Plant Design

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Plant Design

• The objective of Plant Design is to define the
  equipment, piping, instrumentation and all
  process requirements needed to build and operate
  a process plant.
• Plant design normally starts with a process
  scheme
• Process Requirements (chemical and petrochemical
  applications ) - Plant Capacity, in MTPY (metric
  tons per year) , Product specification in terms
  of purity or maximum content of certain
  impurities
• Process Design
• A process flow diagram (PFD) is a diagrammatic
  representation of a process using symbols to
  represent the various components (equipment,
  lines, and control instrumentation) that make up
  the unit. Only the main components are shown.
• Piping and instrumentation diagram (PID) show
  how industrial process equipment is
  interconnected by a system of pipelines. PID
  schematics also show the instruments and valves
  that monitor and control the flow of materials
  through the pipelines.
• This document will be the basis for developing
  the piping drawings and for specifying the
  instrumentation and control systems. It is a
  rather detailed document and for this reason,
  each PID covers only a small part of the
  process. So, a typical petrochemical unit may
  have 20 to 30 PIDs, while larger units may well
  have 60 to 100.

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Applications
Process Plants built as engineering
construction (EC) projects require complex
piping. These projects include the
following chemical plants Biotech
plants Brewery Crude oil refineries Food
processing Fertilizer plants Oil Gas Nuclear
Power plants Pharmaceutical Pulp Paper
mills Water Treatment plants
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PFD Example
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PID Example
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PID Example
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Piping Instrumentation Diagram

• Symbolic representation of a plant, with its
  equipment, piping, and instrumentation clearly
  identified. It is the basis for all detail
  engineering work. Also known as Mechanical Flow
  Diagram (MFD).

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Categories

• PID drawings fall into two categories
• 1) Dumb, which are basically CAD-centric 2D
  diagrams
• 2) Intelligent data-centric diagrams that range
  from simple database connectivity to a full-blown
  data model that includes engineering rules,
  automatic design validation, standards
  compliance, integration with design and
  calculation packages, and the like.
• The PID stage of design is generally considered
  engineering, and the physical stage is considered
  design or layout.

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Purpose Scope

• The responsibility for the Process and technical
  content of the PIDs lies with the Process,
  Mechanical, Piping and Instrument disciplines.
• It is the responsibility of personnel on the
  project team to ensure that the standards
  described within this document are maintained,
  and that any deviations from these standards are
  documented and reported to the PID Coordinator,
  checked by all Disciplines and approved by the
  Area Manager
• --------------------------------------------------
  -----------------------
• Scope - This instruction outlines the Work
  Process and Project Settings for PID development
  and the corresponding milestone issues of the
  document.

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Description

• Piping is the physical elements that interconnect
  the equipment and in which the process streams
  flow. Piping comes in different sizes and
  materials. It is the duty of the process engineer
  to specify the size and materials of the piping
  and also the thermal insulation, if required. The
  term piping also includes accessories such as
  elbows, tees, valves, flanges, etc. The most
  common material is carbon steel. Other metals,
  such as various grades of stainless steel, and
  plastic materials, such as PVC, Teflon, are also
  used.
• Instrumentation is devices used to measure,
  control, and monitor the process variables. These
  variables can be flow, temperature, pressure,
  liquid level, viscosity, and others. Control
  valves and relief valves are also an important
  part of the instrumentation.

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Representation

• PID shows all of piping including the physical
  sequence of branches, reducers, valves,
  equipment, instrumentation. The PID are used to
  operate the process system.
• A PID should include
• Instrumentation and designations
• Mechanical equipment with names and numbers
• All valves and their identifications
• Process piping, sizes and identification
• Miscellaneous - vents, drains, special fittings,
  sampling lines, reducers, increasers and swagers
• Permanent start-up and flush lines
• Flow directions
• Interconnections references
• Control inputs and outputs
• Interfaces for class changes
• Vendor and contractor interfaces
• Identification of components and subsystems
  delivered by others
• Intended physical sequence of the equipment
• A PID should not include

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Classification

• Legends and Symbol Diagrams/Standard Details
• Process PID - Process PIDs define on-plot
  process unit design, as well as off-plot tankage
  and shipping systems
• Utility Plant PID - Utility Plant PID's define
  utility units such as cooling towers, air
  compressors, boilers, unit drain collection
  systems, fire water systems, and water treatment
  plants.
• Utility Distribution PID - Show the distribution
  of utilities within a given process. Valving and
  instrumentation on piping are shown for main
  headers up to and including branch root valves.
• Interconnecting (Rack) PID They are the
  connecting link between individual process,
  utility plant, and utility distribution PID's.
  They are usually prepared for the offsite pipe
  racks and link the various process and utility
  plants.
• Vendor PID - They are prepared for systems which
  support major equipment packages.

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PID Format

• PID's are to be prepared with the following
  format and organization
• All PID drafting shall be by Computer Aided
  Drafting (CAD), using PID software
• PID's shall follow the format of the Legends
  and Symbols and current project Standard
  Drawings.
• The PID Coordinator for the project will
  identify and assign numbers and titles to all
  PID's.
• PID's include
• o Water Systems, Cooling Water, Utility Water,
  Raw Water, Fire Water
• o Steam, Condensate, Boiler Blowdown, and Boiler
  Feed Water
• o Air, Nitrogen, Natural Gas, Fuel Gas, etc.
• o Chemicals and Additives
• o Waste Water, Sewer, Effluent
• o Relief System
• Interconnecting PID's are prepared to
  represent the offsite interconnecting piperacks
  and piping.
• They are generally segregated as follows
• o Above Ground Process Lines

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Accompanying Deliverables From The PID

• Equipment List
• An Equipment List shall be issued in a timely
  manner to compliment the PIDs and Updated
• judiciously as additional design data or vendor
  data becomes firm.
• Line Designation Table (LDT)
• The Line Designation Table (LDT) shall be issued
  from Bentley Data Manager each time a PID issue
• is made, starting with the IFA issue.
• Other List
• The Valve, SP items and Instrumentation Lists
  shall be issued from Bentley Data Manager each
  time a
• PID issue is made, starting with the IFA issue.
• Tie-In Control List
• A Tie-in Control List shall be issued indicating
  the extent of the Vendor
• package battery limits each time a PID issue is
  made starting with IFA.
• Holds List
• A "Holds" list must be issued each time a PID
  issue is made starting with IFD. The "Hold"
  indicates
• where the information used as input to the PID
  is preliminary and the item is used with risk in
  the
• downstream design.
• Revision list
• A Revision List defines the changes made in the
  design so that appropriate action can be taken to
• accommodate those changes. A Revision List must
  accompany any issue of the PID after IFH if the

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General Responsibilities

• Area Manager - has overall responsibility for all
  engineering work, including preparation,
  approval, stamping and issue of PID's
• Lead Engineers - Prepare and, OWN all PID's.
• Coordinate PID information between systems and
  related areas of plants.
• Process Engineer - Issue Process Flow Diagrams,
  issue process data sheets for equipment, Develop
  process equipment list .
• Piping Engineer - Issues the piping material
  classification index and the piping material
  specifications. Assign line numbers and prepare
  the Line Designation Tables. Verify the
  conformance of the PID to equipment data sheets
  and specifications.
• Mechanical Engineers - Prepare and issue an
  Equipment List showing all equipment on the
  project. Provide Lead Engineers with equipment
  requirements that are to be shown on PID's. Work
  jointly with Lead Engineers to develop Material
  Handling PIDs on jobs with
• significant Material Handling equipment.

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