•Plant Design The objective of Plant Design is to define the equipment, piping, instrumentation and all process requirements needed to build and operate a process plant. Plant design normally starts with a process scheme Process Requirements (chemical and petrochemical applications ) - Plant Capacity, in MTPY (metric tons per year) , Product specification in terms of purity or maximum content of certain impurities Process Design – 1. A process flow diagram (PFD) is a diagrammatic representation of a process using symbols to represent the various components (equipment, lines, and control instrumentation) that make up the unit. Only the main components are shown. 2. Piping and instrumentation diagram (P&ID) show how industrial process equipment is interconnected by a system of pipelines. P&ID schematics also show the instruments and valves that monitor and control the flow of materials through the pipelines. This document will be the basis for developing the piping drawings and for specifying the instrumentation and control systems. It is a rather detailed document and for this reason, each P&ID covers only a small part of the process. So, a typical petrochemical unit may have 20 to 30 P&IDs, while larger units may well have 60 to 100. • • • Applications Process Plants built as engineering & construction (E&C) projects require complex piping. These projects include the following: chemical plants Biotech plants Brewery Crude oil refineries Food processing Fertilizer plants Oil & Gas Nuclear Power plants Pharmaceutical Pulp Paper mills Water Treatment plants . PFD Example . P&ID Example . P&ID Example . Also known as Mechanical Flow Diagram (MFD). with its equipment.Piping & Instrumentation Diagram Symbolic representation of a plant. piping. . It is the basis for all detail engineering work. and instrumentation clearly identified. • The P&ID stage of design is generally considered engineering. and the like. . and the physical stage is considered design or layout. automatic design validation.Categories • P&ID drawings fall into two categories: • 1) Dumb. which are basically CAD-centric 2D diagrams • 2) Intelligent data-centric diagrams that range from simple database connectivity to a full-blown data model that includes engineering rules. integration with design and calculation packages. standards compliance. This instruction outlines the Work Process and Project Settings for P&ID development and the corresponding milestone issues of the document.Purpose & Scope • The responsibility for the Process and technical content of the P&ID’s lies with the Process. Mechanical. and that any deviations from these standards are documented and reported to the P&ID Coordinator. Piping and Instrument disciplines. checked by all Disciplines and approved by the Area Manager ------------------------------------------------------------------------- • Scope . . • It is the responsibility of personnel on the project team to ensure that the standards described within this document are maintained. It is the duty of the process engineer to specify the size and materials of the piping and also the thermal insulation.Description • Piping is the physical elements that interconnect the equipment and in which the process streams flow. The term piping also includes accessories such as elbows. control. valves. flanges. . The most common material is carbon steel. Teflon. tees. if required. and plastic materials. temperature. • Instrumentation is devices used to measure. pressure. Control valves and relief valves are also an important part of the instrumentation. Other metals. such as various grades of stainless steel. such as PVC. Piping comes in different sizes and materials. are also used. and monitor the process variables. and others. etc. liquid level. These variables can be flow. viscosity. A P&ID should include: • • • • • • • • • • • • • • • • • • • Instrumentation and designations Mechanical equipment with names and numbers All valves and their identifications Process piping. tees and similar standard fittings extensive explanatory notes . drains. valves. sampling lines. equipment. instrumentation.Representation • P&ID shows all of piping including the physical sequence of branches. The P&ID are used to operate the process system. increasers and swagers Permanent start-up and flush lines Flow directions Interconnections references Control inputs and outputs Interfaces for class changes Vendor and contractor interfaces Identification of components and subsystems delivered by others Intended physical sequence of the equipment A P&ID should not include: manual switches equipment rating or capacity pressure temperature and flow data elbow. sizes and identification Miscellaneous . reducers. special fittings.vents. reducers. Interconnecting (Rack) P&ID –They are the connecting link between individual process. boilers.Classification • Legends and Symbol Diagrams/Standard Details • • Process P&ID . They are usually prepared for the offsite pipe racks and link the various process and utility plants.They are prepared for systems which support major equipment packages. fire water systems. and utility distribution P&ID's. unit drain collection systems. air compressors. Vendor P&ID . utility plant.Utility Plant P&ID's define utility units such as cooling towers. as well as off-plot tankage and shipping systems Utility Plant P&ID .Process P&ID’s define on-plot process unit design. • • • . and water treatment plants. Valving and instrumentation on piping are shown for main headers up to and including branch root valves. Utility Distribution P&ID .Show the distribution of utilities within a given process. Sewer. Boiler Blowdown. They are generally segregated as follows: o Above Ground Process Lines o Above Ground Utility Lines o Underground Process and Utility Lines . Raw Water. Effluent o Relief System • Interconnecting P&ID's are prepared to represent the offsite interconnecting piperacks and piping. Fuel Gas. The P&ID Coordinator for the project will identify and assign numbers and titles to all P&ID's. o Water Systems. etc. o Chemicals and Additives o Waste Water. P&ID Format P&ID's include. Cooling Water. using P&ID software P&ID's shall follow the format of the Legends and Symbols and current project Standard Drawings.• • • • P&ID's are to be prepared with the following format and organization: All P&ID drafting shall be by Computer Aided Drafting (CAD). Natural Gas. Condensate. Utility Water. Fire Water o Steam. and Boiler Feed Water o Air. Nitrogen. starting with the IFA issue. Revision list A Revision List defines the changes made in the design so that appropriate action can be taken to accommodate those changes. A Revision List must accompany any issue of the P&ID after IFH if the changes are too extensive to be distinguished in the revision box and by clouding. . starting with the IFA issue.Accompanying Deliverables From The P&ID Equipment List An Equipment List shall be issued in a timely manner to compliment the P&ID’s and Updated judiciously as additional design data or vendor data becomes firm. SP items and Instrumentation Lists shall be issued from Bentley Data Manager each time a P&ID issue is made. Line Designation Table (LDT) The Line Designation Table (LDT) shall be issued from Bentley Data Manager each time a P&ID issue is made. Tie-In Control List A Tie-in Control List shall be issued indicating the extent of the Vendor package battery limits each time a P&ID issue is made starting with IFA. Other List The Valve. The "Hold" indicates where the information used as input to the P&ID is preliminary and the item is used with risk in the downstream design. “Holds” List A "Holds" list must be issued each time a P&ID issue is made starting with IFD. Assign line numbers and prepare the Line Designation Tables. Piping Engineer .has overall responsibility for all engineering work.Issues the piping material classification index and the piping material specifications. . Coordinate P&ID information between systems and related areas of plants. approval. issue process data sheets for equipment.General Responsibilities • • • • • Area Manager . Work jointly with Lead Engineers to develop Material Handling P&ID’s on jobs with significant Material Handling equipment. Develop process equipment list . Mechanical Engineers . including preparation.Issue Process Flow Diagrams. Provide Lead Engineers with equipment requirements that are to be shown on P&ID's.Prepare and issue an Equipment List showing all equipment on the project. stamping and issue of P&ID's Lead Engineers .Prepare and. Verify the conformance of the P&ID to equipment data sheets and specifications. OWN all P&ID's. Process Engineer . Sanjay Phadke Neilsoft Manikchand Ikon Building 7th Floor CTS 18 & 18/1 Dhole Patil Road Pune 411001 .