【Weekly Question 20090608】Management of instruments for new projects

The last edit to this post was made by zhaohh3211 on 2009-6-11 08:08; in short, it’s about ensuring that the measurement and testing devices function properly. 1. Determine the appropriate number of personnel and their roles for the instrumentation team. 2.72 hours of preparation for the assessment. 3. Drawing organization. 4. Calculate the 4 rates. 5. Improve DCS monitoring by considering hardware spares and software backups. 6. Provide measurement reports for the unit. 7. Propose improvement suggestions based on the on-site conditions. 8. Conduct technical training. 9. Accident plan drills.

In addition to organizing and summarizing documents, drawings, various records, and verification logs, it is also necessary to formulate relevant procedures based on the characteristics of the instrumentation equipment, as well as to carry out technical training and accident prevention drills.

In my opinion: 1. Organize and archive instrument data, as-built drawings, and calibration records. 2. Improve the list of instrument spare parts and ensure that these parts are available. 3. Ensure comprehensive technical support from the manufacturer, and provide training for those who are not familiar with the instruments. 4. As soon as possible, copy the source code for modules, programs, etc., to the appropriate locations. 5. Keep daily inspection records up to date

1# LZ Gas Station 1. Collection, organization, and archiving of completion documents； 2. Staffing and position allocation for instrument operators ； 3. Targeted in-house training or outsourced training ； 4. Make thorough preparations for the system integration trial operation and the 72-hour evaluation ； 5. Collect relevant information on the installed equipment and formulate a rectification plan ； 6. Develop a spare parts inventory plan based on the importance of each piece of equipment in the production process ； 7. Acceptance after 7.72 hours of testing, as well as the organization and archiving of acceptance documents ； 8. Summarize the strengths and weaknesses in terms of people, machinery, materials, and the environment, and adopt corresponding countermeasures.

I. Management of archiving the final delivery documents:
1. Preliminary design specifications
2. Detailed design specifications
3. Documents related to technical agreements
4. System configuration, I/O point lists, and design specifications for all instruments and equipment
5. Drawings (including process piping and instrumentation diagrams P&ID, control block diagrams for complex systems, diagrams for sequential control, logical control, and timing control, system configuration diagrams, cabinet hardware configuration diagrams, floor plans of control room equipment, layout and wiring diagrams for various cabinets, layout and wiring diagrams for auxiliary panels and control consoles, floor plans for indoor instrument cables and wires, I/O card wiring tables or circuit wiring diagrams, power supply system diagrams, and grounding system diagrams)
6. Factory acceptance test reports (FAT) and site acceptance test reports (SAT)

II. Final configuration screens after delivery; all such screens should be printed out, bound into volumes, and archived.

III. Assign maintenance personnel based on the scale of the installation (for on-site maintenance and configuration).

IV. Develop practical training plans and manuals to ensure thorough training.

V. Prepare a “DCS Operator Manual” and provide training for end-users.

VI. Establish a practical inspection system along with detailed evaluation criteria.

VII. Formulate rules for modifying or disabling (restoring) interlock protection systems, implementing a three-level management mechanism: after a request is made by the production unit, it must be approved and signed by the production unit itself, the instrumentation maintenance team, and the mechanical equipment and safety departments before the maintenance team can carry out the necessary actions. VIII. Management of spare parts and accessories

This post was last edited by wopale3 on 2009-6-12 at 15:21. As soon as a project is initiated, the recruitment of staff begins, with a management structure established based on specialties and functions. At different stages, depending on the specifics of the project, the responsibilities of the staff also become more defined, along with their respective job scopes and documentation. Once the installation is put into operation, the staffing structure, roles, and corresponding job specifications have been initially determined. This is also the time when the information is most complete and the staff roster is relatively full. 1. Archive documents, assigning them to specific units and individuals; 2. Perform system backups and store them in the team units, instrument workshops, and maintenance departments; 3. Train the support staff (after the front-line staff have completed their training, they may leave); 4. Conduct summaries of the commissioning process to improve operating procedures; 5. Begin formulating accident response plans; 6. Prepare maintenance plans and spare parts schedules; 7. Determine whether to improve control systems, such as those using APC; 8. Assign duty personnel for 24-hour, 72-hour, monthly, and annual operation and maintenance schedules

If the ISO10012 measurement and testing system is taken into consideration, many procedural tasks can be covered under this system.