Process diagrams

Draft V2.P1
Contents
1 Introduction 5
1.1 Terminology 5
1.2 Methodology 6

2 Process Diagrams Overview 7

3 Block Flow Diagrams 8

3.1 At TC1 8
3.1.1 BFD at TC1 - Use 9
3.2 At TC2 9
3.2.1 BFD at TC2 Use 10
3.3 Format of BFD-TC1/2 10
3.4 Timing of BFD-TC1/2 10
3.5 BFD at later project stages 11

4 Key Drawings & Layout 12

4.1 Drawing Layout 12
4.2 Key or Legend Drawings 12

5 Process Flow Diagrams 13

5.1 Process Topology 13
5.2 Process Stream Information 13
5.3 Utility Stream Information 14
5.4 Equipment Information 14
5.5 Process and Safety Critical Instrumentation 14
5.6 Process Flow Diagram TC1 15
5.6.1 PFD at TC1 Use 16
5.7 Process Flow Diagram TC2 16
5.7.1 PFD at TC2 Use 18
5.8 Process Flow Diagram TC3 19

6 Process & Instrumentation Diagrams (P&ID or PID) 20

6.1 PIDs at any TC will not contain 20
6.2 PID-TC1 20
6.2.1 PID at TC1 Use 21
6.3 PID-TC2 21
6.3.1 PID at TC2 Use 23
6.4 PID-TC3 23
6.4.1 PID at TC3 Use 23
6.5 PID-TC4 23
6.5.1 PID at TC4 use 24
6.6 PID-TC5 24
6.6.1 PID at TC5 use 25
6.7 PID-TC6 25
2
6.7.1 PID at TC6 Use 25

7 UPIDs 26
7.1.1 UPID-TC2 26
7.1.2 UPID-TC2 Use 27
7.1.3 UPID-TC3 27
7.1.4 UPID-TC4 27
7.1.5 UPID-TC5 27
7.1.6 UPID-TC6 27

8 Process Sketches 28
8.1 Simple Sketches 28
8.2 Layout Sketches 28
8.3 Equipment Sketches 28
8.3.1 Equipment Sketches at TC1 28
8.3.2 Equipment Sketches at TC2 29
8.3.3 Equipment Sketches at TC3 31

9 External Reference Documents 32

9.1 Supporting International Standards 32
9.2 Generic Cost Estimate Classification Matrix 33

10 Appendix A – Glossary of Abbreviations 34

11 Appendix B – Systemisation 35
11.1 Equipment Numbering 35
11.2 Line Numbering 36
11.3 Use of Systemisation 37

12 Appendix C – PFD/PID Layout 38

12.1 The Basic Layout of the Drawing 38
12.1.1 Borders & Frames 38
12.1.2 Title Block 39
12.2 Layout of PFD/PIDs onto the Basic Layout 40
12.3 Conventions for laying out & drawing PFD/PIDs 42
12.4 Document numbering 42

13 Appendix D - Key Drawings – Details 44

13.1 Piping and Line Symbols 44
13.1.1 Pipeline Symbols 44
13.1.2 Pipeline Identification 45
13.1.3 Fluid Code 45
13.1.4 Pipe Diameters 45
13.1.5 Materials of Construction (MoC) 45
13.1.6 Insulation Code 46
13.1.7 Valve & Line Items 46
13.1.8 Control Valves 47
3
13.2 Instrumentation, Annotations & Acronyms 48
13.2.1 Line Symbols 48
13.2.2 Instruments 48
13.2.3 Instrument Symbol Lettering 49
13.3 Specialist symbols 50
13.4 Key Drawing 3 - Equipment Symbols, Annotations, and Acronyms 52
13.4.1 Equipment numbers 52
13.4.2 Area Numbers 52
13.4.3 Equipment Symbols 52
13.4.4 Drawing Annotations 53

4
1 Introduction
The objective of this guide is to provide guidance, within the design phases of a project, when the
major five process drawings are produced, what their typical content (TC) would be and what the
purpose and function of the diagrams are. It also demonstrates how Chemical Engineering design
integrates with other professions as the design matures.

This guide covers the Five most commonly used Process Diagrams:

1. Process Block Flow Diagrams (BFD).

2. Process Flow Diagrams (PFD).
3. Process & Instrumentation Diagrams (P&ID).
4. Utility Process & Instrumentation Diagrams (UPID).
5. Process Sketches.

It excludes:

 Drawings to ANSI/ISA 5.1 or ISO 14617 – 5 which resemble P&ID/UP&IDs but are detailed
pictorial representations of the physical process of the control system and should be
produced by EC&I group in support of their electrical drawings.
 Mechanical Flow Diagrams (MFD) which resemble Process Flow Diagrams (PFD) but are
pictorial representations of operational sequences rather than process steps and would be
produced by Mechanical Engineers.

1.1 Terminology

There is no exact terminology for the phases of a project and many companies have their own (or
even no) descriptions; but between the start of the design of a process and the point that the bulk
of chemical engineering design has been completed there are typically five stages.

1. Project Start-up  Typically the point at which a team is formed to implement the
construction of a process plant or at least see if it is possible. At this point the main
objective is available and the main constraints are identified.
2. Optioneering/Concept  The Chemical Engineers will often have multiple options for
process routes and technologies and early tasks primarily revolve around identifying the
best options to meet the constraints. As options are considered, retained or discarded the
design concept becomes clear.
At this point the main risks from the process will be identified by a formal safety review of
the materials, scale and process stages (sometimes called HAZOP 0); these will define the
primary safety and operational design challenges in the next stage.
Additionally these reviews will start the documentation required later for DSEAR and
COSHH assessments.
3. Outline Design In this phase the Chemical Engineers will identify the bulk of the
equipment needed to build the process but critically will have addressed how to control the
process and manage any key safety issues.
HAZOP 1 is conducted on this design but using guide words on functional sections of the
process; at this point (unless identified) the basic process plant design and operation will
be defined.
4. Engineering Design  In this phase the other professional engineers who may have been
on the project team to ensure the scheme was practicable and advise on their
requirements will start to build up teams to deliver their elements of the project.
This phase is most readily identified as the increased levels of manpower are significant
and the level of expenditure on the project jumps significantly.
Chemical Engineers will be detailing their design e.g. pipe sizing, utilities, equipment
specifications & defining utilities.
HAZOP 2 is conducted in this stage using the detailed HAZOP process to ensure the
5
 detailed implementation of safety and operability has been addressed in the design. The
overall design is usually frozen (fixed) at this point but design continues to define detail.
Chemical Engineers will typically be involved with other formal safety reviews; particularly
in support of Process Control Safety and workplace risk assessments.
5. Detail for Manufacture & Construction  Typically at this point Chemical Engineers are
supporting the procurement process and generating equipment data sheets. Additionally
test protocols for equipment being purchased and the start of commissioning procedures
are being generated.
HAZOP 3 (sometimes called mini-HAZOPs) would be conducted to ensure variations in
design identified during construction were acceptable.
HAZOP 4 (or an alternative formal safety review) would be conducted on vendor
equipment to ensure that it confirmed to expectations identified in earlier HAZOPs.

1.2 Methodology

The guide will demonstrate the evolution of various process diagrams defined against the project
stages and safety stages.

6
2 Process Diagrams Overview
Process diagrams are produced at discrete phases in the execution of a project typically defined by
the end of project stages or major risk assessment stages (HAZOPs) as shown in Figure 1.

Management
Project Review 1 Project Review 2 Project Review 3 Project Review 4
Review PR1 PR2 PR3 PR4
Phases

Cost
Estimate Class 5 Class 4 Class 3 Class 2 Class 1
Class

DETAIL FOR MANUFACTURE

Project &
OUTLINE ENGINEERING
OPTIONEERING CONCEPT CONSTRUCTION
Stages DESIGN DESIGN
Manufacture, Assembly & Test
Procurement

BLOCK FLOW DIAGRAMS BFD SUPERSEDE OR BFD SUPERSEDE OR BFD SUPERSEDE OR

UPDATE UPDATE UPDATE
TC1 TC2

PFD PROCESS FLOW DIAGRAMS

PFD UPDATE PFD UPDATE
BFD -TC2 TC1 TC2 TC3

Drawing PROCESS & INSTRUMENT DIAGRAMS

Stages TC1 TC2 TC3 TC4 TC5 TC6

UTILITY PROCESS & INSTRUMENT DIAGRAMS

TC1 TC2 TC3

PROCESS SKETCHES
TC1 TC2 TC3

Safety HAZOP 0 HAZOP 1 HAZOP 2 HAZOP 3

HAZOP 4
Reviews Main Key Hazard Detailed Management of
VENDOR EQUIP.
Hazards Management Safety Change
Assessment

Figure 1 Production of Process Drawing

They are functionally representative of the process at any specific point of design maturity and as
such their content will reflect the maturity of the design. As a result, each diagram will have differing
Technical Contents (TCn) depending on the design stage it depicts.

The term ‘Technical Content’ is used to outline the minimum level of technical information needed
to reach a stage, companies have varying standards – but often companies outside the historical
Chemical Engineering remit have no standards.

Note the term “HAZOP” is used to define a formal safety review that either follows BS EN 61882 or
utilises a similar process.

7
3 Block Flow Diagrams
During the optioneering and concept project phase multiple process options will initially be reduced
to between 1 and 3 potential candidates; to minimise unproductive effort BFDs will be produced at
Technical Content 1 (TC1).

All block diagrams depict a process or process plant in simplified form by means of shapes
(block/rectangles/arrows/circles etc.) which are interconnected by flow lines representing streams
of materials or energy flows.

The shapes may represent the following:

 processes;
 process steps;
 unit operations;
 process plants or groups of process plants;
 plant sections;
 major equipment.

3.1 At TC1

The block flow diagram shall contain at least the following information:

 Shape Name;
 Name of ingoing and outgoing materials;
 Direction of main material flows between shapes.

8
Figure 1 BFD at TC1

3.1.1 BFD at TC1 - Use

The BFD-TC1 will be primarily used in the initial selection of processes to identify and exclude non-
viable options, without excessive effort.

3.2 At TC2

The following additional information will be required:

 Quantity of the main material flows between the shapes;

 Flow rates or quantities of ingoing and outgoing materials;
 Flow rates or quantities of ingoing and outgoing energy or energy carriers;
 Main material flows between the shapes representing energy or energy carriers;
 Characteristic operating conditions if required for clarity;
 Hazardous material flows and generation if required for clarity.

9
Figure 2 BFD at TC2

The BFD-TC2 by defining hazardous material flows and characteristic operating conditions will
support HAZOP 0 by graphically identifying the location of hazardous materials.

Finalised BFD-TC2 diagrams will have been utilised at HAZOP 0 and updated if required.

3.2.1 BFD at TC2 Use

The BFD at TC2 will have a range of uses and users.

 Project management, can see the complexity of the task and start to get a view of the scale
of the cost.
 Safety can identify major risks and chemicals used – this starts the development of the
COSHH and Hazardous Areas documentation.
 Chemical engineers can start to manage the major risks.
 Process selection can be undertaken with sufficient information to make a viable selection.

3.3 Format of BFD-TC1/2

As there will be large numbers of BFD-TC1 sketches, most of which will not be used after this point
they do not require to be formally issued as a discrete drawing but often form part of the process
description documentation used for process selection.

For the selected process at BFD-TC2 it should become a formal discrete drawing.

3.4 Timing of BFD-TC1/2

BFD 1 ends approximately 50% of the way through the duration of the optioneering/concept stage
10
 BFD 2 ends after HAZOP 0 updates are finalised, approximately 70% of the way through the
duration of the optioneering/concept stage.

The remaining 30% is typically utilised in broad costing of the proposal and project planning.
Typically cost estimates for the proposed process are generated and a process selected, the
process stages identified in the BFDs may be used to develop the initial project planning work
breakdown structures.

3.5 BFD at later project stages

Information contained in BFDs would typically be shown in PFDs in later project stages leaving the
risk that out of date information could be present in project files. The simplicity of BFDs however is
often useful at later stages when a general overview of a process is required.

At the start of each project stage after concept the Lead Chemical Engineer will determine if the
BFDs are required for the next stage, if required they will be identified as a deliverable and updated
as needed, otherwise they will be superseded by the appropriate PFD and marked as such.

11
4 Key Drawings & Layout
4.1 Drawing Layout

PFD’s typically mark the start of formal engineering design and as such they (and PIDs/uPIDs) are
produced as recognisable engineering drawing format, conforming to international standards for
drawing practice e.g. ISO 5457, 7200.

A more detailed description of PFD/PID layout can be found in Appendix C – PFD/PID Layout.

For the rest of the document much of the drawing (The Frame, Notes, Equipment List and if
applicable Stream Data) will not be shown for clarity.

See Appendix C – PFD/PID Layout for more detail on the layout of PFD/PIDs.

4.2 Key or Legend Drawings

PFDs and PIDs utilise symbology and terminology that is usually specific to chemical engineering
and/or to the process. Typically for a project two Key Drawings are produced and maintained
throughout the life of the project to ensure clarity and standardisation across the project
documents. Note; -they can also be called “Legend or Lead Sheets in some companies.

Symbols used in PFD/PFDs in theory should comply to local standards such as EN ISO
10628:2014 Parts 1 & 2 or EN ISO 14617:2002 Parts 1 to 12, however many companies often
have had their own symbol set in use prior to the release of these standards and continue to use
them to maintain consistency. Additionally, the international nature of many companies and the
lack of sufficient symbols to cover all eventualities result in blends of symbols.

The number of Key drawings varies with the project size.

 Small projects may have the Key information located in the notes block of the drawing
 Typical medium sized projects have usually between 2 and 3 Key Drawings
 There is no upper limit on the number of drawings but 50+ is not unusual on large projects.

Whilst the number of drawings varies, they meet the following conditions:

 Every symbol or annotation used in the PFD/PID’s with its description appears on these
drawings
 All users of the drawings can correctly interpret the drawings – without having to access
external standards/documents.
 Major plant items do not usually appear as they are defined in the key blocks in the
PID/PFD.

Significantly more detail on the content of Key Drawings is given in Appendix D - Key Drawings –
Details

12
5 Process Flow Diagrams
Process Flow Diagrams (PFD) provide a more detailed picture of a process utilising a standardised
symbol set.

PFDs are typically started at the beginning of Outline Design however under certain circumstances
they may replace BFD-TC2 e.g.

 Optioneering has resulted in only one process at the end of BFD-TC1 and
 The process is sufficiently definable to produce a meaningful PFD and
 The Lead Chemical Engineer elects to replace the BFD-TC2 with a PFDs containing the
same information.
 Note – It will typically require more PFDs than BFDs to represent the same process due to
the increased detail provided by the PFD.

If BFD-TC2 is replaced with PFD(s) it will contain the same information but the rectangular stages
will be replaced by equipment symbols.

The process flow diagram (PFD) represents a major step up from the BFD in terms of the amount
of information that it contains. The later stage PFD contains the bulk of the chemical engineering
data necessary for the design and primary hazard assessment (HAZOP 1) of a process.

The basic information provided by a PFD can be categorised into one of the following:

 Process topology.
 Process Stream information.
 Utility Type.
 Equipment information.
 Process and Safety Critical Instrumentation, in later versions.

Each aspect of the PFD will be considered separately.

5.1 Process Topology

The location of major pieces of equipment and the connections that the process streams make
between equipment are referred to as the process topology.

Equipment is represented by symbols that identify specific unit operations. The symbols used
typically will be taken from ISO 10628 Part 1 and 2 or derived from ISO 14617 Parts 1 to 12;
although it is not uncommon for companies to use in-house symbols or for novel equipment to have
its own symbol developed for a project.

Each major piece of process equipment is identified by a number on the diagram (e.g. V001). A list
of the equipment numbers along with a brief descriptive name for the equipment is printed along
the top of the diagram.

The convention for formatting and identifying the process equipment numbers (sometimes called
systemisation see Appendix B – Systemisation for more information) will be dependent upon the
maturity of the drawing at that stage.

5.2 Process Stream Information

Each of the process streams will be identified by a number located next to the stream. The
direction of the stream is identified by one or more arrowheads. The process stream numbers are
13
 used to identify streams on the PFD, and the type of information that is typically given for each
stream is dependent upon the maturity of the PFD.

This links the stream to information on a flow summary or stream table, which is often provided
below the process flow diagram or as a separate attachment to the PFD depending upon the TC.

5.3 Utility Stream Information

Utilities are services that are available to support the process and typically include various types of
compressed air, cooling water, refrigerated water, steam, condensate return, inert gas, drains, flare
systems and process vent systems.

Utilities will have standardised fluid codes (for each company) e.g. PA for Process Air to allow the
drawing to be interpreted..

Whatever Fluid Codes and associated descriptions are used in Process Diagrams for a project they
will be shown in tabular form on the Key Drawings to ensure clarity and standardisation across the
project documents.

Electricity used to power motors and generators is a utility that is not identified directly on the PFD
but is treated separately.

5.4 Equipment Information

Equipment information will be maintained on the Process Equipment Schedule which is a Project
Master Document only information required for HAZOP 1 or for clarification of the process will be
detailed on PFDs.

In general adding detailed Equipment Information to PFD’s at any TC is not considered good
practice due to the complexities of synchronising the Drawing to the Master Document.

5.5 Process and Safety Critical Instrumentation

At TC2 & 3 levels process critical and safety instrumentation with their associated control loops will
need to be shown on PFDs to aid in process understanding or to support hazard assessments
(HAZOP 1).

This instrumentation will be kept to a minimum and ‘standard’ instrumentation would not be shown.

For example a simple case where pump P-1 fills vessel V001 and the pump is controlled by
LICA001 with level trip LA001 acting as a safety overfilling trip if LICA001 fails.

14
 If level within the vessel is process critical as well as safety critical (e.g. prevention from overfilling)
then case 1 would be shown.

If only overfilling was safety critical then case 2 would be shown (LICA001 would be implicit).

The reason for including this information at this point is to ensure that the viability of the process
and its safe operation can be considered before large teams of engineers are assigned to the
project and costs escalate. Late inclusion of this data into the design consideration often results in
projects terminating after excessive levels of expenditure.

5.6 Process Flow Diagram TC1

This PFD will either replace BFD-TC2 or be a new drawing in either case it will be a formal drawing
with its own number.

The drawing will contain:

 All of the key process data shown (shown in red on Figure 4 PFD at TC 3) in BFD-TC2.
 All major equipment symbols type of apparatus and machinery, except drives, needed for
the process – denoted by an Alpha Numeric code (e.g. P001 for pump 001).
 Ideally major equipment numbering is now fully systemised (see Appendix B –
Systemisation) introducing systemised numbering at later points results in significant
remedial effort (not shown see section on systemisation).
 Descriptions for equipment and machinery, except drives shown on a table at the top of the
drawing.
 Major process streams will be numbered (Shown in red in Figure 5 PFD at TC2).
 All utilities will be identified by type as they enter the drawing.
 Route and direction of the ingoing and outgoing major material flows.
 Denomination of energy types and/or energy carriers (e.g. Cooling Water Feed – CWF).
 Key utilities needed for the process to function (e.g. CA for compressed air).

15
Figure 3 PFD at TC 1
(Note drawing frame and notes etc. not shown for clarity)

5.6.1 PFD at TC1 Use

 The main use for this drawing is for inclusion into the description of the overall process
(typically used to introduce new people to the process).
 It is also used to judge the breakdown of the overall process shown in the BFDs – too many
items will result in a crowded drawing at later stages, too few looks sparse.
 A general estimate of cost – AACE Level 5 Screening or Feasibility see Table 1 on page 25.

5.7 Process Flow Diagram TC2

This drawing is often used for HAZOP 1 and thus should additionally contain
(shown in blue in Figure 7 PFD at TC2):

 Minor process streams.

 All of the key process data (including major utilities) shown as a table on the drawing with
stream number, description, phase and total flow shown on a table; other data would be
tabulated in the mass and energy balance as a separate document.
 All minor equipment (but not inline equipment) will be shown & numbered.
 All Process and Safety Critical Instrumentation shown.
 All key valves and line items shown.

16
Figure 5 PFD at TC2
(Note drawing frame and notes etc. not shown for clarity)

Historically PFD’s were not used for HAZOP this was typically undertaken at PID TC2 and many
individuals feel that this is the correct approach. In a cost and time conscious environment however
the impact of delaying the HAZOP may be considered unacceptable, e.g. for a medium sized
project;

 Typically team sizes at PFD TC2 are relatively small (equivalent to 5 to 6 full time
employees) and overall project expenditure low – around £20,000 per week. Between PFD
TC2 and PID TC2 the team size grows significantly and thus the cost per week can double
or triple; more critically a significant period of time can elapse, with expenditures in the
hundreds of thousands.
 It is not unusual to find at HAZOP 1 that a process has a hidden problem that either
requires significant redesign, with significant time delays or even cancels the project.

Current practice therefore is to undertake HAZOP 1 at this point to reduce the financial risk of
developing the design without a formal review.

17
5.7.1 PFD at TC2 Use
 The success/failure of the management of major process hazards identified at BFD TC2 can be
assessed.
 Project management can identify discrete tasks and develop a basic Work Breakdown
Structure.
 A general estimate of cost – ASTM Level 5 Screening or Feasibility see Table 1 on page 25.
 This PFD will typically be used for the detailed mass and energy balance as well as the initial
equipment sizing and basic plant layout.

18
5.8 Process Flow Diagram TC3

PFD-TC3 is exactly the same as PFD-TC2 except:

 HAZOP 1 comments will have been included (shown in green).

Figure 6 PFD at TC 3
(Note drawing frame and notes etc. not shown for clarity)

19
6 Process & Instrumentation Diagrams
(P&ID or PID)
The piping and instrumentation diagram (PID), is a pictorial representation of every item of
equipment required to make the product and includes all ancillary equipment.

For example operators may take a sample from a line and measure its density manually at a local
operators station and the data entered into the control system – the density measuring equipment
and the data input terminal would be shown on the PID.

Thus the PIDs are the most complex of the process drawing and as such evolve over a significant
period as the design matures and this is covered by six content standard phases.

6.1 PIDs at any TC will not contain

 Operating Conditions Temperature, Pressure, Chemical composition – These are on the Mass
& Energy Balance or the PFD.
 Stream Flows – These are on the Mass & Energy Balance.
 Equipment Locations – On layout drawings & Process Mechanical DPDs but walls, rooms or
plant areas may be denoted for clarity.
 Pipe Routing & Lengths – On Process Mechanical BIM model.
 Supports, Structures, and Foundations – On TC&A BIM model.
 Characteristic data (duty/size) of equipment – this is now given on the equipment schedule.
 Detailed control functions e.g. instrument sensor type, data/signal conditioning, relays etc. – (If
these are required then control and instrumentation engineers then should produce a drawing
to ISA5.1)
 Manual switches, electrical isolators and indicating lights; unless they are process/operationally
critical or identified in Human Factor reviews.
 Elbows, tees, these are part of the pipe and installation fittings (e.g. pipe hangers).
 Extensive notes – this will be included in the Process Description.
 Actuation Valves (solenoids that control the compressed air to pneumatically controlled valves)
or actuator tubing for pneumatically operated valves or equipment.

6.2 PID-TC1

At the end of HAZOP 1 the lead process engineer may produce an early version of PID-TC1 as
well as update PFD-TC2 to PFD-TC3 if:

 The project is going straight from Outline Design to Engineering Design with the existing
design teams.
 The level of change between PFD-TC2 and PFD-TC3 is minor.

Alternatively, PID-TC1 is started at the beginning of Outline Design.

PID-TC1 includes the basic operational aspect of the plant and will contain:

 Major process streams, shown in heavier line.

 All major equipment symbols, shown in heavier line.
 Major equipment symbols will, where possible, reflect the elevation of the equipment.

 Major equipment standby unit’s symbols now shown.

 Sumps, bunds & gullies.
 Equipment numbers all systemised.
20
  All equipment will be numbered.
 All utilities will be identified.
 All Process and Safety Critical Instrumentation shown.
 All key valves and line items shown.

Figure 7 PID at TC1

Note drawing frame and notes etc. not shown for clarity

6.2.1 PID at TC1 Use

 It is primarily used to judge the breakdown of the overall process shown in the PFDs into PIDs
– too many items will result in a crowded drawing at later stages, too few looks sparse.
 Used to generate Work Breakdown Structures for project management.
 Typically the point at which other professional groups start to increase in size as they start to
develop their designs.
 Scoping - plant layouts start to be developed so that a civil engineering design can be started;
alternatively an assessment if the plant can fit into the existing civil engineering design can be
made.

6.3 PID-TC2

During Outline Design PID-TC1 drawings will be upgraded to TC2 standard by the addition of
significant levels of details and represents one of the largest tasks for the chemical engineers.

At this standard it the PID will contain nearly every item needed to complete the process, this
will also include purely mechanical and manual items, e.g.

 The process requires the transfer of a material from a keg by hand, weighing it then
adding it to a vessel.
 The keg, process ventilation, benches, note identifying manual transfer, weighing scale
and note for manual addition will appear on the PID.

21
 In addition to the requirements from TC1 the TC2 standard would at a minimum add:

 All minor piping, including utilities, drains and vents.

 All minor equipment required for the process.
 All drives shown with type and a unique a number comprising systemisation numbers
and unique numbers.
 Line numbers – including data on diameter, fluid, pipe specification, insulation, materials
of construction, unique number comprising systemisation numbers and unique numbers.
 All valves with their symbols identifying type with a unique number comprising
systemisation numbers and unique numbers.
 All line fittings with a unique number comprising systemisation numbers and unique
numbers.
 All instruments and where required hard wired control loops with unique number
comprising systemisation numbers and unique numbers.
 All alarms, trips and switches with unique number comprising systemisation numbers
and unique numbers; this would include mechanical position switches.
 All pipe falls with direction.
 Minimum distance data e.g. 2m between bend and flowmeter.
 Elevation data.
 Battery limits for Project with Vendors, Other projects, Site utilities etc.
 Flags both on and off the drawings showing the source/destination equipment and
drawing number.
 Where a vendor is providing an item of equipment this is usually shown using a box with
a chain link boundary; the inputs and outputs (including data) will be shown but the
outline of the contents of the box will be shown as dotted lines, if known, if unknown it
will be shown as an empty box.

Vendor PIDs will be treated individually.

 Structural information (walls, room boundaries, shielding, joggle boxes) will be shown;
only if required.

Figure 8 PID at TC2

Note drawing frame and notes etc. not shown for clarity

22
6.3.1 PID at TC2 Use

 PID-TC2 will be required for HAZOP 2, along with a clear process/control description,
material safety data, basic layout (PFD at TC2), outline environmental assessment and
basic operability assessment at a minimum.
 Production of a class 4 cost estimate – other professions will not have sufficiently mature
designs to get a better estimate at this point.

6.4 PID-TC3

This will be PID-TC2 with any changes required from HAZOP 2.

At this point the design will be frozen and later changes subject to change control procedure.

Figure 9 PID at TC3

Note drawing frame and notes etc. not shown for clarity

6.4.1 PID at TC3 Use

 Start of Hazardous Area assessments.

 Start of Safety Integrity Assessments with CE&I.
 Contributes to Class 2 or 3 estimate with information from other professions.
 Typically the point that chemical engineering design changes role from
design/development to detailing a fixed design and managing change.

6.5 PID-TC4

During the early stages of detailed design minor changes to the process design will be required to
meet the physical reality of the plant.

For example:

23
 1. A valve needs to be moved along a line and its number changed to match its new area.
2. A PID at TC3 shows one condensate trap on a steam line but the installed length requires
two traps.
3. An item of equipment is identified as not being able to achieve its duty without additional
equipment.

These changes will undergo a three-step review:

 The chemical engineering lead with an independent process reviewer will determine and
record, on the PID modification sheet, if the proposed change has any safety or
process impact if not (e.g. example 1 above) the modification will be approved & marked
onto the PID.
 If the chemical engineering lead with an independent process reviewer identify that there
is a minor impact (e.g. example 2 above requires modifications to the condensate
system) they will assess and recorded on a Note For Record (NFR) the effects of the
impact and if there is no safety or process impact the modification will be approved &
marked onto the PID.
 The change may result in some minor process/safety impact (e.g. example 3 above
requires more equipment for the same function) in this case a mini-HAZOP would be
held with a chemical engineering lead, Independent chemical engineer and safety
representative. These should take 1 to 2 hours and typically no more than 2 per PID
should be expected; if acceptable the change will be marked onto the PID.

PID-TC4 will record all of the changes on the PID Modification Sheet from detail design, Minor
impact NFRs & all mini-HAZOPs.

6.5.1 PID at TC4 use

 Primarily this is the management of change and recording the change.

 Changes can lead to cost overrun, safety issues, delays and managing them is critical at
this point.

6.6 PID-TC5

Vendor equipment at earlier stages will have been shown as a chain link box with only
inputs/outputs or outline detail.

Under normal circumstances Vendor PIDs provided during the procurement process that meet PID-
TC3 and would be accepted ‘as is’ into the project.

Some vendors however do not produce PIDs or other there are other issues that require that a PID
of the vendor’s equipment is produced. These PIDs will need to be upgraded to meet PID-TC3
standard.

24
Figure 4 Typical Vendor PID
Note drawing frame not shown for clarity

6.6.1 PID at TC5 use

 The primary function of this stage is to ensure that vendor packages provide the
safety/operational function assumed in earlier stages of the design.
 It also ensures that latent safety/operational issues embedded in vendor packages are
identified and resolved.

6.7 PID-TC6

Any changes made during construction will be recorded onto the PID Modification Sheet and at the
end of commissioning the drawing updated and released as the ‘as installed’ version.

These changes will be subject to the safety assessments identified for PID-TC4.

6.7.1 PID at TC6 Use

 This stage is simply to ensure that the plant operators get a complete and accurate set
of documents describing their plant.

25
7 UPIDs
Utility production and distribution usually follows well known guidance (e.g. Spirax Sarco’s steam
guidance) and the major design challenge is the routing of the distribution systems. As a result
UPID-TC1, showing the basic outline of the utilities distribution is normally not required.

If a utility is novel (e.g. -80°C coolant) or process/safety critical the uPID will follow the guidance for
PID-TC1 to TC6. Note ‘novel’ is dependent on the industry e.g. the provision of flare stacks and
their associated systems in Oil & Gas plants is normal.

uPID’s are effectively route maps for the distribution or collection of a utility or feed and as such
have no control or equipment shown. They would however show in-line items, such as filters,
flanges, reducers and so forth. They also identify where the utility/return goes to and returns from in
the “flags”.

7.1.1 UPID-TC2

These will only cover the distribution of the utility and be drawn to PID-TC2 standard for HAZOP 2.

The point of use of a utility or it’s return will be defined the drawing flags however a chain link box
can be added to increase legibility. Note – some companies show control connections but this can
cause confusion and is not recommended.
TP002

Site Cooling LF099 0001-CWS-100-CS

Water Supply Site Project

100*50
004-CWS-50-CS
0002-CWS-100-CS

003-CWS-100-CS

DWG 123-145 005-CWS-50-CS

LF101

LF102

Typical Flag Drawing

DWG 123-199

DWG 123-145
DWG 123-145
R101

HX103

HX104

that the line

V101

DWG 123-199
V101 goes to or
returns
from
HX104
HX103
R101
V101

Equipment
number
that the line
DWG 123-199

DWG 123-145

DWG 123-145

DWG 123-145

connects
HX103

HX104
R101
V101

too
003-CWR-100-CS
0002-CWR-100-CS

005-CWR-50-CS

004-CWR-50-CS

TP003

Site Cooling
0001-CWR-100-CS
Site Project Water Return

Figure 5 Typical uPID

26
7.1.2 UPID-TC2 Use

 This identifies the sizes of major utilities and their interconnectivity to ensure that
sufficient space is allocated to route the lines.
 It will also identify the need for and location of utility provision.
 It also ensures that if a PID has a utility “flag” then there is provision for the supply or
return.

7.1.3 UPID-TC3

UPID-TC3 will include any changes identified in HAZOP 2.

0007-CA-50-CS Secure Compressed Air 0008-CA-50-CS

Vent to Safe DWG 123-003 DWG 123-003

Place
V152 Supply V134

0005-CA-25-CS
TP001
80*50

0008-CA-25-CS
0001-CA-80-CS 80*50 0001-CA-50-CS
Site CA Supply
Site Project

0005-CA-25-CS

DWG 123-199
R110
0003-CA-25-CS

DWG 123-129
DWG 123-004
Room 101

R110
0002-CA-25-CS

0004-CA-15-CS
006-CA-25-CS

Breathing Air
DWG 123-199

DWG 123-145

DWG 123-145
DWG 123-145

CA Tool Supply
R101
V101

R102

Stations
T234

Figure 6 Base uPID for HAZOP

Note the uPID typically has no valves or equipment shown – those appear on the PID’s however
valves (in red) not within the scope of the design are shown so that HAZOP functionality specified
(“Site to provide isolation for the system”) can be seen.

7.1.4 UPID-TC4

During the early stages of detailed design minor changes to the process design will be required to
meet the physical reality of the plant.

UPID-TC4 will follow the same process as PID-TC4.

7.1.5 UPID-TC5

UPID-TC5 will follow the same process as PID-TC5, given that most of the utilities are likely to be
derived from Vendor’s standard designs.

7.1.6 UPID-TC6

UPID-TC6 will follow the same process as PID-TC6. Any changes made during construction will be
recorded onto the UPID and at the end of commissioning the drawing released as the ‘as installed’
version.

27
8 Process Sketches
Process Sketches cover a wide range of diagrams:

 Simple sketches embedded into documents to aid clarity.

 Layout sketches to define equipment relationships or function.
 Equipment sketches to define equipment (typically vessels).

Drawing that support specific documents such as Flammable Zones are excluded from this guide.

8.1 Simple Sketches

These are utilised to provide clarification in textural documents. There are no specific rules for
these sketches, except that:

 Any process plant symbols match (or are placed on) the Key Drawings for clarity.
 Equipment numbers and descriptions are consistent with the Equipment schedule.

8.2 Layout Sketches

Again these are utilised to provide clarification on the relationship and/or location of process plant.
There are no specific rules for these sketches, except that:

 Any process plant numbers and descriptions are consistent with the Equipment
schedule.
 Key dimensions and relationships are clearly shown.

It is recommended that these sketches be produced by a Mechanical Engineering Designer and

formally issued as sketches or layout drawings.

8.3 Equipment Sketches

Equipment sketches define the process requirements, typically for a vessel.

They do not provide mechanical or other data (unless this is added by a SQEP designer at a late
stage).

These sketches are embedded into process data sheets for TC1 and TC2 standard; at TC3 a
designer will have produced a formally issued the sketch or drawing and only the sketch/drawing
number would be displayed on the data sheet.

8.3.1 Equipment Sketches at TC1

These will be limited to data sheets for the main process items where they are safety or process
critical and show:

 Major dimensions.
 Approximate shape.
 Major nozzles.
 Manways, Agitator and Other Equipment nozzles/flanges.
 Descriptions of nozzles and flanges will appear on the data sheet.
 Major design requirements e.g. elliptical shell end.
 Nozzle information on data sheet.

28
 Ref Description

N1 Outlet – Base
N2 Level Switch – Top
N3 Level Transmitter – Top
N4 Access Nozzle – Top
N5 Access Nozzle – side
N6 Temp Transmitter – horz cone
N7 Level Probe – horz. cone
N8 Agitator – Top
N9 CIP Inlet 1 – Top
N10 CIP Inlet 2 – Top
N11 Vent to scrubber – Top
N12 Inlet 1 – Top
N13 Inlet 2 – Top
N14 Inlet 3 – Top
N15 Inlet 4 – Top
N16 Inlet 4 – Top
N17 pH Probe – horz cone

Figure 7 Basic Equipment Sketch and Nozzle Schedule at TC1

Note – this is only the sketch and nozzle data, the rest of the data sheet is not shown for clarity.

8.3.2 Equipment Sketches at TC2

This will only be shown on data sheets for all major process equipment and show:

 All TC1 data.

 Nozzle sizes.
 Nozzle specifications (e.g. ANSI #150 flange).
 Nozzle location, height, radial or 3D location.
 Nozzle number (or letter if required by client only).
 Typical construction or process requirements (e.g. number of legs).

Note main mechanical design details (legs, lugs, bolt downs are now shown).

29
 Ref Description Size Connection Radius Angle ° Height
Type mm mm
N1 Outlet –Base 80 mm NB ANSI 150lb **500 Centre 500
N2 Level Switch – Top 50 mm NB ANSI 150lb 1400 315 VTA
N3 Level Transmitter – 80 mm NB ANSI 150lb 1400 225 VTA
Top
N4 Access Nozzle – Top 600 mm NB ANSI 150lb 1400 270 VTA
N5 Access Nozzle – side 600 mm NB ANSI 150lb R13 0 VTA
N6 Temp Transmitter – 50 mm NB ANSI 150lb 700 270 700
horz cone
N7 Level Probe – horz. 50 mm NB ANSI 150lb 700 90 700
cone
N8 Agitator – Top 200 mm NB ANSI 150lb 0 Centre VTA
N9 CIP Inlet 1 – Top 200 mm NB ANSI 150lb 1400 180 VTA
N10 CIP Inlet 2 – Top 200 mm NB ANSI 150lb 1400 0 VTA
N11 Vent to scrubber – 100 mm NB stub 300 mm 1400 337.5 VTA
Top high
N12 Inlet 1 – Top 80 mm NB ANSI 150lb 1200 90 VTA
N13 Inlet 2 – Top 80 mm NB ANSI 150lb 1600 90 VTA
N14 Inlet 3 – Top 80 mm NB ANSI 150lb 1600 45 VTA
N15 Inlet 4 – Top 50 mm NB ANSI 150lb 1200 45 VTA
N16 Inlet 4 – Top 50 mm NB ANSI 150lb 1600 67.5 VTA
N17 pH Probe – horz 80mm NB ANSI 150lb 700 225 VTA
cone

Figure 8 Equipment Sketch at TC2

( Note – this is only the sketch and nozzle data, the rest of the data sheet is not shown for clarity ; VTA – Vendor to advise
8.3.3 Equipment Sketches at TC3

All major equipment sketches at TC3 will be produced by internal or vendor designers and
approved for chemical engineering content by the chemical engineers. They are effectively the
General Arrangement (GA) drawings for the item.
9 External Reference Documents
Reference Title
1 EN ISO 10628:2014 Parts 1 & 2
2 EN ISO 14617:2002 Parts 1 to 12
3 Standard Classification for Cost Estimate Classification
System, ASTM E2516 − 11

9.1 Supporting International Standards

Process Diagrams to the ISO standard critically demonstrate the physical sequence of equipment
and systems, as well as how these systems connect whilst providing the basis for the development
of system control Outlines, allowing for further safety and operational investigations, such as
HAZOP.

ANSI/ISA 5.1:2009 is often encountered as a PID ‘standard’ but it is predominantly focused upon
the production of a control diagram that reflects the actual physical control system. This results in
highly complex drawings which are primarily control engineering drawings with the process
relegated to a supporting role.

32
9.2 Generic Cost Estimate Classification Matrix

Table 1 ASTM Generic Cost Estimate Classification Matrix (ref 3)

Primary Characteristic Secondary Characteristic

DEGREE OF END USAGE METHODOLOGY EXPECTED PREPARATION
PROJECTION ACCURACY EFFORT
DEFINITION RANGE
ESTIMATED

Expressed as Typical Typical estimating Typical ± Typical degree

% of complete purpose of method range relative of effort relative
CLASS

definition estimate to index of 1 to least cost

(that is, Class index of 1[B]
1 estimate) [A]
5 0 % to 2 % Screening or Stochastic 4 to 20 1
feasibility (factors or
models, or both)
or judgment
4 1 % to 15 % Concept study Primarily 3 to 12 2 to 4
or feasibility stochastic
3 10 % to 40 % Budget Mixed but 2 to 6 3 to 10
authorization primarily
or control stochastic
2 30 % to 70 % Control or Primarily 1 to 3 5 to 20
bid/tender deterministic
1 70 % to 100 % Check Deterministic 1 10 to 100
estimate or
bid/tender

Note A If the expected accuracy range index value of ‘1’ represents +10/-5 %, then an index value
of ‘10’ represents +100/-50 %.

Note B If the preparation effort index value of ‘1’ represents 0.005 % of project costs, then an index
value of ‘100’ represents 0.5 %.

33
10 Appendix A – Glossary of
Abbreviations
The following abbreviations are in general use, not all used in this guide.

Glossary
BFD Block Flow Diagram
CAD Computer Aided Design
CBS Cost Breakdown Structure
COSHH Control Of Substances Hazardous to Health
EC&I Electrical, Control and Instrumentation
HAZOP Hazard and Operability Study
MFD Mechanical Flow Diagram
PID Process (&) Instrument Diagram
PFD Process Flow Diagram
SQEP Suitably Qualified and Experience Person
WBS Work Breakdown Structure

34
11 Appendix B – Systemisation
Numbering plant and equipment is often referred to as ‘systemisation’ and is a key function
of the PID/PFD.

11.1 Equipment Numbering

Are typically unique to a company/facility, but their approach is usually similar e.g.

Area Number AA-123.12

Plant & areas within plants tend to have unique
identification numbers/letters to aid location of the item.
(Note 1)

Unique Equipment Type/Group P

Typically One or possibly two letters
Unique ID Number 1234
Typically 4 digits but can be 8 or more
Standby – not used if there is only one item A
A standby/duty pair would be coded A or B but this can go
to F or further if needed.

Example

The third standby (C) pump (P) number 25874 located in HEP-600.01 P 25874 C
the HEPtane plant, area 600, room 1.

Table 2 Equipment Numbering – possible example

Note 1 – if the bulk of the equipment on a drawing in in one area then this is identified in the
drawing title box and does not appear on the equipment numbers on the drawing.

Note 2 – equipment type letters (sometimes called groups) vary but ISO 10628 in 2001
proposed the following; this table has been removed in later versions but is included here to
give an idea of a possible approach.

35
Table 1 Typical Equipment Type Letter Code
A Equipment or machine, if it cannot be classified under one of the following
groups
B Vessels, tanks, bins, silos
C Chemical reactors
D Steam generators, gas generators, furnaces
F Filters, liquid filters, gas filters, screening devices, screening machines,
separators
G Gears
H Lifting, conveying and transport
K Columns
M Electric motors
P Pumps
R Agitators, vessels with agitator, mixers, kneaders, stirrers
S Centrifuges
T Driers
V Compressors, vacuum pumps, blowers, fans
W Heat exchangers
X Feeding and distribution facilities, special equipment
Y Drives (drive units), not electric motors
Z Crushing machines, grinding machines

11.2 Line Numbering

Line numbering follows a similar process and is equally company/facility unique however a
typical numbering system is shown below.

Area Number or Code A123.12

(Usually shown in title block)
Fluid Code AA
(Note 2)
Pipe Nominal Bore XX

Material of Construction AA

Insulation / Trace Heating AAA

(Note 3)
Example

Chilled Water line, 50mm NB, in In Title CW 50 SS 150A/N

Stainless Steel, 150mm Block
insulation.

Note 1 – if the bulk of the equipment on a drawing in in one area then this is identified in the
drawing title box and does not appear on the equipment numbers on the drawing.

Note 2 – fluid codes are standardised (on the Fluid Schedule) to companies standards but
have two typical formats:

36
  Simple codes all fluids of the same type are grouped together with one code e.g.
CW for chilled water.
 Complex codes where a fluid is similar but has differing temperatures/pressures/
small compositional variations e.g. CW1 is at 4°C but CW2 is at 16°C. °C.
This allows equipment data sheets to be simplified.

Note 3 – Insulation/Trace heating is sometimes shown as a code in the line number not as a
line type on the drawing; codes are very variable but usually show – insulation thickness,
insulation type and if applicable trace heating type.

11.3 Use of Systemisation

The obvious use is that during procurement all of the equipment can be identified, purchased
and installed & in operation instructions can be clear and unambiguous.

Maintenance is another major user of systemised numbering to organise parts and spares,
identify failure trends and simply find infrequently used items in remote areas of large plants.
In reality the maintenance management systems typically set and drive systemisation
numbering.

37
12 Appendix C – PFD/PID Layout
In the UK PID/PFDs in common with all engineering drawings are draw on a basic sheet
conforming to BS 8888. This standard sets a common style for engineering drawings and
other drawing standards have similar requirements.

12.1 The Basic Layout of the Drawing

In most countries drawings are typically produced on sheets corresponding to the main ISO
A series (A0 to A4); in North America and Mexico ANSI Standard Paper Sizes (A to E). The
paper sizes are very close; as shown below

ISO mm inches USA inches

Sizes
A0 841 * 1189 33.1 * 46.8 E 34.0 x 44.0
A1 594 * 841 23.4 * 33.1 D 22.0 x 34.0
A2 420 * 594 16.5 * 23.4 C 17.0 x 22.0
A3 297 * 420 11.7 * 16.5 B 11.0 x 17.0
A4 210 * 297 8.3 * 11.7 A 8.5 x 11.0

Table 2 ISO & ANSO Paper Size Comparison

For the purposes of this guide only ISO sized sheets will be considered.

For PFD/PIDs A0 size drawings are now not usually used, as they are too large to handle in
a modern office and A1 is more typical, also the print size usually selected for the drawings
allows A3 prints of A1 drawings to be legible and easily handled in an office.

All drawings will have the same graphical features:

 Borders & Frames

 Grid Reference
 Title Block

Note: PID/PFD Drawings for A0 to A3 are always drawn in landscape format.

As engineering drawings are now typically produced on printers where the printer cannot
print to the edge of the paper and use oversize paper to compensate, trimming marks are
used to identify where to cut off the excess, to obtain the correct sheet size.

12.1.1 Borders & Frames

A border is then shown 20mm inset on the left-hand edge and 10mm inset on the other
edges. Inset from the border by 5mm is the drawing frame and this marks the extent of the
drawing. The gap between the border and the frame is divided into a Grid Reference to
allow easy location of items on a drawing,

38
 6 1 2
Key:
1 - Trimming marks
10 2 - Trimmed format
1 2 3 5
A
3 - Grid Reverence (Alpha/Numeric)
3 4 - Drawing Frame
B
5 - Drawing Space
4 6 - Untrimmed (printer) size

3 5 Dimensions in mm
5
20

Figure 9 Borders & Frames

12.1.2 Title Block

The Title Block is located in the bottom right-hand corner of the drawing inside the frame.
1 2 3 4 5 6 7 8 9 10 11 12

A A

B B

C C

D D

E E

F F

Drawing No

G Title G

HAZOP Status
Drawn By
Approved By
Issue Date
Drawing Type – PFD/PID Scale - NTS

H H
® Joe Blogs – Legal Owner

1 2 3 4 5 6 7 8 9 10 11 12

Figure 10 Basic Layout for an Engineering Drawing

The Title Block has the following Mandatory Information (Recommended no characters in
brackets)

 Legal owner (unspecified)

 Date of issue (10)
 Identification number (16)
 Sheet number (4)

39
  Title (25)
 Approval person (20)
 Creator (20)
 Document type (assembly, subassembly, detail, etc.) (30)

Optional Information

 Revision index (2)

 Number of sheets (4)
 Responsible department (10)
 Document status (20)
 Paper size (4)
 Technical reference (20)
 Copyright Notice (usually very long)

Depending upon the company producing the drawing the blocks often contain far more
information.

12.2 Layout of PFD/PIDs onto the Basic Layout

Clearly the basic layout can be used for PFD/PIDs but ISO 10628 and historical practice has
identified a common layout for PFD/PIDs so there are commonly used positions for:

 Notes
 Basic Equipment details
 Stream Data (on PFD’s only)
 The drawing itself.

Notes are located in the area above the title block and extend from the left hand edge of the
block to the frame. Note – ISO 10628 does not show this but in practice this area is typically
always needed as the drawings progress and title blocks are rarely as small as the standard
shows (the standard does not even contain the mandatory information!)

Basic Equipment Details (item name, number, size, etc.) are located in a table at the top of
the drawings. Note ISO 10628 shows this at the bottom and either position is valid but it’s
more common to see it at the top.

Stream Data – generated from mass and energy balances (number, contents, flowrate, etc.)
is positioned in a table at the bottom of the drawing for PFD’s. Typically, by the time PID’s
are being drawn the amount of information is to large and the tables become a standalone
document, either a drawing or report. Note ISO 10628 shows this along the top of the
drawing without the Equipment Details, normally both are present to provide clarity.

40
 The Drawing itself occupies the residual area.

Figure 11 Layout of PFD/PID main elements

41
12.3 Conventions for laying out & drawing PFD/PIDs

There are certain conventions to the layout of the PFD/PID, many of these derive from
mechanical engineering drawing practices that are often unreferenced in chemical
engineering standards, some are identified in standards like ISO 10628 and others are just
to aid clarity. The following is a list of common conventions, but some companies have their
own versions, that make a “good” PFD/PID.

 The Process starts on the left hand side of the drawing and proceeds towards the
right hand side.
 Gas and Gaseous wastes are shown moving towards the top of the page
 Liquid and solid wastes are shown moving toward the bottom of the page.
 Utilities are shown moving down the page

 Horizontal scale is not required so the width of equipment varies to suit the drawing
layout.
 Ideally the vertical relationships of equipment should be maintained, e.g. if vessel A
is above vessel B then this should be depicted on the drawing. This is especially
important for gravity flows.
 Where this is not practical (e.g. two pumps physically next to each other but have to
be drawn one above the other) elevation data should be used to identify the
relationship between the equipment.

 Main process lines are shown with heavy lines (even if they have their own colours)
 Utilities should be shown by thinner lines.
 Vessels and equipment should be shown with heavy lines

 Flow direction should be marked with an arrow or slope information.

 Lines leaving/entering a drawing should either have
o A battery limit marker showing it is leaving/arriving from the extents of the
design.
o A connection flag showing the drawing number that the line re-appears on or
arrives from and the equipment number that it connects too.

 Each PID should have a maximum of 2 major items of equipment (reactors,

columns, etc.) to allow legibility of the final drawing.
 Line colours should be selected for clarity both on screen and on paper, e.g. yellow
is good on a screen but difficult to read on paper.

12.4 Document numbering

This document does not discuss in detail document change control (for drawings in this
case) and the methods used to identify changes between the various stages.

Typically a drawing will have a unique number followed by a version number, as the drawing
is updated the unique number remains fixed but the version number changes. Document
numbering and version numbering are usually very project/customer specific in addition the
method used to produce the drawing will result in a differing approach:

Historically with hand drafted drawings change control was in some companies (but not all)
implemented in the following steps:

1. A unique number is issued, and it is also issued a provisional ‘P’ code

a. NNNN-NNNNN-NNNN – P1 – The P1 indicating this is the first version,
updates are then numbered P2, P3 and so forth.
2. Changes to the drawings are marked onto printouts, (Red for additions, Blue for
deletions, Green for notes to the draftsman) Comments and updates on the

42
 drawings would often be marked in wavy lines called ‘clouds’.
After HAZOP 1 changes are also recorded in change control records to record the
development of the design.
3. When sufficient changes had been identified the drawing would be redrawn,
checked, and issued with the next version number.
4. For formal drawing issue (e.g. to client for approval, for HAZOP) the drawings will be
changed from P to A then B, C and so forth, modifications to ‘As’ would then be A1,
A2 etc.

With CAD drawings, typically (but not always) adopts computer software numbering systems
crossed with the historical system:

1. A unique number is issued, and it is also issued a provisional ‘P’ code.

2. Minor updates are made to the drawing but saved as new versions e.g. P001.001,
P001.002 etc.
3. After HAZOP 1 changes are also recorded in change control records to record the
development of the design.
4. Major updates would be P001.002 to P002.001.
5. When the drawing is formally issued it will be changed from P to A then B, C and so
forth.
6. Copies of the files are retained at each stage for record purposes.
7. ‘Clouds’ are used when a formal issue occurs but uncertainties exist in the design
shown.

43
13 Appendix D - Key Drawings –
Details
This section provides more detail on the content of Key (or Legend) drawings, the drawings
have not been produced in this document as they would not be legible at A4 but examples of
the content in typical European style have been included.

The drawing(s) contains any symbol shown on the PID(s) with the exception of capital plant.
There is no strict definition of “capital plant” but typically a PFD/PID will have one or two
items that the surrounding plant services.

They should contain sufficient information that a user can interpret all aspects of the
information contained in the PID(s). The format of the drawings is typically tabular, arranged
to maximise use of the available space on the page. It should be noted that some companies
produce this information as a document.

The amount of information will impact the number of drawings produced; on a single PID all
of the information may be contained within the notes section of the drawings but other larger
projects may need many drawings. For example the White Rose Carbon Storage Project
required over 50 pages to define this information.

This Appendix aims to outline the typical information that would be included in these sheets.

13.1 Piping and Line Symbols

13.1.1 Pipeline Symbols

Example:-

Primary Line – main process flow

Secondary or Utility Line

Jacketed Line

Insulated Line – Insulation

100
thickness shown

CW-50-SS-100A/N Line number on main line see Line

Numbering section 11.2

Note – pipelines of differing materials are not typically given their own symbol as the pipe
numbering code has this information.

44
13.1.2 Pipeline Identification

This is a simplified version of the pipeline systemisation, see 11.2 Line Numbering for
details.

Following this will be the tables detailing

13.1.3 Fluid Code

Code Fluid Details

CA Compressed Air
CS1 Caustic Soda 40%
CS2 Caustic Soda 16%
EFF Effluent in
TWF Tower Water Feed 12°C
CWF Cooling Water Feed 6°C
CWR Cooling Water Return 16°C
TWR Tower Water Return 26°C

13.1.4 Pipe Diameters

Pipe Diameter Code Details
25 25mm Nominal Bore
32 Not to be used in Project – non-preferred size
50 25mm Nominal Bore
65 Not to be used in Project – non-preferred size
80 80mm Nominal Bore
90 Not to be used in Project – non-preferred size
100 100mm Nominal Bore

13.1.5 Materials of Construction (MoC)

Material Code Material Description
CS Carbon Steel
SS1 Stainless Steel 304
SS2 Stainless Steel 316
CD Copper Domestic

45
 13.1.6 Insulation Code
Insulation Code Details
MW Mineral Wool
MWC1 Mineral Wool with Aluminium outer cladding
MWC2 Mineral Wool with Steel outer cladding
PE1 Polyurethane foam – Open cell
PE2 Polyurethane foam – Closed cell
PE2C1 Polyurethane foam – Closed cell with Aluminium
outer cladding

Notes –

1. All tables will typically refer to more detailed schedules where significantly more
detail is provided.
a. Given that larger projects can have 100 fluids alone it is not unusual to see a
reference to the Fluids Schedule rather than any detail.
2. Some insulation codes incorporate the insulation thickness.
3. Some Fluid codes incorporate the colour to paint the line.

13.1.7 Valve & Line Items

There are likely to be a large number of valves and line items , so this will be one of the
largest tables. The number of valves will also be increased by

 Showing normally open valves as a line but normally closed valves as solid black.
 Showing the installation method into the line (flanged, welded, type of weld join,
screwed, etc)
 Similarly installation methods and small deviations in type increase the number of
line items.

Example:-

Generic Valve – used before the exact type is

determined.
Diaphragm Valve

Check Valve

Ball Valve – normally closed

Ball Valve – normally open

Ball Valve – normally open – flanged installation

Ball Valve – normally open – welded installation

Valves also have an additional set of functional codes associated with them e.g.

NO Normally Open
NC Normally Closed
LC Locked Closed
LO Locked Open

46
 FB Full Bore

13.1.8 Control Valves

Control valves typically are based on hand valves so the basic valve symbol is retained but
the actuator is shown.

The shape of the actuator used to depict the method of actuation but this has changed over
the years and currently squares and circles tend to predominate in PIDs but their meaning(s)
and uses vary greatly.

Square.
Historically this used to be hydraulic as it’s supposed to look like a piston
Currently tends to be electrical operation; S in the box for solenoid, M for motor
but P for pneumatic or H for hydraulic do occur.
Circle
Historically this was an electrical solenoid
Currently tends to be pneumatic operation but S in the circle for solenoid, M for
motor or H for hydraulic do occur.

Dome,
Historically this is pneumatic operation, it is meant to look like a pneumatic
actuator.
Currently it is pneumatic operation but typically limited to pressure regulators.

One thing that is constant however is that control valves must show the position that the
actuator moves the valve to in the vent of failure: of either the valve power or the control
system.

There are two common methods to identify the three typical failure states: an abbreviation
under the valve or a symbol on the actuator stem. The more common of these being the
symbol on the actuator stem which is shown on the Key Drawing.

No Fail state defined;

Acceptable in a PFD but not in a PID

Fail Closed (FC)

Fail Open (FO)

Fail In place (FIP

Note – there are a range of symbols for other fail states e.g. Fail closed after a delay; these
tend to be detailed symbols for instrumentation diagrams but sometimes appear on chemical
engineering drawings.

47
13.2 Instrumentation, Annotations & Acronyms
13.2.1 Line Symbols

These can be added to the pipeline table Table 1 Typical Equipment Type Letter Codebut it’s
generally better to keep them separate to avoid confusion.

Generic Instrument Signal

Short dashes are also common

Generic Electrical Signal

Typically power to an actuator
Mechanical Connection
Movement of one item initiates
movement in another

Boundary of vendors plant

Two typical types shown

Wall or Floor
used to delineate areas of plant

13.2.2 Instruments

The instrument information tends to be the largest part of the 2nd Key Drawing.

Firstly the meaning of the basic instrument shapes and the internal horizontal lines are
detailed e.g.

Local Local Control

Panel Room
Basic Instrument

Computer Based Control System

Shared Display/Control Function

Containing user accessible pre-programmed
algorithms that implement a local function

The horizontal lines can be shown as a series of dashes to indicate the instrument is inside a
control panel or it has a hidden function; this is unusual and not recommended in process
drawings.

Note – the symbols are always in the orientation shown.

There are a range of other symbol shapes but these typically refer to control systems that
have been superseded in industry. E.g.

for Programmable Logic Control.

48
 Where symbols touch communication between the functions is assumed to occur e.g. for an
instrument that has display in a local cabinet and is also connected to the control computer;
which is controlling a valve using the measured value. You would see the following.

13.2.3 Instrument Symbol Lettering

Next the meaning of the text within the symbols is defined from the following table from ISO
3511/2 1984.

Note – The letter and description will vary from country to country and by company and
compliance with standards is rare.

1 2 3 4
First Letter Succeeding Letter
Measured or Initiating Variable Modifier Display or Output
Function
A Alarm
B Users Choice (1)
C Controlling
D Density Difference
E All Electrical Variables (2)
F Flow rate Ratio
G Gauging, Position or Length
H Hand (manually operated) High
I Indicating
J Scan
K Timer or Time Programme
L Level Low
M Moisture or Humidity
N Users Choice (1)
O Users Choice (1)
P Pressure or Vacuum
Q Quality Integrate or Totalise Integrating
R Nuclear Radiation Recording
S Speed or Frequency Switching
T Temperature Transmitting
U Multi-variable (4)
V Viscosity
W Weight or Force
X Unclassified (3)
Y Users Choice (1)
Emergency or
Z
Safety Acting

49
 Notes
(1) Where letters are required for repetitive use in a project these may be utilised

(2) Note added to the PID to specify the property measured

X is used for variables that are used to a limited extent, providing it is suitably
(3)
identified
(4) For multiple inputs of dissimilar variables being fed into a single unit

Typical examples of how the letters and symbols are used are shown below

FIC Flow Indicator Controller

Computer Controlled
Readouts in control room
LI Level Indicator
Readout on local panel

Level Indicator Alarm –

HH Readouts in control room
LIA
H Alarms shown alongside
L
QI Computerised Quality Analyser
Readouts in control room
Measured value (pH) shown alongside
pH
PI Pressure Indicator
Local readout at or near measurement point
Typically a simple gauge

13.3 Specialist symbols

Most projects utilise specialist equipment or complex equipment multiple times that if
depicted on a PID would make it impossible to read. Subsequently simplifications of the
equipment are used to ensure clarity – the detailed information is shown once, with it’s
simplification.

For example a Schuf Rising Disk valve has the body of the valve welded directly into the
base of a tank. The body allows the attachment of sample and rinse, caustic washout and
product/drain lines by raising/lowering the disks a series of action can be performed e.g.

50
 Rinsing the sample
line

And/or

Caustic cleaning the

product and drain
lines

Rinsing product and

or drain lines

And/or taking a
sample

Emptying tank via the

product line

Or draining the tank

during tank cleaning

Clearly portraying this degree of complexity is not practical so a simplified symbol is

developed -

Tank Base

Sample Point
Rinse Water
Caustic In
Drain

Product

51
13.4 Key Drawing 3 - Equipment Symbols, Annotations, and Acronyms
13.4.1 Equipment numbers

Typically equipment is identified by a letter/number system.

The letter is usually a mnemonic P for Pump etc and a table similar to that shown in Table 1
Typical Equipment Type Letter Code, is typically reproduced here, but with the letters
showing the meanings used.

e.g. for the letter A the table shows:

A Equipment or machine, if it cannot be classified under one of the following

groups

However in the UK “A” is often used for Agitator

A Agitators, vessels with agitator, mixers, kneaders, stirrers

The number is typically a unique number either

 Comprising a letter with an area number and a unique number

 A letter with a unique number – the area number is identified on the PID and on
other documents.

There are however many variations on the numbering system the only common point they
share is that each item is unique.

13.4.2 Area Numbers

A table of the area numbers and their descriptions will then follow e.g.

Area Sub Area Description

100 Tanker offloading
110 Acid offloading
120 Alkali offloading
200 Reactor Hall
210 Reactor 1
220 Reactor 2
300 Product purification
310 Ultra-Filtration
320 Reverse Osmosis
400 Shipping
800 Utilities
810 Compressed Air
820 Tower Cooling Water

13.4.3 Equipment Symbols

For some companies all symbols used on PID’s are shown on the key drawings but typically
major items are not.

52
 There are no clear rules on this but typically if an item is a major plant item – it is being
supported by other equipment items and represents a significant expenditure then it is not
shown here and it is fully identified on the PID it only occurs there; then it is not shown on the
key drawing.

All other items are identified on the key drawings, even if they are identified in the PID
equipment table; e.g.

Centrifugal Pump

Shell & Tube Heat Exchanger

Plate Heat Exchanger

13.4.4 Drawing Annotations

PFD/PID/uPIDs have a significant amount of additional annotations, these typically are to

provide clear details on the engineering design intent and/or help the user to understand the
process.

It should be noted that these annotations are often company specific but typically sufficiently
clear to be understandable to chemical engineers.

Some examples

Project battery limit identifier

See Battery limit schedule for full listing

Slope of pipe run or floor and its direction
1:100

Connection flag from/to other drawing

within the scope of the project, typically
contains:
200-001 Drawing number e.g. 200-001
Equipment number P123.A
P123.A
Note While Iso 10628 shows a simple
arrow with text this is more common.
FIC Critical process dimensions – here
1
defining the position of a flow meter,
Note 29
“Note 29” will add additional details e.g.
Min 10D Min 40D “pipe to be horizontal to ±2 degrees..

Elevation data – used to define heights of

4.0 equipment against the project zero
datum. Values usually in metres as the
data is typically for civil construction.

SC Specification Change, used to identify

specification changes.

53
 E.g. here the materials of construction
SC change after the valve from SS1 to SS2

CW-50-SS1-100PE2C1 CW-50-SS2-100PE2C1

54
 14 Version Control
V1 Initial release Dec 2019
V2.P1 PID drawings improved to show annotations Dec 2020
Key Drawing section enhanced
Key Drawing annex added Awaiting IChemE
uPID section enhanced Formatting
PFD/PID layout annex added
Approx. 17 pages of additional info

55