PROCESS FLOW DIAGRAM

PROCESS & INSTRUMENTATION

DIAGRAM
REAL - a member of Reliance Group ~ An Overview
 PFD / P&ID / MSG

 Process Flow Diagram

 Basic processing scheme showing all major equipment, main flow
streams, major control systems, operating pressures & temperatures, and
heat and material balances.

 Piping and Instrumentation Diagram

 Fundamental design & engineering document indicating process, piping,
mechanical & electrical requirements of the plant.
 Transmits design information to the engineering, construction, start-up
& operations.
 Forms the design basis for the project after Client approval.

 Material Selection Guide

 Indicates all major equipment, piping materials, corrosion allowance &
lining details.
 About P&ID
 Piping and Instrumentation Diagram
Used For
 Preliminary piping material control and take-off including valves and
special materials.
 Preliminary plot plan layout including piperack widths and no. of levels.
 Basis for 3D model work.
 Establishing basic job documents:-
• Line Designation Tables.
• Instrument Schedules.
• Insulation and Steam Tracing Requirement.
• Range of Piping Material Schedules.
• Major Equipment List.
• All piping design documents.
 Controlling the changes to engineering scope of work.
 Establishing methods of plant commissioning, start-up and operation.
 Owner of P&ID is Process/Systems group during detailed engineering &
Operations/CTS group after start-up.
 About P&ID
 Piping and Instrumentation Diagram
Types
 Process Unit P&ID's
 Process unit design based on the PFD's.
 Utility P&ID's
 Utilities like steam raising, water treating, air compressors, or inert gas
 Offsites P&ID's
 Tankages,blending, loading & shipping systems & other offsite systems.
 Auxiliary P&ID's
 Vendor eqpts. like compressor lube & seal oil systems or package boilers.
 Interconnecting P&ID's
 Offsite interconnections between process, utility and offsites.
 Inputs for P&ID
 Process
 Process Flow Diagram
 Preliminary Utility Balance
 Vessels Design Sketches Showing Liquid Levels & Internals
 Data Sheets for equipment (fired heaters, compressors, exchangers etc.)
 Cooling Methods and Requirements
 Major Equipment List
 Heat and Material Balance
 Steam Requirement
 Effluent Systems
 Line design conditions
 Line numbers, sizes and specifications
 Plant safeguarding and safety requirements (PSVs, de-pressurising etc.)
 Inputs for P&ID
 Project
 Mechanical specifications which include:
 Design philosophy and applicable codes/standards.
 General & project specific specifications.
 Installed equipment sparing philosophy.
 Drivers, power medium (steam or electrical).
 Noise and pollution requirement.
 Applicable standard drawings.
 Future provisions.
 Drainage systems.
 Basic engineering design data - from Licensor
 Piping material classification index.
 Preliminary plot plans and site plans.
 Physical properties/specifications of feed, product & intermediate
streams.
 Client specifications
 Information on P&ID
 Piping
 All main flow lines, including valves with sizes.
 Line numbers, sizes, specifications, insulation, paint & steam tracing.
 Piping class and specification breaks.
 Auxiliary systems, e.g start up, shut down, pump out, seal, flushing,
decoking, regeneration, snuffing systems, etc.
 Tie in numbers and schedule.
 Boiler codes and limits.
 Sample points and types.
 Steam traps and types.
 Tight shut off valves and operating blinds.
 Complete operation vents and drains.
 Major expansion joints.
 PSV block valves, locks etc.
 Special piping items.
 Information on P&ID
 Equipment
 All major equipment with nos., titles & summary/key design information
 Vessels key internals
 Scope of vendor package units & tie-ins
 Material classification of vessels & trims
 Utility services to equipment including steam out & maintenance reqt.

 Instruments
 Principal instrumentation/Control systems.
 Methods of interfacing field instruments to main control systems.
 In-line instrument requirements.
 All instrument numbers.
 Control valve sizes and manifolding.
 Relief valve type, set pressures & size.
 P&ID Initiated Tasks
 Piping
 Plot plan/piping studies & piperack layout studies.
 Vessel nozzle orientations and piping layouts.
 3D Plant models.
 Vessel instrumentation, platforms and ladders (for vessel purchase).
 Valve take offs and MRQ.
 Bulk MTO and MRQ.
 Long delivery piping and valves (alloy) MRQ and order.
 Battery limit schedules - showing all lines crossing the BL.

 Control Systems
 Enquiry for control valves, relief valves, orifice plates.
 Instrument data sheets.
 Progress instrument installation schedule and issue.
 P&ID Initiated Tasks

 Civil
 Plant preliminary U/G system
 U/G bulk material take off
 Piperack study

 Electrical
 Single line diagrams
 Electrical load summary
 Area classifications

 Mechanical
 Vessel drawings
 Nozzle sizes and locations
 P&ID Initiated Tasks
 Operations
 Logic Diagrams - Representation of operation for start-up & shutdown
of all units.
 Construction & QAQC
 Hydrotest Diagrams - Erected piping split into independent isolated
sections for hydrotesting.
 Loss Prevention
 Cause & Effect, Sequence Flow Diagrams - For plant safety shutdown
systems & F&G (fire and gas) systems.
 Hazop Study
 Process
 Line Designation Table
 THAT’S ALL ABOUT

PFDs and P&IDs

REAL - a member of Reliance Group
 LINE
DESIGNATION
TABLE
~ An Overview
REAL - a member of Reliance Group
 What is an LDT ?
 Pertinent design information for all the lines in a plant.

 Contains all the piping information, viz. line number, flow

data, line size, class rating, operating and design conditions
and hydro testing pressure.

 Basis for calculating wall thickness, stress analysis,

insulation, painting and tracing requirements, instrument
design data and field pressure testing.
 Contents of LDT
 Line Information [Line Numbering]
Line No. = Unit+Fluid Type+Seq.+Dia.+Pipe Spec+Insul.Type+Insul. Tk.
 Unique and not re-used, if cancelled.
 New Lines Assigned For
 Lines originating from a piece of equipment
 Line size change, i.e. in major headers.
 All piping specification changes.
 Line branches.
 Changes in flow conditions on utility headers.
 Major changes in process condition (i.e. downstream of control valves).
 Battery limits.
 New Lines Not Assigned For
 Passing of a line from one plant or unit to another.
 Small Pressure/Temperature change, pipe size & flange rating change.
 Contents of LDT
 Line Information [Other Parameters]
 Insulation Type & Tk. Based on Normal Operating Temperature
 H - Heat Conservation
 C - Cold Conservation
 PP - Personal Protection
 Lines to be Steam or Electrically Traced
 Type (Steam or Electric)
 Specification
 Painting Requirements Dictated by Project Specification
 Routing (From-To)
 Originating and/or terminating equipment no.
 Originating and/or terminating line no.
 Terminating in air (atmosphere, grade, OWS etc.).
 Reference P&ID(s)
 P&ID numbers of P&ID(s) containing the line
 Contents of LDT
 Operating Conditions
 Sources of Information
 Process Flow Diagrams
 Process Stream Data Sheets
 Project Design Data
 Project Utility Balances
 Vendor Data
 Based on the Above
 Mass Flow
 Volume Flow Rate
 Weight Percent Vapour
 Pressure
 Temperature
 Viscosity and Density at operating conditions
 Velocity
 Pressure Drop
 Contents of LDT
 Design Conditions
 Upset
 Most severe short term coincident conditions of temperature and
pressure governing piping design for pressure temperature rating
and wall thickness.
 Based on abnormal operating conditions including loss of cooling
medium,instrument failure, inadvertently closed valve, etc.
 Code
 Design conditions used to establish pipe wall thickness and flange
rating and are based on the upset conditions taking into
consideration allowances as defined in ANSI B31.3 Section
302.2.
 Not to be less than the normal operating condition.
 Contents of LDT
 Design Conditions
 Test
 All piping shall be pressure tested, except for piping open to the
atmosphere, e.g. vents and drains downstream of the final block valve.
 Type
• H - Hydrostatic Min. 150 % of Design Pressure
• P - Pneumatic Min. 110 % of Design Pressure
• P/H - Hydro Pneumatic Special cases like large flare headers
• S - Service At normal operating pressure
** Hydrostatic testing is preferred over pneumatic since latter is hazardous operation.
 Minimum & Maximum Temperatures
 Governs piping stress and flexibility requirement
 Minimum operating temperature on depressurization of systems.
 Maximum operating temperature by steam-out or defrost conditions
occurring at a low coincident pressure.
 Maximum & minimum operating temperatures occurring on a short term
basis but not necessarily governing the upset conditions.
 THAT’S
ALL
ABOUT

LDT
REAL - a member of Reliance Group