Piping and Instrumentation Diagram Development

An essential guide for developing and interpreting piping and instrumentation drawings

Piping and Instrumentation Diagram Development is an important resource that offers the fundamental information needed for designers of process plants as well as a guide for other interested professionals. The author offers a proven, systemic approach to present the concepts of P&ID development which previously were deemed to be graspable only during practicing and not through training. 

This comprehensive text offers the information needed in order to create P&ID for a variety of chemical industries such as: oil and gas industries; water and wastewater treatment industries; and food industries. The author outlines the basic development rules of piping and instrumentation diagram (P&ID) and describes in detail the three main components of a process plant: equipment and other process items, control system, and utility system. Each step of the way, the text explores the skills needed to excel at P&ID, includes a wealth of illustrative examples, and describes the most effective practices.

This vital resource:

• Offers a comprehensive resource that outlines a step-by-step guide for developing piping and instrumentation diagrams
• Includes helpful learning objectives and problem sets that are based on real-life examples
• Provides a wide range of original engineering flow drawing (P&ID) samples
• Includes PDF?s that contain notes explaining the reason for each piece on a P&ID and additional samples to help the reader create their own P&IDs

Written for chemical engineers, mechanical engineers and other technical practitioners, Piping and Instrumentation Diagram Development reveals the fundamental steps needed for creating accurate blueprints that are the key elements for the design, operation, and maintenance of process industries.

Preface xix

Acknowledgement xxiii

About the Companion Website xxv

Part I Fundamentals of P&ID Development 1

1 What Is P&ID 3

1.1 Why Is P&ID Important? 3

1.2 What Is a P&ID? 4

1.3 P&ID Media 4

1.4 P&ID Development Activity 5

2 Management of P&ID Development 9

2.1 Project of Developing P&IDs 9

2.2 P&ID Milestones 9

2.3 Involved Parties in P&ID Development 11

2.4 P&ID Set Owner 12

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

2.6 P&ID Evolution 12

2.7 Tracking Changes in P&IDs 12

2.8 Required Man‐Hours for the Development of P&IDs 13

3 Anatomy of a P&ID Sheet 15

3.1 Title Block 15

3.2 Ownership Block 15

3.3 Reference Drawing Block 15

3.4 Revision Block 15

3.5 Comments Block 16

3.6 Main Body of a P&ID 19

4 General Rules in Drawing of P&IDs 21

4.1 Items on P&IDs 21

4.1.1 Pipes or Other Flow Conductors 21

4.1.2 Equipment 21

4.1.3 Instruments 21

4.1.4 Signals 22

4.2 How to Show Them: Visual Rules 22

4.2.1 Line Crossing Over 24

4.2.2 Equipment Crossing 25

4.2.3 Off‐Page Connector 26

4.2.4 Color in P&IDs 26

4.3 Item Identifiers in P&IDs 26

4.3.1 Symbols 27

4.3.2 Tags 28

4.3.3 Name 29

4.3.4 Technical Information 29

4.4 Different Types of P&IDs 32

4.4.1 Legend P&IDs 33

4.4.2 System P&IDs 34

4.4.3 Network P&IDs 34

4.4.4 Interarea P&IDs 34

4.4.5 Detail P&IDs 36

4.5 A Set of P&IDs 39

4.6 P&IDs Prepared in Engineering Companies Compared to Manufacturing or Fabricating Companies 42

4.7 Dealing with Vendor or Licensor P&IDs 43

5 Principles of P&ID Development 45

5.1 Plant Stakeholders 45

5.2 The Hierarchy of P&ID Development Rules 45

5.3 Plant Operations 46

5.3.1 Process Parameters 46

5.3.2 Process Parameter Levels 47

5.3.2.1 Pressure Levels 48

5.3.2.2 Temperature Levels 49

5.3.2.3 Liquid/Solid Levels 49

5.3.2.4 Flow Levels 50

5.3.2.5 Analyte Levels 50

5.3.3 Parameter Levels versus Control System 50

5.3.4 Parameter Levels versus Safety 51

5.3.5 Parameter Levels versus Operator Role 52

5.3.6 General Procedure of P&ID Development 53

5.4 What Should a P&ID Address? 53

5.4.1 Normal Operation 53

5.4.2 Nonroutine Operation 53

5.4.2.1 Reduced Capacity Operation 54

5.4.3 Reduced Efficiency Operation 57

5.4.4 Start‐Up Operations 58

5.4.5 Shutdown 59

5.4.6 Inspection and Maintenance 60

5.4.6.1 Quantitative Approach to Maintenance Requirement 60

5.4.6.2 Qualitative Approach to Maintenance Requirement 60

5.4.7 Operability in Absence of One Item 61

5.4.8 Provision for the Future 61

5.5 Conflicting Check and Merging Opportunities Check 63

5.5.1 Conflict Check 63

5.5.2 Merging Opportunities Check 63

5.6 Dealing with Common Challenges in P&ID Development 64

5.7 Example: Development of P&ID of a Typical Pump 65

Part II Pipes and Equipment 69

6 Pipes 71

6.1 Fluid Conductors: Pipes, Tubes, and Ducts 71

6.2 Pipe Identifiers 71

6.2.1 Pipe Symbol 71

6.2.2 Pipe Tag 71

6.2.2.1 Do All Pipes Need to be Tagged? 73

6.2.2.2 Which Span of Pipe Route can be Considered One Piece of Pipe? 73

6.2.2.3 How is the Pipe Tag Shown on a P&ID? 73

6.2.3 Pipe Off‐Page Connector 74

6.3 Pipe Tag Anatomy 74

6.3.1 Area or Project Number 74

6.3.2 Commodity Acronym 74

6.3.3 Pipe Material Specification Code 74

6.3.4 Pipe Size 77

6.3.5 Pipe Sequential Number 78

6.3.6 Other Pipe Tag Information 78

6.4 Pipes Crossing “Borders” 79

6.4.1 Implementing Spec Break 80

6.4.2 Reasons for a Spec Break 82

6.5 Goal of Piping 82

6.5.1 Magnitude of Flow in Pipe 83

6.5.2 Direction of Flow in Pipe 84

6.5.3 Providing Fluid with Enough Pressure at the Inlet 84

6.6 Piping Arrangements 84

6.6.1 Backflow Prevention Systems 85

6.6.2 Diversion of Flow 87

6.6.3 Distribution of Flow 87

6.7 Pipe Route 88

6.7.1 Slope 88

6.7.2 No Liquid Pocket 89

6.7.3 No Gas Pocket 89

6.7.4 Free Draining (Self‐Draining) 89

6.7.5 Free Venting 90

6.7.6 Gravity Flow 90

6.7.7 Vertical or Horizontal Pipe 90

6.7.8 Straight Piping 90

6.7.9 Minimum or Maximum Length or Distance 90

6.7.10 Other Special Pipe Routes 91

6.8 Piping Movement 91

6.9 Dealing with Unwanted Two‐Phase Flow in Pipes 92

6.9.1 Liquid–Gas Two‐Phase Flow 92

6.9.2 Gas–Liquid Two‐Phase Flow 94

6.9.3 Solid–Liquid Two‐Phase Flow 94

6.10 Tubes 94

6.11 Double–Wall Pipes 95

6.12 Pipes for Special Arrangements 96

6.12.1 Piping for Bypassing 96

6.12.2 Piping for Recirculation 96

6.12.3 Piping for Units in Series 96

6.12.4 Piping for Units in Parallel 97

6.12.5 Piping for Pressure Equalization 97

6.13 Pipe Size Rule of Thumbs 97

6.14 Pipe Appurtenances 97

6.14.1 Pipe Fittings 98

6.14.1.1 Pipe Direction Change 98

6.14.1.2 Reducers (Enlargers) 98

6.14.1.3 Three‐Way Connections 100

6.14.1.4 Pipe Connections 100

6.14.1.5 End‐of‐Pipe Systems 100

6.14.2 Specialty Items 102

6.14.2.1 Flange‐Insulating Gasket 102

6.15 Other Approach about Piping 103

6.16 “Merging” Pipes 103

6.17 Wrapping–Up: Addressing Requirements of Pipe during the Life Span 103

6.18 Transferring Bulk Solid Materials 104

Reference 104

7 Manual Valves and Automatic Valves 105

7.1 Valve Naming 105

7.2 Valve Functions 105

7.3 Valve Structure 105

7.4 Classification of Valves 105

7.4.1 Valve Plug: Throttling vs. Blocking Valves 106

7.4.2 Valve Selection 108

7.4.3 Multi‐port Valves 108

7.4.4 Double‐Seated Valves 110

7.5 Valve Operators 110

7.6 Different Types of Actuators 111

7.7 Basis of Operation for Automatic Valves 112

7.8 Tagging Automatic Valves 113

7.9 Tagging Manual Valves 113

7.10 Valve Positions 113

7.10.1 Regular Position of Blocking Valves and Decision Methodology 113

7.10.2 Failure Position of Automatic Valves and Decision Methodology 114

7.10.3 More Concepts about Failure Position of Automatic Valves 115

7.11 Valve Arrangement 117

7.11.1 Valves in Series 118

7.11.2 Valves in Parallel 118

7.12 Control Valves and RO Combinations 119

7.13 Operating in the Absence of Valves 119

7.13.1 Operating in the Absence of Control Valves 119

7.13.2 Operating in the Absence of Switching Valves 122

7.14 Valves in Role of Unit Operation 122

7.15 Special Valves 123

7.15.1 Check Valves 123

7.15.2 Regulators 124

7.15.3 Safety‐Related Valves 125

7.16 Valve Combinations 126

7.17 End of Valve Arrangements 126

7.18 Valve Sizing Rule of Thumbs 127

7.19 Merging Valves 127

7.20 Wrapping Up: Addressing Requirements of Valve During the Life Span 127

References 128

8 Provisions for Ease of Maintenance 129

8.1 Introduction 129

8.2 Different Types of Equipment Care 129

8.3 In‐place In‐line Equipment Care 129

8.4 In‐place Off‐line Equipment Care 130

8.5 In‐workshop Off‐line Equipment Care 131

8.6 Preparing Equipment for Off‐line Care 131

8.7 Isolation 131

8.7.1 Requirement of an Isolation System 131

8.7.2 Type of Isolation System 132

8.7.3 Placement of an Isolation System 135

8.7.4 Inbound Versus Outbound Blind Location 135

8.7.5 Merging Isolation Valves 135

8.8 Bringing the Equipment to a Non‐harmful Condition 136

8.8.1 Cooling Down 136

8.8.2 Emptying and Then Draining/Venting 136

8.8.2.1 Location and Number of Drain/Vent Valves 137

8.8.2.2 Size of Drain/Vent Valves 138

8.8.2.3 Other Usages of Drain/Vent Valves 138

8.9 Cleaning 139

8.9.1 Solid/Semi‐Solid Removal Methods 139

8.9.2 Washing Systems 139

8.9.3 Purging Methods 140

8.10 Ultimate Destination of Dirty Fluids 140

8.11 Making Equipment Easy to Remove 141

8.12 Wrap‐up 142

9 Containers 143

9.1 Introduction 143

9.2 Selection of Containers 143

9.3 Containers Purposes 144

9.4 Transferring Fluids Between Containers 145

9.5 Container Positions 146

9.6 Container Shapes 147

9.6.1 Closing Parts of Containers 148

9.6.2 Open Top or Fully Enclosed Containers 148

9.7 Container Identifiers 148

9.7.1 Container Symbol 148

9.7.2 Container Tags 149

9.7.3 Container Call‐outs 149

9.7.3.1 Tank Call‐outs 149

9.7.3.2 Vessel Call‐outs 150

9.7.3.3 Tag of Container in Duty of Conversion 151

9.8 Levels in Non‐flooded Liquid Containers 151

9.9 Container Nozzles 151

9.9.1 Nozzle Duties 151

9.9.2 Nozzle Locations 152

9.9.3 Nozzle Elevation Versus Liquid Levels 153

9.9.4 The Size, Number, and Rating of Nozzles 155

9.9.5 Merging Nozzles 155

9.9.6 Nozzle Internal Assemblies 156

9.9.7 Nozzle Externals 157

9.10 Overflow Nozzles 157

9.11 Breathing of Non‐flooded Containers 158

9.12 Blanketed Tanks 160

9.13 Heating (or Cooling) in Containers 161

9.14 Mixing in Containers 162

9.15 Container Internals 162

9.16 Tank Roofs 162

9.17 Tank Floors 163

9.18 Container Arrangement 164

9.19 Merging Containers 164

9.20 Secondary Containment 165

9.21 Underground Storage Tanks 166

9.22 Sumps 167

9.23 Wrapping‐up: Addressing the Requirements of the Container During its Lifespan 167

10 Pumps and Compressors 169

10.1 Introduction 169

10.2 Fluid Mover Roles 169

10.3 Types of Fluid Movers 169

10.4 A Brief Discussion on the Function of Fluid Movers in a System 169

10.5 Fluid Mover Identifiers 171

10.5.1 Fluid Mover Symbol 171

10.5.2 Fluid Mover Tag 171

10.5.3 Fluid Mover Call‐out 173

10.6 Liquid Movers: Dynamic Pumps 173

10.6.1 Centrifugal Pumps 173

10.6.1.1 P&ID Development on the Suction Side 174

10.6.1.2 P&ID Development on the Discharge Side 175

10.6.2 Low Flow Intolerance and Minimum Flow Protection System 176

10.6.2.1 Which Pumps May Need a Minimum Flow Pipe 176

10.6.2.2 Where Should we Position the Recirculation Line? 177

10.6.2.3 Where Should the Destination Point of the Recirculation Pipe Be? 177

10.6.2.4 What Should the Size of the Recirculation Pipe Be? 178

10.6.2.5 What Should the Arrangement on the Recirculation Pipe Be? 178

10.6.3 Cavitation 180

10.6.4 Very Small Centrifugal Pumps 181

10.6.5 Different Types of Spare Pump 182

10.6.6 Centrifugal Pump Arrangements 182

10.6.6.1 Centrifugal Pumps in Parallel 183

10.6.6.2 Centrifugal Pumps in Series 184

10.6.7 Pump Warm‐up or Cool‐down System 185

10.6.8 Piping Spec. for Centrifugal Pumps 187

10.6.9 Centrifugal Pump Drives 187

10.6.10 (Liquid) Seal Systems in Centrifugal Pumps 187

10.6.11 Merging Pumps 189

10.7 Liquid Movers: PD Pumps 190

10.7.1 PD Pump P&ID Piping 191

10.7.1.1 Reciprocating Pumps P&ID Piping 191

10.7.1.2 Rotary Pumps P&ID Piping 192

10.7.2 PD Pump Arrangements 193

10.7.3 Merging PD Pumps 193

10.7.4 Tying Together Dissimilar Pumps 193

10.7.5 PD Pump Drives 193

10.7.6 Sealing Systems for PD Pumps 194

10.7.7 Metering Pumps (Dosing Pumps) 194

10.7.8 Liquid Transfer – Summary 195

10.7.9 Pumps: Duty Other than Pumping! 195

10.8 Gas Movers: Fans, Blowers, Compressors 196

10.8.1 Low Flow Intolerance and Anti‐Surge Systems 196

10.8.2 P&ID Development of Gas Movers 197

10.8.3 Gas Mover Drives 198

10.8.4 Auxiliary Systems Around Fluid Movers 198

10.8.5 Gas Transfer – Summary 199

10.9 Wrapping‐up: Addressing Requirements of Fluid Movers During the Life Span 200

Reference 200

11 Heat Transfer Units 201

11.1 Introduction 201

11.2 Main Types of Heat Transfer Units 201

11.3 Different Types of Heat Exchangers and Their Selection 202

11.4 Different Types of Heat Transfer Fluids and Their Selection 203

11.5 Heat Exchangers: General Naming 204

11.6 Heat Exchanger Identifiers 204

11.6.1 Heat Exchanger Symbol 204

11.6.2 Heat Exchanger Tag 204

11.6.3 Heat Exchanger Call‐Out 205

11.7 Heat Exchanger P&ID 206

11.7.1 Vents and Drains 206

11.7.2 Isolation Valves 207

11.7.3 Chemical Cleaning Valves 207

11.7.4 PSDs 207

11.8 Heat Exchanger Arrangement 207

11.8.1 Heat Exchangers in Series 207

11.8.2 Heat Exchangers in Parallel 209

11.9 Aerial Coolers 209

11.9.1 Aerial Cooler P&ID 210

11.9.2 Dealing with Extreme Temperatures 211

11.9.3 Aerial Cooler Arrangement 211

11.10 Merging Heat Exchangers 212

11.11 Wrapping‐up: Addressing the Requirements of a Heat Exchanger During its Life Span 212

11.12 Fired Heaters and Furnaces 213

11.12.1 Process Fluid Side 213

11.12.2 Flue Gas Side 213

11.12.3 Firing Side 214

11.13 Fire Heater Arrangement 215

11.14 Merging Fired Heaters 216

11.15 Wrapping‐up: Addressing the Requirements of Fired Heaters During their Lifespan 216

12 Pressure Relief Devices 217

12.1 Introduction 217

12.2 Why Pressure Is So Important? 217

12.3 Dealing with Abnormal Pressures 217

12.3.1 Active Versus Passive Solutions 219

12.3.2 Where Could Passive Solutions Be Used? 219

12.3.3 Where Should Active Solutions Be Used? 219

12.4 Safety Relief System 219

12.5 What Is an “Enclosure,” and Which “Side” Should Be Protected? 220

12.6 Regulatory Issues Involved in PRVs 220

12.6.1 Codes Versus Standards 221

12.7 PRD Structure 222

12.8 Six Steps to Providing a Protective Layer 222

12.9 Locating PRDs 223

12.10 Positioning PRDs 223

12.11 Specifying the PRD 225

12.12 Selecting the Right Type of PRD 225

12.12.1 Pressure Relief Valve Type 225

12.12.2 Rupture Disks 226

12.12.3 Decision General Rules 226

12.13 PRD Identifiers 226

12.13.1 PRD Symbols and Tags 226

12.13.2 PRD Technical Information 227

12.14 Selecting the Right Type of PRD Arrangement 228

12.15 Deciding on an Emergency Release Collecting Network 230

12.16 Deciding on a Disposal System 232

12.16.1 Liquid Disposal 232

12.16.2 Gas/Vapor Disposal 233

12.16.3 Two‐Phase Flow Handling 234

12.17 Protecting Atmospheric Containers 235

12.18 Merging PRDs 236

12.19 Wrapping‐Up: Addressing the Requirements of PRDs During their Lifespan 238

Part III Instrumentation and Control System 239

13 Fundamentals of Instrumentation and Control 241

13.1 What Is Process Control? 241

13.2 Components of Process Control Against Violating Parameters 241

13.3 Parameters Versus Steering/Protecting Components 242

13.4 How Many Steering Loops Are Needed? 242

13.5 ICSS System Technology 243

13.5.1 Use of PLC for a BPCS 243

13.5.2 Use of DCS for a SIS 244

13.5.3 Alarm Systems 244

13.5.4 ICSS System Symbology 244

13.6 ICSS Elements 245

13.7 Basic Process Control System (BPCS) 245

13.8 Instruments on P&IDs 247

13.8.1 Fundamental Terminology 247

13.8.2 Identifiers for Equipment and Instrumentation 247

13.9 Instrument Identifiers 248

13.9.1 Acronyms 248

13.9.2 Divider Types 249

13.9.3 Symbol Type 250

13.9.4 Additional Information and Tag Number 252

13.10 Signals: Communication Between Instruments 252

13.10.1 Signal Types 253

13.10.2 Signal Functions 253

13.10.3 Signal Math Functions 254

13.10.4 Signal Selectors 254

13.11 Different Instrument Elements 255

13.11.1 Primary Instruments 255

13.11.1.1 Temperature Measurement 256

13.11.1.2 Pressure Measurement 257

13.11.1.3 Level Measurement 258

13.11.1.4 Flow Measurement 258

13.11.1.5 Process Analyzers 260

13.11.2 Transmitters 262

13.11.3 Controllers 263

13.11.4 Indicators 263

13.11.5 Final Control Elements in a BPCS 263

13.11.5.1 Control Valves 264

13.11.5.2 Variable Speed Devices on Electric Motors 264

13.12 Simple Control Loops 264

13.12.1 Level Control Loops 265

13.12.2 Pressure Control Loops 265

13.12.3 Temperature Control Loops 265

13.12.4 Composition Control Loops 266

13.12.5 Flow Control Loops 266

13.13 Position of Sensor Regarding Control Valves 266

14 Application of Control Architectures 269

14.1 Introduction 269

14.2 Control System Design 269

14.3 Selecting the Parameter to Control 269

14.4 Identifying the Manipulated Stream 270

14.5 Determining the Set Point 271

14.6 Building a Control Loop 272

14.6.1 Feedback Versus Feedforward 272

14.6.2 Single‐ versus Multiple‐Loop Control 273

14.7 Multi‐Loop Control Architectures 274

14.7.1 Cascade Control 274

14.8 Feedforward Plus Feedback Control 276

14.8.1 Ratio or Relationship Control 279

14.8.2 Selective Control 280

14.8.3 Override and Limit Control 281

14.8.3.1 Override Control 283

14.8.3.2 Limit Control 286

14.8.4 Split Range and Parallel Control 286

14.8.5 Clarification of Confusion 288

14.8.5.1 Cascade Versus Ratio 288

14.8.5.2 Single Loop Versus Ratio 288

14.8.5.3 Selective Versus Override 288

14.9 Monitoring Parameters 289

14.9.1 Container Sensors 290

14.9.2 Fluid Mover Sensors 290

14.9.3 Heat Exchanger Sensors 291

14.9.4 Fired Heater Sensors 291

15 Plant Process Control 293

15.1 Introduction 293

15.2 Plant‐Wide Control 293

15.3 Heat and Mass Balance Control 293

15.4 Surge Control 295

15.4.1 Disturbances in Process Parameters 295

15.4.2 Disturbance Management 296

15.4.2.1 Absorption 296

15.4.2.2 Rejection 296

15.4.3 Disturbance Versus Fluid Phase 296

15.4.4 Dampening Gas/Vapor Flow Surge 297

15.4.5 Dampening Liquid Flow Surge 298

15.4.6 The Purpose of Containers in Process Plants 301

15.5 Equipment Control 302

15.5.1 Do We Need to Control at All? 302

15.5.2 Principles of Equipment‐wise Control 302

15.6 Pipe Control System 304

15.6.1 Control of a Single Pipe 304

15.6.1.1 Control of Pressure in a Pipe 304

15.6.1.2 Control of Flow in a Pipe 304

15.6.2 Controlling Multiple Pipes 306

15.6.2.1 Flow Merging 306

15.6.2.2 Flow Splitting 308

15.7 Fluid Mover Control System 309

15.7.1 Pump Control Systems 310

15.7.1.1 Centrifugal Pump Control 310

15.7.1.2 Positive Displacement (PD) Pump 314

15.7.2 Gas Mover Control Systems 316

15.7.2.1 Capacity Control Methods for Gas Movers 316

15.7.3 Anti‐Surge Control 319

15.7.4 Lead–Lag Operation of Fluid‐Movers 319

15.8 Heat Transfer Equipment Control 320

15.8.1 Heat Exchanger Control System 320

15.8.1.1 Direct Control System 320

15.8.1.2 Bypass Control System 321

15.8.1.3 Control of Heat Exchangers Experiencing Phase Change 324

15.8.2 Air Cooler Control 327

15.8.3 Heat Exchanger for Heat Recovery 327

15.8.4 Back Pressure Control of Heat Exchangers 328

15.8.5 Fired Heater Control 328

15.9 Container Control System 331

15.10 Blanket Gas Control Systems 332

Reference 332

16 Plant Interlocks and Alarms 333

16.1 Introduction 333

16.2 Safety Strategies 333

16.3 Concept of a SIS 333

16.4 SIS Actions and SIS Types 333

16.5 SIS Extent 336

16.6 Deciding on the Required SIS 336

16.7 The Anatomy of a SIS 336

16.7.1 SIS Element Symbols 336

16.7.1.1 SIS Primary Elements: Sensors 337

16.7.2 SIS Final Elements 337

16.7.2.1 Switching Valves 337

16.7.2.2 Switching Valve Actuator Arrangements 338

16.7.2.3 Valve Position Validation 338

16.7.2.4 Merging a Switching Valve and a Control Valve 338

16.7.2.5 On/off Action of Electric Motors 339

16.7.3 SIS Logic 339

16.8 Showing Safety Instrumented Functions on P&IDs 340

16.9 Discrete Control 343

16.10 Alarm System 344

16.10.1 Anatomy of Alarm Systems 345

16.10.2 Alarm Requirements 345

16.10.3 Alarm System Symbology 346

16.10.4 Concept of “Common Alarm” 347

16.11 Fire and Gas Detection System (FGS) 347

16.11.1 Manual Alarm 350

16.12 Electric Motor Control 351

16.12.1 Simple Motor Control 351

16.12.2 The Focal Element of Motor Control: mcc 351

16.12.3 All About Relationships with Electric Motors 351

16.12.4 P&ID Representation of Commands and Responses 352

16.12.5 P&ID Representation of Principal Arrangement for Inspection and Repair 353

16.12.6 Examples 355

Part IV Utilities 357

17 Utilities 359

17.1 Utility System Components 359

17.2 Developing P&IDs for Utility Systems 359

17.2.1 Identifying the Utility Users 359

17.2.2 Utility Distribution and Collection Network Topologies 359

17.2.3 Designing the Detail of a Utility Network 361

17.2.4 Placing Priority on Utility Users 362

17.2.5 Connection Details of Utility to Process 363

17.3 Different Utilities in Plants 363

17.4 Air as a Utility in Process Plants 363

17.4.1 Instrument Air (IA) 363

17.4.2 Utility Air (UA) or Plant Air (PA) 364

17.5 Water as a Utility in Process Plants 364

17.5.1 Utility Water (UW) or Plant Water (PW) 364

17.5.2 Potable Water 364

17.6 Heat Transfer Media 364

17.6.1 Steam 365

17.7 Condensate Collection Network 366

17.8 Fuel as Utility 366

17.8.1 Fuel Oil 366

17.8.2 Fuel Gas 366

17.9 Inert Gas 367

17.9.1 Blanket Gas 367

17.9.2 Purging Gas 367

17.10 Vapor Collection Network 367

17.11 Emergency Vapor/Gas Release Collection Network 368

17.12 Fire Water 368

17.13 Surface Drainage Collection Network or Sewer System 370

17.14 Utility Circuits 372

17.14.1 Air Circuit 372

17.14.2 Steam–Condensate Circuit 374

17.14.3 Cooling Water Circuit 375

17.14.4 Natural Gas Preparation System 375

17.15 Connection Between Distribution and Collecting Networks 375

Part V Additional Information and General Procedure 379

18 Ancillary Systems and Additional Considerations 381

18.1 Introduction 381

18.2 Safety Issues 381

18.2.1 Different Types of Hazards 381

18.2.2 Hazards and Injuries 381

18.2.3 Mechanical Hazards 381

18.2.4 Chemical Hazards 382

18.2.5 Energy Hazards 382

18.2.5.1 Noise Barrier 382

18.2.5.2 Burning Prevention 382

18.2.6 Safety Showers and Eye Washers 383

18.3 Dealing with Environment 384

18.3.1 Arrangements for Maintaining the Temperature of the Process 384

18.3.2 Winterization 385

18.3.3 Deciding on the Extent of Insulation 389

18.3.4 Summary of Insulation 390

18.4 Utility Stations 390

18.5 Off‐Line Monitoring Programs 392

18.5.1 The Program Component 392

18.5.2 Sampling System 393

18.5.3 Sample Extraction Device 393

18.5.4 Sample Transferring Tube 394

18.5.5 Sample Conditioning System 394

18.5.6 Sample Hand‐Over System 395

18.5.7 Waste Sample Collection System 395

18.5.8 Sampling Station Structural Frame 395

18.5.9 Showing a Sampling System on P&IDs 396

18.5.10 Sampling System for Process Analyzers 396

18.6 Corrosion Monitoring Program 396

18.7 Impact of the Plant Model on the P&ID 397

18.8 Design Pressure and Temperature Considerations 398

18.8.1 Decision on “Design Pressure @ Design Temperature” Pair 399

18.8.1.1 Deciding on “Design Pressure” 399

18.8.1.2 Deciding on “Design Temperature” 399

18.8.2 Sources of Rebel Pressures 400

18.8.3 Sources of Rebel Temperatures 400

18.8.4 Design Pressure and Design Temperature of Single Process Elements 400

18.8.5 Design Pressure of Connected Items 401

18.8.5.1 Design Pressure of Connected Equipment–Equipment 402

18.8.5.2 Design Pressure of Connected Equipment–Sensor 403

19 General Procedures 405

19.1 Introduction 405

19.2 General Procedure for P&ID Development 405

19.2.1 P&ID Development: Piping and Equipment 405

19.2.2 P&ID Development: Control and Instruments 406

19.3 P&ID Reviewing and Checking 409

19.3.1 Format Check 409

19.3.2 Demonstration Rules Check 410

19.3.3 Technical Check 410

19.3.4 Design Check 412

19.4 Methods of P&ID Reviewing and Checking 412

19.4.1 Systematic Approach 412

19.4.2 Scanning Approach 412

19.5 Required Quality of P&IDs at Each Stage of Development 413

20 Examples 417

Index 453

MOE TOGHRAEI is an independent consultant and instructor. He has more than 20 years of experience in the chemical process industries. He provides consultancy in process and project engineering areas. He also has developed and instructed dozens of technical courses, including tailor-made courses for companies, public courses and online courses. His online courses are available through the University of Kansas and University of Dalhousie.