Costing of Pipelines - 1

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. 1. Introduction
The selection of the optimal pipeline route, diameter, material, wall thickness, pump station location, pump units and operational equipment or facilities is typically the result of economic analysis and investment capital evaluation of the most reasonable scenarios developed through the design phase. Typically, even before the detailed design of a pipeline system has begun, an order-of-magnitude cost study will be performed, with the goal of determining the feasibility of continuing to invest time and capital in the design phase of the project. For a typical cross country pipeline project, the cost of pipe and its associated construction and installation costs can be as much as 80% of the capital investment , therefore , the selection of the pipe, with regard to the type of material, size etc. is very important. A piping works engineer requires not only wide engineering knowledge not necessarily in depth , but certainly an understanding but he must also have an understanding of engineering economics, costs of metallurgical, methods of pipe fabrication, erection and sufficient knowledge of mechanical, civil, electrical and instrumentation engineering to discuss the requirements.

2. Direct and Indirect Costs Associated with Piping

The direct cost of piping is related to the purchase and installation of piping along with accessories. i.e. it deals with raw materials, labour, energy etc. Indirect cost includes: Design and engineering cost, which cover the cost of design and cost of engineering of the piping system, purchasing, procurement and construction supervision. Contractors fees (Technology Fee) Contingency allowance, this is an allowance to cover for unforeseen circumstances ( labour disputes, design errors etc.).

3. Economic Evaluation of the Piping System

 As the purpose of investing money in modern piping system is to earn money, some means of comparing the economic performance of piping is needed. For a small piping system , and for simple choices between alternative processing schemes , the decisions can usually be made by comparing the capital and operating costs. More sophisticated evaluation techniques and economic criteria are needed when decisions have to be made between large, complex piping systems, particularly when the piping systems differ widely in scope, time scale, etc. Making major investment decisions in the face of uncertainties that will undoubtedly exist about plant performance, costs, the market Government policy and the world economic situation, is a difficult and complex task (if not an impossible task) and in a large design organisation, the evaluation would be done by a specialist group.

4. Economics of Pipe Diameter Concept

The sizing of process lines can be divided into two categories

Lines which do not contain pumping equipment Lines which contain pumps or compressors

Lines in the first group are sized on the basis of available pressure drop, while those in the second must be based on an economical pipe size ( the smaller the pipe , the less the pipe costs but the higher the pumping costs, and thus an optimum size must exist). Paradoxically, however, it is uneconomical to make economic studies on each process line for a proposed plant. The designer, therefore, must have some means of determining which lines justify careful cost analysis. The designer can select a conservative line size which will definitely fulfill the requirements. But will the next smaller size be more economical? The only manner in which this can be determined definitely is by careful economic analysis. If the possible saving , however, is not far from the cost in the man-hours required to make the study, it is better to select the conservative size without further use of valuable time. If, on the other hand, the possible savings are substantial, then further detailed study is indicated.

5. Inch Meter and Inch Diameter Concept

Purpose: The purpose of inch meter and inch diameter is :

a. To find out piping erection load b. Manpower planning c. Piping work progress monitoring d. Costing The following example will illustrate the concept of the inch-meter and the inch-dia: Q.1 Elbow 2" size, 20 nos., are to be fitted in a pipeline. Find out the inch dia? Ans: Inch dia : size x no. of weld joints x no. of elbows = 2 x 2 x 20 = 80 inch dia. Q. 2 Find out the inch meter for 20 m pipeline of 2" size Ans: Inch meter = Pipe size in inches x length in m = 2" x 20 = 40 inch meter Note : Inch meter will be more relevant in case of yard piping whereas inch dia will be more relevant in case of plant piping.

6. Dividing the Cost of the Pipe Work

The costs of process industry pipe work are usually sub-divided as below: 1. Piping design and engineering: The cost of design work associated with the pipe work including layout studies , scheming , analysis and detailing. 2. Materials: The cost of all bought out materials , i.e. pipe flanges, fittings, valves, expansion units, etc. 3. Fabrication: The cost of site fabrication , off-site fabrication, done in a shop away and adjacent to site. 4. Erection: The cost of erecting on-site fabricated pipe work and pressure testing. This includes preliminaries, variation orders and error rectification if any.

Economic Fluid Velocity (ft/s) Pipe diameter d (in) Pump discharge pipe (d/3 + 5) ft/s Pump suction pipe (d/6 + 1.3) ft/s Steam or gas line 20 d ft/s

Pressure drop available Remark (Ib/in2) / 100 ft 2.0 0.4 0.5

For liquids, a velocity in excess of 20 ft/s should never be specified in order to avoid erosion of the pipe. On suction lines to the pump, the pressure drop should always be less than 50% of the total head developed by the pump.

7. Suggested Steam Pipe Velocities in Pipe Connecting Steam Turbines SERVICE - STEAM Inlet to turbine Exhaust, non-condensing Exhaust - condensing TYPICAL RANGE -ft/s 100 - 150 175 - 200 400 500

8. Relative Economics of Various Materials of Construction S.No. 1 2 3 4 5 6 7 Material Carbon steel (C.S.), A-53, seamless Carbon steel (C.S.), A-53, welded galvanised Wrought iron, galvanised Unplasticised polyvinyl chloride Carbon steel, lead lined Carbon steel, PVC lined Stainless steel Connection Welded Screwed Screwed Sock, weld Flanged Flanged Welded 1.00 0.84 1.61 1.79 4.11 4.76 15.00 Factor

9. Material Estimation
There are three main topics of pipe work estimation as mentioned below:

S.No. 1 2 3

Stage Preliminary First control Second control

Accuracy +/- 25% +/- 20 % +/- 10 %

Basis Based on %age of total plant cost Based on completed P and Is etc. Final P and I, all pipe work details, drawings, material list etc.

10. Fabrication Cost Estimation

The contents of fabrication cost estimation comprise the following: 1. Fabrication 2. Fabrication / Welding 3. Welding 4. Supports

11. Erection Cost Estimation

The contents of fabrication cost estimation comprise the following:

1. Erection 2. Supports 3. Testing of completed pipelines

12. Rates for Fabrication and Erection

The schedule of rates under the fabrication and erection work are established in man hours which should be representative of the gang time to complete the operation. The type of rate will depend on the client and contractor relationship on the basis of the contractors tenders. The rates shall be included or excluded, allowances for construction plant, tools, tackle and consumables. Typical rates for various piping materials are enclosed for reference. These include labour, consumables, tools, tackles and overheads.

13. Typical Rates for Fabrication, Erection and Testing of Pipelines for Costing with Example
a) Mild steel (MS), B and C class piping: Rs. 45/- per inch dia per metre length. b) SS 304 piping ( Sch 5): Rs. 90/- per inch dia per metre length. c) PVC Piping: Rs.45/- per meter length. d) Cu Piping: Rs. 100/- per inch dia metre. e) Pipe fitting reducer, bend etc. SS 304: Rs. 125/- per inch dia MS: Rs. 60/- per inch dia Copper: Rs.140/- per inch dia f) Fabrication and erection of MS supports= Rs. 4500/- per MT. Q. Find out the labour cost for making a MS reducer of 2" x 4" size? Ans: MS Reducer 2" x 4" = 4x60 = Rs.240/- (Considering 4" dia) Q. Find out the labour charges for fabrication and erection of a MS pipeline of 50 NB (2") MS B or MS C of 400 m length fabrication and erection? Ans: 2 x 400 x 45 = Rs.36,000/Typically the quantum of pipe fabrication, erection and testing of pipe work shall be expressed as shown below:

1. MS B and C class piping : 12450 inch mtr 2. SS 304 piping : 2850 inch mtr 3. PVC piping : 285 inch mtr 4. Cu piping: 695 inch mtr

14. Typical Calculation for Piping Cost Raw material Sheet width mm Raw material base rate Rs/kg Packing and Rs/kg forwarding Conversion Rs/kg Excise % Sales tax/ VAT % Insurance % Transportation Rs/kg Total Cost Rs/kg Modvat Benefit Rs/kg Cost to Co. Rs/kg Rs/mtr Factors SS Condensor tube 78.50 1.00 16.00 4.00 0.20 0.79 40.00 19.09 5.53 0.29 2.00 146.19 19.09 127.11 93.81 Copper Condensor tube 140.00 1.40 50.00 30.62 8.88 0.46 2.00 233.37 30.62 202.74 246.74

15. General Scope of Work for Piping Fabrication and Erection

Fabrication, cutting, welding, assembly in position as per drawing. All raw material i.e. pipe, reducers, bends, flanges, sockets etc. and hardware i.e. nut, bolts, gaskets etc. shall be supplied by client. Fitment includes assembly of fittings i.e. flanges, bends, valves, reducer, fabrication of tees, fitment of non return valve, valves, gaskets, nut bolts, sockets for pressure gauges fabrication and fitment of thermowell, etc. Pipe work shall be carried out as per piping drawings/ specifications/ instructions given to construction engineer. After assembly, complete pipeline to be welded by taking necessary precautions to avoid stresses. If stresses developed , those are to be removed and welded as per standard practice and instructions of the site co-ordinator. One in-position weld is allowed for line which cannot be welded on ground. After welding , finishing and grinding , pipeline to be hydraulically tested at pressure specified in the order. After hydraulic testing, pipeline to be painted with redoxide ( one coat).

 After painting, pipeline to be assembled in position and with necessary clamps and supports.

16. List of Tools, Tackles and Machinery Required to Carry Out the Piping Works
To be arranged by contractor: 1. Rectifier 2. H.F. unit 3. Transformer 4. Grinders- AG7 5. Winch 5 MT 6. Chain block 3 MT 11 mtr. Lift 7. Ropes / pulleys 8. FF2 grinder 9. Hacksaw/Files etc. and other tools and tackles. 10. Pipe voice 11. G Q 4 Grinder 12. Abrasive cutting machine 13. Gas cutting

17. Contractor Manpower List of Piping, Fabrication and Erection

For piping, fabrication and erection: 1. Experienced Mechanical Engineer as in-charge 2. Supervisor 3. Highly skilled fitter for SS 304 4. Highly skilled fitter for MS B and C class piping and fabrication 5. Welders for SS TIG, Welders for SS Tacking, Welders for MS Tacking 6. Helpers/Riggers

18. Additional Cost Information

Piping cost may vary between 20 to 66 %. Piping cost may be a headache to the estimator as he/she is asked to give the cost even before engineering and execution. The estimator needs to convert the preliminary flow sheet into a fair approximation of an actual design. The estimator should have the skill to draw quick and rather accurate free hand isometric sketches, which will be of inestimable value.

19. Methods used for Estimation

 Piece by piece method ( Detailed costing) Finagling factor ( 40 % of equipment cost) N system.

20. N System
The N system is based on the fact which has been tested many times, that the costs of strings of pipes of different sizes but of the same material and class of pipe bear constant relations to each other. The N system was introduced by R.A. Dickson (Chem. Eng. Nov 1947, PP 121-123)

21. How to use the N System

Step I : Calculate the cost of the reference sizes of the strings of pipe in question. StepII : Then use the N factors to get the cost of the same string in the required size. Continued from - Costing of Pipelines - 1 22. Piping Cost Estimation Piping always represents a sizable part of the total installed cost of any process plant. It may run to 20 percent or even more of the entire cost of the plant, including land and buildings, and may total from around 10 percent to as high as two-thirds of the cost of the equipment. But piping is usually complicated and often consists of a myriad of small, rather inexpensive parts. Its estimation can therefore be a headache to the estimator. It makes his problem no easier that he is often asked for a reasonable estimate long before the final plans exist and before the project engineers have any idea how much piping will actually be needed. In this case, he must not only be an estimator, but he must be able quickly to convert the preliminary flow sheet into a fair approximation of an actual design to know what his estimate will involve. For this purpose the ability to make quick and rather accurate free-hand isometric sketches is of inestimable value. However, the estimation of the piping need not be arduous if the estimator will make use of the N system developed by the another during the last several years. This system, first disclosed in Chemical Engineering (R.A. Dickson, Chem. Eng., November, 1947, pp 121-123) has now been carried much further and includes most kinds of pipes with which the chemical engineer is likely to be concerned. The N System of Calculating Piping Costs. This new system of estimating piping cost is quicker than the piece-by-piece, and more accurate than the finagling-factor, system, the two methods ordinarily used by estimators. The first requires picking of each length of pipe with its fittings and valves and pricing the material and labour costs in detail, then adding them all up for the total cost. The second consists in taking a percentage of the total cost of a project as the cost of the piping. This percentage the finagling factor, is supposed to be around 40 percent.

* The author wishes to express his appreciation to the firms listed and to may others who prefer to remain anonymous, but who helped by furnishing cost data on which the N-factor tables are based. Specific acknowledgement is made to Armstrong Cork Co., Inc.; Mundet Cork Corp.; Johns Manville, Inc.; Cooper Alloy Foundry Co.; Taylor Forge and Pipe Works; Andrews Knapp Construction Co.; Knapp Mills Inc.; The Saran Lined Pipe Co.; The Rie-Wil Co.; and The Duriron Co. See, for example, Table 10-33 of the N factors. The costs of different sizes of steel Pipe, butt-welded, schedule 40, black, with fittings and valves as specified, will be to each other approximately as the N factors. As the table shows, a string of 2-in nominal diameter pipe will cost 1.84 times as much as the same string in 1 in. Take, for example, a string of such pipe of 2-in nominal diameter: Item 500 pipe 7 fittings 2 valves Unit Cost $ 0.23 7.00 22.00 Total Cost $ 115.00 49.00 44.00 $ 208.00

The same string in 1-in nominal diameter: Item 500 pipe 7 fittings 2 valves Unit Cost $ 0.13 4.50 11.00 Total Cost $ 65.00 32.00 22.00 $ 119.00

Hence, 208/119 = 1.84, the N factor for 2-in. pipe in terms of 1 in. pipe as unity. Not only has the N-factor System been tested thoroughly, but it also shows up satisfactorily over a period of time. Several checks of this fact have been made. For example, table 10-39 was selected at random, and comparable strings were figured for 4- and 12-in. pipe, using first the costs of 1935, and then July, 1949, costs. Despite the fact that the costs of each string had risen approximately 83 per cent from 1935 to 1949, the N factor for 4-in. pipe for 1935 was 0.249, and for 1949; 0.248. How the N-factor System Is Used: To use the tables, first calculate the cost of the reference sizes of the strings of pipe in question. Then use the N factors to get the cost of the same string in the required size. The index of N-factor tables includes 66 materials and weights of piping, counting some insulated, some bare. If the N system is adopted, this means that prices and costs of installation of

these materials for the reference sizes only need be kept on file, instead of material and labour cost of every size of every material and wall thickness in common use. (Also as later explained, if less accurate estimating suffices, data given here can be factored to the date of use by using one of the available cost variation indexes.). The tables cover only the cost of putting the strings of pipe together. The costs of burying or supporting pipelines are easily calculated. Moreover, many times the proposed lines lie on the ground or are supported on existing structures. These conditions are far too variable to include in any tables of costs. An example of use: Assure that several strings of pipe of various sizes have been taken from the flow diagram of a small project involving some additional piping. The specifications of pipe, fittings and valves are: Pipe: steel, schedule 40, butt-welded, black, bare Fittings: forged steel, screwed. 2,000# cold-water pressure Valves: bronze, screwed ends, 200 # cold-water pressure Assume that the pipe is to be installed on existing support. First consult the index of N-factor tables. The specifications of the pipe, fittings and valves in Table 10-33 correspond to those required. The reference size, i.e., the size for which N = 1.00, is 1 in. Next, calculate the cost of hypothetical string of 1-in. pipe of the required specifications. (Or take the cost from Table 10-33, giving the cost of the reference string in July, 1949. Then factor this cost to date of use.) As in Table 10-33, the installed costs may be found to be: Per foot of pipe .............................. $ 0.13 Per fitting ....................................... 4.50 Per valve ......................................... 11.00 Calculate all the strings taken from the flow diagram as 1-in. pipe, then multiply by the N factor for the actual size:

For comparison, the total cost of piping calculated by the conventional pieceby - piece system would be S764, as shown in the following check:

What Data Are Needed: The N-factor tables were derived by actual calculation of the installed costs of typical strings of pipe in all the sizes mentioned in each table, and in all the different weight and materials of construction listed in the 66 tables. For uniformity, all have been calculated on the basis of July, 1949, materials and labour costs in the New York area. For each specification the costs so calculated for the several sizes have been compared with the cost of one reference size which is taken as 1.00. The comparative costs of the other sizes of the same material are then listed as multipliers of the reference size. In Table 10-1, for example, the sizes range from to 12 in. The reference size is 3 in, and the N factors (i.e. relative costs compared with that of the reference size range from 0.320 to 6.730). Hence, the N factors are all based on the reference size (or in a few cases, two reference sizes) for each piping specification, and to figure any string of pipe, it is necessary only to figure the cost for the reference size in that particular specification. Once the cost of the reference size is known, the costs for any other size or for several sizes can be determined immediately by multiplying by the proper N factor. This means that it is necessary to keep upto-date the cost data only for the reference size (or sizes) in each specification, since the N factors remain constant through an extremely wide range of material and labour cost variations. Estimating without Current Data: This means also that it is unnecessary to keep up-to-date data even on the costs for the reference strings, if a somewhat lower degree of estimating accuracy can be tolerated than is possible by having up-to-date figures. For this purpose, each of the tables includes as a second part (or in some cases, as a second and third part) the detailed calculations for the reference size or sizes for these materials are based on July,

1949 costs. As long as labour and material costs do not change much from July, 1949, these figures can be used directly. But since such costs are not likely to be stated in the future, it is possible to factor them to the date of use by the judicious use of one or more of the available cost indexes, in comparison to the index for July, 1949. Cost Indexes: Many cost indexes are available monthly in the Survey of Current Business, published by the U.S. Department of Commerce. Among these are several building cost indexes for various kinds of labour and for a number of basic materials. The Survey, as well as the magazine Engineering News-Record, also publishes the ENR Construction Cost Index, which is widely used by estimators in dealing with plant and equipment cost variations, although it is intended to cover only heavy construction costs. Some organisations have successfully applied their own modifications to the ENR Index in using it to factor plant and equipment costs. The magazine Chemical Engineering regularly publishes the comparative equipment cost indexes for process industries compiled quarterly by the evaluation engineering firm of Marshall and Stevens, together with this firms 1947 industry average, covering equipment costs in a wide range of industrial and commercial activities. None of these indexes applies directly to piping costs and must therefore be used with care. However, experience has indicated that such factoring can be sufficiently accurate at least for pre-construction cost estimating. The only indexes that actually deal with piping cost, as far as the author knows, are not so readily available as those mentioned. These are the Handy Indexes of Public Utility Costs, put out for the estate of William W. Handy by Whitman, Requard and Associates, of Baltimore, and Benjamin L. Smith and Associates, of Albany. This compilation is issued every six months and lists several kinds of piping including gas mains and power plant piping.

Table for N System Pipe: aluminium, Aleoa alloy 618-T6, standard weight, bare, 1/2 to 12 Fittings: aluminium, welding Valves: and 1" aluminium, screwed, gate; 1 to 12" aluminium, flanged, gate, 125# Reference size: 3#

Making and Importance of Process P & ID (Piping & Instrumentation Diagram)

Posted by Ankit Chugh on 10:54 PM0 Comments and 0 Reactions

Introduction:
The successful conversion of a conceptual idea into actual execution of process industry is the basic aim of any process engineer .Normally a project passes through various phases , viz., basic engineering , detailed engineering equipment fabrication /procurement , civil/structural work , erection and commissioning .The conceptual idea , either from the process development cell (for new processes) of from the marketing engineer (as per the customer) requirement , is converted to executable documents during basic engineering stage , and thus governs the successful completion of the project.

Piping & Instrumentation Diagram (P&ID) is one of the important basic engineering documents in the form of drawing , which truly represents the process plant It shows pipelines interconnecting all equipment , instruments ,

control systems, valves , etc. for the completeness of the process plant .Since detailed engineering work for any process plant depends more on the P & ID , its correctness and completeness is very much essential .Any wrong information provided in the P&ID at the initial stage may to a big disaster or may entail heavy expenses later .Hence , great attention is required for the preparation of error free P&ID .Good quality P& ID may deistically cut the engineering man hour requirement for the successful completion of a project .In this article, the details for the preparation of process P & ID are discussed.

Normally process plants have static equipment like storage tanks, columns , heat exchangers, etc. and rotating equipment like pumps, blowers, etc. These equipment are connected to each other by a complicated pipeline network for the completeness of the process. Measuring instruments like thermocouple for temperature measurement , and controlling devices like temperature control valve , are mounted on the equipment or pipelines for operating the plant at desired conditions. Although a single step process like blending of two compounds can be represented in a single Piping & Instrumentation Design (P & ID) , a process having a large number of processing steps like reaction , filtration , drying , etc. would need to have many P & IDs for the complete representation of the process plants .For ease of understanding , the complete process plant is functionally divided into various units .For example a reactor with the other related equipment , pipelines and instruments required for carrying out a reaction process may be covered in one unit while filtration operation my be specified with another unit number accordingly the individual units.

In a big chemical process industry, the processing units are spread over a large area .Although two different units may be far away from each other they are connected by pipelines or the continuous flow of fluid from one unit to another Interconnection between two units is represented by Interconnecting P & IDs Similarly, another engineering document, Utility P & IDs , provides information regarding the distribution of utilities like water ,steam fuel etc. in the required locations. This article deals only with preparation of Process P & ID .

Process P & ID provides detailed information of the process plant like type of equipment , the details of pipelines , i.e. , size material , identification number, types of instruments and controlling devices etc. Operation, start-up, maintenance, safety and aesthetic aspects (discussed below ) are mainly considered during the preparation of process P & ID .

Operation
Process P & ID is prepared following the operational sequence of the process .For example , say a process needs step like chemical reaction , followed by filtration and drying of the product .Process P & ID shows the corresponding equipment like reactor, filter and dryer in the same order . All equipment is to be shown connected with pipelines, fittings and instruments necessary to carry out the process . Clear understanding of the process is very much essential for the preparation of a good quality process.

Process P & ID provides detailed information of the process plant like type of equipment , the details of pipelines , i.e., size material , identification number , types of instruments and controlling devices , etc.

P & ID Elevation of all equipment are normally are normally fixed in the prior stage .Equipment in the Process P & ID are shown at different levels with marked elevations .For example , head tank for reactant is shown above the reactor in Process P & ID for representing the gravity flow of reactant from head tank to the reactor .Likewise , the other equipment like critical pipelines , instruments , control valves etc., is shown at the appropriate elevations .Normally , heavy rotating equipment like pumps , compressors etc., is located at , lower elevation i.e. ground floor .Therefore , rotating equipment is placed at a lower in the Process P & ID also .

Start-up
Start-up of any process plant may need some additional steps which are not required for the normal run. Special care should be taken for such steps at the initial stage of P & ID preparation .For example safety seals in the critical gaseous lines need to be filled with liquid before commissioning of the plant .Valve with hose connection is shown in the process P & ID for liquid seal filling .Critical equipment is by passed using temporary pipeline connections during water test run to avoid contamination .Process P & ID is marked with such types of requirements for the plant start-up.

Maintenance
Maintenance is an important aspects to be looked into during the preparation of Process P & ID .For example , electric hoist required for lifting heavy equipment is shown above it. Bypass line with regulating valve for control valve is provided for talking it out for maintenance without affecting the running plant. Some times it is marked in the P & ID to provide sufficient room for cutout in the floor above the vertical tube bundle from the heat exchanger body . If such type of information is not provided initially , it may be missed out in the various engineering stages and may lead to problems at the later stages . To avoid such possibilities, Process P &ID , should be critically examined from the maintenance point of view during preparation stage .

Safety
For the safe operation of any process plant , safety measures cannot be overlooked .Hence , the preparation of Process P & ID needs the attention of safety aspects also .HAZOP study is carried out keeping in view each and every safety and operation step .For example , the exhaust of obnoxious gases near the plant operators is harmful to their health .Such gases are diffused in the atmosphere at a higher elevation .These safe elevations are normally marked in the process P & ID Safety interlocks are provided to ensure safe operation of the process plant .For example, failure of a running pump for a critical operation may disturb the complete process plant . To avoid this situation , the stand -by pump should be started without any time lag .- Necessary interlock is shown in the process P & ID .Some metallic pipelines and equipment handling hot fluids are insulated for body protection .Here heat saving may not be an important criteria for the selection of insulating , but it is essential for the operators safety .

Such safety requirements are clearly marked in the P & ID .Requirement of safety valves in pressurized system, minimum flow lines for centrifugal pumps , high and low alarms etc. , are to be critically seen during the preparation of Process P & ID .

Aesthetics
Though it is not concerned with the plant operation, aesthetic look of process P & ID is important for better presentation of the document and ease of understanding for the user .Complex presentation of the pipelines, i.e., lots of cross-crossing , may even lead to wrong pipeline routing and hence due attention should be paid to the aesthetic aspect during the preparation of process P & ID.

Process P & ID Preparation

The following documents are essentially required for the preparation.

Making of any Process P & ID

1. Process Flow Diagram (PFD)

2. Equipment List

3. Fluid List

4. Equipment layout

5. Interlock Description

6. Vendor information (for related equipment).

Details of these documents are given in the Annexure. Checklists for vessel,pump, pipeline and instrument are prepared and presented in figs1 to 4.These checklist are self-explanatory and include all essential information to avoid any pitfalls during the preparation of process P & ID.

Although experience plays a major role systematic approach is equally essential for producing error-free process P & ID. Table 1 highlights the major steps for the preparation of any process P & ID.

Typical Example
A hypothetical case is considered here for better understanding of the process P & ID preparation .Before proceeding further , let us first understand about the overall process .

Process Description
Process flow sheet for the selected case is shown in fig.5 In this process the main products is produced by reacting the reactants A and B in a batch reactor (jacketed) 03 R001 A/B/C/D (four numbers) fitted with agitator. Initially fixed amount of reactant B is pumped using transfer pump 02 P001 A/B (one operating + one standby) to the reactor from the storage tank 01T001 .In parallel, reactant A is pumped using transfer pump 01P001 A/B (one operating + one standby) from storage tank 01T001 to the over head tank 03T001 . Prefixed amount of reactant A is fed to the reactor at a constant flow rate during the course of the reaction . Exothermic heat of reaction is removed by cooling water circulating in the jacket of the reactor to maintain the reaction temperature .Homogeneity of the reaction mass is maintained by using an agitator .

Generated gases are continuously removed from the reactor and fed to the waste gas scrubber (packed bed column) 05C001 .Solvent is fed counter currently to the scrubber for absorbing the generated obnoxious gases .Once the batch reaction time is over , product slurry after cooling is transferred to storage tank 04T001 . Later product slurry is pumped by slurry is pumped by slurry pump 04P001A/B (one operating + one standby) to the filter unit 06F001 where the liquid is filtered out and filtered out and filter cake is washed with water Reactant A is recovered in the Recovery unit 07U001 from the filtered liquid and recycled back to the process .Finally product cake is dried in dryer 08H001, pulverized 09A001 and packed for shipment .

Process P & ID Preparation

The enclosed area marked in the process flow sheet (fig 5) has been considered for the preparation of the Process P & ID .Process P & ID (fig.6) is developed based on the steps discussed in table 1 and checklist presented in fig 1 to 4 Line sizing is done for the minimum pressure drop at low cost piping, i.e. economic size of pipeline (this is beyond the scope of this article) .All equipment, instruments and lines are numbered for their identification .For example, 03R001 A represents .Reactor A : 50-FA-03-05-XA1 represents line for reactant A Intel to the reactor (where line size is 50 NB , fluid code is FA, unit number is 03, line number is 05 and pipe class code is X A1). All instrument Society of America standards .

Related Article: Piping & Instrumentation Diagram

Piping and Instrumentation Diagram (P&ID) Layout

The layout of the P&ID should resemble, as far as practicable, that of the process flow diagram. The process relationship of equipment should correspond exactly. Often it is useful to draw equipment in proportion vertically, but to reduce horizontal dimensions to save space and allow room for flow lines between equipment. Crowding information is a common drafting fault - it is desirable to space generously, as more often than not, revisions add

information. On an elevational P&ID, a base line indicating grade or first-floor level can be shown. Critical elevations are noted.For revision purposes, a P&ID is best made on a drawing sheet having a grid system - this is a sheet having letters along one border and numbers along the adjacent border. Thus, references such as "A6", "B5", etc., can be given to an area where a change has been made.

Flow Lines On Piping and Instrumentation Diagram's

All flow lines and interconnections should be shown on P&IDs. Every line should show direction of flow and be labeled to show the area of project, conveyed fluid, line size, piping materialor specification code number (company code) and number of the line.

Interconnecting Piping and Instrumentation Diagram (P&ID)

This drawing shows process and service lines between buildings and units, etc. and serves to link the P&IDs for the individual processes, units or buildings. Like any P&ID, the drawing is not to scale. It resembles the layout of the site plan, which enables line sizes and branching points from headers to be established and assists in planning pipe ways. A P&ID shows all of piping including the physical sequence of branches, reducers, valves, equipment, instrumentation and control interlocks. The P&ID are used to operate the process system.

A Piping and Instrumentation Diagram (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

This figure depict a very small and simplified Piping and Instrumentation Diagram:

Piping and Instrumentation Diagram

A Piping and Instrumentation Diagram (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

Fig. 1 shows the basic types of lines, fitting symbols, and valve symbols used in flow diagrams. Instrumentation Drawing Symbols. Figure 1

Figs. 2 and 3 show the symbols used to denote common process equipment. Again, these are not exhaustive lists, but they contain the majority of symbol types for equipment. Separators and towers, in particular, can have a wide range of internal devices, and this results in many variations of equipment symbols. Similarly, there are different, and yet common, ways of indicating the same types of heat exchangers.

Figure 2

Figure 3 Fig. 4 shows some of the typical symbols used for pumps, compressors, and the devices which are used to drive them. Often, the diagram will show the type of driver associated with a pump or compressor, particularly if the driver is itself part of the overall plant process, such as a steam turbine. If a pump or compressor is shown without a driver, then the conventional understanding is that it is driven by a motor.

Figure 4

Here are some general guidelines: - check valve on pump discharge line - block valves on the discharge and suction side of pumps - drain valve on pump suction - bypass around flow control valves - double block and bleed where necessary - line numbering including line size and mat'l of construction - show set pressure, in- and outlet diameters on PRVs - legend sheets - lines continueing to the next drawing should be at the same height, show drawing nr. - main process lines should be thicker than utility lines - Install flowmeters upstream of a flow control valve. - If your drawing shows elevation, the flowmeter should ideally be installed on the vertical portion of the pipe where flow is going upward. - Install temperature gauge at the outlet of a heat exchanger.