Background for P&ID Check (Process)

Purpose)
This background is used for P&ID check which is performed by GES engineer and this
document explains general rule for indication of P&ID.
(Note) Indication of P&ID shall be represented based on project specification.

[P&ID]
P&ID means “Piping and Instrument Diagram” and P&ID is prepared based on PFD (Process
Flow Diagram).

1. General
P&ID is composed of the following drawings.

(1) Lead Sheet : Symbols/Lines/変数/簡略図 of instrument system are difined in Lead Sheet

(2) P&ID : Process Unit / Utility Facility / Offsite Facilities with Equipment / Piping /
Instrument

(3) Header Diagram (= Distribution Diagram) : For Utility Header (Steam / BFW / Steam
Condensate / Cooling Water / Plant Water / Potable Water / Plant Air / Instrument Air /
Nitrogen / Fuel Oil / Fuel Gas , etc)

(i) For Flare System

(*) The following flare is equipped for treat special service.
Sour Flare : Acid gas, such as H2S gas. Steam trace is required in order to avoid
condensation of water
High Pressure Flare is considered for relieving from high-pressure-service in order to
decrease cost.
Cold Flare : treat low-temperature relieving gas. Material shall be selected for low-
temperature.

(ii) For Blow Down System / Drain Recovery System / Slop Oil Recovery System / Flushing
Oil System
(*)The followings are drain recovery systems.
Hydrocarbon Oil Recovery System: Recovered hydrocarbon is mixed with feed or is
treated by incineration.
Solvent Recovery System: Solvent is recovered from absorber and is recycled.
Harmful Fluid Recovery System: Harmful component, such as benzene, is recovered
and recovered harmful fluid is mixed with feed,
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 basically.
Chemical Sewer Recovery System : Chemical, such as waste acidity or waste alkali is
recovered and is treaded by neutralization.
Then, neutralized waste is disposed as waste
water.
Clean Water Sewer System : Waste water which does not includes oil, such as rain
water, is treated
Oily Waste Sewer System : Oily waste water is recovered and treated in order to
remove oil.

(4) Interconnecting Diagram : Interconnecting Diagram indicates piping on pipe rack / pipe
sleeper between units.

(5) Vendor P&ID : Vendor P&ID is prepared by vendor of equipment and it shows detail of
required piping/instrument/etc.

2. Configuration / Symbols of P&ID

The followings are general rule of configuration of P&ID.
(1) Equipments
Equipments are located on P&ID as per the following basic rule.
Upper Side of P&ID : Condenser / AFC / Reflux Drum
Middle of P&ID : Column / Vessel / Heat Exchanger
Lower Side of P&ID : Pump

(2) Piping
The followings are piping symbols which indicate service of lines.

Piping / Fittings is represented on P&ID for the following purpose.

- Normal operation
- Start up / Shut down operation
- Special operation
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 - For operation of equipments
- Maintenance
- Emergency
- Drain system
- Vent system
- Other systems for safety
- Sampling

(2) Instrument
The followings are instrument signal symbols which indicate service of lines.

(i) Instrument is represented on P&ID in order to indicate the following function.

- Controller / Indicator for normal operation

- Controller / Indicator for Start up / Shut down operation
- Controller / Indicator for Special operation
- Alarm for abnormal condition
- Interlock System
- Emergency Shutdown System, such as Interlock / Emergency Stop of Compressor,
Emergency shutdown of furnace, Emergency depressuring, Emergency isolation for
leakage from pump mechanical seal.
- Sequence control for automatic operation
- Instrument at site

(ii) The followings are instrument to be represented on P&ID.

- Level Gage / Temperature Gage / Pressure Gage
- Level Transmitter / Level Switch
- Flow Element / Transmitter
- Temperature Element / Transmitter
- Control Valve / Shutdown Valve
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 - Pressure Safety Valve
- On-line Analizer

3. Line Connection of P&ID

(1) Process Line
Generally, line is indicated as below.
Upstream : Left side of P&ID
Downstream : Right side of P&ID
Flow is indicated from left side to right side of P&ID.

(2) Utility Line

Utility line can be connected from upper / lower / left / right side of P&ID.

4. Indication of Piping on P&ID

(1) Line Number
Line number is consisted with the following items.

(i) Line Size (ex. 8”)

(ii) Fluid Symbol
(ex.)
P : Process Fluid
SH : High Pressure Steam
SM : Middle Pressure Steam
SL : Low Pressure Steam
WB : Boiler Feed Water
WCS : Cooling Water Supply
WCR : Cooling Water Return
NG : Nitrogen Gas
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FG : Fuel Gas
AI : Instrument Air
(iii) Unit Number (ex. 01)
(iv) Line Serial Number (ex. 011)
(v) Piping Service Class : specified based on Rating / Material / Corrosion Allowance /
Service
(ex.)

A : Rating
11 : Material
(ex. 11,13: Carbon Steel (Non-Killed),
15: Carbon Steel (Killed),
31: 304SS)
2 : Corrosion Allowance (C.A.)
B : Service
(ex. A: General,
B: Hydrocarbon/Steam/BFW,
C: Steam (General),
D: Steam (Superheated),
E: Alkali / Rich Amine,
F: Liquid/Vapor including CO2,
G: Lube Oil / Seal Oil,
J: Potable Water / Instrument Air,
K: Air Form Liquid)

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(vi) Type of Insulation / Insulation Thickness

If insulation is required for piping, it should be represented on P&ID, including insulation

thickness.
Insulation thickness is calculated based on table, which shows relationship between
operating temperature vs. insulation thickness (the above mentioned table is included in
project specification).

[Hot Insulation]
Hot insulation is required for the following purpose
- To avoid decreasing temperature of fluid by heat loss.
- To avoid solidification by heat loss, especially during winter season
Note) Potable water line shall be insulated in order to avoid increasing temperature by solar
radiation, since potable water is used for eye washing incase of emergency.

[Cold Insulation]
Cold insulation is required in order to avoid heat input from outside.
Note) If heat loss is allowed with considering process view point, cold insulation is not
required.

[Personnel Protection Insulation]

Personnel Protection Insulation is required for the service where operating temperature is
higher than 70deg.C(*) in order to avoid burn of skin, even if heat loss is allowed view point
of process reason.
(*) For reference

[Trace / Jacket]
If insulation is not enough in order to keep temperature of fluid, the followings are to be
considered.
- Steam trace or electrical trace
- Jacket Piping

[Acoustic Insulation]
Acoustic insulation is required in order to avoid noise if noise is occurred and is higher than
the criteria of noise.
(The Criteria of noise is specified in project specification.)

5. Valve Selection
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 The followings are valve symbols.

(1) Block Valve

Block Valve is required the following purpose.
- To isolate one system from another systems during normal operation or shutdown of
plant.
- To isolate equipment for maintenance or cleaning during normal operation, such as
Pump / Compressor / Heat Exchanger / Filter / Control Valve.

The following valves are used as Block Valve

- Gate Valve
- Butterfly Valve
- Ball Valve

(2) Throttle valve

Throttle valve is required in order to control flow rate, such as outlet of cooling water side
of cooler or bypass valve for control valve.

The following valves are used as Throttle Valve

- Globe Valve
- Needle Valve
- Angle Globe Valve
(* Gate Valve / Butterfly Valve can be equipped at outlet of cooling water side from cooler
as throttle valve, if COMPANY agree to use.)

6. Opening / Closing of Valve

In general, normally opened valve is represented on P&ID without any special note.
However, the following symbol is required in order to clear valve opening/closing for some
part.
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 NO (= Normal Open)
NC (= Normal Close)
(Note) Another way to represent opened/closed valve :
ALL Closed Valve is indicated as black-filled-valve.

Some of manual valves are locked at opened (or closed) position with chain (wire) / key In
order to avoid mis-operation of manual valves.
LO (Locked Open) (*= CSO (Car Sealed Open)) : fixed with opening position
LC (Locked Close) (*= CSC (Car Sealed Close)) : fixed with closed position

7. Prevention of Backflow
Check valve is required for the following service in order to avoid back flow.
- Discharge of Pump
- Discharge of Compressor
- Incase mixing of two lines, upstream of mixing point on each line.

The followings are type of check valve.

- Ball Type Check Valve
- Piston Type Check Valve
- Lifting Type Check Valve
- Swing Type Check Valve
However, generally, type of check valve is not represented on P&ID.
(* If it is necessary to specify type of check valve on P&ID, type of check valve can be
represented as “NOTE” on P&ID.
ex. Check valve at the discharge of compressor is specified as xxxx.)

(*) Stop Check Valve : Stop check valve equip handle in order to fix inside disc and used as
check valve and block valve.
Stop check valve can be considered if there is cost merit, such as high pressure steam
service.

8. Piping Symbols (Others)

The followings are piping symbols (others).

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(i) Flame Arrestor
Flame arrestor is required in order to avoid propagation of flame.
Flame arrestor is made from wire mesh or small clearance material.
Fire cannot go through small clearance material and fire will extinguish.

(ii) Strainer
Strainer is used to remove small particle which is included in fluid in order to avoid
damage / plugging for equipment at downstream. The followings are type of strainers and
the type of strainers shall be represented on P&ID.
- Y type strainer
- T type strainer
- Bucket type strainer
- Cone strainer

(iii) Steam Trap

Basically, Type of steam trap is not represented on P&ID.

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(iv) Blind Flange
Blind flange is equipped on the end of utility header in order to perform maintenance
utility header by removing the blind flange, if required.

(v) Welded End Cap

Welded end cap is equipped on the end of utility header in order to avoid leakage.
(vi) Breather Valve
Breather valve is located on tank (or vessel) in order to adjust pressure by breath in /
breath out.
(ex.) When liquid is drawn off from tank by pump and N2 blanket system is not work by
accident, pressure of tank will decrease and tank may be damaged. Air can be sucked
through breather valve (= “Breath In”) in order to avoid damage of tank

(vii) Exhaust Head

(viii) Static Mixer
When two kind of fluid is mixed in piping, static mixer is required at downstream of mixing
point in order to mix completely, if required. Static mixer equips baffle plate.
(ix) Silencer
When high pressure steam is relief to atmosphere for blowing purpose, big noise occurs.
Silencer is required at the relief point of high-pressure-fluid in order to decrease noise.

(x) Desuperheater
When operating temperature of steam is superheated and saturated steam is required,
desuperheater is equipped on steam line in order to decrease temperature by introducing
BFW through spray nozzle of desuperheater.

(xi) Ejector
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(xii) Flange
Basically, flange of piping is not represented on P&ID. However, flange is required for
special purpose, flange is represented on P&ID.
(ex.) Blind plate / Buttery Limit of Construction Buttery Limit

(xiii) Reducer
(xiv) Screwed Cap / Screwed Plug
(xv) Removal Spool
(ex) “Removal Spool” is required in order to
(絵を追加　BPA Main Reactor OVHD の MH)
(xvi) Swing Elbow
Swing elbow is used in order to change connection of lines by change direction of “Swing
Elbow”.
(xvii) Weep Hole
Weep hole is equipped on vent-to-atmosphere line in order to drain out rain water.
(xviii) Piping Header
Piping header shows side view of header line.
(xix) Funnel
Funnel is used for recover drain water or oily water.

9. Isolation
“Isolation” is required in order to achieve the following purpose.
- Isolate two systems during normal operation
- To avoid leakage of process fluid to atmosphere
- For Maintenance / Rectify of equipment / instrument
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- To enter equipment (Column / Vessel) safely for inspection / maintenance

(1) Temporary / Permanent Blind

(i)Temporary Blind
Temporary blind is prepared for maintenance, etc.
Generally, temporary blind is not so thick, if strength of blind is not required to bear
normal operating condition.

(ii) Permanent Blind

Permanent blind is equipped in order to separate process line and another system.
Permanent blind is required to bear normal operating condition and thickness of
permanent blind is larger than that of temporary blind.

Permanent blind is required for the following service.

- Normally no use, but line is used for emergency case. It is necessary to avoid
contamination of fluid.
- Normally no use line of utility which is connected to process line.
- Normally no use line which is connected to higher pressure service or etc, such as
toxicity service, flammable service, volatile service, high rating service (>300#), high
temperature service, vacuum.
- Drain / Vent for the above said services
- Battery limit for system, incase of shutdown for maintenance
- Line which leakage to another system is not allowed

(2) Spacer / Spectacle Blind

(i)Spacer
(ex) Fluid flows at normal operation. However, blind plate is installed in order to isolate
unit / equipment in order to perform maintenance or another purpose.
Spacer is required for the above said location in order to secure space to install
permanent plate (or thicker temporary blind).

(ii) Spectacle Blind (SB) (= 8-Figured Flange)

Spectacle blind is consisted with blind and spacer.

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(3) Double Block Valve
Double block is required for the service that is mentioned in chapter “Permanent Blind” in
order to ensure isolation.

10. Battery Limit

(1) Limit of plant
(i) Inside Battery Limit (ISBL): Inside of Plant
(ii) Outside Battery Limit (OSBL): Outside of plant

(2) Area Battery Limit

If some companies work on design of plant together and it is required to clarify work
demarcation of each company. Area Battery Limit shows battery limit of work
demarcation.

(3) Limit of Construction

Battery limit of construction is required if some companies work on construction of plant
together and it is required to clarify work demarcation of construction of each company.

11. Piping Service Class Break

Piping service class break is required for the following break.
- Break of Rating based on design pressure
- Break of Design Temperature / Operating temperature
- Break of Design Pressure / Operating Pressure

Break point shall be decided in order to bear material for all operating conditions.

- As for operating pressure, it should be considered that upstream pressure reaches to the
farthest manual valve if there are some valves.
(*) If the above said farthest valve is defined as “LO”, it is not necessary to consider that
upstream pressure reaches to the farthest “LO” manual valve.

- Generally, piping service class break is defined at valve.

- Material break can be defined at check valve.

(ex.) Sample of piping service class break are shown as below.

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12. Utility Connection Configuration
There are two kinds of utility use (a) and (b) as below.
(a) Utility for continuous use: (ex) Steam is introduce into system during normal
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 operation
(b) Utility for temporary use: (ex) Steam is introduced into system in order to purge
hydrocarbon during shutdown

Utility connection configuration for (a) and (b) is shown as below.

13. Sampling Connection

Sampling connection is consisted from the following items.
Sample Cooler
Valves
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(i) Sampling Connection for non-hazardous service

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(ii) Sampling Connection for hazardous service
(with Sample Cylinder)
- Lethal Fluid
- LNG
- Vapor

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14. Special Consideration on Piping Design
(i) Gravity Flow
Height of downstream piping shall not be higher than height of piping inlet
(* Any “Pocket” is acceptable.)

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(ii) No Pocket
Both “High Pocket” and “Low Pocket” is not allowed.

(iii) No Liquid Pocket (= “No Low Pocket”)

High pocket is acceptable.
Ex.) Wet Acid Gas Line (* Trace is required.)
Saturated Vapor Line

(iv) No Vapor Pocket (= “No High Pocket”)

Low pocket is acceptable.
Ex.) Pump suction line (* “No Vapor Pocket” is not represented on P&ID as a common
sense. )

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(v) Free Drain
Low Pocket is not allowed.
Horizontal line is acceptable.
Ex.) Inlet / Outlet Piping of PSV
Outlet Piping of Condenser (incase of two phase flow)
Lead tube of Differential Pressure Instrument for Vapor Service
Upstream / Downstream Piping for Valve on Steam Line (Normally Close)

(vi) Slope
Low Pocket is not allowed.
Piping shall be designed in order to flow drain toward specified direction.
Slope shall be required for horizontal line (“1 / 500” means that piping shall dip 1m height
per 500m distance.)

Ex.) Flare Header

Gravity Flow Line, for liquid service which is easy to solidify.
Underground Piping (Self-Venting System)
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(vii) In View (= “Visible”)
Valve shall be located near instrument in order to operate with checking indication of
instrument at site.

(viii) Bottom Flat

Bottom of piping is flat in order to avoid remaining liquid in piping.
(* Eccentric reducer shall be used for “Bottom Flat” line.)

(ix) Top Flat

Top of piping is flat in order to avoid remaining vapor in piping.
(* Eccentric reducer shall be used for “Top Flat” line.)

(x) Straight Run

Line shall be straight for specified length.
Ex) Inlet piping of centrifugal compressor (ex. 5D)
Downstream of restriction orifice / control valve in order to avoid cavitation ?

(xi) Symmetrical
Piping shall be arranged in order to distribute flow equally.
Ex.) Distribute two-phase-fluid into two lines equally.
Draw off liquid from column with two lines

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(xii) Min.
Minimize distance as much as possible, if piping arrangement can be designed.

(xiii) Min. *D (***)

Minimum distance of *D is required.
*D means that distance is specified as (factor) x (piping diameter).
Ex.) 10D for 8” : 8 x 25.4 x 10 = 2032 [mm]

For example, minimum distance is required for the following items.

Upstream/Downstream of orifice flow element in order to keep flow condition in piping
steady.
Material of flare header with considering fluid temperature.
Assume that low temperature (lower than -46 deg.C) relief into wet flare subheader and
material shall be selected SS. However, fluid temperature will increase and it is not
required to select SS. The portion of SS is specified as minimum distance as “Min. *D”.

(xiv) Max. *D (***)

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Maximum distance is specified.

(xv) High Point

ex) Control valve for wet acid gas service shall be located at “High Point” in order to avoid
remaining liquid in control valve

(xvi) Low Point

ex) Drain shall be located at “Low Point” of line in order to drain out liquid in line.

(xvii) Top Conn.

“Top Conn.” shall be specified at the mixing point in order to enter vapor into
liquid/vapor service from top side.

(xviii) Top / Side Conn.

“Top / Side Conn.” shall be specified at the mixing point, side of vertical line or top of
horizontal line. ??? for what purpose??
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(xix) Easy Access
If access of valve / instrument shall be easy for frequent operation of valve or another
reason, “Easy Access” shall be represented.

(xx) On Ground
Control Valve is required to locate on ground for maintenance.

(xxi) Grouped
If some valves shall be located nearly in order to operate, these valves shall be
specified as “Grouped”.

(xxii) “TWO PHASE FLOW”

If fluid is two phase, there is possibility to occur vibration. “TWO PHASE FLOW” shall
be represented in order to design support of piping for vibration.

15. Indication of Instrument System

(i) General
The following drawing shows DCS instrument system.

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(ii) Indication of Information on Instrument System
Instrument Number : Instrument Number is consisted with the following items.
Unit Number (ex) 04
Functional Identification (ex) FIC
Instrument Serial Number (ex) 001
Suffix (ex) A/B/C or S for Spare Instrument

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Sample of Functional Identification is as below.

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FI : Flow Idicator
LC : Level Controller
PIC : Pressure Indicator Controller
PV : Pressure Control Valve
PSV : Pressure Safety Valve

The followings are Instrument Symbols.

Local
Instrument

The followings are instrument symbol for flow element.

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The followings are suffix of level primary element.

The followings are pressure primary element.

The followings are suffix of temperature primary element.

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The followings are symbol of hand switch.

(iii) Control Valve

The followings are kinds of control valves
- Control Valve
- Emergency Shutdown Valve
- Emergency Depressuring Valve
- Remote Operated On/Off Valve

Control valve is consisted with Actuator and Valve.

Generally, globe valve is used as control valve.
(*) Angle valve or butterfly valve can be adopted as control valve.

Air Actuated Valve : Generally, control valve is controlled by air actuater.

(= Air Actuated Valve)

Air Failure Action : When instrument air failure occurred, air actuated valve will open or close
or keep the position.
FO (Failure Open)
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 FC (Failure Close)
FL (Failure Locked)

Stopper for Control Valve : If control valve is not allowed to close completely, mechanical
stopper (or stopper by software) shall be equipped.

(*) Motor Operated Valve : If control valve is controlled by electric power, this control valve is
called “Motor Operated Valve”.

TSO (Tight Shut Off) : If control valve shall be closed completely and leakage shall be limited
strictly, valve shall be noted as “TSO”.

The followings are symbols of control valve.

Generally, if valve size is bigger than 8”, hand wheel is equipped and bypass is not adopted.
The reason is as below.
- Globe valve which is bigger than 8” requires special order and the cost is relative high.
- It is difficult to control flow rate with using manual valve which is larger than 8”.
- It is expected that plugging of foreign material may not occur if control valve size is bigger
than 8”.

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(iv) Indication of Instrument System on P&ID
Sample of instrument system is as below.

- Control Loop

- Cascade Control Loop :

Cascade Control Loop is adopted in order to avoid sudden condition change

- Split Range Control

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- Feed-forward Control

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- Compensation

- Double Control Loop

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- On/Off Control by DCS

- Emergency Shutdown System

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- Pump Auto Startup System

Around Equipment : The following items are represented on P&ID around equipment.
Nozzle
Vent
Drain
Utility Connection : When maintenance of equipment is performed, inside of equipment shall
be purged by nitrogen. For the above said purpose, Utility Connection is required for
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equipment.

Liquid Level (Interface Liquid Level)

Pump

Spare Pump : Spare pump is basically required, since rotating machine is easy to be
damaged with compared to other equipment, such as vessel.
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Driver :
Check Valve : Check valve is required at discharge line in order to avoid back flow through
standby pump.

Strainer : Strainer is required at suction line in order to remove small particle, since if small
particle is send to pump, pump will be damaged.

Drain/Vent : Drain is required for maintenance of pump in order to withdraw liquid from the
inside of pump.
Vent is required in order to fill pump with liquid completely, since if vapor is remained inside
of pump, pump impeller may be damaged by cavitation.

Pressure Gauge : To check the head developed and control the discharge valve opening.
Safety Valve :
Pulsation Damper : for reciprocating pump, pulsation dumper is required.
Check Valve Bypass :
Pump Minimum Flow Bypass

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