Introduction to Basic Process Documents

By Jaswant Tawde

Slide 1
The Basic Process Documents
Key Stages
Process Design Basis

PFD

P&ID

EPD

IPDS

Line list

Slide 2
 Process Design Basis
Product, Quality, Quantity;
Raw material, specification, source etc;
Product / Raw material unloading, storage dispatch, packaging.
Utilities: RW, CW, IA, Elec, FG, IG, LP, MP, HP;
Battery limit condition specified;
Location of plant
Site Conditions: Temperature (WB & DB), pressure, rainfall
through out year (Max, Min., Average)
IBR, SMPV, CCOE, OISD, API, IS;
Restriction in equipment sizing

Slide 3
Slide 4
 Process Flow Diagram
Process Flow (only process lines, utility lines neglected);
Basic Process Control defined;
Flow, temp., pressure identified;
Equipment tag numbers;
Stream number identified for Reference with H&MB;

Material Flow Diagram;

MOC & CA identified for equipment and piping;

Special requirement such as NACE, HIC identified;

Slide 5
 Piping & Instrument Diagram
Most important document of process department
Used during all phases of the plant
Bidding

Engineering

Construction

Commissioning

Operation & maintenance

Any future modification of the plant

Since all the equipment and instrument appear on the P&ID some
packages use it as a central point for storing data base.

Slide 6
A P&ID is:
Language of Symbols
Schematic of Process
Displays Relative
Orientation/Configuration
Communication Tool
A P&ID is not:
Piping Isometric
Equipment Fabrication
Diagram
Scale Drawing
Control Logic Diagram
Something to Convey
Process Information!
Slide 7
 A P&ID should include:
Instrumentation and designations
Mechanical equipment with names and numbers
All valves and their identifications
Process piping, sizes and identification
Miscellaneous - vents, drains, special fittings, sampling lines, reducers,
increasers and swagers
Permanent start-up and flush lines
Flow directions
Interconnections references
Control inputs and outputs, interlocks
Interfaces for class changes
Seismic category
Quality level
Annunciation inputs
Computer control system input
Vendor and contractor interfaces
Identification of components and subsystems delivered by others
Intended physical sequence of the equipment

Slide 8
 A P&ID should not include:

Instrument root valves

control relays
manual switches
equipment rating or capacity
primary instrument tubing and valves
pressure temperature and flow data
elbow, tees and similar standard fittings
extensive explanatory notes

Slide 9
 Piping & Instrument Diagram
Sometimes called as engineering flow diagram;
All lines identified (SU, utility, maintenance, drains, vent)
Piping details;
Instrumentation details.
Equipment interface with piping and instruments;
Elevations details;
Scope of supply for equipments identified;
Notes describe any special requirements as applicable;
Specialty items such strainers, sampling details, corrosion
coupons etc;
Protective items such as breather valve, relief valves, flame
arrestors;

Slide 10
 Tag number
Thousands of components are to be procured therefore all items are
tagged
Tag numbers are provided to equipment, instruments, lines,
specialty items and all miscellaneous items that are to be procured.
These tag numbers are also useful to be referred in other
documents such as DCS loop, cause and effect diagram.
Tag number are only referred during plant operation &
maintenance

Slide 11
 Basic Point in P&ID
How the process flow actually takes (consistency with PFD)
Pump

Pressure

Gravity

Type of material solid, liquid or gas

How is the pressure rating is defined

What is the basis of selecting equipment / line pressure

Pump Shutoff pressure

PSV (set pressure, location, equipments being protected by

PSV)
HIPS (High integrity instrument protection system)

How the piping spec breaks have been defined

Slide 12
 Basic Point in P&ID
What is the basis of selecting design temperature
Max. Process temperature with design margin

Inadvertent flow some other line or equipment

Fire case

Auto-refrigeration / steam out

Why particular MOC is used at particular location

How material spec breaks have been defined

Process fluid corrosion properties

Design pressure and temperatures

How the material cost are kept to minimum

Cladding (reduce the thickness of costly material)

Glass lined / rubber lined pipes

Refractory lining

Slip on flanges
Slide 13
 Piping Details
Fluid Code (CW, PA, IA, HC etc.)
Line Number (Line list, Isometrics)
Piping Specification
Design temperature & Pressure (Max.)

Piping material

Corrosion allowance

Special requirement such NACE, IBR, HIC, 5D bend, Electric

PWHT, Radiography

Flange rating and type

Type of fitting

Valves, Check Valves

Gasket, Bolts

Insulation type and thickness

Slope, Free draining, No Pocket Slide 14
 Piping
Line list
Preliminary BOM (Valves, check valves, tee)
Plot Plan
Equipment Layout
Line routing
Pipe rack details
Piping Isometrics

Slide 15
 Instrumentation
All instrument tag numbers
Instrument type
Instrument connection details
Isolation and draining & venting

Sometimes shown on legends P&ID

Also refer instrument mounting details

Scope break between piping / instrument dept.

Location of indication
DCS

PLC

Local

Panel Mounted
Slide 16
 Instrumentation Control Valve
Control valve type
Control valve size

Control valve isolation & bypass size

Control valve air fail position

Handwheel

Control valve positioner

I/P Converter

Solenoid valve

Cavity vent or HP side

Drain

Slide 17
 Instrumentation - Control
Operational control, DCS interlock and SIS
interlock
Each control loop Single or Multivariable

How the signals are transmitted to / from control

system
System where the control is realized DCS /
PLC
Alarms

Interlocks

Interlocks numbered

Inputs and output interlock identified

Slide 18
 Instrument
Instrument list
I/O list

DCS graphics

Instrument data sheet

Instrument mounting details

Slide 19
 Equipment - Vessel
Equipment tag number
Type of equipment
Design pressure and temperature
MOC
Vent and drains
Equipment trims
Interface with piping
Interface with instruments
Relative nozzle elevation
Equipment isolation (slip plate, blinds)

Slide 20
 Equipment Pump / Blower / Comp.
Equipment tag number
Type of equipment
Design pressure and temperature
MOC
Capacity & Head
Piping / Instrumentation
Capacity control, surge, min. flow
Vent / Drain
Seal / Vent / Heating / Cooling details
Elevation difference required for NPSH

Slide 21
 Equipment - Package
Equipment tag number
Black Box
Package boundary limit (Scope)
Interface with piping
Interface with instruments
All utilities provided
Is the package complete

Slide 22
 Clouds
All revisions on the P&ID
Indicate scope of project (Brownfield Project)
Early tie-in
As built correction
Where ever many clouds are used they should be
defined prior to use

Slide 23
 Storage of Liquid

Bund & Dykes

Drainage details
Tanker loading / unloading
Static charge

Slide 24
 Holds

If any details on the P&ID is likely to change in the future

indicate that as HOLD.
Hold for relief valve size, inlet & outlet line sizes
Hold for package details, pump inlet out nozzle size

Hold for vessel nozzle size, in line instruments

Holds boldly marked and in different layer
Department of hold is mentioned
Hold list updated

Slide 25
 Flare lines

Free draining, no pocket

Weep hole for atmospheric relief valve outlet
Full Bore for PSV inlet and outlet valve
Locked open for PSV inlet and outlet valve
Valve steam horizontal for PSV inlet and outlet
valve
PSV Set pressure
PSV orifice designation, inlet / outlet size

Slide 26
P&ID Key Stages

PRELIMINARY

IFD

POST HAZOP

IFC

AS BUILT

Slide 27
 PRELIMNARY

PRELIMINARY Distributing to departments & client

for comments
IFD No engineering is done on this
document
Intent is to collect and incorporate in
POST HAZOP
the IFD P&ID

IFC

AS BUILT

Slide 28
 IFD

PRELIMINARY P&ID review meeting

All points discussed
IFD P&ID updated based on P&ID review
Our EDP defines the minimum
POST HAZOP information that has to be on IFD P&ID
No vendor information is available
IFC Relief lines (Preliminary sizes)
Holds to be mentioned
AS BUILT

Slide 29
 P&ID Revision Request (DCN)
It is a procedure to make small changes on P&ID
so that many revisions of the P&ID are avoided.
It also serves to give information to other
departments as and when it is available
DCN register needs to be maintained
Master P&ID needs to be updated
Master P&ID to be parked in P:\Locker
In case of LSTK jobs this is a tool to track
variation in cost & time
In such cases project department approves the
DCN

Slide 30
 P&ID - EDP
Detailed Review of P&ID 7.23
Preparation of P&ID (Utilities & Offsite) 7.28
Preparation of P&ID 7.74

Slide 31
 Intelligent P&ID

An intelligent P&ID contains engineering data,

such as process data (normal and maximum
operation pressure, temperature, flow rate and
manufacturing data), and facilitates design
verification (performs rule-based design
verification to produce technically sound design
and enforce industry, company, and regulatory
standards).

Slide 32
 Intelligent P&ID
Integrates with Instrument Data Manager (IDM), WireWorks, PDS 3D
Piping module, and SmartPlant products
Extensive reporting capabilities are available to create deliverables such as
line lists, equipment lists, Electrical userlist, Instrument list, I/O List
Includes reserved palettes for customizing piping, equipment, and instrument
menus
Fast and efficient setup of the schematic design using assemblies (existing,
proven best practices designs)
Design verification with user-definable options, such as checking against the
pipe specification to allow checks that make sense in the different phases of
the project
Relational database forms a powerful yet flexible data repository that allows
reporting, interfacing with external systems, and modifications
Design multiple processes on a single diagram and perform design checks on
these individual systems
Customer-definable design verification capabilities

Slide 33
 POST HAZOP

PRELIMINARY

IFD

Usually there is one issue of P&ID

POST HAZOP
after hazop is conducted

IFC

AS BUILT

Slide 34
 ISSUED FOR CONSTRUCTION

PRELIMINARY

IFD

All the vendor data are incorporated

POST HAZOP
All line sizes are indicated
IFC Control valve sizes indicated
Relief valve size indicated
AS BUILT Piping tapping details indicated
In short no holds on the P&ID

Slide 35
 ISSUED FOR CONSTRUCTION

PRELIMINARY

IFD

Unplanned changes made during

POST HAZOP construction are captured during this
revision
IFC Most neglected phase
AS BUILT
It is very important to client because
it is the basic input for all future
projects

Slide 36
Thank you

Slide 37