1.3.1 So who sets the standards?

1.4.1 Drawing office operating manual

1.4.2 Drawing office organizational structure

1.4.3 Office discipline

1.4.4 Methods of work initiation, control and reporting

1.4.5 Draughting procedures

1.4.6 General information on drawings

1.4.7 Issued for approval

Approval drawings are required mainly for layouts but may be used for any drawing where specific items are required to be drawn to the Engineer’s attention. An approval drawing need not be complete or fully dimensioned, but must clearly define the concept.

The approval drawing is a scheme, which requires approval from the Engineer. These drawings are not to be issued for Tender, Construction or to any Consultant or Contractor to use as final drawings.

After approval of a drawing with all appropriate signatures the drawings need not be re-issued for final approval unless specifically requested on the approval form.

To summarize

• Approval drawings are for internal use only, i.e. between Client/Design Department
• No construction may be carried out using an approval drawing
• Where approval of any drawing is required, it must be issued to the responsible Engineer or Manager
• If a second or third approval is required, the drawing must state this.
• Drawing numbers refer to a single drawing or document. Two or more drawings cannot have the same number
• A duplicate drawing can be issued and stamped accordingly
• Where approval has been sought, the final drawing must indicate this.
• An approval drawing which has been approved need not be re-submitted

1.4.8 Issued for final approval

On completion of final drawings and prior to issue, a print shall be made and this shall be handed over to the Project Engineer for his signature and to record that final drawings have been issued to his approval, all previous comments having been acted on to his satisfaction. This shall not be used for further modifications.

1.4.9 Issued for information only

There are a number of situations where a drawing may be issued for information only, i.e. these drawings may be worked to for manufacture or construction.

• Drawings may be issued to a Civil Contractor for planning his construction program
• Drawings may be issued to a supplier to assist in determining type of merchandise best suited to our requirements
• Drawings may be issued to a Quantity Surveyor for preparation of Bill of Quantities
• Drawings may be issued inter-departmental to expedite work. In each of the above cases the Drawings must be clearly stamped: for information only not to be worked to

1.4.10 Issued for tender

• Drawings shall be as complete as possible before issuing for tender purposes. The more: information given at this stage the more accurate the quote and the less likely future claim for extras
• Where possible send out detail drawings at tender stage
• Whenever possible have drawings checked before going out on tender
• Tender closing date must be realistic.
• An extension to the tender closing date may be given at the discretion of the Resident Engineer on request by one or more of the Tenderers. However, should this occur tenderers must be notified of the new date.
• Manufacture/Fabrication time allowed on Tender should tie in with program requirements but again be realistic towards the Supplier.
• Tender documents shall carry a reference to all drawings, specifications etc., which form part of the Tender.

1.4.11 Issued for manufacture or construction

• Any variations between drawings at tender stage and construction issue shall be highlighted by way of a revision on the drawing.
• In conjunction with issuing the drawing for construction to the fabricator issues shall also be made to client, i.e. Plant etc., and to a Quantity Surveyor should he be involved.

1.4.12 As built

• Represents the final revision to all drawings reflecting actual changes made during the construction and commissioning of the plant.
• Will form part of the Plant Operating and Maintenance documentation and must be archived on completion of the project.

1.4.13 Analysis

The checking procedure entails a methodical step-by-step study of all phases of the design of a given item in relation to the function it performs. The philosophy underlying this approach is not concerned with appraisal of any given part per se. Rather the appraisal focuses on the function, which the part, or the larger assembly containing the part, performs. This approach is designed to lead the analyst away from a traditional perspective which views a part as having certain accepted characteristics and configurations. Indeed, it encourages the analyst to adopt a broader point of view and to consider whether the part will perform the required function as efficiently and as inexpensively as possible.

1.4.14 The checklist

It is useful to develop a checklist to systemize the checking activity. The following is a general checklist, which should be supplemented by more specific items from the checkers.

Determine the function of the item then establish:

• Can the item be eliminated?
• If the item is not standard can a standard item be used?
• If it is a standard item, does it completely satisfy the application or is it a misfit?
• Does the item have greater capacity than required?
• Can the mass be reduced?
• Is there an off-the-shelf item that could be substituted?
• Are closer tolerances specified than are necessary? (h) Is unnecessary fine finishes specified?
• Are unnecessarily fine finishes specified? (j) Is “Commercial quality” specified?
• Can the item be easily and cheaply transported? (I) Can cost of packaging be reduced?
• Are suppliers being asked for suggestions to reduce cost?
• A very important question is “What does it cost to perform the function done by this part?” or “Is the importance of the function to be performed commensurate with the cost of performing it?”

1.4.15 Dimensional accuracy

This is of crucial importance. Dimensions must be checked on a local and overall basis. Particular attention must be given to mating parts, e.g. base plates, foundations, etc.

The orientation of each element must be checked in relation to the total unit. In this respect, an orientation diagram must be included on the drawing showing the relevant position of the item in question.

1.4.16 Checking procedures

• All drawings produced need to be checked before issue for tender
• Except under special circumstances, drawings should be checked in a different department than the section producing them.

A suggested color code for checking

• Red – Incorrect
• Yellow – Correct
• Green – To be used by draughtsman when correcting errors. Green through red indicating alteration has been done
• Should there be revisions to a drawing once it has been signed off as checked then it should be returned for a further check
• Where there is a point of contention between Checker and the originating Draughtsman, the Chief Draughtsman should be consulted

1.4.17 Printing and filing

Printing and filing activities need to be defined in a drawing office to ensure the highest level of efficiency together with the best utilization of available printing equipment.

Printing of all drawings

Printing requirements normally fall into three categories:

• Printing for developing of working drawings
• Printing for issuing internally
• Printing for issuing externally

• All Prints should be officially requested. This may take the form of an Issue Slip, or a Print Request Slip.
• Where a job is deemed to be urgent then the Chief Draughtsman must prioritize.
• All other printing shall be done on a “First come First served” basis

Registering of drawings

• All drawings must be registered in the Master Drawing Register.
• Vendor’s drawings on arrival in Drawing Office shall be registered with all the relevant information, i.e. request for Drawing Office Number to be given to drawing, registering in Drawing Register, filing and returning of copies to interested parties

1.5.1 Introduction

Although we acknowledge that a large number of mature organizations have adapted a range of standards to suit their particular needs it is appropriate in this manual to provide recommendations with direct traceability to an international set of rules. The following recommendations are therefore taken from AS 1100.101-1992 Technical Drawing – General Principles – the Australian Standard for Technical Drawing.
This standard is in agreement with the following International Standards.

1.5.2 Size of drawing sheets

1.5.3 Thickness of format lines

Recommended line thicknesses in mm for format lines are per the table below.

1.5.4 Thickness of drawing lines

The thickness of drawing lines is covered in detail in the standards and is based on line group types which may be 1.0, 0.7 & 0.5 mm (line group 1.0 mm typically used on A0 sheet sizes) through to 0.35, 0.25 & 0.18 mm (line group 0.35 mm which may be more appropriate for A4 sheets). The standard specifically states that the minimum line thickness on a drawing after reproduction (including reduction) should not be less than 0.18 mm.

1.5.5 Text types and character heights

The following text types are provided for in the drawing standards.

• Upright Gothic
• Sloping Gothic
• ISO 3098/1 Type B Upright
• ISO 3098/1 Type B Sloping
• Microfont

The height of the characters should be one of the following (in mm) with minimum character line thickness not less than 10% of the height

• 2.5 mm
• 3.5 mm
• 5 mm
• 7 mm
• 10 mm
• 14 mm
• 20 mm

The height of the characters should not be less than 1.7 mm on a reduced drawing reproduction.

1.5.6 Ratio of text size to corresponding line thickness

The ration of line thickness to text size is generally 1:10 and one of the following sets of standard text sizes and corresponding line thickness’ is often used. Note that although Set 2 does not strictly meet the Australian Drawing Standard it is often referenced in other standards – the attached tables reference to the South Africa standard (SABS 0111 1990).

1.5.7 Title block

Title block layouts are normally laid out as standard templates with unique logos pertaining to the individual company. The standards cover a variety of designs with dimensions for different sheet sizes but specific layout is not dictated. As a general rule however the title block should be located in the bottom right hand corner of the drawing sheet or when this restricts the drawing layout the top right hand corner may be used.

As a minimum however the Title block contains the following:-

• Name of firm, organization or department
• Title or name of drawing
• Drawing number
• Signatures or initials and dates
• Additional information such as scale, method of projection, native sheet size etc.
• Provision to show revision level and drawing status.

Other information of relevance may include:

• A space may be added to the top or added to the left hand side of the company title block, in which space the Contractor’s details and title block may be added
• A further space may be added in the same area for the Contractor’s drawing number
• The Contractor shall indicate the persons responsible for producing the drawing, the title, scale, project name, date, revision etc. in the spaces provided for in the company title block

1.5.8 Reference drawings

• Where applicable, all reference drawings shall be noted in an appropriate place, on all drawings
• Smaller series drawings (A4 and A3) may bear reference drawing numbers as a note, in an appropriate position, on the drawing
• Where a drawing is of sufficient complexity and size that warrants being split over several pages, continuation lines shall be conveyed by means of either of the under mentioned symbols. Note that the direction of the arrow shall indicate the direction of information flow.

1.5.9 Recommended sheet sizes versus drawing types

As stated previously many companies have established in-house standards regarding a variety of drawing areas not covered by ISO standards. A typical recommendation of drawing sheet size versus drawing type is as per below. Bear in mind the reduction of drawing size when reproducing large drawings must not allow the line thicknesses or character heights to fall below the values stated in the standards for legibility. Reductions of more than 2 drawing sizes will in nearly all cases make portion of a drawing illegible.

Process drawings and diagrams

• American Society of Mechanical Engineers (ASME)
  • ASA Y32.11 Graphical Symbols for Process Flow Diagrams
  • ASA Z32.2.3 Graphical Symbols for Pipe Fittings, Valves & Piping

Instrumentation drawings and diagrams

• Instrument Society of America (ISA) (now known as The Instrumentation Systems and Automation Society)
  • ISA–S5.1–1984(R1992) Instrumentation Symbols and Identification
  • ISA-S5.3-1983 Graphic Symbols for DCS/Shared Displays
  • ISA-S5.4-1989 Instrument Loop Diagrams
  • ISA-S5.5-1985 Graphic Symbols for Process Displays

Electrical drawings and diagrams

• International Electrotechnical Commission (IEC)
  • IEC Publication 27 Letter Symbols to be used in Electrical Technology
  • IEC Publication 50 International Electrotechnical Vocabulary
  • IEC Publication 617 Graphical Symbols for Diagrams

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2.3.1 Plant equipment numbering

Plant area numbering
Plant area numbering is a useful tool in large plants with complex processes in that it readily enables all personal to identify equipment with a particular section of plant. Plant Area numbering schemes normally use either a 3 digit or 4 digit numeric system in the form XXX where a plant areas may be 100, 200, 300 etc and identify discrete plant sections (e.g. Furnace Area, Waste Heat Boiler Area, Converter Area etc). Plant Area numbers are then used as the preliminary number in identifying all physical plant equipment and instrumentation tags.

Plant equipment numbering
All physical plant equipment must be given an equipment number. The equipment number will normally take the form of either 1, 2 or 3 alpha characters followed by either 3 or 4 numeric characters. The alpha characters may be site specific but are normally tied to a specific company standard and identify the functional component (e.g. P or PMP for pump, V for vessel etc). The numeric characters are unique for each device of a particular type – i.e. P100 and P101 may identify 2 pumps. When used in combination with a Plant Area number the full equipment number may appear as XXXP100 and XXXP101 (e.g. 100P100 and 100P101).

Line numbering
All process lines are similarly given line numbers normally in the form of a series of alpha and numeric characters which identify the following line elements:-

• Plant Area Number  (e.g. 100)
• Service                     (e.g. LP for low pressure steam)
• Sequence Number    ( a unique number e.g. 001)
• Pipe Size (Nominal) ( e.g. 100 for 100 mm NB)
• Line Material            ( e.g. CS for carbon steel)

The resulting line number would appear as 100-LP-001-100-CS. The sequence number changes each time there is a break in the integrity of the pipe – either a flanged joint or any other form of change in the pipe.

2.3.2 Plant equipment symbols

Plant equipment symbols are used in conjunction with plant equipment numbers to identify discrete items of plant and show their interconnection to the rest of the process. Symbols shown in the table below represent some established ASME standards. Note that ISA also produces a wide variety of symbols for hand valves as well as control valves. Many software vendors provide symbol libraries for popular CAD software which contain literally thousands of symbols.

2.4.1 Instrument numbering (tagging)

Instrument Tag Nos.
As with Equipment numbers all instruments (including virtual instruments that exist in a DCS, PLC or other shared system) are given unique identifiers called tag numbers. The ISA tagging system is virtually universally adopted in terms of the basic construction of a tag number. The ISA system comprises a group of alpha characters which describe both the variable being measured (or controlled) together with the broad characteristics of the instrument itself. The first alpha character in the tag always identifies the physical variable with which the instrument is associated (e.g. Pressure, Temperature, Flow etc). Subsequent alpha characters identify the function of the instrument and may be comprise more than one additionally character. Hence FIC would refer to a Flow Indicating Controller, PAHL would refer to an alarm device on pressure with both High and Low alarm settings. Once the basic alpha tag characters are established a group of numeric characters are added to identify the loop number. These may be 3 or 4 or more numerals but all devices interconnected on the same loop must have the same loop number – the individual instruments are therefore differentiated by their alpha character functionality. As with the equipment numbering system large plants employing an Area numbering scheme may add the plant area number in front of the tag to create the full tag number. As an example tag number 100PT001 and 100PIC001 are respectively a pressure transmitter and a pressure indicating controller in plant area 100 on loop number 001. The table below lists the ISA alpha character system.

2.4.2 Instrument symbols

Bubbles
The ISA standard employs a simple system to identify instruments on process drawings by using “bubbles” – the terminology originating from the fact that the original symbol set used circles exclusively. The symbol set has now been expanded to account for the emergence of shared systems such as DCSs, PLCs and host software systems which all have multiple levels of functionality within one box. The system endeavors to identify the location of the instrument function (field, control room, auxiliary panel etc) and when used in conjunction with the instrument tag gives the reader of a diagram a clearer understanding of the overall control loop and strategy. The ISA bubble symbol set is shown in the attached table.

Primary and final elements
The ISA standard recognizes that many primary and final elements cannot be fully described by a bubble and tag number alone and therefore caters to the use of a wide variety of symbols to show the technology associated with a primary or final element. An example of these symbols is shown in the tables below.

Extended functionality
The ISA standard further recognizes that certain instruments may have a complex or unique functionality that cannot be full described by a tag number and bubble and to this end it allows for the inclusion of a small box/boxes outside the bubble with a symbol to identify the specific detail of the instrument. A representative table of ISA functionality legends appears below.

The SAMA system
The Scientific Apparatus and Manufacturers Association further expands on the ISA extended functionality system by using a range of blocks linked together to describe the functionality within a control loop. Although seldom employed these days it provides a useful tool for identifying control and measurement functions within complex loops. A table of SAMA functions and an example of the scheme are shown below.

Example of a SAMA Scheme for describing the control strategy of a 3-element boiler drum level control system.

2.4.3 Instrument interconnections

The ISA standard also provides for the interconnection of bubbles to show, on process drawings, the media by which they communicate – be it pneumatic, electrical, non-contact etc. The table below lists how the bubbles are interconnected.

2.5.1 Electrical equipment numbering

Component numbering
Components of an electrical circuit are numbered by means of a single alpha character combined with a sequential digit each time a component of a new type is used. The standards for the alpha character may vary from company to company and it is normal to draw a legend sheet to explain the use on a particular set of drawings. The attached table broadly coincides with the recommendations of the IEC Publication 27 standard for letter designations.

2.5.2 Single line symbols

IEC Publication 617 provides an extensive range of symbols which are used in electrical circuits. These are normally employed in both single line and electrical schematics but differ from those symbols employed in ladder logic schematics. Typical examples of the IEC symbol set are shown below.

2.5.3 Wire numbering system

Although there is no set standard for wire numbering of electrical circuits the generally accepted rules are to use a numeric system with 3 (or more) digits in which the number increments each time there is a break in the circuit (i.e. terminal, fuse etc).

The reader should be aware that there are individual country standards (e.g. AS3000 – Australian Wiring Rules) that govern the use of certain letters (e.g. L, A, N, E) in wire numbering systems involving potentially lethal voltages.

3.1.1 Process block diagram

The block diagram is where it all starts, here we look at the basic components and determine our requirements, and this is a diagram of the concept, giving a very broad view of the process.

In our example below we have listed all our ingredients and shown that milk, sugar and black coffee make up different permutations of the final product. This diagram is only concerned with the fact that milk is a requirement; the supply, storage and transfer requirements are beyond the scope of the block diagram. With this philosophy diagram complete we now need to determine the technical requirements, we do this by simultaneously developing two documents; these documents are the ‘Process Flow Diagram’ and the ‘Process Description Manual’.

3.1.2 Process flow diagram or piping flow diagram

The PFD is where we start to define the process by adding equipment and the piping that joins the various items of equipment together. The idea behind the PFD is to show the entire process (the big picture) on as few drawing sheets as possible, as this document is used to develop the process plant and therefore the process engineer wants to see as much of the process as possible. Attention to small detail, such as flanges, nozzles, reducers, instrumentation etc is not shown on the PFD. This document is used to determine tank sizes, pipe sizes.

For those familiar with Mimic panels and SCADA flow screens you will notice that these resemble the PFD more than the P&ID with the addition of the instruments, but not the instrument function.

Mass balance
In its most simple form, what goes in must come out. The totals at the end of the process must equal the totals input into the system.

Mass balance example
Continuing with our bottled coffee plant, if we design our system to produce one thousand 1-litre bottles of black coffee per batch then all we would need is a 1000L water tank and a 1000L autoclave.

Assuming all our ingredients are in liquid form, to make coffee with milk and sugar we use the following recipe:

• 10 liters coffee concentrate
• 20 liters syrup
• 100 liters milk
• 1000 liters water

From this you can see that using our original 1000 liter design, we would have an overflow of 130 liters per batch. In addition, if we filled the 1000 liter autoclave with water first, then there would be no room for the other ingredients and we would end up bottling water. This is a very simple example, but should be sufficient to give an idea as to the function of the PFD.

3.1.3 Process description

The process description details the function / purpose of each item of equipment in the plant. This is developed at the same time that the Process Flow Diagram is being developed and should assist the process engineer to determine the plant requirements.

This description should contain the following information:

Installation operation – The installation produces bottled coffee

Operating principles – Each part of the process is described

Water supply – Filtered water at ambient temperature is supplied to the water holding tank, the capacity of the tank should be sufficient for all recipes

Coffee supply – Due to the viscosity of the coffee syrup, the syrup is fed from a pressurized vessel to the autoclave, this line should be cleaned frequently with warm water. There will be batches of caffeinated and decaffeinated coffee, the coffee tanks and pipelines must be thoroughly cleaned between batches

Milk supply – There will be an option for low fat or full cream milk, the milk supply should be sufficient for three days operation and should be kept as close to freezing as possible to ensure longevity of the milk

Sugar supply – Sugar will be supplied in a syrup form, we will offer the coffee with no sugar, 1 teaspoon (5 ml of syrup) or two teaspoons (10 ml of syrup). Syrup lines must be cleaned on a regular basis

Circuit draining/make-up – How to start-up or shutdown the facility, cleaning and flushing

Liquid characteristics – A detailed description on analysis of each liquid type in the system. Includes specific gravity, viscosity, temperature, pressure, composition etc

Specific operating conditions linked to the process – The installation operates 24 hours a day 365 days a year. As the installation deals with foodstuffs, all piping and vessels are to me manufactured from stainless steel

Specific maintenance conditions linked to the process – Hygiene levels to be observed.

Specific safety conditions linked to the process – Hygiene, contamination of product

Performance requirements – The amount of product the plant must be able to produce in a given time frame

We see from the process description that we need to pressurize the vessels; we are dealing with syrups so we need to clean the lines with warm water, we have an autoclave that requires heating and cooling, the milk requires refrigeration. Our PFD now starts to look something like the figure shown below.

From the above we can see that, as we develop the PFD and process description, questions get asked of the process and it is the resolution of these questions that leads to the final design.

From the PFD in figure 3.3 we would ask:

• Do we connect the boiler to municipal water or use a buffer tank?
• Do we need dematerialized water for the boiler, in which case we would need a water treatment plant
• What would be the lowest temperature on the plant, do we need to put steam tracing on the syrup lines?

Once we have asked and answered all the relevant questions, our PFD, mass balance and process description should all be complete, we are now ready to start with the design of the P&ID.

The following figure shows the Process Flow Diagram for a chlorine scrubber plant, complete with mass balance, note what is and is not shown on the PFD.

PFD shows:

• Numbers on the pipelines that correspond to the mass balance table
• Equipment reference numbers and descriptions that will correspond to the process description
• The composition and data relating to each item in the system

PFD does not show:

• Pipe numbers, sizes or valves
• Instrumentation of any kind
• Flange sizes or numbers

The process engineer develops the Process Flow Diagram; he uses this as a tool to develop his equipment criteria in order to establish equipment requirements, in our above example he would as the following questions:

• What is the optimum temperature at which all the ingredients will combine?
• For how long must the ingredients be stirred in the autoclave?
• How long will it take the autoclave to heat the ingredients to the required temperature (heat transfer)?

The process engineer must know the composition of the ingredients as changes to the composition will affect the taste / strength of the final product.

Note: The above shows the importance of understanding the process engineer’s role, however, what no design document can tell us, is the budgetary constraints that were placed on the process engineer during the design phase of the project.

Situation 1: In the coffee plant example, let’s assume our engineer called for the syrup vessel to be steam traced, this was vetoed due to budgetary constraints, now two years after construction you are sitting in the middle of winter with a solid lump of glucose.

Situation 2: The plant buyer sources a cheaper batch of coffee, it comes out looking like tea and tasting like milk. You adjust the amount of coffee per batch to make up for the lack of strength.

Question 1: Did you reduce the amount of water proportionally per batch, or do you now flush away a couple of liters of profit per batch?

Question 2: Has anyone revised the mass balance? Has anyone shown the buyer the new mass balance that proves that his cheaper coffee is actually more expensive?

Better still, did the buyer familiarize himself with the product properties before starting his search for a cheaper product?

3.1.4 Piping and instrumentation diagram (P&ID)

The Piping & Instrumentation Diagram, which may also be referred to as the Process & Instrumentation Diagram, gives a graphical representation of the process including hardware (Piping, Equipment) and software (Control systems); this information is used for the design construction and operation of the facility.

Other synonyms for the P&ID are:

• MFD – Mechanical Flow Diagram: Used where materials handling is predominant
• EFD – Engineering Flow Diagram
• UFD – Utility Flow Diagram

The PFD defines “The flow of the process” The PFD covers batching, quantities, output, and composition.

The P&ID also provides important information needed by the constructor and manufacturer to develop the other construction input documents (the isometric drawings, or orthographic physical layout drawings, etc.). The P&ID provides direct input to the field for the physical design and installation of field-run piping. For clarity, it is usual to use the same general layout of flow paths on the P&ID as used in the flow diagram.

The P&ID ties together the system description, the flow diagram, the electrical control schematic, and the control logic diagram. It accomplishes this by showing ALL of the piping, equipment, principal instruments, instrument loops, and control interlocks. The P&ID contains a minimum amount if text in the form of notes (the system description minimizes the need for text on the P&ID). The first P&ID in the set for the job should contain a legend defining all symbols used; if some symbols are defined elsewhere, it may be appropriate only to reference their source. The P&ID is also used by the start-up organizations for preparing flushing, testing, and blow-out procedures for the piping system and by the plant operators to operate the system. The correctness and completeness of the P&ID drawings are critical to the success of a plant start-up program.

There are several other facts concerning P&IDs that are important. First, regardless of how sophisticated the Design P&ID may be, there is a wealth of information that exists, and is needed by the typical operating plant, that does not exist during the initial design phase of the facility; and this information continues to grow throughout the plant’s operating life.

Because many plants serve 20 years or more, maintenance personnel need effective tools for corrective (repair) and preventive maintenance. During corrective maintenance, Intelligent P&IDs can assist the operator in finding information needed foe personnel assignment and location of spare parts. Engineering documents assist maintenance personnel by defining what is broken and determining how to replace it. The P&ID is the index to this data, providing quick access to the information and a tool to update and track that information after changes are made.

The operation phase concerns issues of safety as well as the process itself. The operator needs to keep a history of the processes, as well as the updates and changes to the plant data model. Intelligent P&IDs facilitate compliance with legislation such as OSHA and ISO, requiring that the P&ID and instrument data sheets are kept up-to-date and accessible.

Also, in today’s marketplace, the majority of projects are existing plants; either through re-work, upgrade, modernization program etc.

P&IDs for these facilities that are either purely paper-based, or only based on generic (dumb graphics) CAD systems, most likely AutoCAD or MicroStation.

Additionally, there exists a massive amount of legacy data in these plants, concerning all phases of the plant operations environment. Capturing this information and linking it to the existing P&ID, or even better, linking it to newly created Intelligent Design P&IDs, would provide an extremely valuable tool to the typical plant operator.

The typical plant operations environment uses the P&ID as the principal document to locate information about the facility, whether this is physical data about an object, or information, such as financial, regulatory compliance, safety, HAZOP information, etc.

The P&ID defines “The control of the flow of the process” Where the PFD is the main circuit, the P&ID is the control circuit.

Once thoroughly conversant with the PFD & Process description, the engineers from the relevant disciplines (piping, electrical & control systems) attend a number of HAZOP sessions to develop the P&ID.

HAZOP
Hazard operability studies have a full set of rules and procedures, which are beyond the scope of this course. In its most basic form, the HAZOP looks at each item of equipment in the process and by applying a given set of rules to each item determines suitability and possible problems. It is the resolution of these problems that leads to the development of the P&ID.

Returning to our coffee bottling plant as shown in figure 3.4, we see that if the holding tank runs dry while we are trying to fill the autoclave, the system will come to a standstill. We can resolve this problem by installing a level low switch on the holding tank; the level switch can then give an alarm when the tank level drops below a predetermined point.

Comparing figure 3.4 above to the PFD in figure 3.2, two things become immediately apparent:

• The level of detail in the P&ID is far greater than that of the PFD, focus has moved from the operation as a whole and now focuses, in great detail, on the operation of each piece of equipment.
• Showing this level of detail takes a great deal of space and includes far more lines on the drawing, for this reason rules are laid down detailing the amount of equipment to be shown per P&ID.

3.1.5 P&ID standards

Before development of the P&ID can begin a thorough set of standards is required, these standards must define the format of each component of the P&ID. We look first at what should be shown on the P&ID and then we will discuss each item in greater depth.

Mechanical equipment
Mechanical equipment is shown in an outline form and indicates all associated equipment that is pertinent to the function of the equipment. For a vessel this would include any; trays, spray nozzles, demisters, packed sections etc.

Equipment numbering
Equipment numbering varies from installation to installation. The equipment numbering system for a particular plant should be defined in the relevant equipment numbering specification.

Presentation on the P&ID
There are 3 common formats for presentation. Again, the accepted format should be defined in a standard – either a company, national or international standard.

Valves
Valves fall into two main categories, control valves and hand valves. The control systems engineer specifies the control valve, while the hand valve is usually selected by the piping discipline.

Hand valves
Hand valves are denoted using the relevant symbol; a clear symbol is used to represent a normally open valve while an opaque symbol is used for normally closed valves. A solitary valve symbol is assumed to be a hand valve, as a control valve would show the control configuration and may be accompanied by an instrument “bubble”.

Again, the manner in which the hand valve is displayed is dependant on the standard used by the originator of the P&ID.

Control valves
Control valves use the same basic valve type symbol as the hand valve, the following differences differentiate hand valve from control valves.

• Control valves do not use clear and opaque symbols to show standard positions
• Control valves show a failure position in the event of a power loss, these positions are Fail open (FO) , Fail Closed (FC) or Fail Indeterminate (FI) used when the valve will remain at the same position it was when the power was lost
• Control valves display the type of control i.e. actuator, diaphragm, solenoid etc
• Control valves should appear in the instrument list

Examples:

The example in figure 3.5 shows a globe control valve with a pneumatic diaphragm actuator and an electro-pneumatic positioner together with a temperature element (TE) in a thermowell (TW) connected to a temperature transmitter (TT). This level of detail is not normally required on a P&ID and is often simplified to that shown in figure 3.6

Piping
Piping is shown on the P&ID using major & minor pipelines, these pipelines are drawn in different thicknesses, usually with major process lines depicting product lines and minor lines for utilities.

Pipe numbering

Pipe numbers as assigned to each process line in a P&ID (as discussed in Chapter 2) will change every time a component of the pipe number changes or when there is a change or split in the pipe run. As previously discussed pipe numbers are made up of a variety of numbers or codes that are grouped together to form a unique number. These are typically:

• Unit or area number
• Service
• Sequence number
• Pipe size
• Line class or line material

Example
figure 3.7 below shows how a pipe reducer causes the pipe number to change; the format for this number is Area- Service- Sequence No. – Pipe size – Line material.

Nozzles & Flanges
Nozzles and flanges need to be accurately portrayed on the P&ID, as this information will be carried over to the design of the physical tank.

Equipment & instrument numbering systems
In order to be able to develop the PFD & P&ID into meaningful documents we need compile them according to specific standards and numbering systems. This information has already been covered in some detail in Chapter 2.

A completed P&ID may therefore appear as the example below which has been derived from the PFD for a gas scrubber shown previously.

3.1.6 Standardization of symbols

Regardless of the drawing standards adopted by a company a consistent use of symbol sets throughout a project is essential for both clarity (of the function of the piece of equipment) as well as efficiency in the production of a large number of drawings. Symbol libraries for CAD software are readily available from many software companies based on a wide range of drawing standards (ISO, ISA, ASME etc) and may also form the basis for “hand drawn” document sets. The inclusion of a Drawing Legend in a document package is of great assistance to an outside reader of any schematic diagram. The following pages show some typical symbol sets for a CAD software package.

4.1.2 I/O lists

Name: I/O list or Input/Output list
Function: the I/O list gives an accurate count of all the analog and digital inputs and outputs on the plant or project. This information is used to size the DCS/PLC hardware that will be used to control the plant.
Used by – the instrument engineer to establish/define a specification for the control system. Depending on the format, this can also be a useful tool for the PLC programmer. Many companies base quotations on the number of IOs.

Example:

4.1.3 Data sheet – spec sheet

Name: Data sheet or Specification sheet.
Function: The data sheet contains all the process, mechanical and electrical data relevant to a specific instrument; this can be expanded to a group of instruments with the addition of a tag list. The compilation of the data sheet is a group effort that includes Process, Instrumentation and Piping. Pre-printed sheets or standard templates are available through ISA covering most instrument types.
Used by: the instrument engineer to select the most appropriate instrument to meet the requirements stipulated by the datasheet. This should also be available to the maintenance department throughout the lifecycle of the plant for use when calibrating or selecting a suitable replacement.

4.1.4 Trip alarm schedule

Name: Trip (and) Alarm schedule
Function: Lists the set points, alarm points and trip points of the field instrumentation connected to the process.
Used by: DCS/PLC programmer for programming the alarm or trip at a set process value.

4.1.5 Cable list/schedule

Name: Cable list or Cable schedule.
Function: Lists each cable on the plant, giving its size, length, source and destination.
Used by: The site contractor for the installation of cables uses this document; each cable list generally has a column indicating estimated and actual installed lengths. This could be used by the Purchase department, although this depends on the size of the project and the lead-time of the cable manufacturer. Quantity surveyors use the document to check estimated length vs. installed length for payment to the sub-contractor.

4.1.6 Erection material take-off/Bill of materials

Some of the more modern design software packages enable the user to extract a full list of materials needed to complete the installation of the field equipment. This equipment list is taken off the installation details.

4.1.7 Instrument location plans

The instrument location drawing is used to indicate an approximate location of the instruments and junction boxes. This drawing is then used to determine the cable lengths from the instrument to the junction box or control room. This drawing is also used to give the installation contractor an idea as to where the instrument should be installed.

The detail shows how the location drawing guides the installation contractor in the placement of the field junction boxes and the field instrumentation. It must be remembered that this is only a guide. This drawing is created using experience and imagination, the installation contractor deals with the physical aspects and may find excellent reasons for changing the design.

4.1.8 Cable racking layout

Use of the racking layout drawing has grown with use of 3D cad packages; this drawing shows the physical layout and sizes of the rack as it moves through the plant.

4.1.9 Cable routing layout

Prior to the advent of 3D cad packages, the routing layout used a single line to indicate the rack direction as well as routing and sizes and was known as a ‘Racking & Routing layout’.

4.1.10 Block diagrams – signal, cable and power block diagrams

Cable block diagrams can be divided into two categories: Power and Signal block diagrams. The block diagram is used to give an overall graphical representation of the cabling philosophy for the plant.

4.1.11 Field connections/Wiring diagrams

Function: To instruct the wireman on how to wire the field cables at the junction box
Used by: Installation contractor, when the cable is installed on the cable rack, it is left lying loose at both the instrument and junction box ends. The installation contractor now stands at the junction box and strips each cable and wires it into the box according to the drawing.

4.1.12 Power distribution diagram

Function: There are various methods of supplying power to field instruments; the various formats of the power distribution diagrams show these different wiring systems. The diagrams below show the various options in greater detail. Note the difference between this diagram and the power block diagram
Used by: Various people depending on the wiring philosophy, such as the panel wireman, field wiring contractor.

4.1.13 Earthing diagram

Function: Used to indicate how the earthing should be done. Although this is often undertaken by the electrical discipline there are occasions when the instrument designer may or must generate his own scheme – eg for earthing of zener barriers in a hazardous area environment.

Used by: earthing contractor for the installation of the earthing. This drawing should also be kept for future modifications and reference.

4.1.14 Loop diagrams

Function: A diagram that comprehensively details the wiring of the loop, showing every connection from field to instrument or I/O point of a DCS/PLC. The inclusion of a bubble diagram in the bottom left hand corner of the diagram quickly conveys to the reader the overall loop strategy.

Used by: maintenance staff during the operation of the plant and by commissioning staff at start up.

4.1.15 PLC schematics

PLC schematics give an overview the interaction of the field device (and associated wiring) with the I/O of a PLC or DCS system.

4.1.16 Installation detail – hook-up

Function: To detail how the instrument should be installed by the instrument fitter. Used to list the components required for the installation.

Used by: Instrument fitter to install instrument, estimator to total equipment for purchase.

4.1.17 Other diagrams

Depending on the particular plant a range of other drawings, lists, schedules etc may be required to full document the instrumentation on a plant

Typical of these may be one or more of the following:

• Control Panel General Arrangement Drawings
• Ladder Logic Drawings
• Hazardous Area Drawings
• Installation Specification document

There are no specific standards covering the presentation of these documents and individual projects may differ in presentation although the information they communicate must be concise. An example of a simple general arrangement drawing for a Scada system is shown.

5.1.1 The Load List

A completed P&ID will show the number of motors on the plant as well as the function of each motor. A summary document called a load list provides an overall view of all users of power in a plant.

The load list therefore is used to total the power supply requirements for each device per plant area or process that will be supplied by a mini sub. Load lists are made for each voltage level on the plant.

Sample: The sample in Figure 5.1 shows a typical layout of a load list

5.1.2 The Single Line Diagram

The single line diagram (sometimes called the one line diagram) uses single lines and standard symbols to show electrical cables, bus bars and component parts of a circuit or system of circuits The single line diagram is completely different from a wiring diagram or schematic that shows wire numbers, terminal numbers connections etc. The single line diagram shows the overall strategy for system operation. Duplication of a 3-wire system is reduced by showing single devices on a single wire. A sample single line diagram is shown in Figure 5.2

5.1.3 The schematic diagram (main and circuit)

Continuing where the single line left off, the schematic diagram shows both the main circuit and the control circuit in far greater detail, here all three lines of a 3-phase system are shown. The schematic shows the detailed layout of the control circuit for maintenance and faultfinding purposes rather than the overall picture presented by the single line diagram. An example is shown in Figure 5.3

A schematic diagram therefore shows the following main features:

• Main circuits
• Control, signal and monitoring circuits
• Equipment identification symbols with component parts and connections
• Equipment and terminal numbering
• Cross references – indicating where on the diagram or sequential sheet, the related parts of the equipment can be found.

The above information should be sufficient to explain the function of the circuitry and allow the circuitry to be easily followed when tracing faults.

The main circuit

This is where the difference between a drawing and diagram must be understood; the diagram is not concerned with the physical location of the equipment but rather the functional aspects of the circuits.

Figure 5.4 above shows our motor with a local stop start station located in the field, while the contactor is in the motor control cubicle, the PLC in the control room and the local control panel in the field.

The quantity of circuitry (size or complexity of installation) usually determines the amount of circuitry to be shown on a single sheet. Where an installation has 4 motors in a related circuit, all 4 motors can be shown on the same sheet, while their respective control circuits can be shown on following sheets. These motors are referred to as the main circuit. An example is shown in figure 5.5

Control circuit

Conventional switchgear circuits are drawn from the top down between the horizontal potential lines representing live and neutral. The components and wiring between these two lines is referred to as the control circuit and are as shown in figure 5.6. Whilst there are many variations on this theme they all contain the same level of information.

Electrical equipment

All electrical assemblies and sub assemblies are shown by symbols, with lines interlinking where necessary to show connections.

Switchgear components and contacts

These are shown in the standard reference position i.e. the de-energised or non-operated state, this would mean that NO contacts are shown open and NC contacts are shown in the closed position.

Markings and Designations

Using the letter code and a sequential number that is increased by 1 each time an additional component of the same type is added is the generally accepted method for numbering circuit components.

Component numbering

Components of an electrical circuit are numbered by means of a symbol or equipment designator coupled with a sequential number that is incremented by a digit each time a new component of the same type is inserted into the circuit.

Wire numbering

Wire numbering is dependant on system used, designers whim or company standard, there alpha numeric systems, numeric only and from to wiring. In most electrical schematics the use of the numeric system generally accepted as the standard, with a two or three digit number being increased by 1 each time there is a break in the circuit.

Cross-referencing

Cross-referencing uses a combination of sheet, column and row number to direct the reader to the location of the main or sub assemblies of the component.

5.1.4 Plant layout drawings

The plant layout drawing gives a physical plant layout, where equipment is drawn to resemble the plant item it represents. An example is shown in figure 5.7 and in blow-up detail (for clarity) in figure 5.8

This blow up shows the detail found in a plant layout drawing, these drawings normally consist of both elevation and plan views.

5.1.5 Racking and routing

These drawings are used to show the layout of the plant racking systems, the size of the racks and the cable numbers of all the cables running on that section of the rack. A typical example is shown in figure 5.9

From the blow up in figure 5.10 you can see that symbols have replaced the physical equipment.

5.1.6 Installation detail

The installation detail shows the layout of the equipment and gives an itemised list of all the equipment on the drawing as well as notes on the installation.

5.1.7 Panel layout

The panel layout drawing gives the dimensions of the panel, the layout of the equipment in the panel, an itemised list of all the equipment used as well as quantities. The notes detail various items like specification references (paint, powder coating) and general notes.

5.2 Other electrical documents

5.2.1 Cable schedule

Used mainly for installation purposes, gives a source and destination for each cable and specifies the type of cable.

5.2.2 Point to point schedule

Facilitates wiring installation by showing termination points at each end of every wire.

5.2.3 Hazardous area drawings

A plant location drawing (in both plan and elevation) which shows by means of overlays plant area classifications (by zone and gas group) for potentail leak hazrads throughout a plant.

5.2.4 Ladder Logic Schematics

Detailed schematics of a ladder structure where the discrete rungs represent control circuits in an overall scheme. Most often used a the basic IEC programming language in PLC’s but sometimes used in hard wired relay circuits.

5.3.1 Sample schemtics

The following pages show a range of typical electrical drawing samples such that the reader can view a variety of layout styles which may be used.

6.1.1 Main or supply circuit

In the electrical schematics we saw how the main circuit was displayed separately from the control circuit. In pneumatics or hydraulics we have a similar case where we require either air or oil as part of our main circuit that drives the remainder of the circuit. This portion of the circuit is fairly standard and as a result is usually reduced to a rather simple input symbol (composite) that is used to imply a full system.

From the initial supply, it is pretty much anything goes, though particular attention should be paid to the following points:

• Where pneumatic circuits have electrical connections, these connections are shown on a separate circuit on a separate page.
• Good circuit design should show the return path on hydraulic circuits and the use of baffles on pneumatic circuits.

6.2.1 Lines

6.2.2 Basic symbols

The symbols are made up of circles, squares, triangles and lines.

• Symbols are shown in the de-energized state or at rest.
• Rotation is shown by an arrow symbol on the shaft.
• An arrow passing through a symbol at 45 degrees indicates that the flow through the component can be regulated.

6.2.3 Pipe symbols

The symbol does not indicate the material of the pipe

6.2.4 Couplings

6.2.5 Fluid storage and energy sources

6.2.6 Fluid conditioners

6.2.7 Linear devices

6.2.8 Actuators and controls

6.3 Rotary Devices

6.3.1 Instruments & accessories

6.3.1 Valves

The basic valve symbol consists of one or more envelopes containing internal lines used to indicate flow paths and conditions between the ports.

6.3.2 Two way valves

6.3.3 Three way valves

6.3.4 Four way valves

Snap action with transition: two position, four way valve. As valve element shifts position, it passes through an intermediate position. If this “in transit” condition is essential to circuit function it can be shown in the centre position, enclosed by broken lines.

Typical flow paths for centre positions are as follows:

6.3.5 Speed control valves

Adjustable with bypass speed control. Flow is controlled in the right hand direction, flow in the left hand direction bypasses the control. Representative composite symbols

Component enclosure: the enclosure surrounds a group of symbols to represent an assembly, conveying more information about component connections and functions. External ports are assumed to be on the enclosure line and indicate connections to the component.

6.5.1 Pressure switch sequencing circuits (Mechanical)

It is sometimes difficult to employ limit switches or limit valves to control a sequence. This may be due to the size of the components, the nature of the linkages, or the available space. When such a situation arises, the use of the pressure switch may offer a convenient solution to the problem.

Figure 6.10 illustrates a simple arrangement for pressure-switch sequencing of a double-acting cylinder. The four-way directional-control valve in this illustration is a two-position, double-solenoid valve.

Momentary actuation of pushbutton switch PB will energize solenoid A, shifting the directional-control valve to a position that will deliver air to the cap-end cylinder chamber, causing the extension stroke of the cylinder piston. As the stroke is completed, pressure builds up to a value sufficient to trigger pressure switch PS. An electrical signal is then sent momentarily to solenoid B of the four-way directional-control valve, thus returning the valve to its initial position for delivering air to the head-end cylinder chamber and causing the retraction stroke of the cylinder piston.

6.5.2 Sequencing circuit with electrical control

Figure 6.11 illustrates the sequencing of two double-acting cylinders, each controlled by a double-solenoid, four-way directional-control valve. The sequencing in this circuit is accomplished by the use of four pressure switches. The desired sequence is:

• Extension stroke of piston of cylinder C
• Extension stroke of piston of cylinder D
• Retraction stroke of piston of cylinder D
• Retraction stroke of piston of cylinder C

The cycle begins with the actuation of the start pushbutton, which energizes solenoid 1 of valve A (line 1 in Fig. 6.11). This causes air to be delivered to the cap-end chamber of cylinder C, causing its piston to complete its extension stroke. When the pressure builds up to trigger pressure switch E, an electrical signal is sent through a normally closed set of contacts of relay CRl (line 2 of Fig. 6.11) to energize solenoid 3 of valve B. This delivers air to the cap-end chamber of cylinder D, causing its piston to complete its extension stroke. At the completion of this extension stroke, the pressure build-up triggers normally open pressure switch F, thus delivering an electrical signal to the coil of relay CRl (line 7 of Fig. 6.11). This relay coil is then held energized through a set of its normally open contacts (line 6) in series with normally closed pressure switch H (line 7) .An electrical signal is then delivered through another set of normally open CRl contacts to solenoid 4 of valve B (line 4). This shifts valve B, causing air to be delivered to the head-end chamber of cylinder D and powering the retraction stroke of its piston. At the completion of this retraction stroke, a pressure build-up triggers normally open pressure switch G (line 5 in Fig. 6.11), thus delivering an electrical signal through a set of normally open CRl contacts to energize solenoid 2 of valve A. This returns valve A to its original position, delivering air to the head-end chamber of cylinder C, causing the retraction stroke of its piston. At the completion of this retraction stroke, the pressure build-up triggers normally closed pressure switch H (line 7 in fig 6.11), thus interrupting the holding current in the coil of CR1. As the control relay de-energizes, the signals to solenoids 4 (line 4) and 2 (line 5) are both interrupted. At this stage, the circuit is again in its idle state and ready for the start of another cycle.

The emergency stop pushbutton (lines 2 and 3) can be used to reverse the stroke of the piston of cylinder D, with the retraction stroke of the piston of cylinder C following in its normal sequence. Should it be desirable for the emergency-stop function to return both cylinder pistons simultaneously, a second set of normally open contacts could be incorporated into the emergency stop switch for the purpose of supplying an electrical signal to solenoid 2 (line 5) of four-way directional control valve A.

While such use of pressure switches offers no positional interlock signals, it does offer a convenient method of electrical switching without making mechanical switch mountings directly on a machine. If it is imperative to sense actual position rather than pressure sensing of the cylinder strokes, attention should be given to the method of sequencing by means of limit switches.

6.6.1 Introduction

Ladder diagrams or ladder logic diagrams are specialized schematics used to document industrial control logic systems. The name “ladder” comes from the resemblance to a ladder with two vertical lines for the power and as many horizontal lines (rungs) as required for the circuit components. This section of the course will teach the reader how to compile a ladder logic diagram for a circuit, using good design principles.

6.6.2 General drawing layout

The use of cross-referencing is not required in ladder logic diagrams, what must be remembered is that ladder logic layout differs from electrical schematic layout. With ladder logic the power supply lines are vertical while in electrical schematics these lines are horizontal. All drawings should contain legends of symbols used as well as an index system.

6.6.3 Symbols

Switches

An electrical switch is a device used to interrupt the flow of electricity in a circuit. Switches are essentially binary devices, being either on (closed) or off (open).

Types of switches include hand, limit and process, we have a look at each of these in the symbols below:

Hand switches

As the name implies hand switches are operated by hand (hopefully belonging to a human).

Limit switches

These are switches that are operated by a mechanical movement. This movement could be the result of a relay energizing or current going too high.

Process controlled switches

Process controlled switches are switches that change status with a change in the status of the process.

Contacts

Contacts for switches come in one of two states, normally open or normally closed, this the non-energised position of the contact. This is position that the contact is in when it comes off the shelf

• Speed switch – Position at zero rotation
• Temperature switch – Position at room temperature
• Flow switch – Position at zero flow
• Pressure switch – Position at standard atmospheric pressure

6.7 Ladder Logic

6.7.1 ‘Ladder’ diagrams

Ladder diagrams or ladder logic diagrams are specialized schematics used to document industrial control logic systems. They are called ‘ladder’ diagrams because they resemble a ladder, with two vertical rails (supply power) and as many “rungs” (horizontal lines) as there are control circuits to represent. A simple ladder diagram showing a lamp controlled by a hand switch is shown in figure 6.12 below:

The L1 and L2 designations refer to the two poles of an AC supply, unless otherwise noted. L1 is the live conductor, and L2 is the grounded or neutral conductor. The circuit is reduced to its simplest form and does not go into detail regarding the source of power, this function is left to the single line diagram.

While ladder logic diagrams are shown in the standard operation voltage i.e. 120VAC or 220 V AC, depending on location, they can be used to depict circuits of any voltage, AC or DC.

6.7.2 Wire numbering

Wire numbering is a contentious issue the world over, with a lot of good, bad and downright ugly systems being used. As we dealing with ladder logic here we will look at what has become a fairly common practice regarding wire numbering.

In figure 6.13, the “1” between the contact and the lamp is used to indicate the wire number, while the L1 and L2 are used to indicate the wire numbers of the circuit supply.

Figure 2 shows how the circuit would be numbered, using wire markers.

Figure 6.14 gives an idea of the physical layout of the circuit.

The essential wire numbering criteria to remember is that, any one electrically continuous point in the circuit has the same number regardless of any changes in the conductor.

The following points must be borne in mind for wire numbering:

• Wire numbers are used to assist in construction and maintenance.
• Each conductor in a continuous circuit has a unique wire number.
• Wire numbers only change when there is a break in the continuity of the circuit.
• Every conductor should be labeled at both ends.

7.2.1 Purpose

Describes the preparation of documents to the order of the plant. To inform the Vendors/Contractors of the Engineer’s requirements for the preparation, receipt, review and collection of technical information.

7.2.2 Scope

This specification covers the management of the flow of technical documentation necessary to facilitate the design supply, construction, commissioning, operation and maintenance of the Plant.

7.2.3 Objective

To ensure that all documentation submitted to the Engineer for review, approval and retention is properly prepared and submitted in. a uniform manner suitable for the Engineers needs.

7.3.1 The engineer’s documentation requirements

The Engineer’s requirements for documentation for each procurement package will be shown on the Documentation Requirement Schedule included with each order (DR-Documentation Requirements). This indicates the number of copies required, the submittal dates and the categories of documents required. Individual documents must be supplied in all instances (Annexure 2A), unless the DR is modified to show only a B Column in the weeks column.

The Engineer’s requirements for documentation for each procurement package will be shown on the Documentation Requirement Schedule included with each order (DR-Documentation Requirements). This indicates the number of copies required, the submittal dates and the categories of documents required.

7.3.2 Vendor/contractor document register

Vendors/Contractors are required to generate a register listing all documents that will be submitted against the Engineer’s requirements The Document Register is Item 01 of the Documentation Requirements Schedule and must be the first document to be received by Document Control.

For each document, the register shall show:

• The title of the document {description)
• The vendor document number {the vendor document no.. and its file names must be identical)
• The document category
• The due date for first submission to the Engineer

All documents shall carry a revision control block on which the revision, status and date of revision is entered. All documents submitted shall. have a unique document number allocated by the Vendor/Contractor. If the document is submitted in electronic format, the file name must be identical to the document number.

The title/description of the document shall clearly identify the facility, and equipment where applicable and shall adequately describe the document.

Changes or additions shall be identified by <x>, The Register must be re-submitted for approval to reflect any changes. {e.g. <5> ).

One document may be submitted to satisfy more than one category of the Documentation. Requirements Schedule provided that it is submitted to suit the earliest date of all the categories it covers and that this is clearly noted on the Vendor Documentation Register.

Two paper and one electronic copy of the register shall be addressed to the Engineer’s Lead Document Controller for approval. After review, one copy, either bearing the Engineer’s comments or marked “Status D” as approved, will be returned to the Vendor/Contractor .

Once the register has been approved to a minimum of status “C” (at the Engineers discretion), the information contained on the register will be entered into the Engineer’s document control system.

7.3.3 Review of vendor contractor documents

On or before the due submission date, the Vendor/Contractor shall. submit the copies of the document or document package to the Engineer’s Document Controller under cover of his official transmittal note.

The transmittal note must state the purpose of the submission.

Each individual document must be identified by Its number and revision on the transmittal and where electronic files are attached, the file names including the size. Documents for different purposes must be sent on different transmittals. If documents are submitted via e~mail; the transmittal must be included.

One electronic fife plus two paper copies of each document (except for hand produced documents, material certificates or similar where three hard copies shall be supp1ied) shall be submitted for review.

The electronic file sha1l be in AutoCAD or one of the MS Office Suite of software. Each 3” disk or CD ROM shall contain an index identifying the file name/document number/the Engineer’s document number and the revision of all documents included on the disk or CD ROM.

After review, one copy of each document bearing the Engineer’s comments and with the document status marked on the review sticker will be returned to the Vendor/Contractor under the cover of a Transmittal.

Fourteen (14) calendar days.. except where otherwise specified in the contract shall be . allowed between the receipt by the Engineer of documents for review and the generation of the return transmittal for dispatch of the reviewed documents.

On receipt of the reviewed documents, the Vendor/Contractor shall make any modifications requested and re-submit one electronic file plus two paper copies within 14 (fourteen) calendar. days. Queries regarding comments/changes shou1d be addressed with the relevant SLE staff, prior to resubmittal.

Any re-submittals, which have not included the changes/comments modified, will be returned to the vendor for further revision to the document.

Drawings that are required to be brought to “As-Built” by the Documentation Requirements Schedule must be submitted within 5 working days of applying for a Works Completion Certificate.

7.4.1 The engineer’s record drawings ~ “As-Built”

The Contractor shall record on two (2) set of the Engineers construction drawings all changes and deviations from the latest revision of the construction drawings issued by the Engineer. Upon Works Completion, the Contractor shall deliver these marked-up record prints in “As built” condition to the Engineer after certification as such by the Engineer’s Site Engineer.

7.4.2 Requirements for vendor as-built or final drawings

The Documentation Requirement Schedule will indicate the documents which are required to be brought to “As-Built’ status.

The hard copies shall be stamped with the Vendor/Contractors “Certified” “Final” or ‘’As-Built” stamp (as appropriate} or the revision block suitably updated. The stamp shall also include the certifying signatures of the prime parties responsible, namely the Installation Contractor and the Engineer’s responsible Site Engineer.

The Engineer’s requirements for “As-Built’, Certified, or Final drawings are:

• All manual drawings: 2- paper prints (original or full size) All CAD drawings: 2- original plots (full size)
• 1-electronic file on CD ROM or 3X ” disk Format: AUTOCAD

All “As-Built automation functional analysis documents shall be submitted as follows:

• 1 paper (A4) copy bound in book form 1 CD ROM or 3″ disk; documents to be prepared using one of the Microsoft Office Suite of software.

7.6.1 Scope

This specification covers the requirements for the preparation of Installation, Maintenance, Operating Instruction, and Training material which shall be submitted when required in the package Documentation Requirement Schedule by the Contractor/Vendor for all equipment supplied for the Plant.

7.6.2 Objective

To ensure that all documentation submitted to the Engineer for review and retention is properly prepared in a uniform manner suitable for the Employer’s needs. The Vendor/Contractor shall submit a separate set of documents for Installation Instructions, Maintenance and Operating Instructions, and Training materials.

A separate set of documents shall be submitted for each group of equipment which must function to perform a specific task – for example, a belt conveyor system which comprises of motor control centers, motors, gearboxes, pulleys, bearings, belts, dust collectors, speed switches, lighting, etc.

Each separate set of documents or training material is referred to as a manual in the following text.

7.6.3 Reference documents

7.6.4 Submission for review

The initial submission shall be made as specified in the Documents Requirements Schedule. The Contractor/Vendor shall correct all errors and deficiencies and resubmit the manuals within three weeks after the Engineer has reviewed the initial and further submissions. The final submission shall be made after all data has been gathered but shall in no case be later than;

Four (4} weeks prior to commencement of installation.

Six copies of each manual shall be submitted for review, except for Training documents for which only one copy is required for initial review and six copies for final.

7.6.5 Assembling of manuals

Installation, Maintenance and Operating Instruction shall be supplied as manuals in off white plastic covered 2 or 4 D-Ring binders with a clear front overlay and a clear spine pocket. 4 D-Ring shall always be used if document contains more than 100 pages. Use of other binders including vendor/contractor’s standard will be at the absolute discretion of the Engineer. In all instances binders shall have spine sheets and front overlay insert. (Refer annexure 1)

Coloured dividers shall separate each section of the manual and shall be manufactured from plastic (PVC) and shall be marked numerically to correspond with the index.

Each section of the manual shall be sub-divided and indexed to facilitate quick referencing.

Unless for reasons of clarity, where a larger size is warranted, drawings included in the manual shall be A4 or A3 size. Drawings shall be able to fold out without removal from the manual

Drawings and charts larger than A3 size shall be folded and enclosed in a plastic pocket of A4 size of adequate strength.

The originals of all brochures shall be furnished. Photocopies will not be acceptable, Where a general brochure is applicable to a range of equipment., then the specific item, catalogue number or model number shall be stated.

Exploded views and pictorial descriptions shall be used wherever possible.

Refer to Annexure 1 of this specification for details of the inserts for the front. Overlay and spine pocket. Each volume shall be numbered (e.g. 1 of 1, 1 of 2, 2 of 2,.etc.)

7.6.6 Contents of manual

7.6.7 Training material

The material shall be supplied in software compatible with Windows and shall be Year 2000 Compliant.

The material shall include sections covering the topics listed above.

With reference to Clause 6.2.6, Maintenance .Instructions, Contractors Vendors shall note that for PLC programs the training material shall include complete Level 1 PLC training documentation which shall include:

• Leve1 PLC narrative functional specification
• Fully documented hard copy printout of the PLC program
• Electronic copy of the PLC program
• Copy of logic diagrams as applicable