification, at least including instrument tag numbers b. All junction boxes, terminal strips, bulkheads, ports, grounding connections, etc. and all identifying numbers for all equipment, electrical cables, conductor pairs, and pneumatic tubes c. All utility and energy sources: electrical power, air supply, hydraulic fluid supply. Designate source of power, voltage, pressure, and other applicable requirements. d. All references to supplemental records and drawings such as P&ID Number, etc.

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PIP PCEDO001 Guideline for Control Systems Documentation

e. Location of devices with respect to: associated piping line numbers, associated field equipment numbers, panel front, panel rear, marshaling panel, auxiliary rack, termination cabinet, and control systems I/O cabinets f. The following information is required for: Control valves - fail positions Controller - action as direct or reverse Solenoids - de-energized or de-pressured positions with an arrow; port designations Relays - function (e.g., square root, low select, etc.), port terminal designations, shelf positions, trip connections Critical devices - uniquely labeled as a critical device with logic document reference

g. Where applicable, the DCS tag, communication link (data highway) address, and algorithm type Complex Loop Descriptions A complex loop is generally defined as a system which contains any of the following characteristics: a. Three or more interconnected analog loops b. Calculations c. A program d. Procedural steps involving analog loops e. Not readily definable on the P&ID A complex loop description contains all the documentation necessary to properly describe the operational requirements, instrument components, calculations, logic procedures and detailed configuration and/or programming. Instrument Wiring Documents Junction/Terminal Box Drawing or List a. Junction/Terminal Box documents (drawings or lists) should show the terminal strips with terminal numbers for junction boxes, field control panels, marshaling cabinets, and instrument cabinets and/or racks, with the appropriate identification. b. The Junction/Terminal Box Drawing or List should also show the connections of instrument multicore cables to the terminals, with identification by cable number and core number.

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Conduit/Tray Layout and Cable Routing Drawing/List The Conduit/Tray Layout and Cable Routing (drawing or list) should show the general conduit/tray layout and the following cable/conduit data: identification number, approximate length, type, and routing. Grounding System Drawings The grounding system drawings should show grounding connections to the appropriate power supply systems as well as earth grounding locations for all instrument power systems, wiring system shield grounding, distributed control system grounding, and other appropriate instrumentation and control systems. Instrument Installation Checkout and Calibration/Configuration Procedure A detailed procedure should be prepared to define the responsibility for instrument installation, including complete calibration (or configuration for smart transmitters, etc.) and operational checks of all instrument loops, sequencing and interlock systems, annunciators, and shutdown systems. A checkout form should be used to record calibration, loop check sign-off/approval. Decommissioning Documents Decommissioning documents are often required to show the portion to be decommissioned on a revamp job.

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