Instrumentation Engineer

Activities & Documents – Detail

Design Phase
by Mansoor Mohseni
In the previous article, we learned about the different I&C engineer
roles and responsibilities and the main relevant documents, while
some major points can be described below approaches.

Instrumentation and Control (I&C) systems are integral to the

operation of many industrial processes, including power generation,
oil and gas production, manufacturing, and more. During the Detail
Design phase of a project, a lot of focus is given to the I&C systems
to ensure their efficient and safe operation.

Instrumentation Engineer Activities

Instrumentation Design Engineers play a crucial role in designing,
implementing, and maintaining instrumentation and control
systems in a variety of industries.

Here’s a general view of instrument engineers’ typical activities:

1. System Design: This involves designing the

complete instrumentation system for a project. This includes
the selection of appropriate instruments, defining their
locations, identifying the connection details, etc.
2. Instrument Selection: The engineer selects the appropriate
instruments based on process parameters, system
requirements, and industry standards. These can include
sensors, transmitters, control valves, switches, etc.
3. Preparation of Specifications: Engineers prepare
detailed technical specifications for each instrument. This
 includes technical details, operational conditions, maintenance
requirements, etc.
4. Creation of Design Documents: These can
include P&ID (Piping and Instrumentation Diagrams), loop
diagrams, instrument data sheets, wiring diagrams, installation
details, etc.
5. Interface with Other Disciplines: Engineers need to
coordinate with other disciplines like process, mechanical,
electrical, etc., to ensure that the design is integrated and
conflicts are resolved.
6. Hazard Analysis: They may be involved in HAZOP (Hazard
and Operability) studies to identify potential safety and
operational issues.
7. Vendor Coordination: This involves coordinating with
instrument vendors to ensure that the instruments meet the
specifications. It may also include activities like attending FATs
(Factory Acceptance Tests).
8. Supporting Procurement: Engineers assist procurement
teams in the ordering process. This can involve activities like
technical bid analysis.
9. Testing and Commissioning Support: Engineers provide
support during system testing, commissioning, and startup.
They may also be involved in resolving any issues that arise
during these stages.
10. Providing Training: Instrumentation Design Engineers
may provide training to the operation and maintenance staff
to help them understand how the instrumentation system
operates and how to maintain it.
11. Continuous Improvement: They monitor the
performance of the instrumentation system and suggest
improvements. They also stay up-to-date with the latest
technology trends and industry standards.
These activities can vary depending on the industry, the specific
project requirements, and the organization’s structure and
processes.

Instrumentation Engineer Documents

An Instrumentation Design Engineer is responsible for creating,
reviewing, and managing several important documents throughout
the project lifecycle. These instrument documents serve as
technical guidelines, project records, and communication tools.

Below are some key documents typically prepared by an

Instrumentation Design Engineer:

1. Instrument Data Sheets: These documents provide detailed

specifications for each instrument, including its type, size,
range, accuracy, material of construction, manufacturer details,
etc.
2. Piping and Instrumentation Diagrams (P&IDs): These
diagrams depict the process flow and show the
detailed instrumentation control scheme.
3. Instrument Index: An instrument index lists all the
instruments involved in the project, along with their key details
like tag number, type, location, function, etc.
4. Loop Diagrams: These diagrams show the detailed wiring
connections between field instruments, junction boxes,
marshalling cabinets, and system cabinets.
5. Instrument Location Layouts: These layouts show the
physical location of the instruments in the plant, aiding in
installation and maintenance.
6. Hook-up Diagrams: The hook-up diagrams depict the
detailed installation process for each instrument, including all
the necessary accessories.
7. Bill of Materials (BOM): This includes a list of all instruments
and accessories required for the project.
 8. Cable Schedules: These provide details about the type, size,
length, and route of the cables used for each instrument.
9. Functional Design Specifications (FDS): These define the
expected performance and functional requirements of a
control system.
10. Cause and Effect Matrix: This document outlines how
the control system should react to each possible input signal,
effectively depicting the control philosophy of the system.
11. Factory Acceptance Test (FAT) and Site Acceptance
Test (SAT) Procedures: These provide detailed procedures for
testing the systems at the vendor’s and the customer’s site,
respectively.
12. Standard Operating Procedures (SOPs) and
Maintenance Manuals: These are prepared to provide
guidance to operators and maintenance personnel.
13. Hazard and Operability Study (HAZOP)
Reports: These reports identify potential safety and
operational issues.
The type and detail of these documents can vary based on the
specific project requirements and industry standards.

Instrumentation During the Detail Design

Phase
Below is a general view of I&C engineer activities and documents
during the Detail Design phase:

1) Input Analysis
As the first step of doing a process project during Detail Design,
some data shall be gathered and analyzed for finding the project
requirements, limitations, and considerations.
Normally these inputs include (Technical) Contract (as a basis for
defining the scope of work and supply and following
responsibilities, further to defined Customer/ User
Requirements), Design Basis (Documents and data provided by
licensor or Basic Design Contractor), Business Requirements (based
on commercial items/limitations of contract and customer approach
on supplying of budgets), Approved Vendor Lists (and available
technologies), Standards/ Codes/ Governmental or Local Rules.

Further to these inputs, all stockholder’s concerns and also

company procedures/ practices are the main inputs of doing the
first step of (I&C) detail design.

2) Preparing Specifications and Datasheets

By studying the mentioned inputs further to some activities
(including participation in meetings, conversations/discussions with
other technical disciplines, and doing some calculations) I&C
specialists shall prepare required project specifications, data sheets,
and requirements for some following required documents/
materials/ equipment.

The main items in these steps are

 P&ID’s Preparations/ Finalization

 Overall I&C Requirements Concepts (considerations)
 Plant Process Data
 HAZOP/SIL Studies & Safety Requirements
 Hazardous Area Classification
 Plant Layout/ Project Area (Boundaries/ Limitations/
Locations), and also
 Power/ Utility Requirements.
3) Preparing Documents for Procurement/
Supplying of Materials
I&C Specialists shall prepare all required documents for
Procurement / Supplying of Required Instruments, Auxiliary items
required for Instrumentation & Signaling (including Cables,
Tubes, Fittings, Junction Boxes, Cable Trays, and Ladders, …),
required Project Packages/ Equipment (in the scope of other
disciplines), and also All required systems and sub-systems
(including DCS, ESD, F&G, PLC, …).

Of course, the Procurement phase is very complicated and shall be

done based on exact planning and assigning man-hours at suitable
times. It shall be mentioned here that some of the items in each
project are considered as Long-Delivery items which need more
notices and activation at the preliminary times of the project.

4) Reviewing of Vendor Documents

During Purchasing of Packages/ Equipment/ Instruments /Auxiliary
Items, relevant vendors shall submit required documents that are
monitored and studied by I&C specialists for any probable
comments or approvals (via comparison with project requirements).

Proceeding with each purchase requestion /order will be done by

company procedures in different ways and via project planning and
in some cases, it may include other probable activities (for example
actual tests).

5) Preparing Documents for Site Construction &

Equipment Installations
Of course, some I&C documents are needed during Site
Construction & Equipment Installations, and such items are
prepared during the project progress and planned schedule.

In fact, such documents shall be ready at suitable times, and any

fault or disturbance on such documents may hold the site activities.
6) Core Activities
Some of the I&C activities and documents can be mentioned as
core items due to their importance and extensive action domains.

I&C Project database (Instrument Index) and implementing project

safety requirements, further to the overall control system block
diagram(philosophy) are some examples that have relations to
approximately all I&C activities/ documents (or domains).

7) Different Size of Scope based on Project

Execution Types
Based on different applicable contracts between the client and
Detail Engineering company the size and some types of activities
of I&C scope can be changed. As an example, the mentioned scope
may be found differently if the project is EPC, EPS, Turn-Key, or
other possible cases.

One of the major changes in different project types can be seen in

engaging I&C specialists (from Detail Engineering Company)
in Commissioning & Start-Up phase.

I&C Engineer Activities on Systems & Sub-

Systems
If we make focus on the title of I&C, we can find two main goals as
Instrumentation and Control. In the Instrumentation part of
activities, the relevant specialists shall provide all suitable
instruments with all related site installation considerations, while in
the part of Control, they shall follow suitable systems (including
Hardware & Software) for best performance operations and all
required Interlocks and Safety Logics.
Already we have mentioned that one of the core activities set of
I&C specialists is related to project requirements on the subject of
Systems and Sub-Systems. In such activities and documents, I&C
specialists shall provide suitable systems with all documents to
satisfy the project requirements on functions and communication
links.

For implementing such targets, I&C design engineers shall follow

the sequences shown in Figure-1 to provide some documents by
themselves to help the system vendors in order to provide the
correct documentation.

In fact, the I&C specialists have vital roles to guide the system
vendors on configuring the best arrangement for project
requirements in compliance with other systems and control & safety
functions considered in the project control philosophy.

Just to show such complexity, it should be mentioned that the

brands and models of different systems and sub-systems are not
the same, and in spite of the sizes and their capabilities, all shall
follow the same harmony in the whole project control philosophy.

However, the documentation produced by the system vendor shall

have the same frames, formats, and assignments as other project
documentation and I&C specialists have a serious role in such
target.

Figure -2 shows one model on the main sequences of provision of

required documents by the system vendor. By reviewing this model,
it may be clear that the provision of documents shall follow the
logical routes at the right times, and in some feedback routes the
documents need new revision to satisfy some items.
Figure-2: Issue Model of System RFD (Required For Documents)
Figure-2 also shows different required information and data which
shall appear in different document titles. Such settings normally are
done during a kick-off meeting in which all participants make
agreements for the production of different document titles (which
are usually known as VDIS).

As it is clear in the model, the Detail Design company may inform

the system vendor of project requirements by some predefined
codes and finally, they agreed to the inclusion of codes in each
document title.

I&C Engineer Activities on Purchasing

Some I&C engineer activities and documents are related
to Purchasing sequences which are used for Instruments, Systems,
and Packages (Equipment) in approximately similar ways.

Figure-3: Procurement Service Cycle

Figure-3 shows a model of Purchasing Sequence and by studying it

the role of specialists in the preparation of initial documents and
following activities for vendor document checking and approval of
made items are clear.