What Every Instrument

Engineer Should Know?

Ridham Shah

Automation engineer I Master student Hochschule Bremen

Publié le 6 oct. 2022

What Every Instrument Engineer Should Know?

As instrument Engineers, there are certain things that we need to know

in our workplace.

 The first and foremost important thing is to get the whole

knowledge about the entire process of the plant in which we
work. Whether it can be a small level or a huge industry

 Jobs for instrument engineers can be considered as installation,

calibration, control, and maintenance.

 We may be part of the production department, which develops

automation products or we may be part of the design team or
maintenance of the plant.

 We should know all instruments and their specification which

uses in plants and processes; also knowledge about the
product and its characteristics, so that at the time of
production, we can set parameters like pressure, and
temperature which is suitable for the product.

 P&ID diagram is the most important thing for a better

understanding of plant and process. So as instrument Engineers
we should know all PID symbols, control loop analysis, and
tuning

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  It is very important to have knowledge of basic principles,
working, and construction of instruments for installation and
maintenance.

 Calibration is the most essential job for all instrument

engineers. All the instruments have their own calibration
process that we have to know.

 There is also the usage of PLC/DCS in the automation industries

to ease the plant operations, which again is part of the
instrumentation team’s job as only an instrument engineer
knows about the process in and out.

 Add up to this, to operate PLC we should know the

programming and wiring of the PLC.

 Moreover, Instrument engineers mostly deal with maintenance

(i.e. Preventive maintenance and corrective maintenance) of
field instruments. Therefore, basic electrical wiring we should
know to solve the breakdowns.

Hope now you have a clear understanding of the responsibilities of an

Instrument engineer in any type of Industry.

Control Valve top 7 interview Questions

and Answers

For the Instrument engineer, the topic of the control valve is the most common and
frequently asked question in the interview. So let's discuss the top 7 Questions and
Answers.

1. What is a control valve?

Control Valve is a final control element and it is used to control fluid flow by varying
the size of the flow passages directed by a signal for control. A control valve consists

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of an actuator and a valve. The actuator provides the power to vary the position of
money inside the plot.

2. What are the different types of control valve

Control valves are mainly divided into two parts. The first is depending on the action
and the second is depending on the body. Depending on the action, there are two
types. First is air to close and second is air to open and depending on the body,
there are four types, first is Blofeld, single or double CD. The second is angle valves.
The third is butterfly valves. And fourth is three-way valve third

3. What are the applications of air to close inherently open

control valves?

There are three main applications of the Air to close the control valve Firstly, it is
used in reflex lines. Secondly, it is used in cooling water lines and lastly, it is used
in safety relief services.

4. What is Cv of about?

CV is the capacity of a valve and it is defined as the number of gallons per minute
of water that passes through a fully open valve and a pressure drop of one pound
per square inch.

5. Can you please explain the difference between a normally

closed valve and a normally open valve?

First of all, let me explain what is normally a closed valve. As the name suggests,
normally closed valves remain closed in a de-energized state and open when
energized. On the other side, the normally open valve remains in an open and de-
energized state and is closest when energized.

6. What is the positioner and what is the function of a

positioner?
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 The positioner is a device that makes the valve open or close to eliminate the
process error and achieve the setpoint by generating input signals. The function of
the positioner is to measure the actual position of the valve and take the command
from the controller compare both the signals and make the valve move either in an
open direction or close direction to correct the process error

7. What does an actuator and what are the types of

actuators?

the device which makes the valve to operate through different energy inputs like
pneumatic, electric, hydraulic, etc.

There are mainly four types of actually first is pneumatic, second is pneumatic piston
actuator, third is electric actuator and fourth is a hydraulic actuator.

BASICS OF MOTION CONTROLLERS

BASICS OF MOTION CONTROLLERS

What is motion control?

 Motion control is a branch of automation in which machines' position or velocity is

controlled by a device such as a hydraulic pump, linear actuator, or electric motor,
usually a servo.
 Industrial motion control is a crucial aspect of robotics and CNC machine tools;
yet, it is more complicated than the kinematics of specialized machines.
 Packaging, printing, textile, semiconductor production, and assembly sectors all
use motion control.
 Simply said, Motion Control is the automated movement of objects – and it can be
complicated, which is why it's critical to understand the many motion control
alternatives before choosing the best one!

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 Components of Motion Control

 Electronic and mechanical components are used in today's industrial motion

control systems.
 Although they have gotten smaller and smarter, the key components that make
up a motion control unit for industrial automation have virtually remained the
same throughout the years.
 A motion controller, actuators/motors, sensors, and drives/amplifiers are among
the components.
1. Controller :
 The controller stores the application's desired motion profiles and positions and
sends position commands to the drive.
 Motion control is frequently a closed-loop control system that tracks the real path
and makes necessary corrections for position or velocity.
 There are two types of motion controllers for industrial automation: specialized,
standalone motion controllers and PC-based systems that extend the capabilities
of PLCs and PACs.
 Motion controllers today typically integrate PLC capabilities as a result of
developments in processor technology, obviating the need for a PLC or PC-based
machine controller and lowering total control expenses.
2. Drives/Amplifiers:
 create torque from a low-power current/voltage applied to the servo motor
windings.
 The drive converts the controller's low-energy signal into a high-energy signal that
the motor can understand. Variable-frequency, stepper-motor, analog and digital
servo drives are only a few of the drive types available.
3. Actuators/Motors:
 Actuators/Motors are devices that translate electrical impulses from the drive into
motion. AC/DC servo motors come in a variety of shapes and sizes.
4. Sensors:
 offer information about the motor's location. Potentiometers, tachometers,
quadrature, and absolute encoders are only a few examples of sensors.

Selection and Desing

 Any motion control system is built around a motion controller.

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 Motion controllers accept an input command, such as a motion profile made up of
position commands, and send torque commands to a drive, which drives a motor
and moves a load.
 Knowing the requirements for your individual application is the first step in
selecting the proper motion controller.
 The application's complexity is perhaps the most crucial factor.
 A comparatively basic application, for example, is one that requires only a single
axis of motion and relatively slow speeds.
 A more complicated application, on the other hand, can require many axes of
motion with highly coordinated coordination between them.
 Each of these systems necessitates a unique controller as well as a basic control
architecture decision.
 The trade-off between centralized and distributed control is one of the most basic
architectural considerations to be made in a multi-axis motion control scheme.
 This isn't a black-and-white decision, but rather a range of options. Obviously,
top-level executive functions that decide what should be done must be centralized
in a single processor, but systems can and do partition lower-level operations to
dispersed components (if at all) at various levels.

PID controller theory

PID controller theory

WHAT IS PID CONTROLLER?

PID controller is an instrument that is used to regulate processes variable of

temperature, pressure, flow, speed, etc.

It uses a control loop feedback mechanism to control process variables and is the
most accurate and controlled.

PID control is a well-known method for guiding a system to a desired location or

level. It's almost ubiquitous as a temperature controller, with applications in a
wide range of chemical and scientific operations, as well as automation. PID
control employs closed-loop control feedback to maintain a process's real output
as close as feasible to the target or setpoint output.

Digital PID controller

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A digital PID controller receives the sensor data, which is typically from a
thermocouple or RTD, and converts it to engineering units like degrees Fahrenheit
or degrees Celsius, which are then presented in a digital format.

Block diagram of PID controller

Working of PID Controller

Typically, PID controllers work by adjusting or tuning proportional, integral, or

derivative terms. Input signals are evaluated, and part of the difference is fed
back to the device as a feedback control signal. This value is called the correction
factor.

In the generalized form, the PID controller maintains the output such that there is
zero error between the process variable and setpoint/ desired output by closed-
loop operations.

let's discuss a particular form of controller

P- Controller

The output of a proportional or P-controller is proportional to the current error

e(t). Using the feedback process, it compares the desired or set point to the actual
value. The output is obtained by multiplying the error by a proportional constant.
If the error value is zero, then this controller output is zero.

It requires biasing or manual reset when used alone. This is because it never
reaches a steady state. However, it maintains steady-state errors. When the
proportional constant Kc increases, the response speed increases.

I-Controller

Due to the limitation of the p-controller where there always exists an offset
between the process variable and setpoint, I-controller is needed, which provides
necessary action to eliminate the steady-state error. It integrates the error over a
period of time until the error value reaches zero. It shows the value of the final
control device at which the error is zero.

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D-Controller

I-controller doesn’t have the capability to predict the future behavior of error. So it
reacts normally once the setpoint is changed. D-controller overcomes this problem
by anticipating the future behavior of the error. Its output depends on the rate of
change of error with respect to time, multiplied by the derivative constant. It gives
the kick start for the output thereby increasing system response.

by summing of all the controllers, we can get one generalized equation

where,

= PID control variable

= proportional gain

= error value

= integral gain

= change in error value

= change in time

From this equation, we can find out the process variable and solve the error.

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What is Instrument Hook-up
Drawing
Majid Mirzadeh Avval

Instrumentation and Control Engineer

Publié le 27 sept. 2019

Hook-up drawing is a detailed drawing showing typical installation of

instrument in a correct manner so that instrument operates properly
(gives accurate indication and prevent any issued which could
potentially affect the measurement such as liquid trap in gas impulse
line).

Hook-up drawing indicates tubing slopes, position of instrument in

reference to process tapping point, scope break between instrument vs
piping.

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Hook-up drawing also gives information the requirement of bulk
material for each installation. It also details its specification (size, type
and material) and the quantity.

There are two types of hook-up drawing:

 Process Hook-Up

 This hook-up drawing contains typical installations for

instrument which connects to the process

 Pneumatic Hook-Up

 This hook-up drawing contains typical installations for

instrument which requires instrument air such as control valve

Reference drawing: P&ID, Installation Detail Specification, Piping

Specification

P&ID tells the designer which instrument requires a hook-up drawing. A

good designer can also read whether the instrument tapped in gas
service or liquid service.

Battery limit between instrument and piping shall be made clear, this is
stated in P&ID symbol and typical sheet or piping documents.

Installation detail specification will also specify items that should be

utilized and factor that should be considered in one installation

The purpose of Instrument Hook Up Drawing

As stated earlier, information of the requirement of bulk material is

stated for installation on each sheet hence the bulk material required for
the whole drawings could be summarized and tabulated in a document
named Material Take Off.

During project construction phase, this drawing is also referred as a

guidance of how to install the instrument properly.

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INSTRUMENTATION AND
PROCESS CONTROL
ENGINEERING DESIGN
FOR INDUSTRIES
Suraj Surendran (FS Engineer TÜV Rheinland)

Senior Instrumentation Engineer

Publié le 6 juil. 2021

This article provides general information about step by step process of

Instrumentation and Process Control Detailed Engineering for industries.
Detailed Design Engineering activities are used for designing
Instrumentation and Process Control systems for Oil and Gas, Power
plants, Refineries, Petrochemicals, etc. Instrumentation and Process
Control Engineering design process starts from providing inputs to the
Piping Instrumentation diagram to Vendor documents review and
approval.
The main documents and drawings as part of the Engineering Design
field are as follows,

1. Piping and Instrumentation Diagram

2. Operating and Control Philosophy
3. Control narrative
4. Instrument index
5. Input-output list
6. Specification for Field instruments
7. Datasheet for field Instruments
8. Specification for Control and safeguarding systems
9. Specification for Fire, smoke, and gas systems
10. Technical bid evaluation
11. System Architecture drawings
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12. Loop drawings
13. Instrument junction box termination details
14. Marshalling cabinet termination details
15. Instrument cable routing layout
16. Cable schedule
17. Control room layout
19. Cause and effect matrix- Emergency shutdown systems
20. Cause and effect matrix- Fire and gas systems
21. Electrical and pneumatic hookups
22. Instrument cable specification
23. Vendor documents
24. Material take off
25. SIL Studies

Instrumentation and Process Control Engineering design for

Industries
Oil and Gas, Power plants, Refineries, Petrochemicals, etc use
Instrumentation and process control systems for monitoring control and
safeguarding their equipment and process.
The stages of the Project are as follows
1. Concept Engineering
2. Basic Engineering Design
3. Detailed Design Engineering / Engineering Procurement and
Construction (EPC)

Concept Engineering

This is the initial stage of the project where the Client does research
about the project such as Power Plant, Refinery, or Oil and gas field
development. During this stage, the client will do a study about
financing, economic and technical feasibility. The basis of design
documents is prepared by Process Engineers. Instrumentation and
Process Control Engineers provide basic initial details about the Control
system and field instrumentation requirements. Some clients ask for
costing also. In that cases, Instrumentation Engineers provide costing
based on their previous project experiences.
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Basic Engineering Design

During this stage, a clear idea of the project will be formed. In this stage
of the project, all disciplines of Engineering such as Civil, Electrical,
Mechanical ( Piping, Static, Rotating equipment ), Process,
Instrumentation and Process Control, Project Engineering, etc will have
their documents and drawings developed and ready to use for Detailed
Design of the project

Detailed Engineering Design / Engineering Procurement and Construction (EPC)

During this stage of all disciplines of Engineering such as Civil, Electrical,

Mechanical ( Piping, Static, Rotating equipment ), Process,
Instrumentation and Process Control, Project Engineering, etc will
develop their documents and drawings ready for procurement and
construction. These documents will be used for procurement of
Instruments , Control and safeguarding systems, etc. The drawings
prepared during this stage will be used for the construction,
commissioning, and start-up of the project.

Documents and Drawings for Instrumentation Detailed Engineering

The following documents and drawings are to be prepared for

Instrumentation Detailed Design Engineering.

Instrument Index

This is the basic document prepared as part of Detailed Engineering. This

document will be prepared based on the Piping and Instrumentation
diagram (P&ID) developed by Process Engineers. All Instruments, valves ,
Analyzers, etc will be listed in this document. From this document the
total number of Instruments, type of Instruments, location of
Instruments, size of instruments / valves etc can be identified. This
documents will undergo revisions based on changes on Piping and
Instrumentation diagrams , may be it will be addition or deletion of
Instruments or change of type of instruments etc. This document will be
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updated regularly by Instrumentation Engineer during detailed design
phase of the project.

Instrument Input output list

In this document all Instrument the following will be listed

1. Signal types such as Analog Input, Analog output, Digital input, Digital
output etc.
2. To which system the instruments are connected like Control system,
Emergency shutdown system or fire and gas system.
3. Set points
4. Calibrated range
5. Area classification
This document will be used to calculate how many number of Input
output cards are required for control or safeguarding system.

Technical Specification of Field Instruments and Valves / Control systems

Technical specification of Instruments and valves will mainly include the

following
1. Project Description
2. Items to be supplied by Vendor
3. Inspection and testing of Instruments / Valves requirements
4. Material certifications requirements
5. Spare requirements
6. Training requirements
7. Standards to be followed
8. Documents to be submitted by the vendor
This document will be used for procurement and part of the Request for
quotation send to vendor.

Data sheet for Field Instruments and Valves

Data sheet will mainly specify the following,

1. Type of Instrument or Valve
2. Process data's such as Pressure, temperature, Viscosity etc
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3. Material of construction of body, sensor etc
4. Construction details of Instruments / Valves
5. Accessories requirements
6. Certifications required
7. Hazardous area classification
This document will be part of Request for Quotation which is send to
vendor
Examples of data sheets are given below

Technical Bid Evaluation

Technical bid evaluation by the following steps,

1. Based on request for quotation vendor sends their technical and
commercial offer
2. Technical offer will be reviewed by the Engineering team ( Instrument
Engineers)
3. Technical queries will be send to vendor for clarification
4. Bidder will reply to the technical queries
5. If the reviewing Engineer finds the replies from the vendor
satisfactory, then queries will be closed. If more clarification is required
then the next cycle of clarifications will be send back to the vendor again
and sometimes meetings will be arranged to get clarification on queries.
6. After clarification of queries Instrumentation Engineer will prepare a
technical bid evaluation sheet comparing all the vendors who have
submitted offers and ranking will be given based on offers and technical
offers.
7. Technical bid evaluation sheet will be send to procurement team for
the next process
8. Procurement team will evaluate the commerical offer and based on
technical bid evaluation, procurement order will be placed to the
successful bidder

Vendor document review

Vendor document review is done by the following steps,

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1. Based on the procurement order meeting will be conducted with the
successful bidder to finalize the documents to be reviewed by the
technical team
2.Vendor documents will be reviewed by Instrument Engineers and
comments will be send to vendor to clarify or incorporate.
3. Vendor will either incorporate or clarify comments and send them
back to Instrument Engineer.
4. If the Instrument Engineer is satisfied with the reply from vendor, the
vendor document gets approved.

System Architecture drawing

System Architecture drawing will have the following details

1. Control system / Emergency shutdown systems / Fire and gas
systems
2. Field Instruments connected to systems mentioned above.
3. Communication with other systems such as Electrical switchgear,
HVAC etc
4. Network components
5. Communication with corporate LAN
This drawing will be part of Control / safeguarding systems request for
quotation. Based on this drawing and specification system vendors
prepare their proposal.

Loop drawings

Loop drawing represents the connection between Field Instruments and

Control systems.
The following details will be in loop drawings
1. Cable connection between Field Instruments and field Junction boxes
2. Terminal numbers at field instruments and junction boxes
3. Cable number of connected field cable between field instrument and
junction box
4. Cable connection between field junction box and marshalling cabinet
5. Terminal numbers at field junction box and marshalling cabinet

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6. Input-output card details such as Channel number, rack number, slot
number etc

Instrument junction box termination details

This drawing will include the following details

1. Field cable number for connection between field instruments and
junction boxes
2. Terminal numbers for connecting field cable to junction box
3. Multicore cable number and termination details from junction box

Marshalling cabinet termination details

This drawing will include the following details

1. Multicore cable number and termination details from junction box
2. Terminal numbers for connecting multicore cable at marshalling
cabinet side
Marshalling cabinet will be located in the Control building.

Instrument cable routing layout

This drawing shows the following details

1. Field cable route from Instrument to junction box
2. Multicore cable route from the field junction box to control room
Electrical cable crossings, underground piping, underground facilities
should be thoroughly checked to avoid fouling during Instrument cable
routing.

Instrument cable schedule

This document will have details as mentioned below

1. Cable from Instrument to junction box
2. Cable from the junction box to control room
3. Type of cable used
4. Length of cable

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Control room layout

The control room layout will have the following details

1. Panels such as Control system, Emergency system, Fire and gas panels,
etc
2. Location of panels
3. Dimension of panels
4. Location of Human-machine interface

Cause and effect diagram - Emergency shutdown system

This document will have the following details

1. Initiators like Pressure signal high high
2. Final control elements like Emergency shutdown valve

Cause and effect diagram - Fire and Gas system

This document will have the following details

1. Initiators like Fire, smoke and gas detectors
2. Output devices like flashing beacon, sounders, etc

Electrical and Pneumatic hookups

This document will have the following details

1. Electrical connection to the instrument and junction box, It will
indicate cable glands, cable type, installation requirements, etc
2. Instrument tubing, connectors, Installation requirements of
transmitter, panels, etc

Material take-off

This document will have the following details

1. Specification and quantity of installation materials.
2. Quantity of cable glands, impulse tubing, tube fittings,civil foundation
requirements, support stands etc

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Overview of basic ideas an
Instrumentation and Process
Control Engineer - Overview
of basic ideas to have while
doing Detailed Design
Suraj Surendran (FS Engineer TÜV Rheinland)

Senior Instrumentation Engineer

Publié le 7 juil. 2021

Process Flow Schemes (PFS)

Process Flow Scheme is prepared by Process Engineers. It will give a
basic idea of the equipment, lines connected, and an overview of the
process. As an Instrumentation and Process Control Engineer,
understanding this drawing will create an overview of the process.
Process flow schemes will also have node numbers. In heat and mass
balance for the nodes mentioned in PFS the temperature, flow, and
other process parameters will be mentioned. Instrumentation Engineers
can get more ideas by reading the document and get more clarification
about the process. This will be helpful while preparing datasheets for
Instruments, Control Valves, ESD valves, preparing alarm and trip
settings, etc. Mainly process data will be provided by Process Engineers
but for academic interest and more understanding Instrumentation
Engineers can utilize process documents. Always read the notes and
reference documents mentioned in PFS.

Piping and Instrumentation Diagram ( P&ID) / Process Engineering

Flow Schemes
Piping and Instrumentation diagram gives a clear understanding of the
process, piping systems, Instruments, Instruments connected to which
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system ( Control System / Emergency Shutdown system / Fire and Gas
system), Piping specification (Piping Specification number will be given,
More details will be available in Piping Specification prepared by Piping
Engineer), line sizes, nozzle size, connection to vendor packages, etc.
Piping and Instrumentation diagram is the basic document to prepare
Instrument Index, Input-output List, Datasheets, Cause and Effect Matrix
( ESD and F&G), Process Control narrative. Always read the notes on
P&ID.Piping and Instrumentation diagram is prepared by Process
Engineers. All disciplines ( Civil, Piping, Rotating, Static Equipment,
Materials, Instrumentation, Electrical, HVAC, Project Management) give
inputs or suggestions while preparing P&ID.

Design Basis
The design basis will be there for all disciplines ( Civil, Piping, Rotating,
Static Equipment, Materials, Instrumentation, Electrical, HVAC, Project
Management). A clear understanding of this document for requirements
related to Instrumentation will be good to avoid discrepancies while
creating Instrumentation and Process Control deliverables.
Instrumentation and Process Control Engineer will have their own Design
basis. Requirements mentioned in contract documents will be
mentioned here.

HSE Philosophy / Design Basis

Requirements related to Fire and gas will be mentioned in this
document. Fire and gas Cause and effect, Fire and gas narrative, ESD
cause and effect will involve HSE discipline.

Overall Plot Plan

The overall plot plan will show the location of equipment, the location of
the Control room, and other buildings.

Piping Plot plan

The piping plot plan will show all piping routing. Instruments will be
marked on the piping plot plan. Using this drawing Instrument location
layout, Cable routing layout and Junction box location layout can be
prepared.
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Control Building Layout
Control building layout will show the dimensions, number of rooms, etc.
Control system / ESD system /F&G system vendor can use this drawing
for the location of Marshalling cabinets, Control system cabinets, Server,
HMI screens, etc.

Hazop Studies and Report

Instrumentation Engineer needs to participate in Hazop studies and
provide inputs. If any recommendations are proposed in Hazop
meetings, Instrumentation and Process Control Engineer has to
implement them in their documents or drawings.

Electrical Inputs
For Powering Instruments and Control system / ESD system, electrical
power is required. Instrumentation and Process Control Engineer
requires power requirement calculations from Electrical Engineer. Review
of Single line diagram for Power supply requirements of Instrumentation
and process control system is to be done by Instrument Engineer.

Contract Documents
Very good knowledge and information of Contract documents are
required to understand the client requirements, standards requirements,
etc. This will help in the flawless design of Instrumentation and Control
Systems. All Contract documents need to be checked for consistency
and identify any discrepancies between documents.

Installation of Instrumentation
and Process Control Systems
for Process Plants
Suraj Surendran (FS Engineer TÜV Rheinland)
21
Senior Instrumentation Engineer
Publié le 18 juil. 2021

As part of EPC projects Field Instruments, Control systems, ESD Systems,

Fire and Gas Systems are installed.
We will see the activities involved in the Installation of I&C systems for
an upstream oil and gas processing plant (Refer to the picture above of
the completed plant)

Construction of I&C systems for Process Plants will involve the

following personals
Construction Manager
Instrumentation Engineers - Construction
Instrumentation Supervisors
Instrument Technicians

How do I&C activities start during the construction of start for a

greenfield project? We will go through the details
Initially, Instrumentation Engineers and supervisors mark the location of
Instruments, junction boxes, identify cable routing. Locations will be
marked on nearby structures, vessels, etc. Civil foundations, structural,
mechanical static equipment will be installed first. Based on the work
front available to install Instruments, the Instrumentation team will start
their activities.
Documents used for construction in initial stages ( For I&C
requirements)
Overall Plant Layout - To identify the location of equipment, Control
room, any Instrument buildings, etc
Piping and Instrumentation Diagrams - To identify the Instruments
Instrument Index - Cross Check whether all instruments in P&ID are
listed
Instrument and JB location layout
Instrument Cable tray routing details
Instrument Cable routing layout
Equipment layout

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Control room layout - To identify the location of panels ( Control
System, ESD system, F&G system, Fire and gas panels, Servers, Vendor
panels, etc

Start of Construction / Installation Works

Instrument Installation - When work fronts are ready Instrument team
will start installing instruments on equipment and piping. Instruments
will be installed when the piping/equipment scope is ready for
Instrument installation. Instrument tubings will be installed with the
necessary slope and bend as per Instrument Installation and Pneumatic
hookups. Direct installation or remote installation will be identified from
Pneumatic hook-ups and installation drawings. Accessibility for O&M
activities will be checked.

Junction boxes Installation - Junction boxes will be installed according

to the JB location layout and the Field Instrumentation team will check
for the nearest possible distance to connect Instruments to junction
boxes by field instrument cables. JB installation drawing will also be used
for Installation. Accessibility for O&M activities will be checked.
Field Instrument cable tray installation - Instrument cable tray will be
installed based on cable tray routing layout. The shortest possible
distance will be identified for field cable routing.

Multicore Cable routing - Cable trenches will be dug to lay multicore

cable connecting Junction boxes and Marshalling Cabinets installed in
the Control room. Cable routing layout, Junction box termination,
marshaling cabinet termination details, Control room cable entry details
drawing details will be used for this activity. Also, electrical cable routing,
underground piping details, structural drawings will be referred to to
avoid any clashes with other systems.

Fiber Optic Cable routing - Fiber optic cable routing details will be
referred for installation. If it is routed parallel to the pipeline, the route of
the pipeline will be selected.

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Underground Cable Installation details - Used to identify depth, breadth
of cable trenches, Cable tiles, etc. Based on this drawing cables will be
installed and backfilled.

Control Room - Control system panels, ESD panels, Fire and gas panels,
Marshalling cabinets, Operator screens, Servers, Vendor panels
(Metering, Compressor, Analyzer, Vibration), PCs, Engineering PC's
control room furniture, etc will be installed as per the Control room
equipment layout. Multicore and power cables will be installed under the
false flooring of the control room. Control room civil building layout will
also be referred.

Termination of cables from Instruments to Junction box and

junction box to Marshalling cabinets - Junction box termination
details and Marshalling cable termination details will be used for this
activity.

Quality Control - After completion of each activity Quality Control

Engineer will visit site will identify the approval process.
Other Documents / Meetings
Planning Schedule
Daily, Weekly, and Monthly progress
Daily meetings for construction progress
Client and Contractor meetings
Contractor and subcontractor meetings
The above are the major Construction / Installation activities for process
plants.

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What is an Anti-Surge
Controller and Control
Valve?
Zameer Ansari

Senior Instrumentation & Control Engineer at L&T Energy | Design Engineer | EPC | Ex
McDermott | Ex Aarti Industries
Publié le 31 oct. 2021
It is a common phenomenon in Centrifugal Compressors where demand
at outlet decreases leading to rapid increase in downstream pressure of
compressor. There are two methods which can be applied to prevent
such surges.

1. By Varying the speed of compressor: Using this method, efficiency

of the compressor will be compromised and also speed reduction is not
achieved quick enough to catch the surge.
2. By Using the Anti-surge Controller: This is the most favorite method
to control the surge in industries. This is fast acting and consists of an
Anti-Surge Controller and Control valve. We will be discussing this
method in the upcoming part. One can define Anti-Surge Controller and
Anti-Surge Control valve as below.
“The Controller used to remove the surge from the Compressor very
Quickly using the Control valve is called Anti-surge Controller and
Control Valve is called Anti-Surge Control Valve.”

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Figure shows a typical Anti-surge control schematic. Suction and
Discharge Pressure are very important parameters required to measure
for surge control. Other variables may be included depending upon the
properties of fluid.
As soon as pressure at discharge increases, the control valve opens very
quickly to allow the excessive pressure back at suction, making it an
extremely critical instrument for such operation. The use of high quality
surge controllers, anti-surge valves and additional accessories will allow
for operation closer to the surge point, hence, improving the operational
efficiency.

Sizing and Selection of Anti-surge Control valve:

 Anti-surge Control valve comprises a Valve, Actuator,

Positioner, Solenoid, Position Transmitter, Air Filter and Volume
booster (if required).

 Control valve should have leakage class IV so in normal

condition flow does not get diverted to the suction side.

 The Fail safe position should be “Fail to Open” for obvious

reasons.

 The Valve should not be Undersized or Oversized to keep the

operation within limits.

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  To avoid the leg, Control valve should be located as close as
possible to compressor discharge flange

 Valve Characteristics should be either Linear or Equal

Percentage. Linear is preferred because of anti-noise trims.

 The stroking time of the control valve should be between 0.5 to

2 seconds for both opening as well as closing.

 Instrument air tubing should be kept minimum to prevent

chances of leakage.

Thanks for Reading,

Zameer Ansari
Instrumentation & Control Engineer

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