COMPLETE REVISION April 2008
Process Industry Practices P&ID
PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
SA N M O C T PL O F E M O M R ER C IA L
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In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All Practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these Practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice.
This Practice is subject to revision at any time.
© Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP member companies and subscribers may copy this Practice for their internal use. Changes, overlays, addenda, or modifications of any kind are not permitted within any PIP Practice without the express written authorization of PIP.
Note: PIP PIC001, Piping and Instrumentation Diagram Documentation Criteria, incorporates symbols previously published in standards owned and copyrighted by The Instrumentation, Systems, and Automation Society (ISA). These are printed with agreement from ISA. PRINTING HISTORY Issued November 1998 April 2008 Complete Revision
Not printed with State funds
COMPLETE REVISION April 2008
Process Industry Practices P&ID
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PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria
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Table of Contents
1. Introduction................................. 2 1.1 Purpose............................................ 2 1.2 Scope ............................................... 2
2. References .................................. 2 2.1 Process Industry Practices .............. 2 2.2 Industry Codes and Standards ........ 3 2.3 Government Regulations ................. 3
3. Definitions ................................... 3
4. Requirements.............................. 5 4.1 4.2 4.3 4.4 4.5
General ............................................ 5 Format.............................................. 6 Equipment ...................................... 11 Piping ............................................. 17 Instrumentation and Controls......... 20
Appendixes
Appendix A – Tables and Symbols Appendix B – Cover Sheets Appendix C – Example P&IDs
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1.
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Introduction 1.1
Purpose This Practice provides requirements for designers preparing Piping and Instrumentation Diagrams (P&IDs).
1.2
Scope This Practice describes the requirements for P&ID format and content. The Practice is independent of time in a facility life cycle and encompasses design, construction, operations, and maintenance. This Practice covers the generation of new P&IDs and does not apply to the revision of existing P&IDs. This Practice also applies to P&IDs provided by packaged equipment vendors.
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This Practice applies to all diagrams that fit the definition of a P&ID in Section 3.
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The requirements provided in this Practice can be applied to any CAD system used for developing the P&IDs and are not vendor, hardware, or software specific.
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The requirements provided in this Practice provide a balance between showing all data on P&IDs and making P&IDs legible and easy to read. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The example P&IDs included in the Appendixes of this Practice are not intended to recommend specific design details or requirements. Example P&IDs are included to provide an illustration of how the elements of this Practice are combined into a P&ID. Electronic native files for the text, symbols, and cover sheets are available to PIP Member Companies for input to members’ CAD systems. Development of projectspecific cover sheets is recommended using the PIP native files as a starting point. Additions and/or deletions are allowed to meet requirements. Cover sheet borders and title blocks can be altered.
2.
References
Applicable parts of the following Practices, industry codes and standards, and references shall be considered an integral part of this Practice. The edition in effect on the date of start of P&ID development shall be used, except as otherwise noted. Short titles are used herein where appropriate. 2.1
Process Industry Practices (PIP) – PIP INEG1000 – Insulation Design and Type Codes – PIP PCCIP001 – Instrument Piping and Tubing Systems Criteria – PIP PCSIP001 – Instrument Piping and Tubing Systems Specifications
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– PIP PNE00001 – Design of ASME B31.3 Metallic Piping Systems – PIP PNSM0001 – Piping Line Class Designator System 2.2
Industry Codes and Standards •
American National Standards Institute (ANSI) – ANSI/FCI 70-2-2003 – Control Valve Seat Leakage
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American Society of Mechanical Engineers (ASME) – ASME Boiler and Pressure Vessel Code Section VIII – Pressure Vessels
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The Instrumentation, Systems, and Automation Society (ISA) – ISA 5.1 – Instrumentation Symbols and Identification – ISA 5.2 – Binary Logic Diagrams for Process Operations
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– ISA 5.3 – Graphic Symbols for Distributed Control / Shared Display Instrumentation, Logic and Computer Systems •
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– ISA 84.01 – Application of Safety Instrumented Systems for the Process Industries Tubular Exchanger Manufacturers Association (TEMA)
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– TEMA Standards 2.3
Government Regulations •
Occupational Safety and Health Administration (OSHA)
– OSHA 29 CFR 1910.119 – Occupational Safety and Health Standards, Process Safety Management of Highly Hazardous Chemicals
3.
Definitions
For the purposes of this Practice, the following definitions apply:
accessible: Term applied to a device or function that can be used or seen by an operator for the purpose of performing control actions (e.g., set point changes, auto-manual transfer, or on/off actions) (Reference ISA 5.1) automated valve: Any valve with a locally or remotely controlled actuator. Examples are throttling control valves and on/off block valves. Actuators are typically air-operated (diaphragm or piston), electric or hydraulic, some with a spring-return function. Manually-operated valves are sometimes tagged as automated valves (e.g., if a manual valve is fitted with position switches).
auxiliary P&ID: Used to show details to unclutter other P&IDs (e.g., lube oil system, sample systems, instrument details) Basic Process Control System (BPCS): Control equipment and system installed to regulate normal production functions. It may contain combinations of single-loop pneumatic controllers, single-loop electronic controllers, Programmable Logic Controllers (PLCs), and Distributed Control Systems (DCSs). The BPCS is required to operate the process. Examples of control
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functions included in the BPCS are cascade control, override control, and pump start/stop. Also known as Basic Regulatory Controls. (See also HLCS and SIS) bubble: Circular symbol used to denote and identify the purpose of an instrument or function. The bubble usually contains a tag number. (Synonym for balloon) (Reference ISA 5.1) design pressure: Pressure used in the design of a vessel component together with the coincident design metal temperature for determining the minimum permissible thickness or physical characteristics of the different zones of the vessel. (Reference ASME Boiler Pressure Vessel Code, Section VIII, Division 1, Appendix 3) fail closed (FC): Characteristic of an automated valve that causes the valve to close as a result of specific malfunctions, including loss of signal or motive power. (Reference ISA 5.1)
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fail indeterminate (FI): Characteristic of an automated valve that causes the valve to move to an unknown position as a result of specific malfunctions, including loss of signal or motive power. Some automated valves will not stay at the last position upon failure and instead move with the process differential pressure. Additional equipment may be needed to meet the definition of FC, FO, or FL. (Reference ISA 5.1)
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fail locked (FL) last position: Characteristic of an automated valve that causes the valve to remain in the last (locked) position as a result of specific malfunctions, including loss of signal or motive power. Automated valves may fail indeterminately without additional equipment. (Reference ISA 5.1) fail open (FO): Characteristic of an automated valve that causes the valve to open as a result of specific malfunctions, including loss of signal or motive power. (Reference ISA 5.1) hand switch (HS): Any operator-manipulated discrete control device, including hardwired panel switches and software points. heat exchanger type: Type designation shall be shell and tube, plate and frame, spiral, etc. For shell and tube exchangers, use the three-letter designation describing stationary head, shell, and rear end or head, in that order, in accordance with TEMA. Higher Level Control System (HLCS): Provides sophistication above that of the BPCS. The HLCS is not necessary to operate the process. HLCS functions are typically based in process computers or higher level DCS hardware that interacts with the process by manipulating set points in the BPCS. Examples of control functions in the HLCS are statistical process control and model predictive control. (See also BPCS and SIS)
interlock: System that, in response to a predetermined condition, initiates a predefined action. Typically comprised of binary (on/off) signals and logic used for process control, sequencing, or protective interruption of normal process control functions. Protective interlocks are typically further defined as being either safety-related or commercial-related (asset or production protection). isolation valve: A valve used for isolation of process equipment while performing activities such as purging, de-pressuring or de-inventorying. This valve is also commonly referred to as the primary block valve. line class: Section of the Piping Material Specifications that provides a listing of piping components for specific design conditions.
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logic solver: Control equipment that performs the logic function. It can be either hardwired (e.g., relays) or Programmable Electronic Systems (e.g., DCS-based or PLC-based, including dualredundant or triple-redundant microprocessors). packaged equipment: One or more pieces of equipment furnished by a vendor with supportive devices and components to perform a specific operation as a unit Piping and Instrumentation Diagram (P&ID): Detailed graphical representation of a process including the hardware and software (i.e., piping, equipment, and instrumentation) necessary to design, construct and operate the facility. Common synonyms for P&IDs include Engineering Flow Diagrams (EFDs), Utility Flow Diagrams (UFDs), and Mechanical Flow Diagrams (MFDs) Programmable Electronic System (PES): Logic performed by programmable or configurable devices (Reference ISA 84.01)
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root valve: First valve or valves between the process and an auxiliary device (e.g., an instrument) that contacts the process and is used to isolate the device from the process. This valve is typically a line class valve used for shut-off and isolation.
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Safety Integrity Level (SIL): One of four possible discrete integrity levels (SIL 1, SIL 2, SIL 3, and SIL 4) of Safety Instrumented Systems. SILs are defined in terms of Probability of Failure on Demand (PFD). (Reference ISA 84.01)
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Safety Instrumented Systems (SIS): Systems composed of sensors, logic solvers, and final control elements for the purpose of taking the process to a safe state if predetermined conditions are violated. Other terms commonly used include Emergency Shutdown System (ESD or ESS), Safety Shutdown System (SSD), and Safety Interlock System (SIS). (Reference ISA S84.01) (See also BPCS and HLCS) skirt: Cylindrical supporting structure, welded to the bottom of a vertical vessel and extended to the base support tagged: For the purposes of labeling instrumentation and control components, a hardware device or a software point that is identified with an ISA style tag number
Tight Shut-Off (TSO): Tight Shut-Off is defined in this Practice as ANSI Class V or ANSI Class VI in accordance with ANSI/FCI 70-2 trim: Item attached to equipment as an integral component, identified as part of the equipment that is exposed to the process, and having a function local to the equipment being served. Examples are vent and drain valves, instrument bridles, blind flanges, plugs, or other miscellaneous items associated with a piece of equipment. Typically, trim is purchased independently from the equipment.
4.
Requirements 4.1
General 4.1.1
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Most details available from other types of documentation (e.g., instrument loop diagrams and vessel data sheets) should not be included on P&IDs.
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4.2
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4.1.2
This Practice uses the concepts of typical details with implied components where appropriate to simplify P&IDs. (See the cover sheet in Appendix B for examples.) Additional examples can be added as required.
4.1.3
While the intent of this Practice is to simplify the P&IDs through the use of implied components and cover sheets, this may not be compatible with the work processes or design software used for a project. Therefore, this Practice does not require the use of implied components. It is the responsibility of the project team to determine the compatibility of implied components with project needs and work processes (e.g., safety reviews, material take-off method, integration plan, etc.).
Format 4.2.1
Layout
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Comment: The layout and orientation statements specified herein are recommended as optimal, and slight deviation, although not encouraged, may be required due to space constraints. 4.2.1.1 Piping Orientation
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1. The top of a horizontal line and the left side of a vertical line shall be the top of a pipe.
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2. The bottom of a horizontal line and the right side of a vertical line shall be the bottom of a pipe. 3. A note shall be used to clarify the orientation as required.
4.2.1.2 Drawing size shall be 22 inches x 34 inches.
4.2.1.3 Each P&ID shall be laid out to avoid clutter and allow future modifications. No more than three pieces of major equipment shall be shown on a P&ID. A set of pumps in the same service shall be one piece of equipment for the purpose of a P&ID layout in accordance with Appendix C.
4.2.1.4 Flow Orientation
1. Primary flow shall be shown on each P&ID from left to right. 2. Flow-through equipment shall be shown relative to actual arrangement (e.g., cooling water supply in bottom of exchanger tube bundle and cooling water return out top).
4.2.1.5 Primary process lines shall be shown heavier than secondary and utility lines as described in Section 4.2.3. 4.2.1.6 Connector Symbols
1. Off-page and off-plot connectors for primary, secondary, and instrumentation lines shall be shown entering the P&ID horizontally 0.25 inch from the left inside borderline and exiting 0.25 inch horizontally from the right inside borderline in accordance with Appendix C. 2. Utility connectors can be shown at any convenient location on the body of the P&ID.
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4.2.1.7 Utility P&IDs
1. Utility collection/distribution P&IDs shall be laid out relative to plot plan orientation in accordance with Appendix C. 2. To depict plot plan orientation, utility off-page connectors for a utility connection/distribution P&ID may be positioned vertically in accordance with Appendix C. 3. If match lines are required on utility collection/distribution P&IDs, the lines shall match the connecting drawing match lines in accordance with Appendix C. 4.2.1.8 Connector Descriptions
1. Service description, connector number, P&ID number, and origin/destination shall be shown for off-page and off-plot connectors in accordance with Appendix A-3.
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2. Origin/destination shall be shown as an equipment number, line number, or loop number.
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3. Service description for a piping off-page and off-plot connector shall be shown as name of fluid (e.g., Cracked Gas) or line description (e.g., Reactor Feed, Tower Overhead).
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4. Service description for an instrument off-page and off-plot connector shall be shown as a line function (e.g., Low Level Override) or equipment to be controlled (e.g., PV-10014A/B).
5. Text associated with off-page and off-plot connectors on the left side of the P&ID should be left justified; text associated with offpage and off-plot connectors on the right side of a P&ID should be right justified.
4.2.1.9 Equipment arrangement shall be shown relative to its elevation to grade (e.g., pumps at bottom of P&ID) in accordance with Appendix C.
4.2.1.10 A control valve actuator shall be shown above a horizontal line or left of a vertical line. 4.2.1.11 If a control valve identification bubble is required, the center point of the bubble shall be shown 0.5 inch above and 0.5 in away from the actuator in a horizontal line or 0.5 inch to the left and 0.5 inch away from the actuator in a vertical line. 4.2.1.12 The center point of an instrument bubble shall be shown 0.5 inch directly above an in-line instrument in a horizontal line or 0.5 inch directly left of an in-line instrument in a vertical line. Examples are restriction orifices and stand-alone thermowells. 4.2.1.13 Pump and compressor driver piping, instrumentation, and auxiliaries can be shown on a separate, auxiliary P&ID. “Primary” P&ID and auxiliary P&ID shall be cross-referenced.
4.2.1.14 Typical details shall be used if clutter can be eliminated without detracting from clarity. These details shall be shown on the P&ID, on an auxiliary P&ID, or on a cover sheet.
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4.2.4.2 Equipment Information
1. Equipment numbers shall use a text height of 0.16 inch at a weight of 0.03 inch. 2. Equipment numbers shall be underlined. 3. Equipment title and data shall use a text height of 0.1 inch at a weight of 0.02 inch. 4. Equipment text shall be justified at the top and center. 5. Equipment numbers, titles, and data for fixed or static equipment (i.e., exchangers, vessels, tanks, towers, filters, and material handling) shall be shown within 2 inches from the top inside borderline of the P&ID, directly above the equipment, and on the same horizontal plane as other equipment identification.
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6. Equipment numbers, titles, and data for rotating equipment (i.e., pumps, blowers, compressors, and agitators) shall be shown within 2 inches from the bottom inside borderline of the P&ID, directly below the equipment, and on the same horizontal plane as other equipment identification.
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7. Equipment number, title, and data shall be shown once for identical equipment with the same number, title, and service (e.g., P-601A/B).
4.2.4.3 Line Numbers
1. Line numbers shall be shown in accordance with Appendix A-3. See example shown in Appendix C. 2. Line numbers shall use a text height of 0.1 inch at a weight of 0.02 inch. 3. Line number text shall be placed 0.06 inch from the line and shall be lined up vertically 0.25 inch from the connector. 4. Line numbers at entering off-page and off-plot connectors shall be justified at the top and left. 5. Line numbers at exiting off-page and off-plot connectors shall be justified at the top and right. 6 Line numbering shall be shown with the orientation of the line.
4.2.4.4 Text Arrangement
1. Text shall be shown horizontal if possible. 2. Vertical text shall be placed to the left of supporting graphics if possible. 3. Vertical text shall be read from bottom to top.
4.2.4.5 Abbreviations shall be in accordance with Appendix A-1.
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4.2.4.6 Control Valve Information
1. Control valve failure action abbreviation shall be shown at 0.06 inch directly below the control valve in horizontal lines and 0.06 inch to the right of the control valve in vertical lines. See examples shown in Appendix C. 2. If the valve size is not line size or easily inferred from adjoining pipe, reducers, or equipment, control valve size shall be shown between the actuator and valve body symbol. If necessary, control valve size can be repositioned so as not to be obscured by other items shown on actuator (i.e., position switches, handwheels, etc.). See examples shown in Appendix C.
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3. Control valve seat leakage criteria (i.e., tight shut-off [TSO]) shall be shown between the actuator and valve body symbol. If necessary, control valve leakage criteria can be repositioned so as not to be obscured by other items shown on the actuator (i.e., position switches, handwheels, etc.). See examples shown in Appendix C.
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4.2.4.7 For PSVs, PSEs, and pressure control valves (PCVs), the device size and set pressure shall be shown close to the identification bubble. See examples shown in Appendix C. 4.3
Equipment 4.3.1
General
4.3.1.1 Equipment Symbols
1. Equipment symbols shall be shown in accordance with Appendix A-2. 2. Equipment shall be shown with simple outline representation. 3. Discretion shall be exercised for equipment symbols to not dominate the drawing, but the symbols shall be drawn large enough for clear understanding. 4. Equipment shall not be drawn to scale.
5. Equipment shall be shown relative to associated equipment both in size and general orientation.
4.3.1.2 Nozzles
1. Nozzles, including spares, shall be shown on equipment as single lines. 2. Manways shall be shown as double lines. 3. Process and utility nozzles may be labeled. 4. Nozzle sizes shall be shown, unless the size is implied by piping connections.
4.3.1.3 Equipment not specifically identified in this Practice shall be shown with an equipment symbol that is a reasonable representation of the equipment as it will exist in the field.
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4.3.1.4 Equipment shall be identified by a classification letter and sequence number. Classifications used in this Practice are shown in Section 4.3.12. Comment: The classifications shown in Section 4.3.12 are used on the example P&IDs contained in Appendix C for illustrative purposes only. The classifications are only one example of classifications allowed by this Practice. 4.3.1.5 Equipment Item Number and Title/Service shall be shown as a minimum. Section 4.3.13 provides a complete list of equipment data for all equipment addressed in this Practice. For equipment not covered in this Practice, equipment data shall be shown as necessary. 4.3.1.6 Internals for equipment shall be shown as dashed lines as described in Section 4.2.2.2. Details of internals that have no significant bearing on the piping design and layout or equipment operation shall be omitted.
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4.3.1.7 Equipment elevations shall not be shown unless the elevations are necessary to specify process requirements for associated equipment location or orientation relative to one another.
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4.3.1.8 Associated trim (e.g., vent and drain valves, instrument bridles) for equipment shall be shown.
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4.3.1.9 Auxiliary system requirements for individual pieces of equipment (e.g., lube oil systems, seal flush systems, turbine gland leak-off piping, sample systems) shall be shown on auxiliary P&IDs.
4.3.1.10 Jacketing and tracing requirements for equipment shall be shown. 4.3.1.11 The type of insulation (e.g., personnel protection, heat conservation) for equipment shall be shown as part of the equipment data. Insulation thickness shall be shown where applicable.
4.3.2
Agitators
4.3.2.1 The term agitator shall apply to mechanical mixers and aerators. 4.3.2.2 Agitators shall be shown in accordance with Appendix A-2.
4.3.3
Blowers
4.3.3.1 Blower symbols shall be shown as centrifugal or positive displacement as required. 4.3.3.2 Blowers shall be shown in accordance with Appendix A-2.
4.3.4
Compressors
4.3.4.1 The compressor symbol shall be shown for each stage of multistage compressors. 4.3.4.2 Multistaged compressors can be shown on multiple P&IDs. 4.3.4.3 Compressors shall be shown in accordance with Appendix A-2.
4.3.5
Drivers 4.3.5.1 Drivers shall be shown with the driven equipment and shall use the symbols for motors, diesel engines, and turbines.
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Table 1: Equipment Classifications CLASS
SUBJECT
DESCRIPTION
Mixing Equipment
Agitators, Aerators, Mechanical Mixers
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Blowers
Centrifugal Blowers, Positive Displacement Blowers, Fans
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Compressors
Centrifugal, Reciprocating, Screw, Vacuum
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Mechanical Drivers
Electric and Pneumatic Motors, Diesel Engines, Steam and Gas Turbines
E
Heat Exchangers
Unfired Heat Exchangers, Condensers, Coolers, Reboilers, Vaporizers and Heating Coils, Double Pipe, Spiral, Plate & Frame, Air Coolers
F
Furnaces
Fired Heaters, Furnaces, Boilers, Kilns
P
Pumps
Horizontal and Vertical Centrifugal, Positive Displacement, Vertical Canned, Screw, Gear, Sump
R
Reactors
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Towers / Columns
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Tanks
API atmospheric and low pressure
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Miscellaneous Equipment
Filters, Bins, Silos
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TK
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Vessels
Separators, Driers, Accumulators, Drums
4.3.13 Equipment Data
The following equipment information shall be shown on the P&ID in relation to the appropriate equipment symbol and in accordance with Section 4.2.4.2:
4.3.13.1 Agitators, Mixers
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Equipment/Item Number
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Title/Service
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Power Requirements
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Materials of Construction
4.3.13.2 Blowers
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Equipment/Item Number
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Title/Service
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Capacity (Flow and D/P)
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Power Requirements
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Materials of Construction
4.3.13.3 Compressors
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Equipment/Item Number
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Title/Service
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Capacity (Flow and D/P)
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Instrumentation and Controls 4.5.1
Symbols 4.5.1.1 Instrument and control symbols shall be shown in accordance with Appendix A-4. (Reference ISA-5.1 for additional details) 4.5.1.2 The conventions established by ISA-5.1 shall be followed for tagging and numbering of instrument and control devices. (Reference Appendix A-4) Comment: The tagging and numbering scheme described in the following example is used on the example P&IDs contained in the Appendixes for illustrative purposes only. This example tagging and numbering scheme is only one example of tagging and numbering schemes described in this Practice. The tagging structure is shown in the following example:
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01 FC 100 01 01 – Plant Number (shall not appear on P&IDs or in a bubble)
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FC – Function Identifier (e.g., Flow Controller) 100 – Equipment (or P&ID) Number (optional)
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01 – Loop Sequence Number.
Breaks in the instrument bubble may be used to accommodate longer tag numbers.
4.5.1.3 All measurement types shall be identified by an ISA symbol. 4.5.1.4 If necessary, a descriptive text label may be added (e.g., analysis components like CO, H2, CH4, or unique flow measurement devices like “Mass”).
4.5.1.5 Interlock symbols shall be depicted as follows: a. For discrete, hardware-based interlocks, the conventional diamond symbol shall be used in accordance with ISA-5.1 and ISA-5.2.
b. For PLC-based interlocks, the diamond-in-a-box symbol shall be used in accordance with ISA-5.1 and ISA-5.2.
c. For DCS-based interlocks, the DCS symbol (bubble-in-a-box) shall be used. d. For PLCs integral to the DCS, the PLC symbol (diamond-in-a-box) shall be used. Comment: Reference Appendix A-4 and Section 4.5.6 for additional information.
4.5.1.6 Directional arrows on instrumentation signal lines shall be used only if the function is not obvious (e.g., cascades, selectors, interlocks). 4.5.1.7 Instrument function symbols, shown in Appendix A-4, shall be used to clarify the function of certain tagged instrument bubbles. The symbol shall be placed outside the bubble at the upper right.
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3. The symbols shown in Appendix A-4 shall be used for pressure and temperature regulators. 4.5.3.2 Automated Valves
1. Automated valve fail actions shall be shown with text (FC/FO/FL/FI) in accordance with ISA-5.1. (Reference Section 4.2.4.6) Comment: Using stem arrows as outlined in ISA-5.1 is not recommended. 2. For multi-port automated valves, FL and FI shall be used where appropriate. Comment: FO and FC shall not be used; instead, arrows shall be used to show fail position flow paths. Note that multiple arrows may be required.
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3. Valves with different fail actions for loss of signal and for loss of motive power require an explanatory note.
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4. Valve body sizes shall be shown for all automated valves if not line sized or otherwise implied. (Reference Section 4.2.4.6)
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5. Automated valve specifications or commodity codes shall not be shown. 6. For automated valves, tight shut-off requirements shall be identified by using the abbreviation “TSO.” (Reference Section 4.2.4.6) Comment: TSO defines the seat shut-off requirements for a new valve. Testing requirements, if any, are defined in other unit operation documents.
4.5.3.3 Identifying Tags
1. Valve identifying tags with bubbles shall not be shown if the associated loop tag is readily apparent. 2. An identifying tag with a bubble shall be shown for split range valves, self-contained regulators, or valves located on a separate P&ID from its controller. (Reference Section 4.2.1.6)
4.5.3.4 The ranges (e.g., 0-50%, 50-100%) shall be shown for split range control valves. Comment: The preferred labeling is controller percentage output because it applies to both pneumatic and electronic systems.
4.5.3.5 Valve positioners shall not be shown unless necessary to clarify loop operation (e.g., if used with trip solenoids or pneumatic trip relays). Comment: If shown, valve positioners are normally included with the automated valve symbol and are not tagged.
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PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria
4.5.6
April 2008
Interlocks and Alarms 4.5.6.1 Interlocks shall be shown only symbolically on the P&ID. 4.5.6.2 The functional definition shall be shown on auxiliary documents (e.g., binary logic diagrams, descriptive narratives, truth tables). Comment: Interlocks can be designed for a variety of functions, from simple process sequences to complex safety shutdown systems. A variety of hardware can be used for implementation (e.g., DCS, PLC, relays, redundant, fault-tolerant Safety Interlock Systems).
SE
Alarms can be similarly designed in a variety of ways. Alarms come from hardware, over serial links, from DCS software and can be shown on a variety of facility documents, including P&IDs, alarm summaries, logic and loop diagrams, and operating procedures.
U
Because of this variety, along with individual owner interpretations of the requirements of OSHA 1910.119 and ISA -84.01, many documentation aspects of interlock and alarm system design should be defined by the owner.
SA N M O C T PL O F E M O M R ER C IA L
4.5.6.3 Logic functions or interlocks shall be shown with the proper symbols in accordance with Section 4.5.1. 4.5.6.4 Binary logic gates, input/output tables, or descriptive narratives shall not be shown.
4.5.6.5 All logic function and interlock symbols shall contain an identification that provides reference to a unique logic diagram, narrative, truth table, or program. The reference shall be located within the interior of the symbol. The format of the reference shall be determined by the owner. Descriptive text or a note reference can be placed outside the symbol. 4.5.6.6 If Safety Instrumented Systems (SIS) are distinguished from other interlock systems, the preferred method shall be to add an “S” prefix to the unique interlock identification. 4.5.6.7 Each interlock shall be uniquely labeled, using a serial (not parallel) tagging scheme. The “S” prefix shall not be used to distinguish a unique interlock label. Comment: A valid tagging scheme shall be I-100, I-101, SI-200, SI-201. The scheme I-100, SI-100 should not be used.
4.5.6.8 The type of logic solver hardware or level of redundancy shall not be shown except through the normal use of ISA symbols and the input and output signals described in Section 4.5.1 and the Appendixes. 4.5.6.9 Classifications or Safety Integrity Levels (SIL) shall not be shown for interlocks. 4.5.6.10 All operator-initiated interlock trip and reset hand switches shall be shown.
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Process Industry Practices
COMPLETE REVISION
PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria
April 2008
4.5.6.11 If used, all bypass hand switches for SIS interlocks shall be shown, including all individual initiator and system bypass switches. Comment: Unnecessary clutter can be avoided by use of a table or reference note if large numbers of bypasses are necessary. 4.5.6.12 All hardwired alarms shall be shown. 4.5.6.13 All alarms that require engineering or other review and approval based on safety or operability shall be shown. 4.5.6.14 Hardware-based diagnostic alarms shall be shown. 4.5.6.15 Software-based diagnostic alarms shall be shown only if safety or operationally related (e.g., defined in safety reviews).
SE
Comment: Measurement out-of-range alarms are an example of software diagnostic alarms not generally shown. 4.5.6.16 Required alarms shall be shown with tag and level (e.g., PAH), but alarm trip points or settings shall not be shown.
U
4.5.6.17 For alarms based on analog measurements, the functional tag (e.g., PI) shall be shown inside the bubble and the alarm levels shall be shown outside the bubble.
SA N M O C T PL O F E M O M R ER C IA L
4.5.6.18 High alarms (e.g., H, HH) shall be placed at the upper right outside the bubble, and low alarms (e.g., L, LL) shall be placed at the lower right outside the bubble. Comment: The alarm modifier (A) should not be shown.
4.5.6.19 For discrete alarm points (on/off signals), the complete functional tag and alarm level (e.g., PAH) shall be shown inside the bubble. 4.5.6.20 Standard ISA-5.1 abbreviations shall be used for both trip and alarm functions (e.g., LSHH and LAHH).
4.5.7
DCS Points
4.5.7.1 A DCS point shall be shown if operations manipulates the process with it or receives information from it, or if the point is essential to understanding the functional operation of the process controls. Comment: It is not necessary for every point configured in a DCS to be shown. It is not necessary for implied functions (e.g., I for indicate, R for recorder) to be included in every DCS point tag. It is not the intent of this section to define which DCS points to show for every supplier of a DCS or each type of system that can communicate with a DCS via a software link (e.g., analyzer data highways, anti-surge control systems, vibration monitoring systems, Safety Instrumented Systems, PLCs, tank gauging systems).
Process Industry Practices
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COMPLETE REVISION
PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria
April 2008
Appendixes Summary The Appendixes of this Practice contain tables of commonly used symbols, abbreviations and other identifiers; typical details; and example P&IDs. Appendix A contains symbols and text grouped by function. The symbols and text are shown the same size as would be utilized for a standard, full-size (22 inches x 34 inches) P&ID. Appendix B contains the same data as Appendix A, organized into cover sheets. Cover sheets are also commonly referred to as lead sheets or legend sheets. Appendix C contains example P&IDs that illustrate the text and utilize the symbols and legends on the cover sheets.
SA N M O C T PL O F E M O M R ER C IA L
U
SE
Comment: The cover sheets and P&IDs are drawn as standard, full-size (22 inches x 34 inches) P&IDs, but reduced to standard 8-1/2 inch x 11-inch pages for electronic distribution purposes. It is recommended that the cover sheets and P&IDs be printed on 11-inch x 17-inch pages.
COMPLETE REVISION
PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria
April 2008
Appendix A – Tables and Symbols A-1 Format Tables and Symbols 1. Abbreviations 2. Miscellaneous Symbols A-2 Equipment Tables and Symbols 1. Pumps 2. Compressors and Blowers 3. Drivers and Agitator/Mixer 4. TEMA Type Exchangers 5. Miscellaneous Exchangers
SE
6. Storage Tanks 7. Storage Tanks 9. Miscellaneous Vessel Details 10. Jacketed Pressure Vessels
U
8. Storage Sphere and Furnace
SA N M O C T PL O F E M O M R ER C IA L
A-3 Piping Tables and Symbols 1. Line Data Identification 2. Line Service Codes
3. Piping Line Symbols 4. Valve Symbols
5. Piping Specialty Items 6. Piping Fittings
7. Connectors and Tie-In Symbol 8. Drain Connectors 9. Notes
A-4 Instruments & Controls Tables and Symbols 1. Instrument Identification Letters 2. General Instrument Symbols
3. Instrument Function Symbols 4. Instrument Line Symbols
5. Primary Element Symbols (Flow) 6. Control Valve Actuator Symbols 7. Self-Actuated Devices 8. Miscellaneous Instrument Symbols
Process Industry Practices
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SA N M O C T PL O F E M O M R ER C IA L SE
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SA N M O C T PL O F E M O M R ER C IA L SE
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SA N M O C T PL O F E M O M R ER C IA L SE
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SA N M O C T PL O F E M O M R ER C IA L SE
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SA N M O C T PL O F E M O M R ER C IA L SE
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SA N M O C T PL O F E M O M R ER C IA L SE
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SA N M O C T PL O F E M O M R ER C IA L SE
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COMPLETE REVISION
PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria
April 2008
Appendix B – Cover Sheets
B-1: Symbols and Nomenclature – Typical Piping B-2: Symbols and Nomenclature – Typical Instrumentation B-3: Symbols and Nomenclature – Typical Equipment B-4: Typical Details with Implied Components
SA N M O C T PL O F E M O M R ER C IA L
U
SE
Note: The example cover sheets in this Appendix are not all-inclusive of the potential uses of implied components. The implied component examples shown do not cover all actual occurrences or design possibilities for instrument assemblies, such as the level bridles shown. The user must ensure that the cover sheets capture their piping/instrument requirements for their use of implied components. There are many more systems that may require a cover sheet explanation to show the implied components – pump seals, sampling systems, analyzer systems for example, as well as other types of level systems than those shown here.
Process Industry Practices
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SA N M O C T PL O F E M O M R ER C IA L SE
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SA N M O C T PL O F E M O M R ER C IA L SE
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COMPLETE REVISION April 2008
PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria
Appendix C – Example P&IDs C-1: Example P&ID 1 C-2: Example P&ID 2 C-3: Example Utility P&ID
SA N M O C T PL O F E M O M R ER C IA L
U
SE
Note: The examples shown on the sample P&IDs in this Appendix are not all-inclusive of the potential uses of implied components. The user must ensure that the cover sheets capture their piping/instrument requirements for their use of implied components. There are many more systems that may require a cover sheet explanation to show the implied components – pump seals, sampling systems, analyzer systems for example, as well as other types of level systems than those shown here.
Process Industry Practices
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SA N M O C T PL O F E M O M R ER C IA L SE
U
2
3
4
5
6
7
NOTES
LINES
PIPING SYMBOLS
NOTES:-
GENERAL
A
LINES IDENTIFICATION PROCESS/UTILITY LINE BASKET STRAINER GATE VALVE
ELECTRICAL LINE
B
INSTRUMENT GAS/ PNEUMATIC LINE
BURIED
FLAME ARRESTOR 1. HIGH POINT VENT AND LOW POINT DRAIN NOT SHOWN ON P&ID SHALL BE SHOWN ON PIPING
GLOBE VALVE
ELECTRICAL TRACED LINE
ISOMETRIC / GENERAL ARRANGEMENT DRAWINGS .
ST
ANGLE VALVE
STEAM TRAP
2. ALL SAFETY VALVES DISCHARGE & EQUIPMENT DEPRESSURIZING LINES SHALL BE FREE DRAINING X
X
CHECK VALVE
CAPILLARY LINE
X
ANGLE BALL VALVE
TO VENT HEADER AND HAVE NO POCKETS UPTO AND INCLUDING HEADERS.
UNION VENDOR LIMIT LINE
BUTTERFLY VALVE
ANGLE CHOKE VALVE
3. ALL ISOLATION VALVES IN TAPPINGS OF INSTRUMENTS (SUCH AS PRESSURE, LEVEL AND FLOW
ANGLE CONTROL VALVE
4. LINE NUMBERS SHALL BE INDICATED AS PER LINE LEGEND.
SWITCHES) CAUSING SHUTDOWN SHALL BE LOCKED OPEN.
CENTER LINE INSULATION JOINT L
L
L
L
PLUG VALVE
HYDRAULIC LINE FUTURE
B o
o
o
THREE WAY VALVE
ADAPTER (TUBING PIPE)
BALL VALVE
IT SHOULD BE ENSURED THAT THESE VALVES SHALL BE EASILY ACCESSIBLE.
SS TUBING (PROCESS)
THREE WAY CONTROL VALVE NEEDLE VALVE
SCOPE OF WORK/LINE RATING CHANGE (WITH PIPING SPEC. DESIGNATION)
5. ALL INSTRUMENTS SHALL BE PROVIDED WITH ISOLATION VALVES FOR MAINTENANCE PURPOSE.
FLOW ELEMENT ORIFICE/
6. DRAINS OF LEVEL INSTRUMENTS (NON-SOUR SERVICES) SHALL BE PIPED TO NEAREST DECK DRAIN FUNNEL WITH 1/2" TUBE PIPE.
RESTRICTION ORIFICE CONTINUOUS DRAIN
SPRING LOADED VALVE
7. FOR PUMPS HANDLING SWEET LIQUID, CASING VENTS, DRAINS AND BASE PLATE DRAINS SHALL
TURBINE METER
VANES CONTROL VALVE
BE PIPED WITH VALVE TO NEAREST DECK DRAIN FUNNEL. CASING DRAINS AND VENT FOR PUMPS IN SOUR SERVICE SHALL BE PIPED TO CLOSED DRAIN HEADER RESPECTIVELY.
DIAPHRAGM VALVE LOCALLY MOUNTED
HAND OPER. VANES VALVE
POSITIVE DISPLACEMENT METER
8. PROTECTION AGAINST GALVANIC CORROSION TO BE PROVIDED WHEREVER REQUIRED BETWEEN
CONTROL VALVE
EXPANSION JOINT
LOCAL PURGED
DISSIMILAR MATERIALS.
ROTAMETER JOHANUSMIRECFT
9. ALL VENT GAS PIPING SHALL BE FREE DRAINING WITH NO POCKETS.
CONTROL VALVE WITH HAND WHEEL PANEL MOUNTED /
S
10. ALL LIQUID SAMPLE POINTS EXCEPT FOR WELL FLUID SAMPLES SHALL BE TAKEN FROM CENTER OF
SONIC METER
OPEN DECK DRAIN THE PIPE. WELL FLUID SAMPLES SHALL BE TAKEN FROM VERTICAL PORTION OF THE PIPE. ALL GAS
CENTRAL CONTROL PANEL
(WITH LIQUID SEAL)
SELF ACTUATED PCV (DOWN STREAM) C
SILENCER
LOCAL,PANEL MOUNTED
SAMPLES SHALL BE TAKEN FROM TOP OF THE PIPE. M
ELECTRIC MOTOR
S
SAMPLE POINT 11. INSTRUMENT ISOLATION VALVES SHALL BE AS PER DETAILS GIVEN BELOW. ALL VALVES SHALL
SELF ACTUATED PCV (UP STREAM) DIAPHRAGM SEAL BACK PANEL MOUNTED
RTU
HAND OPERATED VALVE
BE AS PER APPROPRIATE PIPING/INST. SPECS. DIAPHRAGM SEAL ALSO AS PER SPECS. ALL TAKE OFF CONNECTIONS SHALL BE SW (SOCKET WELD) UNLESS OTHERWISE SPEIFIED.
PILOT TUBE REMOTE TERMINAL UNIT
11.1
BACK LOCAL PANEL
VENTURI METER PISTON OPERATED VALVE
203 24
COMPUTER FUNCTION
DRAIN PLUGGED M
PI PI
PI
INLET SIZE, INCHES
1/2"
ORIFICE CODE LETTER
INSTR.
OUTLET SIZE, INCHES
PIPING
1/2" INSTR. PIPING
3/4"
SET PR, KG/CM2G
1-1/2"
PSV 101
MOTOR OPERATED VALVE (TYPICAL FOR PI,PT,PIC,PSH,PSL,PSHL) COMPUTER LOCAL PANEL
DRAIN FLANGED
TAKE OFF CONNECTIONS- PIPING : 3/4", VESSELS : 1.5" FLANGED ALL DIAPHRAGM SEAL TYPE INSTR. TO HAVE 1.5" FLANGED TAPPING. RUPTURE DISC
SHUT DOWN VALVE
11.2
INSTR. SCRAPPER TEE/SPHERE REE ANALYSER
PI *
SP
INTERLOCK
BUTTERFLY CONTROL VALVE
RUNNING LIGHT,LOCAL
PILOT VALVE (XPV)
SPECIALITY ITEM
3/4"
FILTER
PI
LO
PI
CAP (THREADED)
1/2"
FLEXIBLE HOSE
SLOPE(DOWN WARD)
INSTR.
PIPING
3/4"
A
D
PI
1/2"
FUNCTION BLOCK
3/4" LO
1/2"
STRAIGHTENING VANE (FLANGED) BALL CONTROL VALVE
3/4"
DCS/DIDC
RAIN CAP
RUNNING LIGHT,PANEL
PIPING
HAMMER BLIND BLIND FLANGE RUNNING LIGHT,LOCAL PANEL
I
SHUT DOWN
INSTR.
11.3
1/2"
SPECTACLE BLIND CAP (WELDED) FLANGE
SOLENOID VALVE(2 WAY)
LO/LC
NORMALY LOCK OPEN INTERCHANGABLE TO LC
PDI
PDI
MANIFOLD(PER SPECS.)
REDUCER/EXPANDER HOSE CONNECTION SOLENOID VALVE(3 WAY)
N2
1/2"
LC/LO
NITROGRN CATRIDGE
NORMALY LOCK CLOSE INTERCHANGABLE TO LO (TYPICAL FOR PDI,PDT,PDSH,PDSL,PDSHL)
E
OFF/ON SKID OR SHOP FABRICATED POSITIVE CHOKE
I
TAKE OF CONNECTION-PIPING : 3/4", VESSELS : 1.5" FLANGED
SENIOR ORIFICE
ESD/FSD VALVES T-TYPE STRAINER
ADJUSTABLE CHOKE NC
NORMALY CLOSED
NO
NORMALLY OPEN
Y-TYPE STRAINER CONTROL VALVE W/POSITIONER FUSIBLE PLUG FOUR WAY VALVE
TS
TEMPORARY STRAINER
0
28.02.06
NO.
DATE
ISSUED FOR BID
RVG
SG
BY
CHD
QUICK EXHAUST VALVE
ISSUE
APPR.
OIL AND NATURAL GAS CORPORATION LTD. VORTEX FLOW METER
OFFSHORE DESIGN SECTION, E & C DIVISION MR, MUMBAI
F
PIPING & INSTRUMENTATION DIAGRAM (P&ID) FLOW SHEET & INSTRUMENT LEGEND
DEVELOPMENT OF C-SERIES STRUCTURE DRAWING NO.-
JOHANUSMIRECFT
S
7045-OD-1002
REV.
0
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MASTER ➁
Process Diagrams OBJECTIVES After studying this chapter, the student will be able to: • • • • •
Review process diagram symbols. Describe the use of process diagrams and the information they contain. Draw a process flow diagram. Draw a process and instrument drawing. Describe the various process equipment relationships.
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Process Diagrams
Key Terms Electrical drawings—symbols and diagrams that depict an electrical process. Elevation drawings—a graphical representation that shows the location of process equipment in relation to existing structures and ground level. Equipment location drawings—show the exact floor plan for location of equipment in relation to the plan’s physical boundaries. Flow diagram—a simplified sketch that uses symbols to identify instruments and vessels and to describe the primary flow path through a unit. Foundation drawings—concrete, wire mesh, and steel specifications that identify width, depth, and thickness of footings, support beams, and foundation. Legends—a document used to define symbols, abbreviations, prefixes, and specialized equipment. Process and instrument drawing (P&ID)—a complex diagram that uses process symbols to describe a process unit; also called piping and instrumentation drawing.
Types of Process Diagrams Process diagrams can be broken down into two major categories: process flow diagrams (PFDs) and process and instrument drawings (P&IDs), sometimes called piping and instrumentation drawings. A flow diagram is a simple illustration that uses process symbols to describe the primary flow path through a unit. A process flow diagram provides a quick snapshot of the operating unit. Flow diagrams include all primary equipment and flows. A technician can use this document to trace the primary flow of chemicals through the unit. Secondary or minor flows are not included. Complex control loops and instrumentation are not included. The flow diagram is used for visitor information and new employee training. A process and instrument drawing is more complex. The P&ID includes a graphic representation of the equipment, piping, and instrumentation. Modern process control can be clearly inserted into the drawing to provide a process technician with a complete picture of electronic and instrument systems. Process operators can look at their process and see how the engineering department has automated the unit. Pressure, temperature, flow, and level control loops are all included on the unit P&ID.
Basic Instrument Symbols Process technicians use P&IDs to identify all of the equipment, instruments, and piping found in their units. New technicians use these drawings
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MASTER ➁ Basic Instrument Symbols
VALVES S Gate Valve
Needle
Globe Valve
Four-Way
Diaphragm
Angle
Manual Operated Gauge Valve
H
Solenoid Valve CLOSED
Hydraulic
Back Pressure Regulator
Back Pressure Regulator
Pneumatic Operated
Three-Way Valve
Butterfly
M
Ball
Bleeder Valves
Plug
Check Valve
Orifice
COMPRESSORS
Reciprocating Compressor
Pneumatic Operated Butterfly Valve
Motor
Rotameter
Relief PRV
Safety PSV
PUMPS & TURBINE
Vacuum Pump
Centrifugal Pumps
Centrifugal Compressor
Compressor & Silencers
Vertical
T Liquid Ring Compressor
Rotary Compressor
Screw Pump
Centrifugal Compressor (Turbine Driven)
Turbine
Gear Pump
HEAT EXCHANGERS
LINE SYMBOLS Future Equipment Major Process
Hairpin Exchanger
U-Tube Heat Exchanger
Shell & Tube Heat Exchanger
Minor Process Pneumatic Hydraulic Capillary Tubing
Single Pass Heat Exchanger
Reboiler
L L L X X XXX
X
Electromagnetic Signal Heater
Condenser
Electric
VESSELS Drum or Condenser Mixer
Tank
TI
Temp Indicator
TT
Temp Transmitter
TR
Temp Recorder
LI
Level Indicator
LT
Level Transmitter
LC
Level Controller
FI
Flow Indicator
Mixing Reactor Forced-Draft Cooling Tower
Tower
Bin
Furnace
Figure 12.1a
Induced-Draft Cooling Tower
Tower with Packing
FT
Flow Transmitter
FR
Flow Recorder
PI
Pressure Indicator
PT
Pressure Transmitter
PRC
Pressure Recording Controller
Process and Instrument Symbols 253
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Process Diagrams
TI
I
Flow Indicator
Temp Indicator
FI
TT
Temp Transmitter
FT
Flow Transmitter
PIC 105
Pressure Indicating Controller
TR
Temp Recorder
FR
Flow Recorder
PRC 40
Pressure Recording Controller
TC
Temp Controller
FC
Flow Controller
LA 25
Level Alarm
LI
Level Indicator
PI
Pressure Indicator
FE
Flow Element
LT 65
Level Transmitter
PT 55
Pressure Transmitter
TE
Temperature Element
LR 65
Level Recorder
PR 55
Pressure Recorder
LG
Level Gauge
LC 65
Level Controller
PC 55
Pressure Controller
AT
Analyzer Transmitter
P
Variable Being Measured
What It Does
Transducer
Instrument
FIC 55 Control Loop
Figure 12.1b
Field Mounted Remote Location (board mounted)
Remote Location (behind control panel)
Process and Instrument Symbols (continued)
during their initial training period. Knowing and recognizing these symbols is important for a new technician. The chemical processing industry has assigned a symbol for each type of valve, pump, compressor, steam turbine, heat exchanger, cooling tower, basic instrumentation, reactor, distillation column, furnace, and boiler (Figure 12.1). There are symbols to represent major and minor process lines and pneumatic, hydraulic, or electric lines, and there is a wide variety of electrical symbols.
Flow Diagrams New technicians are required to study a simple flow diagram of their assigned operating system. Process flow diagrams typically include the major equipment and piping path the process takes through the unit. As operators learn more about symbols and diagrams, they graduate to the much more complex P&IDs.
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Cooling Tower
Vacuum Pump Product Tank 1 Drum
Furnace Feed Tank
Column Reactors
Product Tank 2
Bottoms Tank
Boiler
Figure 12.2
Process Flow Diagram (PFD)
Some symbols are common among plants; others differ from plant to plant. Some standardization of process symbols and diagrams is taking place. The symbols used in this chapter reflect a wide variety of petrochemical and refinery operations. Figure 12.2 is a PFD that shows the basic relationships and flow paths found in a process unit. It is easier to understand a simple flow diagram if it is broken down into sections: feed, preheating, the process, and the final products. This simple left-to-right approach allows a technician to identify where the process starts and where it will eventually end. The feed section includes the feed tanks, mixers, piping, and valves. In the second step, the process flow is gradually heated for processing. This section includes heat exchangers and furnaces. In the third section, the process is included. Typical examples found in the process section could include distillation columns or reactors. The process area is a complex collection of equipment that works together to produce products that will be sent to the final section.
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Process and Instrument Drawings A P&ID is a complex representation of the various units found in a plant (Figure 12.3). It is used by people in a variety of crafts. The primary users of the document after plant startup are process technicians and instrument and electrical, mechanical, safety, and engineering personnel. In order to read a P&ID, the technician needs an understanding of the equipment, instrumentation, and technology. The next step in using a P&ID is to memorize your plant’s process symbol list. This information can be found on the process legend. Process and instrument drawings have a variety of elements, including flow diagrams, equipment locations, elevation plans, electrical layouts, loop diagrams, title blocks and legends, and foundation drawings. The entire P&ID provides a three-dimensional look at the various operating units in a plant.
Process Legend The process legend (Figure 12.4) provides the information needed to interpret and read the P&ID. Process legends are found at the front of the P&ID. The legend includes information about piping, instrument and equipment
P-12 CT-105
V-2
V-3
PC
P-13
I/P
PCV
PT
D-105
LT
Tk-10
Tk-12
V-4
C-105
Rx-105
V-5 I/P TT
FT
V-1
I/P
P-14
F-105
FC
LC
FCV P-10
V-6
Tk-14
TC LT
TE
TT
TC
I/P
Rx-106
I/P
P-15
LC I/P
EX-105
Tk-16 P-11
Figure 12.3
256
V-7
Process and Instrument Diagram (P&ID)
B-105
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VALVE SYMBOLS Ball
Gate Valve
Bleeder Valves
Minor Process Pneumatic
Pneumatic
Angle Globe Valve
Future Equipment Major Process
Manual Operated Valve
Pneumatic
Plug
Knife Valve
SAFETY (Gases)
Pinch Valve
Relief Valve
Solenoid Valve CLOSED
Diaphragm
Four-Way
Hydraulic
INDUCED DRAFT Crossflow
Butterfly S
Check Valve
LINE SYMBOLS
EQUIPMENT CONT.
X
Mechanical Link
• • • •
X
X
X
Electromagnetic, Sonic Optical, Nuclear Electric
Stop Check
Three-Way Valve
EQUIPMENT SYMBOLS
L L L
Capillary Tubing
Connecting Line
NATURAL DRAFT Counterflow
Non-Connecting Line Non-Connecting Line Jacketed or Double Containment
Vacuum Pump
Horizontal
Software or Data Link
Vertical
INSTRUMENT SYMBOLS Sump Pump
BOILER
Orifice
TI
Temp. Indicator
FI
Flow Indicator
TT
Temp. Transmitter
FT
Flow Transmitter
TR
Temp. Recorder
FR
Flow Recorder
TC
Temp. Controller
FC
Flow Controller
LI
Level Indicator
PI
Pressure Indicator
LT 65
Level Transmitter
PT 55
Pressure Transmitter
LR 65
Level Recorder
PR 55
Pressure Recorder
LC 65
Level Controller
PC 55
Pressure Controller
FE
Flow Element
I
Transducer
Centrifugal Rotameter
Gear Pump
Positive Displacement
FURNACE
Rotary Screw Compressor
Gauge
Reciprocating Pump
Single Pass
Demister
Screw Pump Chimney
Progressive Cavity Two Pass
Spray Nozzle Packed Section
P
Draw Off
C
C
Double-Pipe Spiral Heat Heat Exchanger Exchanger
Generic Tray
TE
Temperature Element
PIC 105
Pressure Indicating Controller
LG
Level Gauge
PRC 40
Pressure Recording Controller
AT
Analyzer Transmitter
Manway
Plate and Frame Heat Exchanger Vortex Breaker
LA 25
Level Alarm
P Air Cooled Exchanger (Louvers Optional)
C
E
Drum APPROVED
Dome Roof Tank
Sphere
10-6-99
DATE GENERAL LEGEND
Condenser
DISTILLATION UNIT Cone Roof Tank
Internal Floating Roof Tank
DRAWING NUMBER
OO6543 REVISION 1
PAGE 1 OF 30
Heater
ABBREVIATIONS
PREFIXES CW- cooling water MU- makeup FW- feed water SE- sewer
Figure 12.4
RX- reactor UT- utilities CA- chemical addition IA- instrument air
D- drum C- column CT- cooling tower
TK-tank F- furnace EX- exchanger
P- pump V- valve
Process Legend
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Process Diagrams S
4"
18"
W
E
Remesh
12" N
2' x 64' x 18" Load-Bearing Beam
Rebar in All Beams
32' 0" Remesh Over Plastic
Remesh
6-8-10 Method
6' 0" 10' 0"
28' 0"
90
8' 0" 28' 0" 64' 0"
Estimating Materials:
Figure 12.5
cu. yds. =
width x length x thickness 27
Foundation
symbols, abbreviations, unit name, drawing number, revision number, approvals, and company prefixes. Because symbol and diagram standardization is not complete, many companies use their own symbols in unit drawings. Unique and unusual equipment will also require a modified symbols file.
Foundation Drawing The construction crew pouring the footers, beams, and foundation uses foundation drawings (Figure 12.5). Concrete and steel specifications are designed to support equipment, integrate underground piping, and provide support for exterior and interior walls. Process technicians do not typically use foundation drawings, but these drawings are useful when questions arise about piping that disappears under the ground and when new equipment is being added.
Elevation Drawing Elevation drawings (Figure 12.6) show the location of process equipment in relation to existing structures and ground level. In a multistory structure, the elevation drawing provides the technician with information about
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RX-300
TK-300
Figure 12.6 Elevation Drawing
C-300
EL-40' 0"
D-56
EL28' 0"
RX-105
EL 16' 0"
TK-105
TK-200
RX-106
equipment location. This information is important for making rounds, checking equipment, developing checklists, catching samples, and performing startups and shutdowns.
Electrical Drawing Electrical drawings (Figure 12.7) include symbols and diagrams that depict an electrical system. Electrical drawings show unit electricians where power transmission lines run and places where power is stepped down or up for operational purposes. A process technician typically traces power to the unit from a motor control center (MCC). The primary components of an electrical system are the MCC, motors, transformers, breakers, fuses, switchgears, starters, and switches. Specific safety rules are attached to the operation of electrical systems. The primary safety system is the isolation of hazardous energy “lock-out, tag-out.” Process technicians are required to have training in this area. Figure 12.7 shows the basic symbols and flow path associated with an electrical drawing. Electrical lines are typically run in cable trays to switches, motors, ammeters, substations, and control rooms. A transformer is a device used by industry to convert high voltage to low voltage. The electric department always handles problems with transformers. Electric breakers are designed to interrupt current flow if design conditions are exceeded. Breakers are not switches and should not be turned on
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69,000 Volts 69 KV
MAIN TRANSFORMER
V As
A
51
Vs 27
Steam Turbine
MCC #1
2.3 KV or 480 Volts
Motor Starter
ELECTRIC POWER PLANT
Motor Starter
M
M
Motor
Motor
V
Voltmeter: measures voltage
27
Under Voltage Relay
A
Ammeter: measures electric current
Vs
On Off
MCC
Motor Control Center
Voltmeter Switch Current Transformer: reduces high voltage to instrumentation.
As
Ammeter switch
50
Transformer Overcurrent Relay (Instantaneous)
Potential Transforming Symbol
51
Transformer Overcurrent Relay (Time delay)
Power Transformer: reduces high voltage
Circuit Breaker: a protective device that interrupts current flow through an electric circuit
Switch
Figure 12.7 260
Fuse
M
Electrical Drawing
13.2 KV 13.8 KV 2.3 KV
480V BUS MAIN POWER DISTRIBUTION
Generator
BOILER
13,200 V 13, 800 V 2,300 V
Motor Circuit Contacts
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MASTER ➁ Process and Instrument Drawings or off. If a tripping problem occurs, the technician should call for an electrician. Fuses are devices designed to protect equipment from excess current. A thin strip of metal will melt if design specifications are exceeded. During operational rounds, technicians check the ammeters inside the MCC for current flow to their electrical systems. Voltmeters, electrical devices used to monitor voltage in an electrical system, are also checked during routine rounds.
Equipment Location Drawing Equipment location drawings (plot plans) show the exact location of equipment in relation to the plant’s physical boundaries (Figure 12.8). One of the most difficult concepts to explain to a new process technician is the scope and size of modern chemical processing. Most chemical plants and refineries closely resemble small cities; they have well-defined blocks and areas connected by a highway of piping and equipment. Equipment location drawings provide information about the neighborhood.
Loop Diagrams A loop diagram traces all instrument connections between the field instrument and the control room panel. This includes instrument air lines, wiring connections at field junction boxes, and control room panels and front connections.
Electrical One-Line Diagrams Like the piping in process systems, the wiring in a unit follows a path. Electrical diagrams show a flow path for distributing power throughout the unit and
TK-2
TK-3
TK-4
Figure 12.8 Equipment Location
8' 0"
TK-1
P-200 D-200
TK-100 18' 0"
TK-200
8' 0" 20' 0"
18' 0"
20' 0"
20' 0" 6' 0"
P-100
EX-200
P-500A C-200
8' 0"
P-201 TK-300
EX-202 10' 0"
P-300
TK-400
P-400
20' 0"
16' 0"
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Process Diagrams to all electrical equipment. These diagrams show the different voltage levels in the unit, electrical equipment such as transformers, circuit breakers, fuses, and motors and horsepower required. It also includes start/stop switches, emergency circuits, and motor control centers. Process technicians can use these diagrams to trace a system from the power source to the load.
Review of Basic and Specialized Symbols Piping and Valves Each plant will have a standardized file for their piping symbols. Process technicians should carefully review the piping symbols for major and minor flows; electric, pneumatic, capillary, and hydraulic elements; and future equipment (Figure 12.9). The major flow path through a unit illustrates the
Figure 12.9 Piping Symbols
Y-type Strainer
RS
Removable Spool Flexible Hose
Duplex Strainer Expansion Joint Basket Strainer
D
Detonation Arrestor
F
Flame Arrestor
S
In-Line Silencer
T
Steam Trap
XXX
Breather Vent Cover In-Line Mixer
Desuperheater
DS
Ejector / Eductor
S
Vent Silencer Diverter Valve
Rotary Valve
Pulsation Dampener
Exhaust Head Flange Future Equipment Major Process Minor Process
LLL
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Electromagnetic, Sonic Optical, Nuclear Electric Connecting Line
Pneumatic
Non-Connecting Line
Hydraulic
Non-Connecting Line
X X
X X
Capillary Tubing
Jacketed or Double Containment
•
•
Mechanical Link
Software or Data Link
•
•
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MASTER ➁ Review of Basic and Specialized Symbols critical areas a new technician should concentrate on. A variety of other symbols are included on the piping. These include valves (Figure 12.10), strainers, filters, flanges, spool pieces, insulation, piping size, pressure rating, material codes, and steam traps.
Pumps and Tanks Pumps and tanks come in a variety of designs and shapes. Common pump and tank symbols are shown on Figure 12.11.
Compressors, Steam Turbines, and Motors Because compressors and pumps share a common set of operating principles and are classified as dynamic or positive displacement, the symbols for compressors may closely resemble those for pumps (compare
GATE VALVES
Manual Operated Valve
Gate Valve
Pneumatic
GLOBE VALVES
Globe Valve
Pneumatic
H
Motor
Hydraulic
M
H
Motor
Hydraulic
Bleeder Valves M
Angle
Needle Pneumatic
BALL VALVES
Ball
M
Plug
Motor or Hydraulic
BUTTERFLY VALVES
Butterfly
Motor
PLUG VALVES
H
Ball
Butterfly
Figure 12.10 Valves
M
Motor or Hydraulic
Plug
M Butterfly
S
DIAPHRAGM VALVES
Solenoid Valve CLOSED
Pneumatic Operated
Motor or Hydraulic
CHECK VALVES M
Diaphragm SAFETY (Gases)
Motor
Check Valve
RELIEF (Liquids)
Four-Way
Check Valve
Stop Check Three-Way Valve
Relief Valve Knife Valve
Pinch Valve Gauge
Rotameter
Orifice
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Process Diagrams
CENTRIFUGAL PUMPS
POSITIVE DISPLACEMENT PUMPS Positive Displacement
Positive Displacement Vertical
Progressive Cavity
Horizontal
Gear Pump
Screw Pump Vertical Screw Pump Sump Pump
Vertical
Vertical Can Pump
Vacuum Pump
Reciprocating Pump
STORAGE SYMBOLS
Dome Roof Tank Bin
Open Top Tank Tank
Tank
Double Wall Tank
Cone Roof Tank
Drum Sphere
Figure 12.11
Internal Floating Roof Tank
Onion Tank
External Floating Roof
Pumps and Tanks
Figures 12.11 and 12.12). In most cases, the compressor symbol is slightly larger than the pump symbol. In the multistage, centrifugal compressors, the narrowing of the symbol from left to right denotes compression of the gas before it is released. This is in sharp contrast to the steam turbine symbol, which illustrates the opposite effect as the steam expands while passing over the rotor. Modern P&IDs show the motor symbol connected to the driven equipment. This equipment may be a pump, compressor, mixer, or generator. Figure 12.12 illustrates the standardized symbols for compressors, steam turbines, and motors.
Heat Exchangers and Cooling Towers Heat exchangers and cooling towers are two types of industrial equipment that share a unique relationship. A heat exchanger is a device used to
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CENTRIFUGAL COMPRESSORS
PD COMPRESSORS
T Centrifugal Compressor
Centrifugal Compressor (Turbine Driven)
Centrifugal Compressor Centrifugal Blower
Reciprocating Compressor Rotary Compressor
Rotory Compressor & Silencers
Rotary Screw Compressor
Liquid Ring Vacuum
Positive Displacement Blower Reciprocating Compressor
Axial Compressor
STEAM TURBINE
MOTORS Agitator or Mixer
Turbine Driver
Doubleflow Turbine
Motor Diesel Motor
Figure 12.12
Compressors, Steam Turbines, and Motors
transfer heat energy between two process flows. The cooling tower performs a similar function, but cooling towers and heat exchangers use different scientific principles to operate. Heat exchangers transfer heat energy through conductive and convective heat transfer, whereas cooling towers transfer heat energy to the outside air through the principle of evaporation. Figures 12.13 and 12.14 illustrate the standard symbols used for heat exchangers and cooling towers. The symbol for a heat exchanger clearly illustrates the flows through the device. It is important for a process technician to be able to recognize the shell inlet and outlet and the tube inlet and outlet flow paths. A heat exchanger with an arrow drawn through the body illustrates whether the tubeside flow is being used to heat or cool the shellside fluid. The downward direction indicates heating; the upward direction illustrates cooling.
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Process Diagrams
Figure 12.13 Heat Exchangers
Plate and Frame Heat Exchanger Hairpin Exchanger
Air Cooled Exchanger (Louvers Optional)
Double-Pipe Heat Exchanger
U-Tube Heat Exchanger
Single Pass Heat Exchanger
C
C
Spiral Heat Exchanger
Heater
Condenser
Shell and Tube Heat Exchanger
Figure 12.14 Cooling Towers
INDUCED DRAFT Crossflow
HYPERBOLIC Chimney Tower
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Reboiler
FORCED DRAFT Counterflow
NATURAL DRAFT Counterflow
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Figure 12.15 Furnace and Boiler
Furnace
Boiler
The symbol for a cooling tower is designed to resemble the actual device in the process unit. Cooled product flows out of the bottom of the tower and to the processing units. Hot water returns to a point located above the fill. The symbol will not show all of the various components of the cooling tower system, but it will provide a technician with a good foundation in cooling tower operation and enough information to clearly see the process.
Furnaces and Boilers The standard symbols file for furnaces and boilers is shown in Figure 12.15. If a proprietary process includes several types of equipment not typically found on a standard symbol file, the designer will draw the device as it visually appears in the unit.
Distillation Columns Distillation columns come in two basic designs, plate and packed (Figure 12.16). Flow arrangements vary from process to process. The symbols allow the technician to identify primary and secondary flow paths. Distillation is a process designed to separate the various components in a mixture by their boiling points. (See Chapter 15.) A distillation column is the central component of a much larger system. This system typically includes all of the equipment symbols found in this chapter. Plate distillation columns include sieve trays, valve trays, and bubble-cap trays. Packed columns are filled with packing material, rings, saddles, sulzer, and rosette.
Reactors Reactors (Figure 12.17) are stationary vessels and can be classified as batch, semibatch, or continuous. A reactor is designed to allow chemicals to mix together under specific conditions to make chemical bonds, break chemical bonds, or make and break chemical bonds to form new products.
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Process Diagrams
Figure 12.16 Distillation Symbols
PLATE TOWER Bubble-cap, Sieve, Valve
PACKED TOWER Saddle, Ring, Sulzer, Rosette
Single Pass Demister Spray Nozzle Chimney Two Pass Packed Section
Draw Off Generic Tray
Manway
Vortex Breaker
Sources of Information for Process Technicians Information used by process technicians comes from a variety of sources. Some of these sources are: • Operating training manuals • Process descriptions • Process control manuals • Equipment summaries • Safety, health, and environment regulations • Operating procedures • Startup and shutdown procedures
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Figure 12.17 Reactor Symbols
Hydrocracking
Fluid Catalytic Cracking
Hydrodesulfurization
Fluid Coking
Mixing Reactor
• • • •
Tubular Reactor
Reformer
Fluidized Reactor
Alkylation
Emergency procedures Process diagrams Technical data books Detailed equipment vendor information
Summary Process flow diagrams (PFDs) and process and instrument drawings (P&IDs) are used to outline or explain the complex flows, equipment, instrumentation, electronics, elevations, and foundations that exist in a process unit. A PFD is a simple flow diagram that describes the primary flow path through a unit. A P&ID is a complex representation of the various units found in a plant. Standardized symbols and diagrams have been developed for most pieces of industrial equipment, process flows, and instrumentation.
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Review Questions 1. Describe a process flow diagram and a process and instrument drawing. 2. Draw the symbols for a gate, globe, and automatic valve. 3. Draw the symbols for a centrifugal pump and positive displacement pump. 4. Draw the symbols for a blower and a reciprocating compressor. 5. Draw the symbols for a steam turbine and centrifugal compressor. 6. Draw the symbols for a heat exchanger and a cooling tower. 7. Draw the symbols for a packed distillation column and plate distillation column. 8. Draw the symbols for a furnace and a boiler. 9. Draw a simple process flow diagram using the symbols from questions 2–8. 10. What information is obtained from a loop diagram? 11. What information is available on electrical one-line diagrams? 12. What information is contained on a plot plan drawing?
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