- Email: [email protected]
Designing control and monitoring systems
Chapter 9
Designing control and monitoring systems Chapter outline 9.1 Conceptual design 9.2 Basic design 9.3 Detail engineering phase 9.3.1 Drawing numbering
49 50 50 51
9.4 Technological documentation—installation and commissioning instructions 52 9.5 As-built documentation 53
Abstract This chapter describe the design phases of control and monitoring systems including Conceptual design, Basic design, Detail engineering, technological documentation and provision of operating instructions and As-built documentation. Additionally the chapter lists different types of documents typically produced in each design phase.
9.1 Conceptual design Basing on their own competence and experience shipyards, designing/consulting offices or Owner’s Technical Departments prepare conceptual designs for new vessels or offshore units or smaller electrical installations that take into account project requirements, technical feasibility with regard to existing capabilities, economic value and market trends. A conceptual design package usually includes: – – – – – – –
technical specification, principal diagrams, necessary plans, P&ID diagrams, General Arrangement drawings (GA), equipment arrangements, equipment Makers List.
Conceptual design defines the main/general parameters of a new vessel or offshore unit, which should not change in the subsequent basic and detailed Ship and Mobile Offshore Unit Automation. https://doi.org/10.1016/B978-0-12-818723-4.00009-0 © 2019 Elsevier Inc. All rights reserved.
49
50 Ship and mobile offshore unit automation
d esign phases. During this stage the vessel control stations are defined and equipment weights are estimated. The conceptual design work is normally completed prior to entering into the main contracts for a new project. This designing phase is usually performed by designing/consulting offices.
9.2 Basic design The basic design phase follows the conceptual design phase. It is usually carried out after award of contract for new build or conversion, but in some projects an Owner may pay for this scope prior to contract award if the bidding shipyards are not felt to be competent for this task. The basic design tasks are carried out by the shipyard design office, or by subcontracted independent design offices. The basic design work is based on the conceptual or contract design, or other documentation defining the desired vessel/offshore unit or installation. The scope of basic design work is much more detailed than conceptual design. The basic design phase is developed according to the technical requirements, Classification Rules and other regulations and standards listed in the contract Technical Specification. The minimum requirements of a project are outlined in the Classification Rules, but usually the basic design work must address additional Owner’s requirements including some which may be described in philosophies i.e. Vessel/offshore unit automation management, power management, dynamic positioning (DP), electrical operation, emergency shutdown (ESD), fire and gas, cable specification and selection, automatic system overview etc. Additional information may be included in control and monitoring systems functional descriptions, design specifications, configurations, data sheets and systems overview developed for Dynamic Positioning system, Power Management system, Propulsion and Control systems, Alarm and Monitoring system, Human Machine Interface (HMI) display etc. Basic design work is normally required to be approved by Owner’s representative, Classification Society and vessel’s Flag State Administration (where applicable). After having approved basic design documents the shipyard design office can proceed to the detailed design phase. At this stage or earlier, the shipyard procurement department will be able to use confirmed design information to prepare reliable Request for Quotation (RFQ) or Information to Tender (ITT) documents to be sent to equipment vendors and subcontractors. The basic design phase is usually performed by design/consulting offices, sometimes with the cooperation of the vessel or offshore unit owner. Examples of basic design phase drawings/documents are presented in Appendix 2.
9.3 Detail engineering phase The detailed engineering phase is developed by the shipyard designing office or shipyard subcontractor and takes into consideration the basic design approved
Designing control and monitoring systems Chapter | 9 51
by the following parties: Owner, Classification Society and vessel’s Flag State Administration (where applicable). The scope and detail of this engineering phase depends on the shipyard’s production technology and methods, and the information needs of the workers or subcontractors employed. For electrical control and monitoring systems, detailed engineering deliverables include working documents such as P&ID drawings, Input/Output (I/O) alarm and monitoring list, schematic and connection diagrams, cable schedules, cable plans, cable tray routing, equipment arrangement drawings, work instructions and other production drawings. The detailed engineering design phase is usually performed by the shipbuilder’s design office and his subcontractors. Examples of detail engineering drawings/documents are presented in Appendix 2.
9.3.1 Drawing numbering Project drawings are numbered according to the shipyard’s internal system, sometimes with an additional set of numbers if required by the Owner’s system. The most widely used numbering system used by shipping and offshore companies, shipyards and consultants worldwide is the SFI Group System developed by Ship Research Institute of Norway and now owned by SpecTec.1 This standard provides a functional subdivision of technical ship or rig information. In this system, electrical, instrumentation and communication systems drawings are numbered as below: 42—Communication Equipment 421—Radio Plant 422—Lifeboat Radio Transmitters, Emergency Radio, Direct Finder 423—Data Transmission Plants (Telex), General Purpose EDB Plants 424—Very High Frequency (VHF) and Ultra High Frequency (UHF) Telephones, etc. 425—Calling System, Command Telephone, Telephone Plants, etc. 426—Speaking Tubes, Tube Post Plants etc. 427—Light and Signal Equipment—Lanterns, Whistles etc. 79—Automation Systems for Machinery 791—Manoeuvre Consoles, Main Consoles 792—Common Automation Equipment (Engine Room Alarm etc.) 793—Automation Equipment for Propulsion Machinery and Transmissions 794—Automation Equipment for Boilers etc. 795—Automation Equipment for Diesel/Turbo Aggregates etc.
1. See web page http://www.spectec.net/technical-coding-solution.
52 Ship and mobile offshore unit automation
797—Automation Equipment for Other Machinery Components. 798—Cables/Leads and Piping for Automation Systems for Machinery 85—Electrical Systems General Part 86—Electrical Power Supply 861—Generators/Alternators 865—Transformers 866—Batteries and Chargers 867—Converters and Rectifiers 868—Shore Supply 87—Electrical Distribution Common Systems 871—Main Switchboard 872—Emergency Switchboard 873—Group Starters 874—Local Starters 875—Distribution Panels and Boards 88—Electrical Cable Installation 881—Cable Trays and Installation in Pontoons and Columns 882—Cable Trays and Installation in Accommodation, Superstructure etc. 883—Cable Trays and Installation of Drilling Machinery on Main Deck 89—Electrical Consumers 891—Electrical Lighting Systems for Machinery in Pontoons and Columns 892—Electrical Lighting Systems in Accommodation, Superstructure etc. 893—Electrical Lighting Systems for Drilling Machinery on Main Deck 897—Electrical Ventilators 898—Electrical Motors
9.4 Technological documentation—installation and commissioning instructions Technological documentation is prepared by the design offices to assist the installation and commissioning of control and monitoring systems onboard. Usually shipyards and their subcontractors perform installation and commissioning work according to written procedures and standard practices, for example there may be a shipyard Standard Practice for Electrical Installation. For complicated systems, there are often prepared additional technological documents including system/equipment drawings, mounting instructions, commissioning manuals and equipment catalogue cards. Technological documentation is usually prepared by the shipyard design/ technological office or its subcontractors. Examples of technological documentation are presented in Appendix 2.
Designing control and monitoring systems Chapter | 9 53
9.5 As-built documentation When a project is finally built and commissioned, the shipyard design office or their subcontractor prepares As-Built documentation includes updated and corrected drawings and documents from basic design, detailed engineering, together with copies of the equipment manuals and operating instructions for the vendor supplied items installed onboard. As built documentation is usually prepared by shipbuilder designing office or its subcontractors.
Designing control and monitoring systems Chapter outline 9.1 Conceptual design 9.2 Basic design 9.3 Detail engineering phase 9.3.1 Drawing numbering
49 50 50 51
9.4 Technological documentation—installation and commissioning instructions 52 9.5 As-built documentation 53
Abstract This chapter describe the design phases of control and monitoring systems including Conceptual design, Basic design, Detail engineering, technological documentation and provision of operating instructions and As-built documentation. Additionally the chapter lists different types of documents typically produced in each design phase.
9.1 Conceptual design Basing on their own competence and experience shipyards, designing/consulting offices or Owner’s Technical Departments prepare conceptual designs for new vessels or offshore units or smaller electrical installations that take into account project requirements, technical feasibility with regard to existing capabilities, economic value and market trends. A conceptual design package usually includes: – – – – – – –
technical specification, principal diagrams, necessary plans, P&ID diagrams, General Arrangement drawings (GA), equipment arrangements, equipment Makers List.
Conceptual design defines the main/general parameters of a new vessel or offshore unit, which should not change in the subsequent basic and detailed Ship and Mobile Offshore Unit Automation. https://doi.org/10.1016/B978-0-12-818723-4.00009-0 © 2019 Elsevier Inc. All rights reserved.
49
50 Ship and mobile offshore unit automation
d esign phases. During this stage the vessel control stations are defined and equipment weights are estimated. The conceptual design work is normally completed prior to entering into the main contracts for a new project. This designing phase is usually performed by designing/consulting offices.
9.2 Basic design The basic design phase follows the conceptual design phase. It is usually carried out after award of contract for new build or conversion, but in some projects an Owner may pay for this scope prior to contract award if the bidding shipyards are not felt to be competent for this task. The basic design tasks are carried out by the shipyard design office, or by subcontracted independent design offices. The basic design work is based on the conceptual or contract design, or other documentation defining the desired vessel/offshore unit or installation. The scope of basic design work is much more detailed than conceptual design. The basic design phase is developed according to the technical requirements, Classification Rules and other regulations and standards listed in the contract Technical Specification. The minimum requirements of a project are outlined in the Classification Rules, but usually the basic design work must address additional Owner’s requirements including some which may be described in philosophies i.e. Vessel/offshore unit automation management, power management, dynamic positioning (DP), electrical operation, emergency shutdown (ESD), fire and gas, cable specification and selection, automatic system overview etc. Additional information may be included in control and monitoring systems functional descriptions, design specifications, configurations, data sheets and systems overview developed for Dynamic Positioning system, Power Management system, Propulsion and Control systems, Alarm and Monitoring system, Human Machine Interface (HMI) display etc. Basic design work is normally required to be approved by Owner’s representative, Classification Society and vessel’s Flag State Administration (where applicable). After having approved basic design documents the shipyard design office can proceed to the detailed design phase. At this stage or earlier, the shipyard procurement department will be able to use confirmed design information to prepare reliable Request for Quotation (RFQ) or Information to Tender (ITT) documents to be sent to equipment vendors and subcontractors. The basic design phase is usually performed by design/consulting offices, sometimes with the cooperation of the vessel or offshore unit owner. Examples of basic design phase drawings/documents are presented in Appendix 2.
9.3 Detail engineering phase The detailed engineering phase is developed by the shipyard designing office or shipyard subcontractor and takes into consideration the basic design approved
Designing control and monitoring systems Chapter | 9 51
by the following parties: Owner, Classification Society and vessel’s Flag State Administration (where applicable). The scope and detail of this engineering phase depends on the shipyard’s production technology and methods, and the information needs of the workers or subcontractors employed. For electrical control and monitoring systems, detailed engineering deliverables include working documents such as P&ID drawings, Input/Output (I/O) alarm and monitoring list, schematic and connection diagrams, cable schedules, cable plans, cable tray routing, equipment arrangement drawings, work instructions and other production drawings. The detailed engineering design phase is usually performed by the shipbuilder’s design office and his subcontractors. Examples of detail engineering drawings/documents are presented in Appendix 2.
9.3.1 Drawing numbering Project drawings are numbered according to the shipyard’s internal system, sometimes with an additional set of numbers if required by the Owner’s system. The most widely used numbering system used by shipping and offshore companies, shipyards and consultants worldwide is the SFI Group System developed by Ship Research Institute of Norway and now owned by SpecTec.1 This standard provides a functional subdivision of technical ship or rig information. In this system, electrical, instrumentation and communication systems drawings are numbered as below: 42—Communication Equipment 421—Radio Plant 422—Lifeboat Radio Transmitters, Emergency Radio, Direct Finder 423—Data Transmission Plants (Telex), General Purpose EDB Plants 424—Very High Frequency (VHF) and Ultra High Frequency (UHF) Telephones, etc. 425—Calling System, Command Telephone, Telephone Plants, etc. 426—Speaking Tubes, Tube Post Plants etc. 427—Light and Signal Equipment—Lanterns, Whistles etc. 79—Automation Systems for Machinery 791—Manoeuvre Consoles, Main Consoles 792—Common Automation Equipment (Engine Room Alarm etc.) 793—Automation Equipment for Propulsion Machinery and Transmissions 794—Automation Equipment for Boilers etc. 795—Automation Equipment for Diesel/Turbo Aggregates etc.
1. See web page http://www.spectec.net/technical-coding-solution.
52 Ship and mobile offshore unit automation
797—Automation Equipment for Other Machinery Components. 798—Cables/Leads and Piping for Automation Systems for Machinery 85—Electrical Systems General Part 86—Electrical Power Supply 861—Generators/Alternators 865—Transformers 866—Batteries and Chargers 867—Converters and Rectifiers 868—Shore Supply 87—Electrical Distribution Common Systems 871—Main Switchboard 872—Emergency Switchboard 873—Group Starters 874—Local Starters 875—Distribution Panels and Boards 88—Electrical Cable Installation 881—Cable Trays and Installation in Pontoons and Columns 882—Cable Trays and Installation in Accommodation, Superstructure etc. 883—Cable Trays and Installation of Drilling Machinery on Main Deck 89—Electrical Consumers 891—Electrical Lighting Systems for Machinery in Pontoons and Columns 892—Electrical Lighting Systems in Accommodation, Superstructure etc. 893—Electrical Lighting Systems for Drilling Machinery on Main Deck 897—Electrical Ventilators 898—Electrical Motors
9.4 Technological documentation—installation and commissioning instructions Technological documentation is prepared by the design offices to assist the installation and commissioning of control and monitoring systems onboard. Usually shipyards and their subcontractors perform installation and commissioning work according to written procedures and standard practices, for example there may be a shipyard Standard Practice for Electrical Installation. For complicated systems, there are often prepared additional technological documents including system/equipment drawings, mounting instructions, commissioning manuals and equipment catalogue cards. Technological documentation is usually prepared by the shipyard design/ technological office or its subcontractors. Examples of technological documentation are presented in Appendix 2.
Designing control and monitoring systems Chapter | 9 53
9.5 As-built documentation When a project is finally built and commissioned, the shipyard design office or their subcontractor prepares As-Built documentation includes updated and corrected drawings and documents from basic design, detailed engineering, together with copies of the equipment manuals and operating instructions for the vendor supplied items installed onboard. As built documentation is usually prepared by shipbuilder designing office or its subcontractors.