Master Document Deliverable List
Instrumentation & Control - All Project Phases
This document provides a comprehensive Master Document Deliverable List (MDL) for an instrumentation and control project, covering all major phases: Conceptual Design, Front-End Engineering Design (FEED), and Detail Design (EPC). The list is categorized to follow a logical engineering workflow.
Phase 1: Conceptual Design / Feasibility Study
Focuses on high-level strategy, technology selection, and initial cost estimates to prove project viability.
- High-Level Control Philosophy: A brief document outlining the basic control and safeguarding strategy.
- Preliminary System Architecture: A simple block diagram showing major control systems (e.g., BPCS, SIS) and potential package interfaces.
- Technology Selection Report: An assessment of suitable technologies and potential vendors (e.g., BPCS/SIS vendor list, instrument technology choices).
- Rough Instrument Count: A bulk estimate of I/O based on preliminary equipment lists.
- Budgetary Cost Estimate: A high-level cost estimate for C&I (e.g., +/- 30% to 50%).
Phase 2: FEED (Front-End Engineering Design)
Develops the conceptual design into a well-defined project basis, allowing for a more accurate cost estimate (+/- 20-30%) and forming the basis for the EPC bids.
- Definitive Control & Shutdown Philosophies: Fully developed versions of the core philosophy documents.
- Basis for Design (C&I): The foundational document for C&I, detailing all codes, standards, and specific project requirements.
- Draft Instrument Index & I/O List: A preliminary but comprehensive list of all instruments and I/O signals.
- Preliminary System Architecture: A detailed diagram showing controllers, servers, workstations, and network topology.
- Critical Instrument Data Sheets: Data sheets for long-lead time items (e.g., control valves, complex analysers) or technically complex instruments.
- Preliminary Cause & Effect (C&E) Diagrams: Draft C&Es outlining the primary shutdown logic.
- Package Interface Strategy: Defines the C&I interface requirements for major vendor packages.
- Control Room Concept/Layout: Preliminary layout and design of the main control room.
- Main Cable Routing Concept: Drawings showing the high-level routing for main cable trays and trunks.
Phase 3: Detail Design (EPC)
3.1. 📘 Core Design Basis & Philosophy
Refines and finalizes the foundational rules, standards, and overall strategy for the entire C&I design.
- Design Basis (C&I): Final issue, incorporating all FEED updates and EPC specifics.
- Control Philosophy: Final issue for implementation.
- Shutdown Philosophy (ESD): Final issue for implementation.
- Fire & Gas (F&G) Philosophy: Final issue for implementation.
- Control Narrative: Detailed unit-by-unit description of control and monitoring operations.
- Alarm Philosophy: Defines alarm management, prioritization, and rationalization (per ISA 18.2 / IEC 62682).
3.2. 📊 Key Lists, Schedules & Indices
Live database documents that track every component and its properties throughout the project.
- Instrument Index: Master list of all tagged instruments, P&ID, service, location, and document references.
- I/O List: Detailed list of all signals (4-20mA, DO, Modbus), system (BPCS/SIS), and cabinet/channel.
- Cable Schedule: Lists every cable, its type, origin (e.g., JB-001), destination, and routing.
- Junction Box (JB) Schedule: Lists all JBs, their location, tag, type, and associated cables/instruments.
- Alarm & Trip Setpoint List: Formal list of all alarm/trip points, values, and priorities.
3.3. 🖥️ System & Network Design
Defines the "brains" of the plant—the control systems themselves.
- System Architecture (BPCS, SIS, F&G): High-level diagram of servers, controllers, workstations, and network.
- Network Architecture Diagram: Details protocols (Ethernet/IP), VLANs, firewalls, and cyber security.
- Functional Design Specification (FDS): Translates Control Narrative into specific logic/HMI requirements.
- HMI/Graphics Design Specification: Defines look and feel, color standards, and navigation for operator displays.
- Cause & Effect (C&E) Diagrams: Matrix or logic diagrams for SIS (ESD) and F&G systems.
- System Cabinet/Panel Layout Drawings: General arrangement and layout for system/marshalling cabinets.
- Power & Earthing Philosophy (Inst): Defines power sources, UPS, and instrument earthing.
- Instrument Power Calculations / Load List: Calculates power consumption to size UPS/power supplies.
3.4. ⚙️ Field & Installation Design
Drawings showing *how* and *where* field devices are physically installed.
- Instrument Location Layout Drawings: Plan drawings showing physical location of instruments, JBs, and local panels.
- Instrument Hook-Up (Installation Detail) Drawings: Standardized drawings for piping/wiring of each instrument type.
- Junction Box Termination/Wiring Diagrams: Shows internal terminal arrangement and wiring for each JB.
- Cable Routing/Tray Layout Drawings: Plan drawings for main and subsidiary cable tray routes.
- Cabinet/Panel Interconnection Diagrams: Shows cable connections *between* major panels.
- Earthing Hook-Up Details: Standardized drawings for instrument and system earthing.
3.5. 📑 Instrument & Equipment Specifics
Contains the detailed engineering data for individual components.
- Instrument Data Sheets: Unique data sheet for every tag, detailing process data, materials, and specs.
- Control Valve Sizing Calculations: To determine CV and valve characteristics (per ISA/IEC).
- Flow Element Sizing Calculations: For orifice plates, venturis, etc.
- Thermowell Sizing Calculations: For wake frequency (ASME PTC 19.3 TW).
- Material Take-Off (MTO) / Bill of Materials (BOM): List of all bulk materials (tubing, fittings, cable, glands).
3.6. 🛡️ Functional Safety & Specialized
Critical documents for SIS and F&G systems, governed by IEC 61511/61508.
- Safety Requirements Specification (SRS): Foundational SIS document detailing all safety functions and SILs.
- SIL Verification Reports: Calculations (FTA, LOPA) proving the SIF design meets the target SIL.
- F&G Detector Layout (Coverage) Drawings: Plan drawings justifying detector placement (e.g., 3D mapping).
- Analyser System Specification: For process analysers (e.g., Gas Chromatographs).
- Condition Monitoring System (CMS) Specification.
- PAGA (Public Address / General Alarm) System Specification.
- CCTV System Specification.
3.7. 📦 Procurement & Vendor Package
Covers documents for buying equipment and defining the interface with large, pre-fabricated skids.
- Material Requisition (MR): Formal package to request bids for instruments, valves, or systems.
- Technical Bid Evaluation (TBE): Engineering analysis and comparison of vendor bids against the MR.
- Package Interface Document: Defines the complete interface for a major package (Compressor, Turbine, HIPPS). Includes:
- Package P&IDs & C&E Charts
- Package Interface I/O List
- Communication Protocol Details (e.g., Modbus Maps)
- Hardwired Interface Details
- Package Control Narrative
3.8. ✉️ Vendor Deliverables (Data)
Documents expected *from* vendors after purchase, managed via a Vendor Document Register (VDR).
- General: Vendor's VDR, IOM Manuals, Spare Parts (SPIR).
- For Field Instruments: GA/Dimension Drawings, Calibration & Material Certificates.
- For Control Systems: Approved System Architecture, Cabinet GA/Wiring, FAT Procedure & Report.
- For Major Packages: All approved interface documents (P&IDs, C&E, I/O), FAT Procedure & Reports.