Introduction To Basic Process Documents: by Jaswant Tawde
Introduction To Basic Process Documents: by Jaswant Tawde
Introduction To Basic Process Documents: by Jaswant Tawde
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;
Slide 5
Piping & Instrument Diagram
Most important document of process department
Used during all phases of the plant
Bidding
Engineering
Construction
Commissioning
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: A P&ID is not:
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:
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
Slide 12
Basic Point in P&ID
What is the basis of selecting design temperature
Max. Process temperature with design margin
Fire case
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
PWHT, Radiography
Type of fitting
Gasket, Bolts
Slide 15
Instrumentation
All instrument tag numbers
Instrument type
Instrument connection details
Isolation and draining & venting
Location of indication
DCS
PLC
Local
Panel Mounted
Slide 16
Instrumentation Control Valve
Control valve type
Control valve size
Handwheel
I/P Converter
Solenoid valve
Drain
Slide 17
Instrumentation - Control
Operational control, DCS interlock and SIS
interlock
Each control loop Single or Multivariable
Interlocks
Interlocks numbered
Slide 18
Instrument
Instrument list
I/O list
DCS graphics
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
Slide 24
Holds
Slide 25
Flare lines
Slide 26
P&ID Key Stages
PRELIMINARY
IFD
POST HAZOP
IFC
AS BUILT
Slide 27
PRELIMNARY
IFC
AS BUILT
Slide 28
IFD
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
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
IFC
AS BUILT
Slide 34
ISSUED FOR CONSTRUCTION
PRELIMINARY
IFD
Slide 35
ISSUED FOR CONSTRUCTION
PRELIMINARY
IFD
Slide 36
Thank you
Slide 37