Over the last several decades, process
instrumentation has become far more
accurate and versatile, but can be more
complex to configure. As a case in point, consider
a basic process pressure measurement:
- A mechanical gauge had a range, a class,
and perhaps an accessory;
- Early electronic transmitters (1970s)
had half-a-dozen settings; and
- Later electronic transmitters (1990s)
added more internal processing, which
meant more settings.
Today’s transmitters are extremely powerful with
internal electronics to process the basic reading,
deliver additional variables, perform internal diagnostics,
monitor other process conditions, self-calibrate,
retain historical performance data, monitor
power quality, and more. Most recently, the growth
of IIoT capabilities adds even more sophistication.
As an example, an Endress+Hauser Proline
Coriolis flowmeter can detect a wide variety of
process conditions beyond the normal set of variables.
Every type of transmitter can’t do every
function, but a full configuration can often require
verification of 100 or more settings.
Multiply this by the hundreds and potentially
thousands of instruments and smart devices
involved in a process unit upgrade, new process
unit, or a greenfield facility, and it becomes clear
why producer companies doing such projects
often hire a primary system provider (SP). It also
explains why SPs hire integration specialist and
partner with instrumentation technicians to do
advanced commissioning. With the right digital
tools, it is much easier and faster to do this detailed
work accurately and efficiently.
Stages of a project
A large-scale project typically consists of three
major sections: Plant design and engineering;
installation and commissioning; and operations
and maintenance.
It’s the middle where problems can develop
because the design work must be realized in an
actual installation and made to operate correctly
so the plant can start up on time. The risk is huge
since a plant that’s not running when it should be
is piling up extra costs and not generating income.
The SP is usually responsible for the automation
and instrumentation parts of the project. Its
function, in broad terms, is to oversee the actual
building contractors while creating the software
programs and networks to support process automation.
This includes the PLC, DCS, as well as
the various networks, HMIs, field device I/O,
instrumentation, loops, and so forth. There are
typically multiple subcontractors performing all
these tasks and the SP has to keep everything
moving and coordinated.
There is also the need to keep everything documented,
as virtually every act, no matter how
trivial, from tightening bolts on a pipe flange to
verifying a control loop, must be specified and
recorded. Yet, even this far into the 21st century,
for many SPs and subcontractors, these are still
manual procedures recorded on paper forms and
entered in some management system after the
fact. Fortunately, there are now digital tools to
meet this challenge.
Step-by-step process
To start the project off on the right foot, all the
information related to the project must be consolidated
and transferred to a digital commissioning
management platform, such as Netilion.
This includes all the device lists, data sheets, work
instructions, drawings, and other documents supporting
the scope of work. This management platform
serves both the site commissioning managers and the individual technicians.
For the manager, it is the mechanism used to
maintain real-time tracking of overall progress and
completed phases. For the technicians, it is the
primary and authoritative guide for work processes
and execution details. Since it is digital, it is also
dynamic. If a change is handed down by the SP, for
example the range on PT-143 needs to be changed
from 0-100 PSI to 0-130 PSI, the instruction can
be changed instantly if the task has not yet been
done, or it can instruct the technician to go back
and make the revision. Since the information is
updated constantly, there is effectively no lag time.
Work done in the field is where training and
skill are critical. It’s one thing to have a work order
to commission a flowmeter, but doing it quickly,
efficiently, and intelligently is another. A technician
must interpret the instructions and determine
how to set many unspecified parameters based
on the function of the instrument in the larger
process context. Most of the main parameters are
spelled out in the work order, but others may not
be, and the technician must determine which must
be specifically configured versus what can be left
in the default setting.
Typical
deliverables
The scope of the instrumentation
commissioning team’s
responsibilities varies by project
requirements. When a
project is comprehensive, the
team will begin during the
planning phase, helping set
commissioning strategy and
scheduling. This can extend
into final equipment selection
based on the piping and instrumentation
diagrams and process
information. Throughout
this phase, the team will gather
loop sheets, motor schematics,
spec sheets, checklists, and
move them all into the digital
management platform.
Once on site, the commissioning
technicians must verify
the work done by the piping
and electrical contractors.
Inspection confirms that the
right device has been installed,
it matches specifications, and
has been connected correctly
before powering-up the device.
Once verified, the actual configuration takes
place. Based on the type of device, configuration
can involve a variety of actions, such as:
- Bump motors to verify rotation;
- Run valves through their full stroke;
- Check instrument response to simulated process
variables;
- Confirm correct scaling at the HMI;
- Confirm VFD settings; and
- Make final adjustments to configurations.
It is also necessary to ensure each device functions
properly in its process context:
- Verify interlocks;
- Testing for batch phase, sequence, and logic;
- Monitor water or other runs; and
- Complete commissioning.
Now the unit is ready for startup and final
hand-over. At this point, the importance of
the digital management platform, like Netilion,
becomes especially clear. Delivering documentation
with the full detailed history of the project is
an easy task since everything has been gathered
and kept in a consistent format, ready to transfer
to the SP’s and client’s servers.
It’s critical for companies to understand that
commissioning services are too critical to accept
the default choice without exploring other options.
With the right choice, it is possible to have a successful
project with all critical deliverables provided,
including:
- Real-time visibility and insights into work
progress, obstacles, and completion;
- Efficient project setup with automatic data
sheets, tag lists, and templates for effective
work planning;
- Collaborative and dynamic digital guides for
work process execution; and
- Intuitive and easy-to-use digital management
platform for all technicians and supervisors.
