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P-ID - Basics PDF
P-ID - Basics PDF
Engineering Practice
I NS ND CO
Loop Piping model
diagram
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ME TROL
Principles of
NTA
PIP
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Isometrics
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Alarm
table
Mechanical
The tips provided here will streamline efforts to data sheets
ME
develop piping & instrumentation diagrams
ESS
C
HA
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NIC
PR
Mohammad Toghraei
AL
Consultant Process
data sheets
FIGURE 2. Before a detailed P&ID can be developed, a BFD and PFD must be devel-
oped to identify the major aspects of the process. The BFD identifies primary streams FIGURE 4. The startup of a reversible
and unit operations. The PFD expands each BFD block, adding tanks, pumps and system often requires a recirculation
some instrumentation. The P&ID pulls it together with fuller details loop; it should be sized appropriately to
minimize costs
A plant with: (to ensure ease of op- All given elements must be de-
r-PXDBQJUBMBOE eration and flexibility), signed to allow them to be appro-
operating expenses
r2VJDLDPOTUSVDUJPO
while meeting all local priately isolated, drained, vented,
r1SPQFSPQFSBUJPO environmental and safety cleaned and flushed (via purging,
Environmental Owner
health and regulatory requirements steaming, or water flushing).
safety (EHS) (Figure 3). 4.Provisions must be made to mini-
codes mize the impact on the rest of
1MBOU Essential elements plant when an item, equipment or
Ideally, the specific ele- unit is out of operation.
Designer Operator ments captured in any The following points should be con-
P&ID should account for sidered when adding different items
A plant with comercially A plant with: full functionality of the to address any of the above four re-
established design r&BTFPGPQFSBUJPO
QSPDFEVSFT r4BGFPQFSBUJPO
plant in all stages of the quirements:
plant lifecycle, as outlined 1.Make sure that no added element
below: within one stage of the plant’s
FIGURE 3. CPI facilities require cooperation 1. All given elements — lifecycle will jeopardize another
among three parties. Each has its own responsibili- including equipment item’s function. For example, add-
ties but EHS requirements are common to all and piping items — ing bypass capabilities with a
must operate well and manual block valve for a safety-
P&ID provides more detailed ele- reliably during normal opera- related switching valve (for the
ments, capturing the real plant on tion, within the window of oper- purpose of making the plant op-
paper while ignoring the scale. ating conditions that is expected erational when the switching
Despite the simplified drawing at the plant. A basic process con- valve is out for maintenance, per
shown in Figure 2, P&ID develop- trol system (BPCS) should be Item 4 from the list above) could
ment goes beyond just expanding implemented to bring parameters jeopardize the operation of the
the PFD. There are some small items within normal conditions. The switching valve in an SIS; that is,
that are not shown but that need to five key parameters of chemical the bypass could be left open and
be developed by the designer for the process operations (temperature, therefore create a safety flaw).
P&ID. Still, the development of the pressure, flowrate, level and com- 2.Decide if added items can be
BFD and PFD requires exhaustive position) may need to be “adjusted” “merged” with each other or not.
studies and rigorous calculations continuously by the actions of the This basically involves check-
and simulations. Going through BPCS to ensure that they meet ing if a single shared item can
these “preliminary” efforts and not the requirements at the inlet and address multiple requirements
bypassing BFD and PFD develop- outlet of each component. within the plant lifecycle or not.
ment is essential, because every 2.The element operates well dur- Whenever possible, items should
single decision for main items on ing non-normal conditions, such be “merged” or “shared” to make
the PFD could have a big impact on as under reduced-capacity condi- the most of capital and opera-
the project. tions, and during process upsets, tional costs. In certain cases, this
startup and shutdown. Engineer- can be justified, especially when
The main goal of a facility ing provisions for working reliably an item needs to be added for the
The main goal of a process plant during low-capacity operating purpose of satisfying Item 3 or 4
is to produce desired quantities conditions, the use of safety-in- above. As these specific compo-
of various products while meet- strumented systems (SIS) to shut nents are not in use all the time,
ing stated quality goals. A sound down the system, and safety-relief a good process engineer will at-
plant design will take into consid- valves are examples of the types of tempt to “merge” them with other
eration the owner’s wishes for the items that can address this stage items so they can carry out mul-
plant (for instance, low capital and of plant lifecycle in P&ID develop- tiple functions.
operating expenses, the ability to ment activities. However, this last practice
build it quickly and so forth), the 3.There are enough provisions to cannot be carried out in all situ-
designer’s requirements (that the ensure ease of inspection and ations. From a redundancy point
design procedures can be trustwor- maintenance; these include in- of view, it is not always good to
thy and commercially established) situ inspection, ex-situ inspection, expect one item to carry out mul-
and the operator’s requirements workshop maintenance and more. tiple duties. Technically, one item
CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2014 63
Engineering Practice
t.VMUJQMFESBJOTBOEWFOUTTIPVMECFJNQMFNFOUFEJOBDPW-
FSFEBSFBUPFOTVSFESBJOJOHPSWFOUJOHXJUIJOBSFBTPOBCMF tp = 2 years tm = 1 year tp = 2 years
UJNF
tm = time between
t8IFOUIFTZTUFNJTTNBMMESBJOWFOU VTVBMMZGPSQJQFT each maintenance, inspection or cleaning event
JO
BOEUIFSFJTOPOFFEGPSEFEJDBUFEWFOUTPSESBJOT
t5IFESBJOPSWFOUTIPVMECFSPVUFEUPBTBGFMPDBUJPO IBSE tp = time between
each plant overhaul or turnaround
QJQFE
JGSFRVJSFE
TABLE 2. OPTIONS FOR ISOLATING A PORTION OF THE PROCESS for normal operation for the pur-
FROM THE PLANT pose of startup recirculation is so
Type Symbol Credibility strong that some process engineers
1 Block valve Not forget to think about the startup op-
(with or without lock) Process acceptable eration during the development of
2 Block valve the P&ID; they simply assume they
(with lock) and blind Process will find a way to accommodate
Safer isolation
3 Double block valve startup somehow without actually
(with lock) and bleed Process planning for it.
Upset conditions. Upset conditions
4 Block valve
can be defined as operation of the
(with lock) and blind Process plant when some of the process pa-
and removable spool rameters are beyond the normal
band. In Figure 5, this situation
is arbitrarily split into two differ-
TABLE 3. DIFFERENT METHODS OF REMOVING MATERIAL ent cases — mild upset and severe
FROM EQUIPMENT FOR INSPECTION OR MAINTENANCE
upset — for any of the five key pa-
Type of Removal method P&ID rameters (flowrate, pressure, tem-
“dirt” perature, level, and composition). In
1 Solid/ t.BOVBM t/PUIJOHJTOFFEFEPO1*% both cases, during upset conditions,
semi-solid: t.BDIJOFBT- t%PXFOFFEiDMFBOPVUwEPPST the process goals have already been
removal sisted
lost so the immediate goal is to
2 Liquids: t'MVTIJOH#Z 'PSBMMUIFDBTFT
UISFFPQUJPOTBSF protect the equipment (hardware
8BTIJOH water BWBJMBCMFUPTIPXPOUIF1*%
conservation) and the health and
t4UFBNJOHPVU 0OMZXBTIJOHWBMWFT
#ZVUJMJUZTUFBN 8BTIJOHWBMWFTUIBUBSFIBSEQJQFE safety of the personnel and neigh-
t$IFNJDBM )BSEQJQFEXBTIJOHTZTUFNXJUI boring communities.
DMFBOJOH#Z TXJUDIJOHWBMWFTGPSBVUPNBUJD To address point upset conditions,
chemical solu- XBTIJOH the facility should be equipped with
tion or solvents
an alarm system and a SIS. The
3 Gases: t/FVUSBMHBT t*GJUJTCZJOFSUHBT
UIFTBNFPQUJPOT alarm setpoints are usually on the
1VSHJOH QVSHJOH GPSiXBTIJOHw BCPWFPQUJPOT
BSF
maximum (or minimum, in some
t7FOUJMBUJPO available here
t'PSWFOUJMBUJPO CZOBUVSBMESBGUPG cases) value of a parameter, and the
BJS
JNBLFTVSFUIFSFBSFBUMFBTU SIS action will be set to the high-
nozzles are available high (or low-low) level. However,
some additional alarm setpoints
For reversible systems (such as sively large circulation loops, so as or additional SIS setpoints can be
reactors that carry out equilibrium not to waste money for piping that added, too.
reactions), startup operation can be is supposed to be used only during The purpose of this SIS action is
supported by recirculation. If the startup. As much as possible, the to shut down a plant and bring it in
system is not reversible, the startup design should try to use the existing the lowest energy state (in terms of
operations can be more complicated pipe arrangement for the purpose lowest pressure, lowest temperature
and case-specific. Figure 4 shows of startup recirculation, especially and so on) Other than “event-based
the basics of this procedure. when high-bore pipe is needed to SIS” explained above, SIS action(s)
If recirculation is to be used dur- support startup efforts. can also be activated by the opera-
ing the startup procedure, efforts The tendency to use the piping ar- tor. This shutdown is named “opera-
should be made to avoid exces- rangement that was implemented tor activated SIS.”
CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2014 65
TABLE 4. EXAMPLES OF REMOVABLE SPOOLS (RS)
Item Potential P&ID example
Engineering Practice location of RS
Centrifugal Suction and PG
PG
pump discharge side
Making sure the suction pressure (and tempera- It needs some calculations. The impact on P&ID could be seen
ture) is enough. This reflects the sensitivity of on suitable in upstream container of pump
centrifugal pumps towards NPSH
Showing the pump’s BPCS for capacity control of FT FC
pump FE FV
FO
S/S COMMAND
Adding pump driver control PM RUN STATUS
115 COMMON TROUBLE ALARM
L/R STATUS STOP
SHUT DOWN COMMAND
S/S
HS
H/O/A
MCC HS FT FC
FE FV
M
FO
Non-normal condition
FE FV
M
FO
FE FE FV
M
FO
FO
Continues on pg. 69
media levels, or peep holes to check these may include portable pres- may include, for example, a pres-
the color and shape of flames in a sure gages, temperature sensors sure tapping (PT) point, or temper-
furnace or boiler. and so on. The P&ID designer may ature point (TP), to be shown on the
In terms of the use of small, por- decide to provide some “test points” P&ID. An example of PT location
table measuring devices that can be instead of fixed gages, to save some could be the suction side of centrifu-
used by operators making rounds, money in non-critical points. This gal pumps. The decision must be
CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2014 67
Engineering Practice
made to either use test points and viding isolation valves is not nec- tions.” This means having provi-
fixed gages that transmit informa- essary for all the equipment in a sions that will allow all five key
tion to the control room, or to imple- plant. Isolation valves are required process parameters to be brought
ment a control loop that depends on to isolate the equipment from the into a safe range:
some parameters based on the criti- rest of the plant if the equipment t&OTVSJOH TBGF UFNQFSBUVSFT
cality of the parameter. is expected to need “off-line care” Options include allowing time
Meanwhile, in-place, off-line care at frequent intervals, in time du- lapses, or options for cooling down
may include chemical or solvent rations that are shorter than the (or warming up, in the case of
cleaning, steaming-out, pigging op- scheduled plant turnaround times). cryogenic services) streams. For
erations and so on. Depending on For instance, if (based on histori- some systems (for instance some
the operation-specific requirements, cal data), the unit expects to need batch operations) that require a
different items should be imple- off-line care every three years but more rapid cooling (or warming)
mented (such as chemical cleaning the entire facility for which you by cooling streams
of valves). are developing the P&ID will need t.BLJOH QSFTTVSF TBGF7FOUJOH JT
For all off-line care a specific ar- planned turnaround work every widely used
rangement must be made to ensure two years, there is no need (at t&OTVSJOH BQQSPQSJBUF GMPXSBUFT
positive isolation of the system from least theoretically) to put isolation As long as equipment is isolated
the rest of the plant. This arrange- valves upstream and downstream from the rest of the plant, there is
ment typically comprises isolation of the unit. This concept is shown no flow going into it, and it is not
valves, drains, vent valves and so on. in Figure 6. a point of concern
The isolation system is discussed in In some cases, companies don’t t.BLJOH MFWFMT TBGF %SBJOBHF PQ-
greater detail below. provide isolation systems for es- tions are needed for tanks, vessels,
For in-workshop care, the provi- sential equipment, such as heat QVNQDBTJOHBOENPSF4PNFHFO-
sions defined by in the P&ID are exchangers. The logic is that they eral rules for sizing and installing
items that will allow the equipment essentially cannot afford to put the drain and vents are in the Box (p.
to be removed from their founda- heat exchanger out of service, so 65)
tion easily and safely. However, adding isolation valves would be ir- t5P FOTVSF TBGF DPNQPTJUJPOT
UIF
the characteristics to satisfy this relevant. body of the equipment (external
requirement are not always shown The answer to the second question and/or internal) must be safe in
on P&IDs (mainly to avoid clutter- is that the isolation system should terms of exposure. These provi-
ing of the P&ID). For example, if be added on all downstream or up- sions involve proper cleaning of
equipment needs to be hoisted for stream connecting pipes, as close as the equipment.
removal, this engineering detail is possible to the equipment. However, Table 5 shows options for mak-
often not shown in the P&ID. Items some companies challenge this and ing the composition safe for dif-
that must be shown on the P&ID in- question if there is real needed to ferent types of materials inside
clude the following: put isolation valves on, for example, of the equipment. Washing and
t*TPMBUJPO WBMWFT UIBU BMMPX UIF a vent pipe to atmosphere or not. purging (through ventilation) are
equipment components to be de- To answer the third question, especially important for walk-in
tached from the rest of the plant it should be stated that there are equipment.
t%SBJOTBOEWFOUT different type of isolation systems. The last step as mentioned above
t3FNPWBCMFTQPPMT 34
UIBUXPVME Table 3 summarizes these methods. JTUPQSPWJEFSFNPWBCMFTQPPMT 34
be used around the equipment to Decision needs to be made about 4PNFUJNFTSFRVJSFE34BSFBMSFBEZ
allow it to be “untangled” from the the type of isolation method. The present due to previous activities
system by removing the piping sys- isolation method depends on fac- on the P&ID. Table 4 provides some
tem interference; this allows for tors, such as the equipment envi- examples.
easy equipment transfer to ronment (for instance, for confined Allocating a utility station in dif-
the workshop spaces or non-confined spaces), ferent locations of the plant, and de-
When it comes to preparing for the fluid type (aggressive or toxic ciding about the required utilities
off-line care, with regard to de- or not), and the pressure and tem- for each utility station, is another
signing isolation systems, the fol- perature of the system. Usually the activity to address this stage of the
lowing three questions should be first type of isolation (Table 2) does plant lifecycle.
answered: not provide enough “positiveness.” 4. Operability of the plant in the
1.To which equipment should the Possibly the only application of this absence of one item. The designer
isolation elements be added? isolation method is for instruments. needs to decide the impact of equip-
2.Where do they need to be placed In such an application, the isolation ment loss on the rest of plant opera-
“around” the equipment? valve is called a root valve. tions and take engineering steps to
3.Which types of isolation systems The next step for making equip- minimize its impact. The wide range
or elements should be used? ment ready for periodic removal is of answers and decisions should in-
To answer the first question, pro- to bring it to “non-harmful condi- clude the following:
68 CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2014
TABLE 6. AN EXAMPLE OF P&ID DEVELOPMENT FOR A PUMP (FOUR PHASES OF OPERATION) (continued)
Case P&ID
Maintenance / Inspection
Adding a pressure gage on discharge and/or
FC
suction side
FV
FO S/S COMMAND
PM RUN STATUS
115 COMMON TROUBLE ALARM
L/R STATUS STOP
SHUT DOWN COMMAND
S/S
HS
H/O/A
I MCC HS FT FT FC
436
PG FE FE FV
PG M
FO
FO
FO
Consider the use of a piping spool piece to facili- It is already created and exists
tate dismantling
Installing pump insulation for personal protection Service temperature is 40°C and there is no need for personnel
protection insulation
Production interruption
Define the pump sparing philosophy Based on RAM analysis, a second pump with the same arrange-
ment is added (to provide 2 x 100% capacity)
1.A parallel, exactly similar spare to the alternate component in- 5.The storage tanks upstream and
system can take care of flow that stead. Examples include having a downstream of the component
would result from the loss of a given manual throttling valve (such as should have enough residence
component. Examples include spare a globe valve) in the bypass line time to continue operations. This
pumps or spare heat exchangers of a control valve, or placing a by- way, if the component goes out
(in highly fouling services). The pass line for a PSV together with of service, the upstream string
installation of spare equipment a pressure gage (or pressure tap- of equipment can still feed the
is popular for fluid-moving equip- ping) and a globe valve. upstream tank and downstream
ment, since interruption of service 3.The feed to the equipment can be components can still be fed by
in pumps and compressors cannot simply bypassed temporarily with the downstream tank. This ar-
be handled through other below marginal impact on the operation rangement will prevent a surge
options. One important example is of the system. that could impact connected plant
having two fire pumps installed in 4.The feed to the equipment can components.
parallel, with two different types be redirected temporarily to an 6.The feed to the equipment is re-
of drives (for instance one with an “emergency reservoir” (such as a directed temporarily to a waste-
electromotor and the other using a tank or pond), and processed later receiving system or flare.
diesel drive pump). by returning it back to the system. 7.Whole plant or unit should shut
2.A parallel component can be used Usually this option is available for down: This option should be
and the flow can be redirected liquid streams. avoided, if possible. However,
CHEMICAL ENGINEERING WWW.CHE.COM APRIL 2014 69
Engineering Practice
Please visit REMBE®, INC. at PTXi Conference & Exhibition, Rosemont, May 6-8, 2014, booth 1228
insufficient “facility resources” is dif- tion and control system, things
ficult to operate.However, from the become more debatable. The three
other side, this is also the case for a main items of integrated control
plant with more than enough pipe and safety system (ICSS) elements
circuits, control valves, alarms and are: Regulatory control system
SIS actions. For example, a plant (BPCS), the alarm system and the
with too many alarms can “overload” SIS. Almost everyone agrees about
the operator and result in a loss of basic process control items should
urgency from the operator when an be shown on the P&IDs. They are
alarm does activate (Figure 7). mainly the elements of the control
“Adding more doesn’t hurt.” This is loops. For alarming systems, the
a popular statement when P&ID same clarity exists. The main de-
developers try to “bypass” conduct- bate is usually on SIS systems, in
ing a rigorous evaluation for the terms of the question of “down to
necessity of an item on the system, which level of detail the safety in-
and thus place it with no real ne- terlock loops should be shown on
cessity. However, designers should the P&IDs?”
remember that in some cases, add- Different companies follow differ-
ing an item might not necessar- ent directions.
ily increase the capital cost of the “Based on my past experience...” The
project — if the item is small and inherent creativity required in cre-
relatively inexpensive — but may ating P&IDs may become hindered,
still increase the operating cost be- if for every single case one refers
cause of required inspection, main- to “past experience.” As unlikely as
tenance, related utility and chemi- it may seem, the “this is what has
cal usage and more. In addition been done before” mentality is not
to that, any new item added to the the most efficient way of developing
system provides a new opportunity this document. That being said, the
for mistakes, cross -contamination, technological innovations, availabil-
leaks and other problems. ity of materials, quality of raw ma-
“Should I add it here on the P&ID terials, required quality of products, Circle 24 on p. 76 or go to adlinks.che.com/50975-24