Contents

Preface xxi

Acknowledgment xxv

About the Companion Website xxvii

Part I Fundamentals of Piping and Instrumentation Diagram Development 1

1 What Is Piping and Instrumentation Diagram? 3

1.1 Why Is P&ID Important? 3

1.2 What Is a P&ID? 4

1.3 P&ID Media 5

1.4 P&ID Development Activity 6

2 Management of Piping and Instrumentation Diagram Development 9

2.1 Project of Developing P&IDs 9

2.2 P&ID Milestones 9

2.3 Involved Parties in P&ID Development 11

2.4 P&ID Set Owner 12

2.5 Required Quality of the P&ID in Each Stage of Development 12

2.6 P&ID Evolution 13

2.7 Tracking Changes in P&IDs 13

2.8 Required Man-hours for the Development of P&IDs 14

3 Anatomy of a Piping and Instrumentation Diagram Sheet 15

3.1 Title Block 15

3.2 Ownership Block 16

3.3 Reference Drawing Block 16

3.4 Revision Block 16

3.5 Comments Block 17

3.6 Main Body of a P&ID 20

4 General Rules in Drawing of P&IDs 21

4.1 Items on P&IDs 21

4.2 How to Show Them: Visual Rules 22

4.3 Item Identifiers in P&IDs 28

4.4 Different Types of P&IDs 34

4.5 A Set of P&IDs 41

4.6 P&IDs Prepared in Engineering Companies Compared to Manufacturing or Fabricating Companies 43

4.7 Dealing with Vendor or Licensor P&IDs 44

5 Principles of Piping and Instrumentation Diagram Development 47

5.1 Plant Stakeholders 47

5.2 The Hierarchy of P&ID Development Rules 47

5.3 Plant Operations 48

5.4 What Should a P&ID Address? 55

5.5 Conflicting Check and Merging Opportunities Check 67

5.6 Dealing with Common Challenges in P&ID Development 67

5.7 Example: Development of P&ID of a Typical Pump 68

Part II Pipes and Equipment 73

6 Fluid Conductors and Pipe Appurtenance 75

6.1 Fluid Conductors: Pipes and Tubes 75

6.2 Pipe Identifiers 75

6.3 Pipe Tag Anatomy 79

6.4 Pipes Crossing “Borders” 84

6.5 Goal of Piping 89

6.6 Piping Arrangements 90

6.7 Pipe Route 93

6.8 Piping Movement 97

6.9 Dealing with Unwanted Two-phase Flow in Pipes 98

6.10 Tubes 102

6.11 Double-wall Pipes 102

6.12 Pipes for Special Arrangements 103

6.13 Pipe Size Rule of Thumbs 104

6.14 Pipe Appurtenances 104

6.15 Other Approach About Piping 110

6.16 Tying-in Pipes 111

6.17 Wrapping Up: Addressing Requirements of Pipe During the Life Span 111

6.18 Transferring Bulk Solid Materials 112

Reference 112

7 Manual Valves and Automatic Valves 113

7.1 Valve Naming 113

7.2 Valve Functions 113

7.3 Valve Structure 113

7.4 Classification of Valves 114

7.5 Valve Operators 120

7.6 Different Types of Actuators 121

7.7 Basis of Operation for Automatic Valves 122

7.8 Tagging Automatic Valves 122

7.9 Tagging Manual Valves 122

7.10 Valve Positions 122

7.11 Valve Arrangement 127

7.12 Control Valves and RO Combinations 129

7.13 Operating in the Absence of Valves 129

7.14 Valves in Role of Unit Operation 132

7.15 Special Valves 133

7.16 Excess Flow Valves 136

7.17 Valve Combinations 136

7.18 End-of-valve Arrangements 136

7.19 Valve Sizing Rule of Thumbs 136

7.20 Merging Valves 138

7.21 Wrapping-up: Addressing Requirements of Valve During the Life Span 138

References 138

8 Provisions for Ease of Maintenance 139

8.1 Introduction 139

8.2 Different Types of Equipment Care 139

8.3 In-place In-line Equipment Care 140

8.4 In-place Off-line Equipment Care 141

8.5 In-workshop Off-line Equipment Care 141

8.6 Preparing Equipment for Off-line Care 141

8.7 Isolation 142

8.8 Bringing the Equipment to a Non-harmful Condition 147

8.9 Cleaning 151

8.10 Ultimate Destination of Dirty Fluids 153

8.11 Making Equipment Easy to Remove 154

8.12 Wrap-up 154

9 Containers 157

9.1 Introduction 157

9.2 Selection of Containers 157

9.3 Containers Purposes 158

9.4 Transferring Fluids Between Containers 159

9.5 Container Positions 160

9.6 Container Shapes 162

9.7 Container Identifiers 163

9.8 Levels in Non-flooded Liquid Containers 166

9.9 Container Nozzles 166

9.10 Overflow Nozzles 173

9.11 Breathing of Non-flooded Containers 174

9.12 Blanketed Tanks 174

9.13 Heating (or Cooling) in Containers 177

9.14 Mixing in Containers 178

9.15 Container Internals 179

9.16 Tank Roofs 179

9.17 Tank Floors 179

9.18 Container Arrangement 180

9.19 Merging Containers 180

9.20 Secondary Containment 181

9.21 Underground Storage Tanks 182

9.22 Sumps 184

9.23 Wrapping-up: Addressing the Requirements of the Container During Its Lifespan 184

10 PUMPS and Compressors 187

10.1 Introduction 187

10.2 Fluid Mover Roles 187

10.3 Types of Fluid Movers 187

10.4 A Brief Discussion on the Function of Fluid Movers in a System 188

10.5 Fluid Mover Identifiers 189

10.6 Liquid Movers: Dynamic Pumps 192

10.7 Liquid Movers: PD Pumps 210

10.8 Gas Movers: Fans, Blowers, Compressors 216

10.9 Wrapping-up: Addressing Requirements of Fluid Movers During the Life Span 221

Reference 221

11 Heat Transfer Units 223

11.1 Introduction 223

11.2 Main Types of Heat Transfer Units 223

11.3 Different Types of Heat Exchangers and Their Selection 224

11.4 Different Types of Heat Transfer Fluids and Their Selection 225

11.5 Heat Exchangers: General Naming 226

11.6 Heat Exchanger Identifiers 227

11.7 Heat Exchanger P&ID 229

11.8 Heat Exchanger Arrangement 231

11.9 Aerial Coolers 233

11.10 Merging Heat Exchangers 236

11.11 Wrapping-up: Addressing the Requirements of a Heat Exchanger During Its Life Span 236

11.12 Fired Heaters and Furnaces 236

11.13 Fire Heater Arrangement 240

11.14 Merging Fired Heaters 240

11.15 Wrapping-up: Addressing the Requirements of Fired Heaters During Their Lifespan 240

12 Pressure Relief Devices 241

12.1 Introduction 241

12.2 Why Pressure Is So Important? 241

12.3 Dealing with Abnormal Pressures 242

12.4 Safety Relief System 244

12.5 What Is an “Enclosure,” and Which “Side” Should Be Protected? 244

12.6 Regulatory Issues Involved in PRVs 245

12.7 PRD Structure 246

12.8 Six Steps to Providing a Protective Layer 247

12.9 Locating PRDs 247

12.10 Positioning PRDs 248

12.11 Specifying the PRD 250

12.12 Selecting the Right Type of PRD 250

12.13 PRD Identifiers 251

12.14 Selecting the Right Type of PSD Arrangement 253

12.15 Deciding on an Emergency Release Collecting Network 255

12.16 Deciding on a Disposal System 257

12.17 Protecting Atmospheric Containers 261

12.18 Merging PRDs 262

12.19 Wrapping-up: Addressing the Requirements of PRDs During Their Lifespan 264

Part III Instrumentation and Control System 265

13 Fundamentals of Instrumentation and Control 267

13.1 What Is Process Control? 267

13.2 Components of Process Control Against Violating Parameters 268

13.3 Parameters Versus Steering/Protecting Components 268

13.4 How Many Steering Loops Are Needed? 269

13.5 ICSS System Technology 269

13.6 ICSS Elements 271

13.7 Basic Process Control System 272

13.8 Instruments on P&IDs 274

13.9 Instrument Identifiers 275

13.10 Signals: Communication Between Instruments 281

13.10.1 Signal Types 281

13.11 Different Instrument Elements 284

13.12 Simple Control Loops 294

13.13 Position of Sensor Regarding Control Valves 296

14 Application of Control Architectures 299

14.1 Introduction 299

14.2 Control System Design 299

14.3 Selecting the Parameter to Control 299

14.4 Identifying the Manipulated Stream 301

14.5 Determining the Set Point 301

14.6 Building a Control Loop 302

14.7 Multi-loop Control Architectures 304

14.8 Feedforward Plus Feedback Control 307

14.9 Monitoring Parameters 321

15 Plant Process Control 327

15.1 Introduction 327

15.2 Plant-wide Control 327

15.3 Heat and Mass Balance Control 327

15.4 Surge Control 329

15.5 Equipment Control 336

15.6 Pipe Control System 338

15.7 Fluid Mover Control System 345

15.8 Heat Transfer Equipment Control 356

15.9 Container Control System 368

15.10 Blanket Gas Control Systems 368

Reference 369

16 Plant Interlocks and Alarms 371

16.1 Introduction 371

16.2 Safety Strategies 371

16.3 Concept of an SIS 371

16.4 SIS Actions and SIS Types 371

16.5 SIS Extent 374

16.6 Deciding on the Required SIS 374

16.7 The Anatomy of an SIS 375

16.8 Showing Safety Instrumented Functions on P&IDs 379

16.9 Discrete Control 381

16.10 Alarm System 382

16.11 Fire and Gas Detection System 387

16.12 Electric Motor Control 390

Part IV Utilities 397

17 Utilities 399

17.1 Utility System Components 399

17.2 Developing Piping and Instrumentation Diagrams for Utility Systems 400

17.3 Different Utilities in Plants 404

17.4 Air as a Utility in Process Plants 404

17.5 Water as a Utility in Process Plants 405

17.6 Heat Transfer Media 405

17.7 Condensate Collection Network 407

17.8 Fuel as Utility 407

17.9 Inert Gas 408

17.10 Vapor Collection Network 409

17.11 Emergency Vapor/Gas Release Collection Network 409

17.12 Fire Water 409

17.13 Surface Drainage Collection Network or Sewer System 412

17.14 Utility Circuits 414

17.15 Connection Between Distribution and Collecting Networks 418

18 Ancillary Systems and Additional Considerations 421

18.1 Introduction 421

18.2 Safety Issues 421

18.3 Dealing with the Environment 424

18.4 Utility Stations 431

18.5 Off-line Monitoring Programs 434

18.6 Corrosion Monitoring Program 438

18.7 Impact of the Plant Model on the P&ID 439

18.8 Design Pressure and Temperature Considerations 440

Part V Additional Information and General Procedure 447

19 Pre-Piping and Instrumentation Diagrams in Chemical Process Engineering 449

19.1 Visual Representation Techniques in Chemical Process Engineering 449

19.2 Universal String of Chemical Process Industries 451

19.3 Pre-BFD Stage Development 453

19.4 BFD Development 457

19.5 PFD Development 459

19.6 PFD Demonstration Rules 465

19.7 H&MBT 466

19.8 Side-by-Side Comparison 467

19.9 Nontraditional Process Drawings 467

19.10 Developing PFD Based on Existing P&ID 468

19.11 Developing P&ID Based on Existing Process Plant 469

20 General Procedures 471

20.1 Introduction 471

20.2 General Procedure for P&ID Development 471

20.3 P&ID Reviewing and Checking 475

20.4 Methods of P&ID Reviewing and Checking 479

20.5 Required Quality of P&IDs at Each Stage of Development 480

21 Examples 485

Index 521