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Module 2.4, 5 & 6 Project Documentation

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Project Documentation

Preparation of Project documents is major role for and Process Automation Engineer

Process Instrument Instrument Hook-up

Flow Diagram Index Specifications Drawing

Piping & Input / Output Instrument Control Room

Instrumentation List (I/O List) Loop Diagram Layout
Drawing (P&ID)
Project Documentation
PFD and P&ID
Use of Standard codes & Symbols
Codes: Codes, or abbreviations, provide a quick and
easy way to identify materials and equipment.

Symbol: Symbols provide a graphical representation

of engineering drawings.

Standard: A standard is a published specification

that establishes a common language

Legend Sheets: The Legends identify what the

abbreviations mean and what the shapes represent

Process Flow Diagram

Essential parts of a process system,
Either all the process as an overview or the units of a process
The main points at which a process is controlled Composition,
physical state and changes to the fluids as they progress through
the process sometimes referred to as mass balance data
Project Documentation
Piping & Instrumentation Drawing (P&ID)
P&ID is a schematic illustration of the functional
relationship of piping, instrumentation, and system
equipment components
• P&ID
• Specific notes section Drawing
• History and Identification section

The operation of the process should flow from left to

right, but the main criteria incorporated within the
design should identify the:
• Main items of equipment used in the process
• The control function the process requires
• Changes which effect the process medium
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PFD and P&ID

PFD P&ID
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Representation

Specific Notes History & Identification P&ID Legend

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Instrument Index
Instrument Index is made for listing all the instruments
loop-wise based on P&ID.

It covers all the required information of the instrument in the loop

• Tag Number
• Description of the Instrument
• Service
• Type of Instrument
• Location of Instrument
• P&ID Number
• Instrument Specification Number
• Hook-up Diagram Number
• Instrument Layout Number
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Instrument Index
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Input / Output List
I/O List
• I/O List is used for defining the type of signal
inputs & outputs of the instruments used.
• It is mainly used for defining the number
& types of signals given to PLC / DCS.
• It is the basic document used for sizing PLC / DCS.

The main data that must include

in an I/O List is as follows.
• Instrument Tag Number
• Service
• Signal Type
• Signal Level
• Instrument Range
• P&ID Number
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I/O List
Project Documentation
I/O List

I/O TYPE
MODBUS REGISTER DATA
S.NO TAGNAME DESCRIPTION SYSTEM from SCADA BIT DISCRETE ANALOG
ADDRESS TYPE TYPE
Host
D - Discrete,
I - Integer (16 bit), FALSE (0) TRUE (1) LOW HIGH
W - Read/Write ENGINEER
F - Float (IEEE), R STATE STATE ENGG. ENGG.
R - Readonly ING UNIT
Real - (Used for VALUE VALUE VALUE VALUE
OPC)
1 C1-COMM SCADA AI/AO 400656 W I N/A N/A 0 100
2 C1-DUTY1 Camp1 Duty 1 SCADA AI/AO 400731 W I N/A N/A 0 100
3 C1-DUTY2 Camp1 Duty 2 SCADA AI/AO 400732 W I N/A N/A 0 100
4 C1-DUTY3 Camp1 Duty 3 SCADA AI/AO 400733 W I N/A N/A 0 100
5 C1-STANDBY1 Camp1 Standby 1 SCADA AI/AO 400734 W I N/A N/A 0 100
6 C1-STANDBY2 Camp1 Standby 2 SCADA AI/AO 400735 W I N/A N/A 0 100
7 C1-STANDBY3 Camp1 Standby 3 SCADA AI/AO 400736 W I N/A N/A 0 100
8 C1-P6303A-HRS Camp1 P6303A run hours SCADA AI 400843 R I N/A N/A 0 100
9 C1-P6303B-HRS Camp1 P6303B run hours SCADA AI 400853 R I N/A N/A 0 100
10 C1-P6303C-HRS Camp1 P6303C run hours SCADA AI 400863 R I N/A N/A 0 100
11 C1-P6303D-HRS Camp1 P6303D run hours SCADA AI 400873 R I N/A N/A 0 100
12 C1-P6303E-HRS Camp1 P6303E run hours SCADA AI 400883 R I N/A N/A 0 100
13 C1-P6303F-HRS Camp1 P6303F run hours SCADA AI 400893 R I N/A N/A 0 100
Project Documentation
Instrument Specifications

Instrument Specification documents are made

with the help of both P&ID & Process Data.

• It helps in specifying the precise requirement of the

process for which the instrument is to be used.
• The major data that must include in the
Specification Sheet is as follows
• Tag Number
• Service
• Type of Instrument
• Range
• Size
• Location, Material, Mounting, Protection
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Instrument Specifications
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Instrument Loop Diagrams
Instrument Loop Diagrams are the graphical
representation of loops.

• ILDs are made using the help of P&ID, I/O List

& Cable Schedule
• ILDs show the detailed flow of signal from
instrument to control system cabinet.
• The major data that must include in an ILD are:
• Components used the loop
• Location of the components
• Termination details
• Interlocks used
• Alarms
• Soft functions
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Loop Diagram
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Interconnecting Diagram
Interconnecting diagrams visually represent the connections and interactions between various electrical components, helping engineers
to troubleshoot and maintain these systems effectively

Motorized Valve Electric Furnace

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Instrument Hook-up Diagrams
Instrument Hook-up Diagrams are the graphical representation
of the method of connecting instrument to the process lines,
equipment, tanks, vessels, etc.

The main data that must include in a

Hook-up Drawing are;

Physical mounting Size & material

of the instrument of various items
in the field used

Various items used List of Tag

for mounting of Numbers for
the instruments which the Hook-
up is applicable
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Hook-up Diagram

Hook-up for Differential Pressure Transmitter

The below diagram shows the required components and tubing for
installation of a differential pressure transmitter (installed below
the tapping point). The required parts are shown in the below table
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Control Room Layout

• Instrument Control Room Layout is one of the important

document which gives the idea about location & dimension
of different items in the control room
• The main data that must include in the Control Room
Layout are
• Dimension of the room
• Entry & Emergency Exit
• Ventilation & Windows
• Lighting arrangement
• Panel Dimension & Location
• Proper placement of operator console
• Cable entry
• Air-lock system
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Panel Layout

Panel Layout
• Refers to the physical design of control panels or enclosures
that house electrical and control equipment (e.g., PLCs,
relays, terminal blocks, power supplies, etc.).
• It ensures that the panel is well-organized for ease of use,
maintenance, and troubleshooting

Standards:
• NFPA 70 National Electrical Code (NEC)
• NFPA 79 Electrical Standard for Industrial Machinery
• UL 508A Standard for Industrial Control Panels
• IEC 60204-1 Electrical Equipment of Machinery
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Control Panels
The following design steps apply to both modular
and custom-built Control Panels
• Controlled-system Design: controlled system determines
the type and quantity of the devices needed; therefore, it is
required to decide on basic features, such as overall
dimensions and power requirements.
• Functional Specification: establishes the relationships
between the components inside the Control Panel. Building
the functional specifications requires expertise. Therefore,
cross-functional teams are to be involved
• Layout Design: Create the layout of the ICP. The layout
design uses CAD-based applications, such as AutoCAD
Electrical Toolset E3, eBase and more
• Electrical Diagram and I/O Diagram: The electrical diagram
and the I/O diagram are two very important documents for
diagnostics and troubleshooting
• Bill of Materials: The BOM is useful for the manufacturer to
order the parts needed and verify inventory levels. It can
also be helpful for list of parts to have in stock for repairs.
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General Arrangement
• Typically used to provide a general overview of the design
and layout of the cabinet
• Depicting the overall layout of the equipment and its
placement within the cabinet
• Internal Arrangement (IA): Detailed view of the internal
components of the cabinet, including the equipment, cable
routing, and any other internal details.
• GA/IA : Design and installation of equipment enclosures,
providing a detailed and accurate representation of the
cabinet’s layout and internal components, ensuring that
the equipment is properly installed and functions correctly

Following are required for preparing GA/IA:

• Equipment List, Floor Plan

• Electrical & Mechanical Drawing
• Cabinet Specifications, Standards & Regulations
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General Arrangement (GA)
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Internal Arrangement (IA)
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Grounding system
Grounding System
Ensures the electrical safety of equipment and personnel by
directing fault currents safely to the ground and reducing the
risk of electrical shocks or equipment damage.
• Electromagnetic interference (EMI) is introduced from motors
and other AC sources, but it can be blocked by a grounded
wire wrapped around the conductors in the cable. These
‘shielded’ wires have a woven or foil mesh just under the
insulation jacket, which is attached to the ground network.
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Grounding System