Essentials of Process Plant and Piping Technology

PRESENTED BY
Dr.R.PERUMAL.,M.Tech.,Ph.D.,MIChE.,
Professor
Department of chemical Engineering
Erode Sengunthar Engineering College
Perundurai Erode 638 057
 Process Plant
Objective

Convert Reactant into Product

Arrangement of Processing Units Target
integrated with one another in a Product Specification
systematic and rational manner
Production output
-Reactors,
-Heat Exchangers,
-Pumps,
-Distillation Columns,
-Tanks etc.

Societal Needs

-Cost of Production
-Safety Aspect
-Environmental Factors and norms
-Statutory and mandatory requirements
 Responsibilities of a Production Engineer

To Achieve Production Target

Quality Assurance
Maintaining quality records
Production Planning and cost optimization
Developing and implementation of process systems
Preparation and execution of maintenance schedule
Smooth operation of the plant
Ensuring process and personnel safety
Energy utilization and Optimization
 Anatomy of a Plant
Anatomy of a Plant consists of
• Plant Layout
Describes the Location of Processing Units

• Process Flow Diagram

Describes the Arrangement of Processing Units

• Piping and Instrumentation Diagram

Describes the Connection and interlocks between Processing Units

• Piping Layout
Describes the Detailed Engineering of the Plant
PLANT LAYOUT
 Process Flow Diagram (PFD)
• The PFD is a diagrammatic
representation of the process

• Illustrates the arrangement of the

equipment and accessories required to
carry out the specific process

•  Indicates the general flow of plant

process

• Shows the relationship between major

equipments

• Does not show minor details such as

piping specification and details
 Process Instrumentation & Control
Objective
 To suppress the influence of external
disturbance
 Ensuring the Process safety and Stability
 Optimizing performance of a process

Need For Control System

To maintain the process parameters at desired
Value(Set Point)
Components of a Control system
 Process Control Loop

Type of Process Control Loop

 Feedback Control
 Feedforward Control
 Feedforward-plus-Feedback Control
 Ratio Control
 Split Range Control
 Cascade Control
 Differential Control
Piping &Instrumentation Diagram(P&ID)
• P&ID, shows the piping and related
components of a physical process
flow. 

• It consists of both major and minor

flows, control loops, and
instrumentation.

• . Piping & Instrument Diagrams

(P&ID) are the core documents of
any plant. Their primary role is to
represent the configuration of the
plant with: all plant objects with
their most generic class, e.g. PUMP
• P&IDs are mostly used by process
technicians and engineering personnel .
 Difference
Difference between
between PFDFlowchart
Process and P &IDand
P&I Diagram
PFD
• It Is Less Detailed
• Gives an overall view of the entire
plant
• This kind of diagram shows the
flow of chemical materials and the
equipment involved in the process.
• process flow diagram will tell us the
relationships between the major
components in the system
• Suitable for study purpose.
P&ID
• It has comprehensive details
•
• It displays all crucial equipment, piping
information, instrumentation details and
pipe routing states
• P&ID, shows the piping and related
components of a physical process flow. 
•
• It consists of both major and minor
flows, control loops, and
instrumentation.
•
• P&IDs are mostly used by process
technicians and engineering personnel.
 PI & D Reading
Reading of P & I D is nothing but the reading the
Symbols and tracing the lines. It includes
• Line Tracing
• Identification and understanding of the
control loops
• Read and understand the Tag Description
• Reading the symbols
• Equipment details and symbols
 Line Tracing
Line Number
• Each line is given a unique number and written above the line. It has 4
parts separated by -. It is Line size - Service Fluid - Line number - Material
Specification and insulation type
Insulation Specification:
3- P- 12007- A 09 –H-30
N : Not Painted /Insulated
PP : Personnel Protected
3 – Pipe Size in inch
S : Internal Treated/External
P – Service Fluid Painted
A : Internal Treated, External
12007 – Unit Number (12 area code 007 Serial number)
coated
A09 – Piping service class ( A- Flange Rating, 09 Piping B : External Coated
E : Electric traced
Material
F : Cold Insulated
H – Insulation Type ( H- hot insuation) I : Hot Insulated
T : Steam traced
30 – Insulation Thickness
V : External painted
W : Jacketed
 Line Tracing – Flow Direction
Flow Direction
• Flows in P & I Ds enter from left or right and direction of flow is shown at the
end.
• The arrow at the end also shows the number of originating equipment and
number of originating P & ID.
• Flow direction in all lines is shown with a small arrow.
Spec Break 
• If a line has part of the line with different spec, a spec break is shown and the
two specs are shown in two directions.
Left Arrow 
• Incoming or Outgoing flow arrow with originating or next P & I D Number
written in the arrow.
Right Arrow 
• Incoming or Outgoing flow arrow with originating or next P & I D Number
and written in the arrow.
 Control Loops
Feedback
• Y
Control
• LC
• Fluid in

• V-100
• LCV-100

• L
T

• Fluid out
• V-100
FC
Feed forward Control

FT Process variable need to be

Fluid in controlled = Temperature
TI
Y

Steam Fluid out

LCV-100
Tag Description
 Instrumentation Numbering

Instrumentation Numbering

 XYY CZZLL

X represents a process variable to be measured.

(T=temperature, F=flow, P=pressure, L=level)
YY represents type of instruments.

C designates the instruments area within the plant.

ZZ designates the process unit number.

LL designates the loop number.

 Instrumentation Numbering

LIC 11003 FRC 82516

L = Level shall be measured. F = Flow shall be measured.

IC = Indicating controller. RC = Recording controller

110 = Process unit no. 10 825= Process unit no. 25

in the area of no. 1 in the area of no. 8.

03 = Loop number 3 16 = Loop number 16

 Equipment Identification
• Different symbols are used for different equipments.
• The details about the equipments are given either at top or at the bottom.
Equipment Number :
• Different letters are used for different equipments followed by 3 digit number. First
number is same as the number of P & ID and next two are sequential number for
the equipment. eg. CP-101. The first letter shows name of the plant and second
letter shows name of equipment. Different letters used for different equipments
are
– T : Tank or vessel
– P : Pump
– H : Heat Exchanger
– R : Reactor
– C : Compressor
Size : The size is given for tanks, vessels.
Capacity : It is given as volume / time basis, eg for a pump or distillation unit.
Material of Construction : It can be SS, CS, Titanium or lined metals.
 PI & D Symbology

• The most common P&ID symbols are listed below:

• Line Symbology
• Piping Symbology
• Valve Symbology
• Filter Symbology
• Instruments and Instrumentation Symbology
• Pump Symbology
• Compressor Symbology
• Vessel Symbology
Line Symbols
Piping Symbols
 Valve Symbols
Valve Symbology

Symbol Name

Relief Valve

Needle Valve

3-Way Valve

Angle Valve

Butterfly Valve
 Valve Symbols
Valve Symbology

Symbol Name

Gate Valve

Globe Valve

Ball Valve

Check Valve

Butterfly Valve
P & I Diagram
P&ID for Benzene Distillation
 P & I Diagram
P&ID for Benzene Distillation

Vessel Lines
T 101-Distillation Column 1. Benzene- Toluene Feed to
Distillation Column
E106 – Reboiller 2. Benzene rich vapour leaving at the
E104 – Condenser top of the column and entering the
V104 – Reflux Drum condenser
3. Condensate Leaving the condenser
at bottom of the condenser
4. Fuel Gas leaving the reflu drum at
the top
5. Benzene reflux to the column
6. Benzene product to storage
7. Toluene leaving at the bottom of
the column
P & I Diagram
P&ID for Benzene Distillation
 P & I Diagram
P&ID for Benzene Distillation

Control Loops
1. Distillation column Bottom Level Control loop
2. Reflux Flow Control loop
3. Fuel Gas Pressure Control loop
4. Reflux Drum Level control loop
P & I Diagram
P&ID for Benzene Distillation
Piping Layout
Piping Layout
 Basic Concepts of Piping
PIPE
A pipe can be defined as a tube made of metal, plastic, wood,
concrete or fiberglass.

Pipes are used to carry liquids, gases, slurries, or fine particles.

A piping system is generally considered to include the complete

interconnection of pipes, including in-line components such as pipe fittings and
flanges.

 Pumps, heat exchanges, valves and tanks are also considered part of piping
system.

Piping systems are the arteries of our industrial processes and the
contribution of piping systems are essential in an industrialized society.
 Design criteria for a piping system
•The initial design of a piping system is established by
the functional requirements of piping a fluid from one
point to another
•The detailed design is decided by criteria such as
- type of fluid being transported,
-allowable pressure drop or energy loss,
- desired velocity,
-space limitations,
-process requirements like free drain or
-requirement of straight run,
-stress analysis,
-temperature of fluid, etc.
 Piping Material

 Guidance of selecting the correct material can be obtained

from standard piping codes.
 ASME Code is used for for Pressure Piping includes
• Power Piping,
• Industrial Gas and Air Piping,
• Refinery and Oil Piping, and
• Refrigeration

Piping Systems.

•The objective being to ensure that the material used is entirely safe under
the operating conditions of pressure, temperature, corrosion, and erosion
expected. 
 Piping Material

Some of the materials most commonly used for power plant piping are discussed in
the following sections.

Steel – Steel is the most frequently used material for piping. Forged steel is extensively
used for fittings while cast steel is primarily used for special applications. Pipe is
manufactured in two main categories – seamless and welded.

Cast Iron – Cast iron has a high resistance to corrosion and to abrasion and is used for
ash handling systems, sewage lines and underground water lines. It is, however, very
brittle and is not suitable for most power plant services. It is made in different grades
such as gray cast iron, malleable cast iron and ductile cast iron.

Brass and Copper – Non-ferrous material such as copper and copper alloys are used in
power plants in instrumentation and water services where temperature is not a prime
factor.
 Commercial Pipe Sizes
Specific pipe is identified by pipe diameter and another non-dimensional
number for wall thickness referred to as the Schedule (SCH). 
Pipe schedule sets the pipe wall thickness. Increasing the wall thickness of
the pipe increases the mechanical strength of the pipe, allowing it to handle
higher design pressures

Pipe Schedule is the term used to describe the thickness of a pipe. The
outside diameter of a pipe is the same for all Schedules in a particular
nominal pipe diameter. For pipe 8-inches and under, Schedule 40 and
Standard
Weight pipe wall thicknesses are the same.
 Schedules 5, 60, 100, 120, & 140 are rarely used.

Nominal Pipe Size (NPS)

Nominal pipe size refers to only the outside diameter (OD) of a pipe 
For example, when we say pipe size is 2 NPS, it refers to all the pipes having
2.375-inch (or 60.3 mm) as outside diameter irrespective of wall thickness
and thus the inside diameter. 
Commercial Pipe Sizes
Pipe Sizes & Schedule
 Pipe Fittings
• A fitting is used in pipe systems to connect straight pipe sections, adapt to
different sizes or shapes and for other purposes, such as regulating (or
measuring) fluid flow.
• Elbows – for making angle turns in piping.
• Nipples – for making close connections. They are threaded on both ends
with the close nipple threaded for its entire length.
• Couplings – for connecting two pieces of pipe of the same size in a straight
line.
• Unions – for providing an easy method for dismantling piping.
• Tees and Crosses – for making branch line connections at 90º.
• Y-bends – for making branch line connections at 45º.
• Return Bends – for reversing direction of a pipe run.
• Plugs and Caps – for closing off open pipe ends or fittings.
• Bushings – for connecting pipes of different sizes
• Reducers – for reducing pipe size.
 
Pipe Fittings
 Methods of Connecting Pipe

• There are three general methods used to join

or connect lengths of pressure piping.
These are:
• Screwed Connections.
• Flanged Connections.
• Welded Joints.
 Screwed Connections
• Threads are cut on each end of the pipe and screwed
fittings such as unions, couplings, and elbows are
used to join the lengths.
• This method is generally used for pipe sizes less than
101.6 mm (4 inch) for low and moderate pressures.
Advantages
•  Piping can be easily disassembled or assembled.
Disadvantages
• subject to leakage and the strength of the pipe is
reduced when threads are cut in the pipe wall.
 Flanged Connections

• This method uses flanges at the pipe ends which are bolted
together, face to face, usually with a gasket between the two
faces.
Advantages over welded connections
• More convenient to assemble and disassemble than the
screwed connections. 
• In order to prevent leakage at flanged connections,
gaskets are usually used between flange faces.
• Gaskets are made of a comparatively soft material which,
when the flanged connection is tightened, will fill in any small
depressions in the flange faces and thus prevent leakage.
 Welded Connections
• In this method, the pipe lengths are welded directly to one another and directly to
any valves or fittings that may be required.
 Advantages over the use of screwed connections or flanged connections:
• The possibility of leakage is removed with the elimination of screwed or flanged
joints.
• The weight of the piping system is reduced due to the elimination of
connecting flanges or fittings.
• The cost of material and the need for maintenance are reduced with the
elimination of flanges and fittings.
• The piping looks neater and is easier to insulate with the elimination of bulky
flanges and fittings.
• Welded joints give more flexibility to the piping design as the pipes may be joined
at practically any angle to each other.
• The main disadvantage of using welded joints for piping is the necessity
of obtaining a skilled welder whenever a connection is to be made.
 Piping Supports
• Piping must be supported in such a way as to
prevent its weight from being carried by
the equipment to which it is attached.
• The supports used must prevent excessive sagging
of the pipe and at the same time must allow free
movement of the pipe due to expansion
or contraction.
• The supporting arrangement must be designed to
carry the weight of the pipe, valves, fittings and
insulation plus the weight of the fluid contained
within the pipe.
 Piping Drainage
• In the case of steam piping, it is necessary to constantly
drain any condensate from the lines.
water hammer  
• If the condensate is not drained then the condensate will
be carried along with the steam and may produce water
hammer and possibly rupture pipes or fittings.
• In addition, the admission of moisture carrying steam to
turbines or engines is most undesirable. 
• Various devices are used to remove this condensate and
moisture from the lines
– eg steam traps
 Steam Separators
• Steam separators, sometimes called steam
purifiers are devices which, when installed in the
steam line, will remove moisture droplets and
other suspended impurities from the steam.
• The separator either causes the steam to
suddenly change its direction of flow or else it
imparts a whirling motion to the steam.
• Both of these cause the moisture and other
particles to be thrown out of the steam stream.
 Steam Traps
• The purpose of the steam trap is to discharge the water
of condensation from steam lines, separators and other
equipment without permitting steam to escape.
• Most traps are designed to discharge any air present in
the lines or equipment.
•  Steam traps should be installed in lines wherever
condensate must be drained as rapidly as it accumulates,
and wherever condensate must be recovered for
heating, for hot water needs, or for return to boilers.
• They are a “must” for steam piping, separators, and all
steam heated or steam operated equipment.
 Piping Insulation
• Most piping systems are used to convey substances that are at
temperatures much higher than that of the surrounding air.
• Examples would include the main steam piping and feedwater piping.
• In order to reduce the amount of heat lost to the surrounding air
from the hot substance, the piping is covered with insulation.
• The insulation not only retains the heat in the hot lines but also
prevents the temperature inside the process plant building
from becoming uncomfortably high.
• Insulation of hot pipe lines will prevent injury to personnel due to
contact with the bare surfaces of the pipe.
• In the case of piping which carries substances at a lower temperature
than that of the surrounding air, insulating the piping will prevent
sweating of the pipe and consequent dripping and corrosion.
 Piping Insulation

• A material suitable for use as an insulation should

have the following characteristics.
• High insulating value.
• Long life.
• Vermin proof.
• Non corrosive.
• Ability to retain its shape and insulating value when
wet.
• Ease of application and installation.
 Piping Insulation Materials
• Diatomaceous Silica – This material is bonded with clay and asbestos and is used
for temperatures up to 1030ºC.
• Asbestos – Pipe covering sections are molded from asbestos fibre and are used for
temperatures up to 650ºC.
• Calcium Silicate – This insulation is made from silica and lime and is suitable for
temperatures up to 650ºC.
• Cellular Glass – This material is glass which has been melted and foamed and then
molded into pipe covering forms. It can be used for temperatures up to 430ºC.
• Magnesia (85%) – This material is composed of magnesium carbonate with
asbestos fibre. It is available in molded form for pipe covering and also is supplied
in powdered form to be mixed with water to form an insulating cement which is
used to cover pipe fittings. Magnesia pipe covering is suitable for service up to
315ºC.
• Glass Fibre – This is glass that has been processed into fibres and then formed into
pipe covering sections which are suitable for temperatures up to 190ºC.
• Plastic Foams – These are plastics that have been processed into a foam during
manufacture and then formed into pipe covering sections. They are available for
temperatures as low as -170ºC and as high as 120ºC.
 Colour Codes and standards

• ASME/ANSI A13.1 – Scheme for the

Identification of Piping Systems
• BS 1710 – Specification for Identification of
Pipelines and Services
• IS 2379 – Pipelines Identification Colour Code
• PFI ES-22 – Recommended Practice for Color
Coding of Piping Materials
 Pipe Colour Code Use in Refinery As per IS 2379
Contents Ground Colour First Colour Band Second Colour Band
Cooling Water Sea green French blue –
Boiler feed water Sea green Gulf red –
Drinking water Sea green French blue Signal red
Plant air Sky blue Silver grey –
Very high pressure steam Aluminium to IS 2339 Signal red –

High pressure steam Aluminium to IS 2339 French blue –

Medium pressure steam Aluminium to IS 2339 Gulf red –

Low pressure steam Aluminium to IS 2339 Canary yellow –

Light diesel fuel Light brown Brilliant green –
Lubricating oil Light brown Light grey –
Flare gases Canary yellow – –
Nitrogen Canary yellow Black –
Oxygen Canary yellow White –
Hydrogen Canary yellow Signal red French blue
Naptha Dark Admirality grey Light brown Black
LPG (Liquid) Dark Admirality grey Brilliant green Dark violet
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