Process and Instrumentation Diagram instrumentation diagram will become.
Development In Water and Waste Water Treatment Different industries tend to use different Plants terminology and presentation of Steven J. Marrano, P.E. technical information. In the chemical Instrumentation and Controls or pharmaceutical sectors of process Engineer control, it is common to have mechanical (or Engineering Flow) diagrams to show major pieces of equipment and associated ratings, and separate process and instrumentation The process and instrumentation diagrams that show how the instruments diagram (“P&ID” as it often called) connect to the process. The water and represents a document that can take on wastewater industry tends to favor a many different forms depending upon hybrid presentation of mechanical and the following factors: instrumentation information on the same drawing. 1) Nature of the process being depicted. The more complicated the process, or the more one process is Process and Instrumentation interconnected to other portions of Diagrams the P&ID, the more complex the P&ID will become. We should begin by reviewing the 2) The individual or firm performing P&ID’s purpose and what information it the design work. Some firms do not depicts. One set of authors1 describes feel the need to develop P&IDs. the P&ID as a “roadmap” to the This approach is used to achieve facility’s design. If we compare the main economies on system design. flow through the plant as the highway 3) Design philosophy. Some design and the various unit processes as philosophies include P&IDs as an secondary roads, we can see that a well item issued with the instrumentation thought out P&ID conveys a great deal or electrical design (developed at the of information to the various members of middle or end of the project). Other the design and operations teams. design philosophies allow the P&IDs to be used as the basis for all other The engineering team developing the design disciplines. In this design of a new facility or an upgrade to philosophy, the electrical, an existing plant selects unit processes mechanical, and piping engineers on that best suit the economic, regulatory, a project would start their work once safety, and convenience criteria set forth the P&IDs are complete. by the plant owner and regulatory 4) Intended audience once the design is agencies. This may be done via a complete. process pilot model and jar testing. 1 Among the several design engineers I Luckiewicz, E., Sandler H: Practical Process Engineering: A Working Approach to Plant have spoken to, these factors dominate Design, Ximix, Philadelphia, PA 1986, pg. 35 tracing depending upon the size of The P&ID is a specialized document that the project. is shown on a side view. P&IDs are a d) Major pieces of mechanical side view representation of a side view equipment (pumps, vendor packages, of all equipment. P&IDs normally do filters, clarification equipment, tanks, not attempt to provide any form of scale etc.). Some designers will also show on their drawings because this is handled installed spare equipment on the on the piping, electrical, mechanical, etc. P&ID. plan drawings. It should be noted that e) Valves and directions of process flow P&IDs sometimes distinguish between f) Field Mounted Instruments- equipment located in different portions Different designers show different of the plant. An example here would be levels of detail on their P&IDs. The a control panel located on the outside of reader should review the discussion a building and how it may be interfaced below for more information via instrumentation to a mechanical g) Electrical equipment- The P&ID component (such as a pump) inside the often shows major pieces of building. As stated above, P&IDs are equipment that require either signal broken out by the unit process operation or power wiring. The reader should to allow sufficient detail to be presented see the discussion below for more on drawings. information. The P&ID will depict the following h) Communications links- The P&ID items2. (Note that this list cannot be all- sometimes shows communications inclusive as no two plants or processes links (software or hard-wired) to the are alike): distributed control system depending a) Material flow- for a water or upon the level of detail and space wastewater facility, this is normally available on the drawings. the fluid being treated. b) Unit process operations- when the P&IDs and the Design Process project has been given further definition, the plant is normally What a P&ID shows depends on the broken down into several portions. design process to be followed and when Some typical portions of a plant may P&IDs are developed. Two approaches include the influent/intake section, to P&ID layout will be considered here. initial treatment (sometimes called pre-treatment), chemical additions, In the first approach, the P&ID is used settling, filtration, flocculation, by all of the disciplines to detail the agitation, mixing, waste components needed to make the process treatment/recycle, storage, etc. operate as intended. Under this c) Piping between the various sections approach, the process designers develop of the plant and process equipment. all of the routing for pipes, pumps, Piping on a P&ID may include valves, etc. The equipment (mechanical) instrument connections or heat engineer then selects his/her equipment in consultation with the process and 2 piping engineers to ensure that process Koslov, J. Schwartz, M: Piping and Instrumentation Diagrams, Chemical objectives can be met. Once these items Engineering Magazine, pp. 85-90, Mc Graw- have been developed, the Hill, New York, July 9, 1984 instrumentation engineer develops how possible. If there are major revisions to the process is to be the project during detailed P&ID monitored/controlled. This task requires development, the P&IDs must be some overlap with the process engineer modified. This adds time and cost to a and the piping designer. As an example, design. One other limitation to this chlorine residual data of water leaving a approach is the project schedule and filter is a state and national monitoring coordination amongst the design team requirement to ensure proper treatment. members. If the P&IDs are not In this situation, the process engineer synchronized with the work of the normally determines that some form of various disciplines, design team chlorine residual measurement is members may use inaccurate needed, while the instrumentation information. engineer determines what method of analyzer will be used. The piping The second approach to P&ID designer will develop input for the development allows the P&IDs to show location of sample piping, where the the instrumentation connections only. sample will be drained to after it is This approach is used when P&IDs are taken, the valves on the analyzer for only used among the instrumentation isolation and maintenance and other designers and engineers (and possibly items (such as pressure regulators or the electrical engineers to double check gages) to facilitate proper operation. instrumentation wiring requirements). The electrical engineer is concerned with These diagrams do not illustrate the power and process control wiring for the same level of detail as the first approach. various pieces of equipment in the They are intended to show how facility. In the chlorine residual instrumentation relates to the process example, the electrical engineer would and possibly show the electrical want to know if the transmitter requires requirements. 120VAC (or if it is a loop powered device) and he/she would want to know The advantage to the second approach is where the signal is wired to (distributed that the documents are less dependent on control system or a local control panel). the other disciplines for information. All of this information is then depicted This leads to simpler drawings that can on the P&ID. be changed without impact to the other members of the design team. The This approach allows a great deal of principle limitation to this approach is input from the various design disciplines that the instrumentation, piping, and before all of the details have been electrical engineers tend to work more worked out. It forces the members of independently of the process engineers. the design team to consider all of the This could lead to situations where issues involving successful critical interfaces are not adequately instrumentation operation. The principle developed. An example can be seen if limitation to the detailed design of one looks at vendor furnished packages P&IDs before detailed design is (such as a chemical feed package for a complete is that the P&IDs must mirror polymer of lime system). If the P&ID the electrical, process, instrumentation only shows instrumentation, it is harder and piping requirements as closely as to tell what piping, electrical, and - Develop the type of mechanical mechanical interfaces may be required. equipment to be used on the project such as metering pumps, distributive Interface Considerations3 pumps, compressors, valves, agitators, mixers, fans/blowers, etc. The detailed design approach requires - Develop details associated with the instrumentation, process, electrical, chemical feed systems such as and mechanical (equipment engineers) to tubing, valves for flow and isolation, supply each other with a great deal of etc. data. Listed below is a partial interface - Selection and layout of piping. checklist for the instrumentation Critical parameters include the engineer developing a P&ID: materials of construction for the pipe, the location of Environmental (Process) Engineers valves/tees/fittings, heat trace requirements, insulation, pipeline - Define the types of unit process sizes, etc. operations in the facility throughout - Develop mechanical equipment the project. numbering system - Develop the process parameters - Develop piping numbering system (normally pressures and flows) - Develop material handling schemes - Define equipment scope (vendor (for items such as cranes to allow furnished package versus individual hoists to move pumps, etc.) components) - Develop special piping for analytical - Develop a general control strategy instruments such as sample and and components to be measured, waste piping interlocked, or trended - Develop special piping for large - Define (with mechanical engineers) valves to allow for mechanical configurations of chemical feed isolation of the valve from the line to systems and other systems related to allow for maintenance. treatment - Develop the necessary utilities (with Electrical Engineers the mechanical engineers) such as air for valves or water for samples, etc. After the piping and mechanical groups have finalized most of their design, the Piping/Mechanical Engineers electrical engineers and instrumentation engineers can begin their work. The Once the unit operations for the facility electrical engineer will have to select have been decided, the piping and and develop power distribution schemes mechanical engineers can begin their for all equipment (when the P&ID shows work. This involves selection and layout equipment horsepower or kW ratings). of all equipment and piping. Depending upon the design firm’s philosophy, the electrical engineer may 3 participate in the wiring of Luckiewicz, E., Sandler H: Practical Process Engineering: A Working Approach to Planrt instrumentation interlocks and may also Design, Ximix, Philadelphia, PA 1986, pp. 36-63 run control wiring from field equipment to the distributed control system (DCS) Example, an ultrasonic level or to the programmable logic controller transmitter may have a level element (PLC). that is interfaced by a cable to an indicating transmitter. Both items Because the electrical engineer’s work is should be shown on the drawings. dependent upon the equipment being - The method of signal transmission specified, it is important that the P&IDs (via an electrical, pneumatic, or be kept up to date to ensure that the digital interface). An example of a quantity, horsepower and control method digital interface would be RS-485 or are adequately shown on these drawings. the Fieldbus protocol. - The measured signal’s location (local In some cases, P&IDs may also show the control panel, distributed control following information: system, vendor furnished mechanical - Type of control required for a given package, motor control center, etc.) piece of equipment (selector - Status inputs from each measured switches, start/stop pushbuttons, signal (analog input, digital input) indicating lights for run/failure - Signals from vendor mechanical conditions, alarms, etc). packages (such as running or failure - Interlocks between mechanical status signals) components - Digital and analog outputs to - Types of communications links equipment (valves, pumps, required between components (the fans/blowers, mixers, agitators, etc.) electrical engineer will be concerned for control by the PLC or DCS with the routing and possibly the termination of this wiring) Structural/Civil Engineers
Instrument Engineers - P&IDs (coupled with a mechanical
plan drawing) provide a general Instrumentation and controls engineers picture for structural requirements have the difficult task of pulling together associated with piping support, all of the information developed by the equipment housekeeping pads process, piping/mechanical, and (quantity), supports or pads for electrical into a cohesive representation vessels (such as chemical bulk tanks of the process. in large water/waste water treatment facilities). Sometimes, P&IDs also On any project, it is recommended that show items like containment areas the process engineer get the for chemicals. These types of details instrumentation and controls engineer are important for the civil/structural involved in P&ID development as early engineer so that the engineer can as possible to ensure that all of the plan their concrete drawings. process goals can be accomplished. The - critical interface points that would be shown on the detailed P&ID are: Checklists for Piping and Instrumentation Diagrams - The location of the various measurements on equipment. 1) General Documentation Practices a) At the beginning of the project, Area 800- Clearwell/Storage some form of agreed to set of Area 900- Utilities (such as abbreviations should be electrical equipment) developed for every piece of process, mechanical, and After these general numbering electrical device systems are established, the Examples: subsequent numbers in the tag A- Agitator can be selected sequentially, P- Pump based on an equipment number, M- Mixer (or motor) or by any other scheme that the F- Filter mechanical, electrical, and FL- Flocculator instrumentation design team members decide to use. b) An agreed to pipe numbering scheme should be developed. We note that there is really no Example: some companies may right or wrong way to number list a pipe’s unique tag by where instruments. Consistency the pipe comes from, where it amongst the instrument tags is of goes to, the line size of the pipe, primary importance. Once a and materials of construction. convention is selected, the user This ensures that all parties know should ensure that everyone where components are to be understands and uses the placed in the piping system. numbering convention. c) Some form of instrument numbering system should be d) Some form of standard symbols employed on the project so that should be selected and presented engineers, designers, and on the cover page for: installers can understand where a i) Valves piece of equipment goes. It is ii) Piping important to recognize that this iii) Fittings on pipe instrument tag number should be iv) Motors stamped on a tag when the v) Pumps instrument is installed in the field vi) Vendor furnished packaged to allow for some form of record equipment keeping during construction and vii) Tanks installation. Examples (applicable to a surface e) The design team should pick water treatment plant): what level of detail will be Area 100- Intake Structure shown on the P&ID as far as Area 200- Mixing interlocks, connections to the Area 300- Flocculation DCS/PLC system, and other Area 400- Pre- Treatment items are concerned. This choice Area 500- Filtration can effect the level of detail to be Area 600- Post Chemical shown on the P&IDs. When a Treatment design team places all the Area 700- Distributive Pumping interlocks between devices on the P&ID, the interconnection panel mounted, a certain symbol between devices is clearly is used to denote this. Functions defined. This approach has the developed in the distributed limitation that drawings can control or PLC system are based quickly become crowded and on whether or not the signal is difficult to read. A drawing software generated and whether showing all the interlocks also or not a human operator can has the tendency to be difficult to adjust or display the value. change once drafted. This leads g) Some form of convention should to increase drafting and design be chosen as to the line types for time. The other approach signal transmission. Example, sometimes used by design teams ISA has standards for pneumatic, involves showing the quantity electric (discrete or analog), and and type of I/O that go from a distributed control signal wiring. device back to the DCS or PLC. These different line types enable This approach simplifies the the reader to understand when a drawing presentation. Its signal is generated by a physical principle limitation is that the device (transducer, converter, interconnection between devices transmitter, switch, relay, (for interlocking, alarm function module, etc.) or is conditions, etc.) is not defined. generated by the distributed Another document (such as a control or programmable logic loop drawing or interconnection control system (via a software diagram) must be provided to function). A simple example of illustrate how all of the this representation can be seen components are connected. when one examines a level Another limitation of this transmitter interfaced to an approach stems from the large analog input on a distributed amounts of coordination between control system. The signal is P&ID, loop drawings, electrical normally electrical (from the drawings, and mechanical field back to the analog input) in equipment specifications. the form of a twisted shielded Because all of these drawings pair cable. We would then note involve different components of that we may use the distributed the project team, an control system to develop uncoordinated change by any calculations for high, low, high- group can lead to confusion and high, or low-low alarm states. equipment mismatch. Therefore This is normally accomplished in this approach requires more software. coordination than the other form of P&ID presentation. h) Some form of convention should f) Some form of symbol for the be developed when a process measurement and the associated flow stream affects different destination must be shown. For portions of the process appearing example, if an instrument on different P&IDs. consists of a transmitter that is i) Some way to ensure that an easy way to verify the additional space is left between quantity and type of I/O. the components must be VI) A layer for signal type addressed. It is common practice (pneumatic, software, to leave a minimum of 3/8” of electrical, etc.) to allow space around pieces of the reader to distinguish equipment between the various signal types. j) If drawings are done on some VII) A layer for items such as form of CAD program, some control panels (if these form of layering system should items are found on a be developed to make the P&ID). Control panels drawings more "intelligent" by are commonly used on allowing different users to find items like chemical different pieces of information systems where the quickly. Some sub-classes of amount of product in a layers may include, but not be tank must be known by limited to: the plant maintenance person and the signal is I) Equipment (distinguish sent to the distributed between process and non- control or PLC system for process equipment with inventory control and unique layer numbers). monitoring. Examples include tanks, pumps, mixers, agitators, 2) After documentation procedures etc. have been established, a structured II) A layer for all piping presentation for information flow III) A layer for all valves- must be developed. In this instance care should be taken to “information flow” refers to data ensure that electrically associated with how one signal or operated valves (motor alarm affects another piece of operated valves) are equipment in addition to data distinguished from associated with device wiring (type pneumatic valves or of I/O, which PLC the device is manual valves. wired to, etc). Many design teams IV) A layer for process text prefer to break out the wiring V) A layer for field mounted information into a “loop style” instrumentation. It is drawing. The term “loop drawing” often useful to segregate is somewhat misleading because it input and output types by tends to imply the current loop found layer. For example, a in analog instrumentation. Many separate layer for analog loop drawings also show discrete inputs and outputs should instrumentation (such as a switch or be used to allow the contact closure) for completeness. A instrumentation engineer complete loop drawing will illustrate how various devices are interconnected. For example, it is control. These should be shown possible that an analog transmitter on either the P&ID or the loop may be given an adjustable contact drawing. In addition some form designed to open or close at some of running status feedback should alarm point. For safety reasons, we be shown. may wish to connect this contact b) Distributive Pumps- Show some directly from the transmitter to the form of start and stop control, mechanical equipment it affects (say interlocks to other equipment or a motor starter connected to a pump). instrumentation, and some form In this instance, the loop drawing of speed control where the pump should not only show the twisted is used in a variable speed shielded wiring from the 4-20mA application. Where multiple transmitter back to the analog input sources of control are available in the DCS, but that a contact closure (such as local start stop at the is interfaced to a motor starter as equipment, start/stop at a motor well. Note that this same control center or switch board, information can be shown on a P&ID and start stop from the by using some form of symbol distributed control system), the (typically a diamond) to denote an P&ID may illustrate all of these interlock. Interlocks on a P&ID functions. Some design firms should be labeled for additional prefer to use the loop drawing clarity and a brief description should with interconnection information. be given. The P&ID should also show 3) On larger projects where a some form of running or failure distributed control or PLC system status (developed at the local performs a great deal of the pump controls or sent to the interlocks via software generated distributed control system for calculations, it is sometimes helpful further action). On pumping to separate out the wiring installations, all of the suction information shown on a loop and discharge piping should be drawing from the functional software shown. If there are interlocks manipulations done in a distributed between the pumps and the control system. The principle valves, the designer should limitation here stems from the decide if the pump interlocks will additional coordination between be shown on the P&ID or will be wiring and interlock requirements. shown on the loop drawings. 4) Critical pieces of equipment to show c) Tanks- Show some form of level on a P&ID: (assumes the P&ID will instrumentation, all valves be used for other detailed design (electrically operated, pneumatic, work: and manual). Agitators or mixers a) Agitators/Mixers/Flocculators- should be shown on a tank if this Show some form of start and stop is how they are to be used in the control, some form of speed field. control. Some installations show d) Pipes- Show heat tracing, the available local controls such pressure gages, all valves, flow as start and stop plus speed meters, direction of material flow throughout the facility, pipe line analog or digital signal ) from the size, pipe line number (see DCS or PLC. discussion above), and pipe f) Flowmeters- The P&ID should material (if applicable). If the show the size of the meter, the pipe continue on another P&ID type of meter to be used (such as some form of connector should a magmeter, venturi, or turbine be used to tell the user where the meter). The P&ID should pipe is picked up elsewhere. It is illustrate strainers to ensure that also important to show items like debris cannot enter the spool pieces if they will effect flowmeter. On large flowmeters items such as flow (above 16 inches) it is common instrumentation for upstream and practice to have some sort of downstream runs of pipe. bypass piping around the meter e) Valves- Show the various types to allow it to be removed from of control available from the service without shutting the valve. This includes the hand station down. In many instances switches on the valve allowing it the flow device and the to be opened and closed at the transmitter are not mounted in valve and connections to a the same housing. A good distributed control or PLC example of this is the venturi system to allow for remote meter. The venturi should be opening and closing. In some treated as a flow element because plants, the open/close status of a differential pressure is the valve is shown both in the developed from the incoming field and in the distributed flow. This differential pressure is control room. Some P&ID supplied to a transmitter for designs also incorporate items status, remote monitoring, and such as an intermediate position remote control as required. The switch on the valve to indicate transmitter would be treated as a that the valve is travelling. The separate bubble on the P&ID. user should determine if valve g) Pressure or Differential Pressure interlocks to other equipment Instruments- The P&ID should will be shown on the P&ID or show the location of these will be shown on the loop instruments. For deep buried drawing. On larger valves (such wells where a pressure transducer as an intake above 16 inches), is used, some form of pressure some form of bypass manifold element should be shown on the should be provided to allow the P&ID in addition to some form valve to be removed from the of indicator. Note that the line for maintenance. If the pressure element (also called the valve is of the modulating type, pressure transducer) is treated as some form of position status a different instrument bubble on should be shown on the P&ID in the P&ID (as described with the addition to the ability to control flowmeter above). Interlocks to the valve position (either by an other items in the plant should be properly documented on the P&ID or on the instrument loop representation of a P&ID and the drawings. The P&ID should appropriate functions. First, we will illustrate some form of block and use a simple well station design to bleed valve to allow the illustrate a case where all control instrument to be calibrated or design information is shown on the removed from service for P&ID (useful for a small project). maintenance without disturbing Next, we will show a possible the plant or the process. Note interface between the P&ID and the that a pressure gage should be loop drawing for part of a process. shown with some form of snubber and some form of isolating device to allow it to be removed from the line without shutting down the process. h) Metering Pumps- Some form of speed control should be shown to every metering pump that is run based on some other process variable (an analyzer or flow for example). The P&ID should show which forms of local and remote control to allow the metering pump to be started, stopped, or remotely controlled from a DCS or PLC. Some P&IDs also illustrate the metering pump running status (if available from the metering pump manufacturer). i) Packaged Equipment- Show all of the status points (both analog and digital values) connected to a local control panel and sent back to the distributed control system. If there are special valve manifolds or interlocks to other pieces of process equipment, the designer must decide what level of detail is to be shown on the P&ID and what level of detail is to be shown on the loop drawing.
An Illustrative Example
It is best to start with some form of
example to show one possible control and use an analyzer to "trim"
the amount of material that the
metering pump is allowed to
Figure 1- Typical P&ID for Small Plant
dispense. Note that in this example, most of the interlocking is shown. In some cases, this will not be possible because of the number of process units involved, the number of interlocks required, or the drawing legibility/pace constraints. Because this involves only one well, no piping line numbers were assigned.
As an example, let us assume that
there are multiple chemical systems in a plant and we wish to develop a strategy for controlling the metering pumps. It is decided that we will make flow the primary variable for References Note that the various letters show ANSI/ISA Standard S-5.01 various functions performed by "instrumentation Symbols and either the DCS or the field Identification" instrument. ISA Standard S-5.1 allows each letter to have a different meaning depending upon its position in the instrument tag. For example, when the letter "S" is used in the first position, it is assumed that we are measuring frequency or speed. When the letter "S" is used in the second position, we are designating a switch (such as FS for flow switch). The same for a letter like L. When used in the first position of an instrument tag, it is understood we are measuring level. In latter positions of a tag, such as FSL, it is understood that "L" is being used as a modifier for the LOW state. In the case of FSL, we mean that the flow switch will become energized when flow is low.