Key Project and Plant Document

P&ID Development
Acknowledgment
Past Project s, Codes & Standards
Pictures from: many sources, internet

150-P-105 A/B 1 +1 Duty + Standby

P&IDs are the “hieroglyphs” database of plant
Process flow sequence and COKER FEED PUMPS

 Process equipment + instrumentation controlling and direction 200 m³/h x 70m 50 kW

DP: 14.5 barg @ DT : 250 °C
protecting the equipment
Equipment: Tag no, name, 150-C-110
capacity, design P/T, sparing COKER FRACTIONATOR
 Life long document - Concept, Design-Engineering, philosophy DP Top/Bottom: 3.5/4.5 barg FV
Construction, Commissioning and Operation DT Top/Bottom: 350/ 450 °C

Pipe: Size, pressure rating, 12”- SPEC-IN-UNIT-LnNo
1 Picture = 1,000 Words MOC, insulation, unit, service FCV
101
and number PIC

Valves: Type, open or closed FT

in normal service, manual or FE

PT

automated
300#150#

Miscellaneous: Vent, drain,

fittings, sampling, reducers
and expanders

P&ID Development 1
 150-P-105 A/B 1 +1 One Pump is spare and on standby

Instruments: Type and tag COKER FEED PUMPS

200 m³/h x 70m 50 kW
number. Set points. Inputs DP: 14.5 barg @ DT : 250 °C
150-C-110
and outputs. Control - local COKER FRACTIONATOR
/ remote/ interlock DP Top/Bottom: 3.5/4.5 barg FV
Mainly Copy & Paste from Past Projects. Plus updates. Codes change!!
DT Top/Bottom: 350/ 450 °C

Spec breaks/ class changes
12”- SPEC-IN-UNIT-LnNo
FCV

Push Buttons 101

Special Requirements: FT
PIC

Start-up, vent, drain, FE

PT

flushing and sampling 300#150#

Scope of supply
demarcation. Vendor and
contractor interfaces

PC

Review PFD
Usually follow ANSI/ISA S5.1 and ISO 14617-
 Equipment arrangement &
Controls
From
LC 101 standard “Instrumentation Symbols and

Add piping details Identification”. [Note: There are other standards too]
 Valves, reducers, expanders  For instruments
 Sizes, Insulation, Heat Tracing etc ▪ 5 digit Identifier as in table below + a loop number

And instrumentation details ▪ PIC 201 is a Pressure Indicating Controller in control loop 201
PFD - Pump
 Controls and interlocks
 Set points
PG

Symbols in company or PG

international standards Column 1 Column 3 Column 4 Column 5

Column 2

Engg companies use past Letter (Measured
(Modifier)
(Readout/passiv (Output/active (Function
value) e function) function) modifier)
project P&IDs as a starting To Drain To Drain
A Analysis Alarm
To Drain
point and modify PID - Pump Point (Test
P Pressure
Connection)

P&ID Development 2
 ISA S5.1

Page 30: Table 4.1 - Identification letters
No line - Field Device. Locally

Page 36: Table 5.1.1 - Instrumentation device and function symbols Mounted. PG, TG, LG etc.

Page 39: Table 5.2.2 - Measurement notations
Single horizontal line - Primary Central Control Room Panel

Page 40: Table 5.2.3 - Primary elements Location

Page 44: Table 5.2.5 - Auxiliary and accessory devices  Front of Central or Control
Room Panel

Page 45: Table 5.3.1 - Line: instrument to process and equipment
Dashed line - Back of Panel

Page 46: Table 5.3.2 - Line: instrument-to-instrument connections Board Good old days
 Inaccessible

Page 49: Table 5.4.1 - Final control element

Page 50: Table 5.4.2- Final control element actuator
Double line - Auxiliary Location
 Front of Local Panel

Page 52: Table 5.4.3 - Self-actuated final control element Field or Remote

Page 55: Table 5.4.4 - Control valve failure & de-energized position
Double Dashed lines - Back of Panel

Page 56: Table 5.5 - Functional diagramming symbols … and so on Local Panel
 Inaccessible
a Square around the Circle, indicates information
is shared as in DCS Control. Graphics on screen.

PI
Square around the Circle, indicates
Hexagon: Computer function
PI - Indicates locally
information is shared as in DCS
Diamond: PLC Function
105

TI

Lines /Signals
Control. Graphics on screen
TI - Indicates in DCS screen

Summary - Common Use
105
 Major Process
 In field Main Panel Local Panel

No line - Field Location Physical PT
 Minor Process/
Device 105
PIT

PT - Transmits only Utility Line
105
PIT - Indicates and Transmits

Single line - Primary Location  Electrical
Virtual
Graphics TIC

TIC - Indicates and Controls via

Dashed line - Not accessible 105
DCS
 Capillary X X X

Letter & numbers to ISA

 Numbers are user assigned  Software O O O

 Sequential with or without unit number XV

XV - Actuated Valve  Pneumatic // // //

Double line – Auxiliary/ Remote  Process line number 105 SV SV - Solenoid Valve
Location  Database or national standards PS
105
PS - Pressure Switch  Hydraulic L L L
105
SDV
105
SDV - Shut Down Valve

Double Dashed - Remote
From: www.aiche.org, “Interpreting-piping-and-
Location
instrumentation-diagrams-symbology”, Robert Cook
Modern Control Room

P&ID Development 3
 Legend Sheets

PFD FC

Legend sheets list all symbols
 Differ between different companies

Review
 Equipment Symbols
 Piping & Valves Symbols

P&ID  Pneumatic  Electronic  DCS  Instrument Symbols

Some prefer to show details in P&IDs for material
count and take-off. Others pack info in Legend
FT FIC FT FIC
FT FIC
sheets and keep P&IDs simple
FV FV FV
FE FE FE

P&IDs are created
Intelligent P&IDs
Inputs .. In stages ..
Corporate drafting standards
 Rome was not built in a day
Intelligent or non-intelligent
using standard populate database
PFD  IT Participation
 Operating conditions - P, T
Piping inputs
software  Equip Info  Equipment  Control
Instrumentation & Controls
 Intelligent (Populate info List
Philosophy Inputs
 Sparing
MOC (Corrosion) Inputs
into a central database  Line Numbering  Line
Safety Studies input
 Isolation
shared with other List  Piping   Design Margins on Alarms,

Commissioning and Start-up
disciplines) Isometric drawings  Trips, and Relief inputs

Corporate Piping Specs
 Non-intelligent - create Line Completion code 
 Type of valves. Size restrictions
drawings only Fabrication etc
Line Sizing
 More .. later
Relief and Control Valve sizing
 May have many layers to .. Process/ Insrt/ Supplier
capture different types of
info

P&ID Development 4
 150-C-101 150-P-105 A/B

Start with past project
Utility/ Flare/Vent/Drain
Title blocks on top FEED SURGE DRUM FEED PUMPS
P&IDs
Main Equipment at Dia x T/T L, mm: 2,500 x 7,500 Flow x Head, m³/h x m 200 x 100
connections ending in a box centre DP : 6.0 barg Power, kW :TBA
DT : 250 °C DP : 15 barg
or headers that run at the DT : 250 °C

Equipment/ P&ID top and bottom of all
Space for spare
 Oil & Gas:1 major equipment  Pump?
for details to be clear in A3 size drawings PC
To LP
From N2

 Rest: 2-4 - 6 A1 size
Ending in box requires
Pump elevation - Distribution

Isolation/ Bypass Valves Not shown
Flare

separate Collection P&IDs NPSHa

Follow PFD sequence for
Special requirements
1,500
PG 300# 150# PG
equipment PG like slope etc PG

 Input stream from left. Exit

right
Mark spec breaks
 MOC changes
0
 Avoid crisscrossing of lines
To Closed  Pressure changes
 Major process lines – thicker Drain
Closed Drain Header 6”-150#-D1010 To Closed
To Closed
Drain
Drain

Add

Isolation, spec blinds and bypass valves for control valves
MOC (Temperature) and Pressure Breaks

Control loops

Control valve FO/FC positions. LO/LC/ CSO/ CSC valves Low Temp

Line number + insulation + heat tracing details

Local gauges and instruments

Reducers / expanders
300# 300# 150#

Sampling points .. Steaming, purging, cleaning and flushing
CS LTCS LTCS
P&ID Feed Drum
To Pump ‘B’ From Backflow Mixing Length
10”- Ao1-2-101-P106 101 LIC 101 Hot Cold Hot Cold
PI x m Min x m Min
150# 300#

101
106 Hot Hot Hot Cold Flare/ Vent Header
PI FCV
Stream Stream Stream Stream 150# 150#
105 8x6 2 8”- Bo1-2-101-P110 8x6
101
8x6 ? 600# 600#
2 10 x 8 2”
HOLD ¾ ¾ HOLD FO HOLD 600 mm
10”- Bo1-2-101-P107 Hot - Ins Hot - Ins
101 ¾HOLD Min
300# 150#
SPL Cold Cold

Stream

Stream
105
Cold

Cold
To Closed
Drain
HP Vent

P&ID Development 5

Single PSV Vs 1 + 1 PSV 1. Why we need inlet vent valves?
Equipment Blowdown
2. Why both outlets are LO?
3. Why do you need outlet drain valves
 For systems with flammable and toxic materials
 For HP systems, where vessel loses its ability (strength)
on heating during fire. PSV will maintain pressure high
LO at its set point. BDV will bring the pressure down
LO
LO LO Flare/ Vent Header

Flare/ Vent Header 150#

DBB inlet for LC 2” 600#
150# 150#
HP systems
600# 600#
2”
Note: Instead of a RO
600 mm
600 mm
Note: P&ID representation. Inlet Min
BDV + RO, one can Min
piping will be symmetrical go for a hard seated BDV
control valve
Manual Automatic - on F&G

PRV
PAHH
PIC/PAH

NOP

Control system maintains stable operation

Different companies opt for different
Trip / shutdown provides primary protection, when
configurations control system fails

Relief provides secondary or ultimate protection or last
line of defence, when control and trip systems fail
PRV
PIC

PAHH
T0 Flare
PALL
T0 Compressor
SDV
Production LAHH
Inflow LALL

SDV Separator
SDV

Options # 1  #2 #3 #4 #5 Oil
RV lifting: a serious incident Water
SDV

P&ID Development 6

Instead of P&ID symbols, text boxes used for
Direct on vapor product
Hot gas bypass. Good with

Must always have vapor low vapor without any non-
clarity
Slow response on low vapor condensable gas
PV
Condensing area varied
PSV PV ?
BDV
PAH PAH
PAHH PAH PIC PIC
PG SDV PIC PIC
PALL PIC PAL PAL
PAL

SDV LAH PCV

LAHH LG LG LG
LALL LIC Condenser
PAHH PAHH Condenser
LAL PALL LAH PALL LAH
LAHH LAHH
LG LIC LG LIC
LALL LG LALL LG
LAL LAL
LV LV
SDV
FCV FCV
LV Column Column

Compressor ASC
Surge Control Anti Surge RO
BDV To Flare
To Flare
Valve
Check valve a must - to
FCV
PAH PIC SC PIC PAH
PSV avoid back flow into
PCV LO
FAH FIC PAL Compressor
Speed Control
PAL
Utility Header
FAL
PSV  Blind Flange or Insert 150# CS 150# 300# 300# SS
Hot gas Bypass
CS SS
LO TAHH Spec Blind if intermittent
PG PALL PG PAHH 150# 150# 150# SS
TG TG PALL
Discharge supply 150# CS
CS SS
Cooler
TAHH
PAHH
300# CS 300# 150# 150# CS
PALL Bearing - Vibration,
LAH Shaft - Axial Movement Spec Blind d/s or
LIC Temperature Trips Blind Flange u/s
Suction LAL if intermittent
LAHH Scrubber Inlet flow measurement and operating speed decide approach VB/ VG
150 #CS 300 #CS
LALL LG to surge and Anti Surge Valve is opened to increase inlet flow
150# 300#
For seal oil / fire case/ reduce start-up load BDV is opened CS CS
LV

P&ID Development 7

Daily Mantra: “All Valves Leak”

API have abandoned 2 dissimilar check valves hypothesis

Leaking valves: Less bulk flow. Still transmit pressure.
Remember Bhopal

Positive Isolation for Vessel Entry and Maintenance

Depending upon service conditions
 Block and Bleed. Double Block and Bleed. Spec Blinds.
Removable Spool Pieces

150# 300#

RPS ? 150# 300#

Title Block
Individual Equipment Check

Line List is prepared by Process and updated
Equipment details matching List, say Pumps
by Piping Equipment List  Concentric reducer with flat top
 Name and Tag No at inlet. Expander at outlet
 Piping MTO. Stress Analysis. Fabrication.
B/L isolation, F, P, T  Suction strainer

Equipment isolation  Min Flow Protection
Construction. Plant Operation  Double Block & Bleed  Outlet check valve
Size Spec Insul Service From To Phase Velocity Density Operating Design Testing P&ID  Spec Blinds, Spade, Spool  Hot bypass across discharge
No P&T P&T Medium No pieces check valve

Depressurization  Inlet and outlet tracing
 Vent & Drain  Suction, discharge and casing

Sampling. Online Analyzer drain

Copious Notes:  Casing Vent
 To transfer design intent to Remember:
operators and op manual Organizations Have No
preparation team Memory
 Key Hazop Findings Good Notes can Save
Lives

P&ID Development 8
 PRV
PAHH
PIC/PAH

NOP

Get them checked within
Next, External Reviews
Control system maintains stable operation
the Dept  Operations

Trip / shutdown provides primary protection, when

Next, Internal Reviews by  Projects
control system fails
 Safety
Relief provides secondary or ultimate protection or last
 Mechanical
Safety Reviews line of defence, when control and trip systems fail
PRV
 Piping  Hazop/ PHA PIC
 Corrosion & Materials  SIL
 Instrumentation & Controls  Alarm Reduction/ PAHH
T0 Flare
 Electrical Management PALL
T0 Compressor
 Civil/ Structural SDV
 Start-up & Commissioning
Update Production LAHH

 Control system Inflow LALL

 Projects SDV Separator
 Alarms & Trips SDV
 Emergency Shut Down Oil
RV lifting: a serious incident Water
SDV

API RP 14 C “Recommended Practice for
Offshore Facility
Exhaust Heated

Wellhead Flow Lines Component
Analysis, Design, Installation, and Testing of
Underwater Flow Lines
Pipeline Pump
Basic Surface Safety Systems for Offshore
Satellite Well
Glycol Powered Glycol
Production Platforms”
Wellhead Injection Lines Pump

Headers
Other Pumps
 Recommends protection system for different type
Pressure Vessel
Compressor Unit
of equipment
Atmospheric Vessels
Pipelines

A comprehensive visual check list
Fired Vessel (Natural Draft)
Heat Exchangers (Shell-

Fired Vessel (Forced Draft) Tube)

P&ID Development 9

Conduct Flare & Relief Analysis
Review supplier drawings
 Identify loads, governing case and size PRVs
 Add vent & drain, sampling, utility tie-ins
 Depressurization Analysis
 Perform Flare network analysis, size, PRV inlet, outlet,  Mark and tag all interfaces
sub-headers and main headers  Check Package (Compressors) Item documents,

Review Plot Plans
P&IDs and identify interfaces and mark
 Check assumed pressure drops of critical lines
 Update control valve pressure drop and size
 Finalize pump NPSHa and suction line sizes

Review Cause & Effect Charts
 Update PSD, ESD, PLC, DCS markings
▪ Push Buttons. Fire & Gas Inputs

Column

Fractionation columns with side streams
 Pressure controls
P&ID is a live document .. From Concept  Engg  Construction  Operation

Fired Heater – Process, Fuel Gas, Fuel Oil and  Plant Modification  Demolition
Combustion Air Control Fired Heater

 Cascade control on firing

P&ID Development 10

P&ID is a ‘live’ document that gets updated
Several revisions - as more
Detailed Engg
info is available during  Line sizing
 Start with PFD showing controls + valves + alarm, trip engineering thru  Size Control Valves, PRV
and relief commissioning  Vessels - Finalize nozzles/ sizes
 Issued for Internal Comments  Owner’s Comments
FEED/Licensor  Select Pumps, Seal system
 Hazop Study  Design  Construction  As Built  Pumps – Flow x Head ▪ NPSHa calcs
 Plant Modification  HX or Heater - no rating or no  HX - Shells
of shells  Heaters - APH, FD/ID Fans
 Add supplier information
 Major lines only  Flare, Vent, Drain and Utility

Basis of  Control loops ▪ Collection & Distribution
▪ Engg Stage: Safety studies. Instrumentation & Controls.  Utility connections ▪ Flare, Steam, CW, FW - huge
Piping. Electrical efforts

▪ Fabrication. Construction - to install. Monitor progress Conceptual Procurement Construction & Commissioning As Built
FEED/ Licensor Detailed Engg Plant Mods
▪ Commissioning. Start-up and Shutdown. Operating Manual Design PFD Fabrication Erection & Startup Production

FEED/Licensor
Engineering - First Pass
After AFD/ Hazop issue

 Safety studies may shift equipment .. Longer pipes
FT FIC FT FIC  Standardization of control valve body – from 3” to 4”
1001 1001
FV FV  MOC changes
FE FE 3” (Hold) 1001
1001 3”x4” 3”x4”
 Non-availability of selected materials. Small quantity procurement
4”
4”-CS-P-1001 4”-SS-P-1002
 Left over from previous projects
3”-CS-P-1003 3”-SS-P-1004
300# 300# 150#

After Operations Review CS LTCS LTCS

Commissioning & Start-up
FT FIC
FT 1001 1001
 Valves relocation
FIC
1001 1001

After Hazop Review, may FV  Start-up lines. Temporary Lines
FV FE 1001
4”
FE 3”) 1001
call for a check valve at 1001  Purging Lines
1001 3”x4” 3”x4” 4”x6”
 Additional sampling points
4”-CS-P-1001 4”-SS-P-1002 Methanol Injection Point 4”-CS-P-1001 6”-SS-P-1002
 Owner-Operator preferential
3”-CS-P-1003 3”-SS-P-1004
Methanol 300# 300# 150# Methanol3”-CS-P-1003 3”-SS-P-1004 engineering
Injection CS LTCS LTCS 300# 300# 150#
Injection
CS LTCS LTCS

P&ID Development 11

After start-up, as-built markups from site
One complete stream from a column missed

After several revisions and versions from different out
sources, P&IDs are as built and handed over
Wrongly routed pump suction lines, making

During operations, plant management may them longer
upgrade the facilities, retrofit, replace or relocate
PRV tail pipe should free drain to flare header
equipment but may have pockets
 A number of contractors may work in a given area
Missing drains for pumps, control valve,
 Each may make his own Demolition and Construction sample points
P&IDs
 Mark carefully in a Master Copy, to avoid conflicts and

Site changes or modifications
update  Flixborough. ACN Incinerator

Get involved - hands on in Engg
Vessel/ Tank LTs of LIC and 1. ANSI/ISA S5.1 and ISO 14617-standard
Team. Not as an external ‘Owner trips to track each other and
Team’ give discrepancy alarm “Instrumentation Symbols and Identification”

Review 3D Piping Models
Identify H2S laden vessels

Human Factor Study “Caution - Pyrophoric Fire on 2. http://www.aiche.org/chenected/2010/08/inter
 Access to PRV, CV exposure to air” preting-piping-and-instrumentation-diagrams
 No piping obstruction to manways
No bends within 20D of a
 Piping, PG/TG projecting in ladder/ flashing control valve. Erosion, 3. http://www.aiche.org/chenected/2010/09/inte
Leak and Fire
stairways - may injure
 Inter-connecting skyways than have
Bends after H2O injection rpreting-piping-and-instrumentation-
to climb and down



All Ucs with check valves
Proper isolation. A single
diagrams

P&ID Reviews
 Two phase lines marked “Slug leaking valve caused Bhopal 4. http://www.aiche.org/chenected/2010/09/inte
and blew off a column top
Prone. Support Properly”
 Proper margin between control and
Min intake height for FD Fans rpreting-piping-and-instrumentation-
PRV avoid chattering, leak and fire
Watch for “Corrosion Under diagrams-symbology
 Watch out for ‘orphan’ check valves Insulation”

P&ID Development 12

Exercises
 Column Bottom thermosiphon reboiler
 2 Parallel Pumps
 Desalter
 Surge Drum
Thank You
 Flare KOD
 Single stage motor driven compressor
 Instrument Air Compressors

P&ID Development 13