Introduction to Basic Process Documents
By Jaswant Tawde
Slide 1
The Basic Process Documents
Key Stages
Process Design Basis
PFD
P&ID
EPD
IPDS
Line list
Slide 2
Process Design Basis
Product, Quality, Quantity;
Raw material, specification, source etc;
Product / Raw material unloading, storage dispatch, packaging.
Utilities: RW, CW, IA, Elec, FG, IG, LP, MP, HP;
Battery limit condition specified;
Location of plant
Site Conditions: Temperature (WB & DB), pressure, rainfall
through out year (Max, Min., Average)
IBR, SMPV, CCOE, OISD, API, IS;
Restriction in equipment sizing
Slide 3
Slide 4
Process Flow Diagram
Process Flow (only process lines, utility lines neglected);
Basic Process Control defined;
Flow, temp., pressure identified;
Equipment tag numbers;
Stream number identified for Reference with H&MB;
Material Flow Diagram;
MOC & CA identified for equipment and piping;
Special requirement such as NACE, HIC identified;
Slide 5
Piping & Instrument Diagram
Most important document of process department
Used during all phases of the plant
Bidding
Engineering
Construction
Commissioning
Operation & maintenance
Any future modification of the plant
Since all the equipment and instrument appear on the P&ID some
packages use it as a central point for storing data base.
Slide 6
A P&ID is: A P&ID is not:
Language of Symbols Piping Isometric
Schematic of Process Equipment Fabrication
Displays Relative Diagram
Orientation/Configuration Scale Drawing
Communication Tool Control Logic Diagram
Something to Convey
Process Information!
Slide 7
A P&ID should include:
Instrumentation and designations
Mechanical equipment with names and numbers
All valves and their identifications
Process piping, sizes and identification
Miscellaneous - vents, drains, special fittings, sampling lines, reducers,
increasers and swagers
Permanent start-up and flush lines
Flow directions
Interconnections references
Control inputs and outputs, interlocks
Interfaces for class changes
Seismic category
Quality level
Annunciation inputs
Computer control system input
Vendor and contractor interfaces
Identification of components and subsystems delivered by others
Intended physical sequence of the equipment
Slide 8
A P&ID should not include:
Instrument root valves
control relays
manual switches
equipment rating or capacity
primary instrument tubing and valves
pressure temperature and flow data
elbow, tees and similar standard fittings
extensive explanatory notes
Slide 9
Piping & Instrument Diagram
Sometimes called as engineering flow diagram;
All lines identified (SU, utility, maintenance, drains, vent)
Piping details;
Instrumentation details.
Equipment interface with piping and instruments;
Elevations details;
Scope of supply for equipments identified;
Notes describe any special requirements as applicable;
Specialty items such strainers, sampling details, corrosion
coupons etc;
Protective items such as breather valve, relief valves, flame
arrestors;
Slide 10
Tag number
Thousands of components are to be procured therefore all items are
tagged
Tag numbers are provided to equipment, instruments, lines,
specialty items and all miscellaneous items that are to be procured.
These tag numbers are also useful to be referred in other
documents such as DCS loop, cause and effect diagram.
Tag number are only referred during plant operation &
maintenance
Slide 11
Basic Point in P&ID
How the process flow actually takes (consistency with PFD)
Pump
Pressure
Gravity
Type of material solid, liquid or gas
How is the pressure rating is defined
What is the basis of selecting equipment / line pressure
Pump Shutoff pressure
PSV (set pressure, location, equipments being protected by
PSV)
HIPS (High integrity instrument protection system)
How the piping spec breaks have been defined
Slide 12
Basic Point in P&ID
What is the basis of selecting design temperature
Max. Process temperature with design margin
Inadvertent flow some other line or equipment
Fire case
Auto-refrigeration / steam out
Why particular MOC is used at particular location
How material spec breaks have been defined
Process fluid corrosion properties
Design pressure and temperatures
How the material cost are kept to minimum
Cladding (reduce the thickness of costly material)
Glass lined / rubber lined pipes
Refractory lining
Slip on flanges
Slide 13
Piping Details
Fluid Code (CW, PA, IA, HC etc.)
Line Number (Line list, Isometrics)
Piping Specification
Design temperature & Pressure (Max.)
Piping material
Corrosion allowance
Special requirement such NACE, IBR, HIC, 5D bend, Electric
PWHT, Radiography
Flange rating and type
Type of fitting
Valves, Check Valves
Gasket, Bolts
Insulation type and thickness
Slope, Free draining, No Pocket Slide 14
Piping
Line list
Preliminary BOM (Valves, check valves, tee)
Plot Plan
Equipment Layout
Line routing
Pipe rack details
Piping Isometrics
Slide 15
Instrumentation
All instrument tag numbers
Instrument type
Instrument connection details
Isolation and draining & venting
Sometimes shown on legends P&ID
Also refer instrument mounting details
Scope break between piping / instrument dept.
Location of indication
DCS
PLC
Local
Panel Mounted
Slide 16
Instrumentation Control Valve
Control valve type
Control valve size
Control valve isolation & bypass size
Control valve air fail position
Handwheel
Control valve positioner
I/P Converter
Solenoid valve
Cavity vent or HP side
Drain
Slide 17
Instrumentation - Control
Operational control, DCS interlock and SIS
interlock
Each control loop Single or Multivariable
How the signals are transmitted to / from control
system
System where the control is realized DCS /
PLC
Alarms
Interlocks
Interlocks numbered
Inputs and output interlock identified
Slide 18
Instrument
Instrument list
I/O list
DCS graphics
Instrument data sheet
Instrument mounting details
Slide 19
Equipment - Vessel
Equipment tag number
Type of equipment
Design pressure and temperature
MOC
Vent and drains
Equipment trims
Interface with piping
Interface with instruments
Relative nozzle elevation
Equipment isolation (slip plate, blinds)
Slide 20
Equipment Pump / Blower / Comp.
Equipment tag number
Type of equipment
Design pressure and temperature
MOC
Capacity & Head
Piping / Instrumentation
Capacity control, surge, min. flow
Vent / Drain
Seal / Vent / Heating / Cooling details
Elevation difference required for NPSH
Slide 21
Equipment - Package
Equipment tag number
Black Box
Package boundary limit (Scope)
Interface with piping
Interface with instruments
All utilities provided
Is the package complete
Slide 22
Clouds
All revisions on the P&ID
Indicate scope of project (Brownfield Project)
Early tie-in
As built correction
Where ever many clouds are used they should be
defined prior to use
Slide 23
Storage of Liquid
Bund & Dykes
Drainage details
Tanker loading / unloading
Static charge
Slide 24
Holds
If any details on the P&ID is likely to change in the future
indicate that as HOLD.
Hold for relief valve size, inlet & outlet line sizes
Hold for package details, pump inlet out nozzle size
Hold for vessel nozzle size, in line instruments
Holds boldly marked and in different layer
Department of hold is mentioned
Hold list updated
Slide 25
Flare lines
Free draining, no pocket
Weep hole for atmospheric relief valve outlet
Full Bore for PSV inlet and outlet valve
Locked open for PSV inlet and outlet valve
Valve steam horizontal for PSV inlet and outlet
valve
PSV Set pressure
PSV orifice designation, inlet / outlet size
Slide 26
P&ID Key Stages
PRELIMINARY
IFD
POST HAZOP
IFC
AS BUILT
Slide 27
PRELIMNARY
PRELIMINARY Distributing to departments & client
for comments
IFD No engineering is done on this
document
Intent is to collect and incorporate in
POST HAZOP
the IFD P&ID
IFC
AS BUILT
Slide 28
IFD
PRELIMINARY P&ID review meeting
All points discussed
IFD P&ID updated based on P&ID review
Our EDP defines the minimum
POST HAZOP information that has to be on IFD P&ID
No vendor information is available
IFC Relief lines (Preliminary sizes)
Holds to be mentioned
AS BUILT
Slide 29
P&ID Revision Request (DCN)
It is a procedure to make small changes on P&ID
so that many revisions of the P&ID are avoided.
It also serves to give information to other
departments as and when it is available
DCN register needs to be maintained
Master P&ID needs to be updated
Master P&ID to be parked in P:\Locker
In case of LSTK jobs this is a tool to track
variation in cost & time
In such cases project department approves the
DCN
Slide 30
P&ID - EDP
Detailed Review of P&ID 7.23
Preparation of P&ID (Utilities & Offsite) 7.28
Preparation of P&ID 7.74
Slide 31
Intelligent P&ID
An intelligent P&ID contains engineering data,
such as process data (normal and maximum
operation pressure, temperature, flow rate and
manufacturing data), and facilitates design
verification (performs rule-based design
verification to produce technically sound design
and enforce industry, company, and regulatory
standards).
Slide 32
Intelligent P&ID
Integrates with Instrument Data Manager (IDM), WireWorks, PDS 3D
Piping module, and SmartPlant products
Extensive reporting capabilities are available to create deliverables such as
line lists, equipment lists, Electrical userlist, Instrument list, I/O List
Includes reserved palettes for customizing piping, equipment, and instrument
menus
Fast and efficient setup of the schematic design using assemblies (existing,
proven best practices designs)
Design verification with user-definable options, such as checking against the
pipe specification to allow checks that make sense in the different phases of
the project
Relational database forms a powerful yet flexible data repository that allows
reporting, interfacing with external systems, and modifications
Design multiple processes on a single diagram and perform design checks on
these individual systems
Customer-definable design verification capabilities
Slide 33
POST HAZOP
PRELIMINARY
IFD
Usually there is one issue of P&ID
POST HAZOP
after hazop is conducted
IFC
AS BUILT
Slide 34
ISSUED FOR CONSTRUCTION
PRELIMINARY
IFD
All the vendor data are incorporated
POST HAZOP
All line sizes are indicated
IFC Control valve sizes indicated
Relief valve size indicated
AS BUILT Piping tapping details indicated
In short no holds on the P&ID
Slide 35
ISSUED FOR CONSTRUCTION
PRELIMINARY
IFD
Unplanned changes made during
POST HAZOP construction are captured during this
revision
IFC Most neglected phase
AS BUILT
It is very important to client because
it is the basic input for all future
projects
Slide 36
Thank you
Slide 37
