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WORK INSTRUCTION
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AND INSTRUMENTATION DEPARTMENTS
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WORK INSTRUCTION

INTERFACE DEFINITION BETWEEN PROCESS

AND INSTRUMENTATION DEPARTMENTS

WI-SSA-ENGDGN-015-E

N. TRICHARD J. MEDINA LUNA C. SEGUIN B. CHAUVIN

11/01/08 1 Updating
ENG QUAL ORGA ENG

Date Revision Description of Revision Prepared by Checked by Approved by

Only the electronic version is updated, before any use the current version of this document shall be verified on the INTRANET network

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REVISION RECORDING

Date Revision Description of Revision Prepared by Checked by Approved by

N. TRICHARD J. MEDINA LUNA C. SEGUIN B. CHAUVIN

11/01/08 1 Updating
ENG QUAL ORGA ENG

N. TRICHARD J. MEDINA LUNA L. STEFANI E. ZIELINSKI

14/09/05 0 First issue
PCS QUAL ORGA ENG

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INDEX

1. SCOPE AND PURPOSE ............................................................................................................................4

2. REFERENCE DOCUMENTS......................................................................................................................4

3. DEFINITIONS .............................................................................................................................................4

4. ACTIVITIES DESCRIPTION.......................................................................................................................5
4.1 PROCESS DATA FORMALIZATION...........................................................................................................5
4.1.1 Instrument process datasheets............................................................................................6
4.1.2 Control and ESD systems development ..............................................................................7
4.1.3 Process Flows Diagrams (PFDs) and Piping and Instrument Diagrams (P&IDs) ...............9
4.2 STUDIES REQUIRING A SPECIFIC PROCESS / INSTRUMENT SUPPORT .....................................................10
4.2.1 HIPPS implementation.......................................................................................................10
4.2.2 Dynamic simulation............................................................................................................10
4.2.3 Operator Training Simulator ..............................................................................................11

5. FLOWCHART ...........................................................................................................................................11

ATTACHMENT A – SPLIT OF WORK TABLE.......................................................................................1/4

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1. SCOPE AND PURPOSE

The purpose of this document is to clarify the split of work between Process and Instrumentation
Departments during basic and/or detailed engineering projects.
The intent of this document is not to create a segregation of responsibilities between the two entities but
to bring a better mutual understanding between disciplines. Consequently, interfaces optimization shall
result in workflow optimization, planning and man-hours savings and ultimately competitiveness
improvement.
This document is established under the responsibility of both Head of Process Department and Head of
Instrumentation Department and subsequent revisions are subject to their approval.

2. REFERENCE DOCUMENTS

• “P&ID Preparation structure” (WI-SSA-ENG-001-E)

3. DEFINITIONS

DCS Data Control system

DCN Design Change Note

ELE Electrical department

ESD Emergency ShutDown

EVA cycle E for Elaborate, V for Verify, A for Approve

FAT Factory Acceptance Test

FEED Front-End Engineering Design

FSLL Flow Switch Low Low

GTP Grille Technique Process

HAZOP Hazard and Operability review

HIPPS High Integrity Pressure Protection System

IFC Issue For Construction

INS Instrumentation department

LSLL Level Switch Low Low

OPPS Over Pressure Protection System

OSD Operating ShutDown

OTS Operator Training Simulator

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PCS Process Department

PFD Process Flow Diagram

PI Pressure Instrument

P&ID Piping & Instrumentation Diagram

PPL Project Process Leader

PSHH Pressure Switch High High

PSL Project Specialist Leader

PSLL Pressure Switch Low Low

SAF Safety Department

SIL Safety Integrity Level

TEG Tri Ethylen glycol

TI Temperature Instrument

TIP Process Technical Instruction

4. ACTIVITIES DESCRIPTION

4.1 PROCESS DATA FORMALIZATION

Process information and data are made available to Instrumentation specialists as follows:
• Through schemes (PFDs, P&IDs): these schemes (especially P&IDs) will display the totality
of the control loops and process/safety instruments. They will be the basis for the
establishment of the instrument list by INS. INS is also a major contributor of the P&IDs
elaboration,
• Through narratives (process control philosophy, shutdown philosophy): these
narratives will complement the above schemes and will be used by INS for the definition of
the control and ESD systems,
• Through schematic diagrams (first issue of cause and effect matrices or logic
diagrams): these diagrams will be used by INS for the definition and development of the
ESD system,
• Through process data sheets for the main instruments: These process data sheets will
lead to the establishment of the instrument specifications by INS,
• Through equipment process data sheets: where operating and design conditions can be
found, together with indication of operating liquid levels (normal, maximum, minimum, trips…)
and fluid densities.
• Through line lists: these documents provide operating and mechanical design conditions of
all the piping systems, on which instruments are attached. INS will collect the data necessary
for the definition of transmitters and local instruments.

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4.1.1 Instrument process datasheets

Instrument Process data sheets will be elaborated for the following items:
• Control valves,
• On/off valves, motorized valves,
• Safety valves and other pressure protection devices (rupture discs…),
• Flow meters, flow elements,
• Restriction orifices,
• On line analyzers,
• Metering packages.
It is under Project Process Leader’s (PPL) responsibility to make sure that the process
datasheet includes all explicit and exhaustive information related to instrument definition
as per the relevant GTP: Operating and design conditions, main stream properties, main
sizing cases, etc… (refer to the table hereafter).
Project Process Leader’s (PPL) shall also make sure that the information, remarks,
comments indicated on process datasheet are clearly and fully understandable by INS
Project Specialist Leader (s) so that INS can use this information as his own during
contacts with vendors.
Should INS engineer transfer process information from process data sheet to an
instrument document (e.g.: instrument data sheet), then INS engineer takes full
responsibility of this transfer without further checking by PCS.
The process data sheets have not to be updated according to instrument data sheets.
More especially, the process data sheets will not be updated to reflect final vendor data at
the end of the project, except when the vendor selection impacts the process design
data.
Note: Instrument process data sheets will be developed depending on the project type,
typically:
• Pre-feed or feasibility: no instrument process data sheets,
• Feed or basic: only for the main instruments (control valves, safety valves, metering
packages and analyzers),
• Detailed: For all instrument listed above.

Equipment / GTP
Associated TIP Remarks
Instrument n°
INS is responsible for the selection of the valve
type and will, on request, provide PCS with the
Control valves 13 TIP 110 – chapter 1 control valve CV (for gas blow-by calculation, for
validation of centrifugal compressor anti-surge
loop…)
INS is responsible for the selection of the valve
On-off valves actuator.
21 -
Motorised valves PIP is responsible for the selection of the valve
itself.
Safety valves 14 TIP 110 – chapter 2 Associated with TIP 170.
Flow elements
26 TIP 110 – chapter 3
Restriction orifices
PCS indicates the product specification and the
On-line analyzers 20/23 -
requirements for range measurement.

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Equipment / GTP
Associated TIP Remarks
Instrument n°
For each drum, the level information can be
Level 12 TIP 120 found on the process vessel data sheet through
convenient sketches and nozzles list.
PCS produces a duty specification and is
responsible for definition of:
- Flow rate range of measurement
- Operating and design conditions
- Product properties
- Measurement accuracy requirement
- Maximum pressure drop
- Sparing philosophy
Metering packages 20/23 -
INS is responsible for the package technical
management and will take care with the
vendor(s) of:
- The exact scope of supply
- Number of meter runs
- Meter run configuration and diameter
- Calibration constraints
- Detailed representation on P&IDs.

Remarks:
• No specific process data will be provided to INS for transmitters and gauges (PI, TI).
The requested data can be found in the following documents:
− in the piping line list
− in other process data sheets (equipment, instruments).
INS will be responsible for the collection of these data and the preparation of the
instrument data sheet, without any PCS checking. PCS remains available for
clarification in cases where the various information could be misleading.
• To indicate control set points, alarms and trips settings, a specific process document:
”alarm/trip set points list” will be issued (case of detailed engineering). This document
allows transmitting the information to the Data Control System (DCS) manufacturer.
The issue shall be in accordance with the project schedule (typically 2 months before
FAT). In any case, these data shall be indicated in the process guidelines for
operating manual issued on the last step of the project.
No specific checking of the final instrument database will be performed by PCS.

4.1.2 Control and ESD systems development

4.1.2.1 Process control description

The process control description shall be the basis for the development of the functional
analysis by INS. For that purpose, it is under PPL’s responsibility to make sure that this
document includes all necessary information related to plant control:
• Every control loop shall be fully described through a description of the entire plant
based on P&IDs,
• Sufficient details shall be given to understand the more sophisticated control loops
(split range, overrides, prioritization, calculation boxes….),

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• When applicable, details concerning the equipment operation shall be given:

− Sparing philosophy: number of equipment in operation, number of spare
equipment…,
− Start-up / Shutdown philosophy: locally or from control room, automatic start-
up…
• For critical packages (TEG, desalting, process fired heaters, water treatment, major
machines such as compressors or injection pumps…). The main process control
loops of the package can be described when tightly linked to the control of the
whole plant. In any case, reference has to be made to the package control
philosophy from vendor after equipment selection.
• No data concerning operating values nor alarms or switches have to be given
(except when required for a better control understanding),
• Discussions between PCS and INS lead engineers are necessary during the
elaboration of this document to ensure the adequacy and mutual understanding of
the reported information,
• The issue of the control description shall be located in the project schedule shortly
after the first issue of P&IDs.
After document issue, the process control description should be commented by INS to
reach the requested level of details. Likewise, PCS will have to review the functional
analysis when issued by INS.
Note 1: the process control description will be based on the main control principles
listed in the Control Philosophy from FEED documentation.

4.1.2.2 Cause & Effect matrix and Shutdown philosophy

The safety functions of the plant have to be specified by PCS. As a consequence, PCS
will prepare the first issue of the Cause & Effect matrices or of logic diagrams
(depending on client’s list of deliverables).
Through this document, PCS will detail all the requested process information for further
development of ESD system by INS. This shall include:
• The shutdown hierarchy of the plant (definition depends on Client’s standards):
− ESD1: total plant shutdown with or without automatic depressurization,
− ESD2/OSD2: shutdown of all the equipment of an area,
− ESD3/OSD3: shutdown of one individual equipment
• For each shutdown function (whatever the level), the following information have to
be fully clarified:
− The causes: fire, equipment failure, control valve failure, blocked flow…
− The detection/activation means: PSLL, PSHH, FSLL,…, including potential
pushbuttons,
− The risk to be feared for the plant, for the plant area or for the equipment,
− The actions activated by this shutdown function (including potential cascade
effect on other shutdown functions (same level or below). If time delay are
requested between detection and actions activation, this shall also be clearly
addressed,

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− On restart step, the requested by-pass switches have to be clarified to inhibit

any FSLL, PSLL, LSLL actions…
The Cause & Effect matrices / logic diagrams have to be developed in conjunction with
INS for all numbering aspect of switches, pushbuttons, by-pass switches, shutdown
functions (if applicable),…
Note 1: The cause and effect matrices/logic diagrams are under INS’ responsibility. For
all the document issues, INS will be the verifier (V) and the approver (A) in the EVA
cycle. PCS will elaborate (E) the first issue of the document to ensure a perfect
understanding and data transfer between PCS and INS. However, for all the other
document issues, INS will fully manage the entire activity.
Note 2: The Fire and Gas Cause and Effect charts will be developed by SAF/INS. PCS
will review the overall consistency of the document with the overall ESD philosophy.
Depending on the project list of PCS deliverables, a shutdown philosophy may have to
be issued as well. This document will list all the ESD functionalities shown in the cause
& effect matrices in a narrative format. This document will be fully under PCS’
responsibility.

4.1.3 Process Flows Diagrams (PFDs) and Piping and Instrument Diagrams (P&IDs)
The Process Flow Diagrams (PFDs) allow a good understanding of the process scheme.
For that purpose, besides heat and material balance information, they include as a
minimum:
• All itemized process equipment,
• Definition of the main control principles by means of a simplified symbolization of the
main control loops.
The Piping and Instrument Diagrams (P&IDs) provide all the information for installation of
process systems. The main responsibilities are shared as follows between PCS and INS
(refer also to Work Instruction “P&ID Preparation structure” (WI-SSA-ENG-001-E)):
• Under PCS’ responsibility:
− Representation of all itemized process equipment (including stand-by)
− Process/utility lines, sizes and recommended material, line insulation, tracing and
heating requirement,
− Process requirements regarding layout (elevation, slopes, min/max length to be
considered…)
− Valves and fittings,
− Indication of all requested process instrumentation, control and safety functions…
• Under INS’ responsibility:
− Complete representation of instrumentation, control loops and safety functions,
− Numbering for instrumentation, control loops, safety interlocks…
− Safety valves type, sizes and number,
− Control valves sizes and number...
After the IFC revision of P&IDs, INS is responsible for the issue of any DCN (Design
Change Note) based on instrumentation modifications only (e.g.: control loop
representation…).

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4.2 STUDIES REQUIRING A SPECIFIC PROCESS / INSTRUMENT SUPPORT

4.2.1 HIPPS implementation

The implementation of safety instrumented systems is becoming more and more frequent
(HIPPS: High Integrity Pressure Protection System, OPPS: Overpressure Protection
System).
The proper definition of these safety instrumented systems involves a multi discipline
work which requires inputs from PCS, INS, SAF and ELE.
PCS’ responsibility consists in:
• Fully describing the proposed overpressure protection system:
− Overpressure sources and associated scenarios for overpressure,
− Main assumptions linked to the overpressure scenarios,
− Overpressure protection system functional requirement.
• Based on the above description, determining the process safety time of the requested
safety functions and the convenient pressure level for the switches. These
calculations may or may not (depending on the system complexity) be based on a
dynamic simulation.

The reliability aspect of the overpressure protection system has to be defined during a
SIL review meeting together with the client (meeting organization by SAF similar to
HAZOP meeting). Once the SIL classification of the instrumented safety system has been
defined, a reliability study may or may not (depending on the system complexity) be
necessary to prove the adequacy of the proposed overpressure protection system (see
note). Should a reliability study be undertaken, then, this study will have to be supervised
by both PCS and INS.

The INS responsibility consists in:

• Selecting the relevant shutdown valves technology according to the PCS datasheet,
• Ensuring that SIL classification requirements have been fulfilled using appropriate
material (transmitter, ESD system, solenoid valve, actuator…)
• Providing a Safety Integrity Level (SIL) calculation report (including safety loop
reliability calculations, vendor’s certificates for material, maintenance requirements
for each element…).
Note: Each element of the overpressure protection system must have a SIL level. For
that purpose, control loops (such as spill over valves) cannot be considered as part of
such a system. As a consequence, they cannot be included in the reliability calculation of
the system.

4.2.2 Dynamic simulation

Dynamic simulation is now frequently part of the process deliverables during detailed
engineering development. The aim of this model is to demonstrate the overall
controllability, safe operability of the plant under start-up, operating, transient and
shutdown conditions. Most of the time, this activity is subcontracted. The supervision is
ensured by PCS.
However, the participation of INS is highly recommended since very specific control
problems can be discussed during this study.

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4.2.3 Operator Training Simulator

If an operator training simulator must be provided, then, the supervision of the OTS
activities is ensured by INS (closely linked to DCS and most of the time, part of DCS
supplier scope of supply).
The supervision of the dynamic simulation included in the OTS is under PCS
responsibility.

5. FLOWCHART

N/A

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Attachment A – Page: 1/4

ATTACHMENT A – SPLIT OF WORK TABLE

Split of work
Documents / Activity Description / objective When? Comments
PCS INS
For the particular case of metering
packages, refer to table in § 4.1.
Process instrument definition including:
- operating and design conditions No process data provided for PI, TI.
X
- stream flowrate and composition After issue of main INS to collect the requested
Instrument Process data
(including any pollutants which may equipment process data information on the piping line list or
sheet (as per relevant GTP,
impact the instrument technology), sheet. on the fluid list.
INSTRUMENT DESIGN AND REQUISITION

refer to § 4.1)
- main stream properties
- main sizing case. No update of the process data sheet
to reflect final vendor’s data at the
end of a project.
Instrument data sheet X
Requisition X
Checking of the compliance of vendors’
Review of Vendors’ After receiving of
offers with the project documentation X
offers vendors’ offers
(process data sheet, general spec, …)
During all phases of the
Contacts with vendors Ponctual information request X
project
PCS attendance at
request for specific After review of vendors’
Clarifications meeting Full understanding of vendors’ offers X
process questions on offers
critical points only.
First issue before
Comparison between the different clarification meetings.
Technical Bid Analysis X
offers Updating after
clarification meetings.
Recommendation for selection of
Selection of Vendors vendors according to technical X With TBA final issue
considerations

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Attachment A – Page: 2/4

Split of work
Documents / Activity Description / objective When? Comments
PCS INS
Requested
The package design is the vendor’s full
INSTRUMENT DESIGN AND REQUISITION

information are:
responsibility. The aim of this
- installed CV for
circulation is definitely not the redesign
control valves
of the package, but the collection of
- maximum discharge
information which may impact the main
flowrate for safety
facilities.
valves
Vendors’ documentation However, should a blatant At documentation
(Continued)

- maximum closure X
circulation inconsistency or an omission be receiving
time for shutdown
detected by a specialist in one of these
valves
documents, then a comment will be
- ∆P for flow
returned to EQP for vendors’
instrument and
clarification or correction.
metering packages
No comment on the document form will
exceeding PCS
be done by specialists. (By EQP if any)
constraints.
Update of instrument representation
For metering package, full transfer of
(diameter, type of instrument, number, After issue of vendor’s
Update of project P&IDs Approval by PCS X vendor’s P&ID on project P&ID if
rating…) according to final vendor’s P&IDs
specific request from the client.
data (if necessary)
INS to comment the first issue of the
Process control After first issue of the
As per § 4.2.1 X process control description to reach
description P&IDs
the requested level of details.
PCS to review the functional
Functional analysis X analysis to check concordance with
CONTROL SYSTEM

control description requirements.

Requisition for control
X
system
Checking of the vendor’s offer
After receiving of
Vendor’s offers review compliance with the project X
vendors’ offers
documentation (general spec, …)
During all phases of the
Contacts with vendor Punctual information request X
project
PCS’ attendance at
request for specific After review of vendors’
Clarifications meeting Full understanding of vendor’s offer X
process questions on offers
critical points only.

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Split of work
Documents / Activity Description / objective When? Comments
PCS INS
CONTROL SYSTEM (Continued)

First issue before

Comparison between the different clarification meetings.
Technical Bid Analysis X
offers Updating after
clarification meetings.
Recommendation for selection of
Selection of vendors vendors according to technical X With TBA final issue
considerations
Update of project P&IDs Update of control loops representation X
X
Synoptics definition Review by PCS (On P&ID basis)
The supervision of the dynamic
Operator Training
See comment X simulation included in the OTS is
Simulator (OTS)
under PCS’ responsibility.
After issue of control
Cause and effect charts First issue prepared X First issue checked by INS. Further
As per § 4.2.2 philosophy. Before
or matrix by PCS (See comments) issues fully managed by INS.
HAZOP review
Shutdown philosophy (if
As per § 4.2.2 X
any)
Requisition for ESD
X
system
Checking of the compliance of vendors’
ESD SYSTEM

Review of Vendors’ After receiving of

offers with the project documentation X
offers vendors’ offers
(general spec, …)
During all phases of the
Contacts with vendors Punctual information request X
project
PCS attendance at
request for specific After review of vendors’
Clarifications meeting Full understanding of vendors’ offers X
process questions on offers
critical points only.
First issue before
Comparison between the different clarification meetings.
Technical Bid Analysis X
offers Updating after
clarification meetings.

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Split of work
Documents / Activity Description / objective When? Comments
PCS INS
Recommendation for selection of
Selection of Vendors vendors according to technical X With TBA final issue
considerations
Update of project P&IDs Update of safety loops representation X
INS partial attendance
HAZOP review X
REVIEW

at request
SIL review X X
Alarms rationalization INS partial attendance
X
review at request

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