Piping and Instrumentation Diagram Development

Moe Toghraei, MSc, PEng, is an independent project and process engineer with more than 30 years of experience in chemical, oil and gas, and water and wastewater engineering. Previously a lead engineer with Colt Engineering, Jacobs, and CH2M in Calgary, he has over 20 years of teaching experience and has developed numerous in-class and online training courses. He has also served as an expert witness in litigation and as a client representative in environmental matters.

• ContentsPreface xxiAcknowledgment xxvAbout the Companion Website xxviiPart I Fundamentals of Piping and Instrumentation Diagram Development 11 What Is Piping and Instrumentation Diagram? 31.1 Why Is P&ID Important? 31.2 What Is a P&ID? 41.3 P&ID Media 51.4 P&ID Development Activity 62 Management of Piping and Instrumentation Diagram Development 92.1 Project of Developing P&IDs 92.2 P&ID Milestones 92.3 Involved Parties in P&ID Development 112.4 P&ID Set Owner 122.5 Required Quality of the P&ID in Each Stage of Development 122.6 P&ID Evolution 132.7 Tracking Changes in P&IDs 132.8 Required Man-hours for the Development of P&IDs 143 Anatomy of a Piping and Instrumentation Diagram Sheet 153.1 Title Block 153.2 Ownership Block 163.3 Reference Drawing Block 163.4 Revision Block 163.5 Comments Block 173.6 Main Body of a P&ID 204 General Rules in Drawing of P&IDs 214.1 Items on P&IDs 214.1.1 Pipes and Other Flow Conductors 214.1.2 Equipment 214.1.3 Instruments 224.1.4 Signals 224.2 How to Show Them: Visual Rules 224.2.1 Lines Crossing Over 234.2.2 Equipment Crossing 264.2.3 Off-page Connector 264.2.4 Color in P&IDs 284.3 Item Identifiers in P&IDs 284.3.1 Symbols 294.3.2 Tags 294.3.3 Name 294.3.4 Technical Information 304.4 Different Types of P&IDs 344.4.1 Legend P&IDs 344.4.2 System P&IDs 344.4.3 Network P&IDs 354.4.4 Interarea P&IDs 374.4.5 Detail P&IDs 384.5 A Set of P&IDs 414.6 P&IDs Prepared in Engineering Companies Compared to Manufacturing or Fabricating Companies 434.7 Dealing with Vendor or Licensor P&IDs 445 Principles of Piping and Instrumentation Diagram Development 475.1 Plant Stakeholders 475.2 The Hierarchy of P&ID Development Rules 475.3 Plant Operations 485.3.1 Process Parameters 485.3.2 Process Parameter Levels 495.3.2.1 Pressure Levels 505.3.2.2 Temperature Levels 515.3.2.3 Liquid/Solid Levels 515.3.2.4 Flow Levels 525.3.2.5 Analyte Levels 535.3.3 Parameter Levels Versus Control System 535.3.4 Parameter Levels Versus Safety 545.3.5 Parameter Levels Versus Operator Role 555.3.6 General Procedure of P&ID Development 555.4 What Should a P&ID Address? 555.4.1 Normal Operation 565.4.2 Nonroutine Operation 565.4.2.1 Reduced Capacity Operation 565.4.3 Reduced Efficiency Operation 615.4.4 Start-up Operations 615.4.5 Shutdown 625.4.6 Inspection and Maintenance 635.4.6.1 Quantitative Approach to Maintenance Requirement 635.4.6.2 Qualitative Approach to Maintenance Requirement 645.4.7 Operability in Absence of One Item 645.4.8 Provision for the Future 655.5 Conflicting Check and Merging Opportunities Check 675.5.1 Conflict Check 675.5.2 Merging Opportunities Check 675.6 Dealing with Common Challenges in P&ID Development 675.7 Example: Development of P&ID of a Typical Pump 68Part II Pipes and Equipment 736 Fluid Conductors and Pipe Appurtenance 756.1 Fluid Conductors: Pipes and Tubes 756.2 Pipe Identifiers 756.2.1 Pipe Symbol 766.2.2 Pipe Tag 766.2.2.1 Do All Pipes Need to Be Tagged? 776.2.2.2 Which Span of Pipe Route Can Be Considered One Piece of Pipe? 786.2.2.3 How Is the Pipe Tag Shown on a P&ID? 786.2.3 Pipe Off-page Connector 786.3 Pipe Tag Anatomy 796.3.1 Area or Project Number 796.3.2 Commodity Acronym 796.3.3 Pipe Material Acronym 796.3.4 Pipe Size 826.3.5 Pipe Sequential Number 836.3.6 Other Pipe Tag Information 846.4 Pipes Crossing “Borders” 846.4.1 Implementing Spec Break 866.4.2 Reasons for a Spec Break 876.5 Goal of Piping 896.5.1 Magnitude of Flow in Pipe 896.5.2 Direction of Flow in Pipe 896.5.3 Providing Fluid with Enough Pressure at the Inlet 906.6 Piping Arrangements 906.6.1 Backflow Prevention Systems 916.6.2 Diversion of Flow 936.6.3 Distribution of Flow 936.7 Pipe Route 936.7.1 Slope 946.7.2 No Liquid Pocket 956.7.3 No Gas Pocket 956.7.4 Free Draining (Self-draining) 966.7.5 Free Venting 966.7.6 Gravity Flow 966.7.7 Vertical or Horizontal Pipe 966.7.8 Straight Piping 976.7.9 Minimum or Maximum Length or Distance 976.7.10 Other Special Pipe Routes 976.8 Piping Movement 976.9 Dealing with Unwanted Two-phase Flow in Pipes 986.9.1 Liquid–Gas Two-phase Flow 986.9.2 Gas–Liquid Two-phase Flow 1006.9.3 Solid–Liquid Two-phase Flow 1016.10 Tubes 1026.11 Double-wall Pipes 1026.12 Pipes for Special Arrangements 1036.12.1 Piping for Bypassing 1036.12.2 Piping for Recirculation 1036.12.3 Piping for Units in Series 1046.12.4 Piping for Units in Parallel 1046.12.5 Piping for Pressure Equalization 1046.13 Pipe Size Rule of Thumbs 1046.14 Pipe Appurtenances 1046.14.1 Pipe Fittings 1056.14.1.1 Pipe Direction Change 1056.14.1.2 Reducers and Enlargers 1056.14.1.3 Three-way Connections 1086.14.1.4 Pipe Connections 1086.14.1.5 End-of-pipe Systems 1086.14.2 Specialty Items 1096.14.2.1 Flange-insulating Gasket 1106.15 Other Approach About Piping 1106.16 Tying-in Pipes 1116.17 Wrapping Up: Addressing Requirements of Pipe During the Life Span 1116.18 Transferring Bulk Solid Materials 112Reference 1127 Manual Valves and Automatic Valves 1137.1 Valve Naming 1137.2 Valve Functions 1137.3 Valve Structure 1137.4 Classification of Valves 1147.4.1 Valve Plug: Throttling Versus Blocking Valves 1147.4.2 Valve Selection 1167.4.3 Multi-port Valves 1177.4.4 Double-seated Valves 1187.5 Valve Operators 1207.6 Different Types of Actuators 1217.7 Basis of Operation for Automatic Valves 1227.8 Tagging Automatic Valves 1227.9 Tagging Manual Valves 1227.10 Valve Positions 1227.10.1 Regular Position of Blocking Valves and Decision Methodology 1237.10.2 Failure Position of Automatic Valves and Decision Methodology 1247.10.3 More Concepts About Failure Position of Automatic Valves 1257.10.3.1 What Is the Failure in Failure Position Discussion? 1257.10.3.2 Actuator Driving System 1267.11 Valve Arrangement 1277.11.1 Valves in Series 1277.11.2 Valves in Parallel 1287.12 Control Valves and RO Combinations 1297.13 Operating in the Absence of Valves 1297.13.1 Operating in the Absence of Control Valves 1297.13.2 Operating in the Absence of Switching Valves 1327.14 Valves in Role of Unit Operation 1327.15 Special Valves 1337.15.1 Check Valves 1337.15.2 Regulators 1347.15.3 Safety-related Valves 1357.16 Excess Flow Valves 1367.17 Valve Combinations 1367.18 End-of-valve Arrangements 1367.19 Valve Sizing Rule of Thumbs 1367.20 Merging Valves 1387.21 Wrapping-up: Addressing Requirements of Valve During the Life Span 138References 1388 Provisions for Ease of Maintenance 1398.1 Introduction 1398.2 Different Types of Equipment Care 1398.3 In-place In-line Equipment Care 1408.4 In-place Off-line Equipment Care 1418.5 In-workshop Off-line Equipment Care 1418.6 Preparing Equipment for Off-line Care 1418.7 Isolation 1428.7.1 Requirement of an Isolation System 1428.7.2 Types of Isolation System 1438.7.3 Placement of an Isolation System 1468.7.4 Inbound Versus Outbound Blind Location 1478.7.5 Merging Isolation Valves 1478.8 Bringing the Equipment to a Non-harmful Condition 1478.8.1 Cooling Down 1488.8.2 Emptying and Then Draining/Venting 1488.8.2.1 Location and Number of Drain/Vent Valves 1498.8.2.2 Size of Drain/Vent Valves 1508.8.2.3 Other Usages of Drain/Vent Valves 1508.9 Cleaning 1518.9.1 Solid/Semi-solid Removal Methods 1518.9.2 Washing Systems 1528.9.3 Purging Methods 1528.10 Ultimate Destination of Dirty Fluids 1538.11 Making Equipment Easy to Remove 1548.12 Wrap-up 1549 Containers 1579.1 Introduction 1579.2 Selection of Containers 1579.3 Containers Purposes 1589.4 Transferring Fluids Between Containers 1599.5 Container Positions 1609.6 Container Shapes 1629.6.1 Closing Parts of Containers 1639.6.2 Open Top or Fully Enclosed Containers 1639.7 Container Identifiers 1639.7.1 Container Symbol 1639.7.2 Container Tags 1639.7.3 Container Callouts 1649.7.3.1 Tank Callouts 1649.7.3.2 Vessel Callouts 1659.7.3.3 Tag of Container in Duty of Conversion 1659.8 Levels in Non-flooded Liquid Containers 1669.9 Container Nozzles 1669.9.1 Nozzle Duties 1669.9.2 Nozzle Locations 1689.9.3 Nozzle Elevations 1689.9.4 Size, Number, and Rating of Nozzles 1709.9.5 Merging Nozzles 1709.9.6 Nozzle Internal Assemblies 1729.9.7 Nozzle Externals 1729.10 Overflow Nozzles 1739.11 Breathing of Non-flooded Containers 1749.12 Blanketed Tanks 1749.13 Heating (or Cooling) in Containers 1779.14 Mixing in Containers 1789.15 Container Internals 1799.16 Tank Roofs 1799.17 Tank Floors 1799.18 Container Arrangement 1809.19 Merging Containers 1809.20 Secondary Containment 1819.21 Underground Storage Tanks 1829.22 Sumps 1849.23 Wrapping-up: Addressing the Requirements of the Container During Its Lifespan 18410 PUMPS and Compressors 18710.1 Introduction 18710.2 Fluid Mover Roles 18710.3 Types of Fluid Movers 18710.4 A Brief Discussion on the Function of Fluid Movers in a System 18810.5 Fluid Mover Identifiers 18910.5.1 Fluid Mover Symbol 18910.5.2 Fluid Mover Tag 19110.5.3 Fluid Mover Callout 19210.6 Liquid Movers: Dynamic Pumps 19210.6.1 Centrifugal Pumps 19210.6.1.1 P&ID Development on the Suction Side 19310.6.1.2 P&ID Development on the Discharge Side 19410.6.2 Low Flow Intolerance and Minimum Flow Protection System 19510.6.2.1 Which Pumps May Need a Minimum Flow Pipe 19610.6.2.2 Where Should We Position the Recirculation Line? 19610.6.2.3 Where Should the Destination Point of the Recirculation Pipe Be? 19710.6.2.4 What Should the Size of the Recirculation Pipe Be? 19710.6.2.5 What Should the Arrangement on the Recirculation Pipe Be? 19710.6.3 Cavitation 19910.6.4 Very Small Centrifugal Pumps 20110.6.5 Different Types of Spare Pump 20110.6.6 Centrifugal Pump Arrangements 20210.6.6.1 Centrifugal Pumps in Parallel 20210.6.6.2 Centrifugal Pumps in Series 20410.6.7 Pump Warm-up or Cool-down System 20510.6.8 Piping Specification for Centrifugal Pumps 20610.6.9 Centrifugal Pump Drives 20710.6.10 (Liquid) Seal Systems in Centrifugal Pumps 20710.6.11 Merging Pumps 20910.7 Liquid Movers: PD Pumps 21010.7.1 PD Pump P&ID Piping 21010.7.1.1 Reciprocating Pumps P&ID Piping 21010.7.1.2 Rotary Pumps P&ID Piping 21210.7.2 PD Pump Arrangements 21310.7.3 Merging PD Pumps 21310.7.4 Tying Together Dissimilar Pumps 21310.7.5 PD Pump Drives 21410.7.6 Sealing Systems for PD Pumps 21410.7.7 Metering Pumps (Dosing Pumps) 21410.7.8 Liquid Transfer – Summary 21510.7.9 Pumps: Duty Other than Pumping! 21610.8 Gas Movers: Fans, Blowers, Compressors 21610.8.1 Low Flow Intolerance and Anti-surge Systems 21710.8.2 P&ID Development of Gas Movers 21710.8.3 Gas Mover Drives 21810.8.4 Auxiliary Systems Around Fluid Movers 21810.8.5 Gas Transfer – Summary 22010.9 Wrapping-up: Addressing Requirements of Fluid Movers During the Life Span 221Reference 22111 Heat Transfer Units 22311.1 Introduction 22311.2 Main Types of Heat Transfer Units 22311.3 Different Types of Heat Exchangers and Their Selection 22411.4 Different Types of Heat Transfer Fluids and Their Selection 22511.5 Heat Exchangers: General Naming 22611.6 Heat Exchanger Identifiers 22711.6.1 Heat Exchanger Symbol 22711.6.2 Heat Exchanger Tag 22811.6.3 Heat Exchanger Callout 22911.7 Heat Exchanger P&ID 22911.7.1 Vents and Drains 22911.7.2 Isolation Valves 23011.7.3 Chemical Cleaning Valves 23011.7.4 Pressure Safety Devices 23011.8 Heat Exchanger Arrangement 23111.8.1 Heat Exchangers in Series 23111.8.2 Heat Exchangers in Parallel 23211.9 Aerial Coolers 23311.9.1 Aerial Cooler P&ID 23411.9.2 Dealing with Extreme Temperatures 23511.9.3 Aerial Cooler Arrangement 23611.10 Merging Heat Exchangers 23611.11 Wrapping-up: Addressing the Requirements of a Heat Exchanger During Its Life Span 23611.12 Fired Heaters and Furnaces 23611.12.1 Process Fluid Side 23711.12.2 Flue Gas Side 23711.12.3 Firing Side 23811.13 Fire Heater Arrangement 24011.14 Merging Fired Heaters 24011.15 Wrapping-up: Addressing the Requirements of Fired Heaters During Their Lifespan 24012 Pressure Relief Devices 24112.1 Introduction 24112.2 Why Pressure Is So Important? 24112.3 Dealing with Abnormal Pressures 24212.3.1 Active Versus Passive Solutions 24312.3.2 Where Could Passive Solutions Be Used? 24312.3.3 Where Should Active Solutions Be Used? 24312.4 Safety Relief System 24412.5 What Is an “Enclosure,” and Which “Side” Should Be Protected? 24412.6 Regulatory Issues Involved in PRVs 24512.6.1 Codes Versus Standards 24512.7 PRD Structure 24612.8 Six Steps to Providing a Protective Layer 24712.9 Locating PRDs 24712.10 Positioning PRDs 24812.11 Specifying the PRD 25012.12 Selecting the Right Type of PRD 25012.12.1 PRV Type 25012.12.2 Rupture Disks 25112.12.3 General Rules for PRD Selection 25112.13 PRD Identifiers 25112.13.1 PRD Symbols and Tags 25212.13.2 PRD Technical Information 25312.14 Selecting the Right Type of PSD Arrangement 25312.15 Deciding on an Emergency Release Collecting Network 25512.16 Deciding on a Disposal System 25712.16.1 Liquid Disposal 25812.16.2 Gas/Vapor Disposal 25912.16.3 Two-phase Flow Handling 26012.17 Protecting Atmospheric Containers 26112.18 Merging PRDs 26212.19 Wrapping-up: Addressing the Requirements of PRDs During Their Lifespan 264Part III Instrumentation and Control System 26513 Fundamentals of Instrumentation and Control 26713.1 What Is Process Control? 26713.2 Components of Process Control Against Violating Parameters 26813.3 Parameters Versus Steering/Protecting Components 26813.4 How Many Steering Loops Are Needed? 26913.5 ICSS System Technology 26913.5.1 Use of PLC for a BPCS 27013.5.2 Use of DCS for a SIS 27013.5.3 Alarm Systems 27013.5.4 ICSS System Symbology 27013.6 ICSS Elements 27113.7 Basic Process Control System 27213.8 Instruments on P&IDs 27413.8.1 Fundamental Terminology 27413.8.2 Identifiers for Equipment and Instrumentation 27513.9 Instrument Identifiers 27513.9.1 Acronyms 27613.9.2 Divider Types 27613.9.3 Symbol Type 27813.9.4 Additional Information and Tag Number 28013.10 Signals: Communication Between Instruments 28113.10.1 Signal Types 28113.10.2 Signal Functions 28213.10.3 Signal Math Functions 28213.10.4 Signal Selectors 28213.11 Different Instrument Elements 28413.11.1 Primary Instruments 28413.11.1.1 Temperature Measurement 28513.11.1.2 Pressure Measurement 28613.11.1.3 Level Measurement 28713.11.1.4 Flow Measurement 28713.11.1.5 Process Analyzers 28913.11.2 Transmitters 29213.11.3 Controllers 29213.11.4 Indicators 29213.11.5 Final Control Elements in a BPCS 29313.11.5.1 Control Valves 29313.11.5.2 Variable Speed Devices on Electric Motors 29413.12 Simple Control Loops 29413.12.1 Level Control Loops 29413.12.2 Pressure Control Loops 29413.12.3 Temperature Control Loops 29513.12.4 Composition Control Loops 29613.12.5 Flow Control Loops 29613.13 Position of Sensor Regarding Control Valves 29614 Application of Control Architectures 29914.1 Introduction 29914.2 Control System Design 29914.3 Selecting the Parameter to Control 29914.4 Identifying the Manipulated Stream 30114.5 Determining the Set Point 30114.6 Building a Control Loop 30214.6.1 Feedback Versus Feedforward 30214.6.2 Single- Versus Multiple-loop Control 30414.7 Multi-loop Control Architectures 30414.7.1 Cascade Control 30514.8 Feedforward Plus Feedback Control 30714.8.1 Ratio or Relationship Control 30914.8.2 Selective Control 31214.8.3 Override and Limit Control 31314.8.3.1 Override Control 31414.8.3.2 Limit Control 31814.8.4 Split Range and Parallel Control 31814.8.5 Clarification of Confusion 32014.8.5.1 Cascade Versus Ratio 32114.8.5.2 Single Loop Versus Ratio 32114.8.5.3 Selective Versus Override 32114.9 Monitoring Parameters 32114.9.1 Container Sensors 32314.9.2 Fluid Mover Sensors 32314.9.3 Heat Exchanger Sensors 32414.9.4 Fired Heater Sensors 32415 Plant Process Control 32715.1 Introduction 32715.2 Plant-wide Control 32715.3 Heat and Mass Balance Control 32715.4 Surge Control 32915.4.1 Disturbances in Process Parameters 33015.4.2 Disturbance Management 33015.4.2.1 Absorption 33015.4.2.2 Rejection 33015.4.3 Disturbance Versus Fluid Phase 33115.4.4 Dampening Gas/Vapor Flow Surge 33215.4.5 Dampening Liquid Flow Surge 33215.4.6 The Purpose of Containers in Process Plants 33515.5 Equipment Control 33615.5.1 Do We Need to Control at All? 33615.5.2 Principles of Equipment-wise Control 33615.6 Pipe Control System 33815.6.1 Control of a Single Pipe 33915.6.1.1 Control of Pressure in a Pipe 33915.6.1.2 Control of Flow in a Pipe 34015.6.2 Controlling Multiple Pipes 34115.6.2.1 Flow Merging 34115.6.2.2 Flow Splitting 34315.7 Fluid Mover Control System 34515.7.1 Pump Control Systems 34515.7.1.1 Centrifugal Pump Control 34515.7.1.2 Positive Displacement Pump 35015.7.2 Gas Mover Control Systems 35215.7.2.1 Capacity Control Methods for Gas Movers 35215.7.3 Anti-surge Control 35515.7.4 Lead–Lag Operation of Fluid Movers 35515.8 Heat Transfer Equipment Control 35615.8.1 Heat Exchanger Control System 35615.8.1.1 Direct Control System 35615.8.1.2 Bypass Control System 35715.8.1.3 Control of Heat Exchangers Experiencing Phase Change 36015.8.2 Air Cooler Control 36315.8.3 Heat Exchanger for Heat Recovery 36315.8.4 Back Pressure Control of Heat Exchangers 36415.8.5 Fired Heater Control 36415.9 Container Control System 36815.10 Blanket Gas Control Systems 368Reference 36916 Plant Interlocks and Alarms 37116.1 Introduction 37116.2 Safety Strategies 37116.3 Concept of an SIS 37116.4 SIS Actions and SIS Types 37116.5 SIS Extent 37416.6 Deciding on the Required SIS 37416.7 The Anatomy of an SIS 37516.7.1 SIS Element Symbols 37516.7.1.1 SIS Primary Elements: Sensors 37516.7.2 SIS Final Elements 37616.7.2.1 Switching Valves 37616.7.2.2 Switching Valve Actuator Arrangements 37716.7.2.3 Valve Position Validation 37716.7.2.4 Merging a Switching Valve and a Control Valve 37816.7.2.5 On/Off Action of Electric Motors 37816.7.3 SIS Logic 37916.8 Showing Safety Instrumented Functions on P&IDs 37916.9 Discrete Control 38116.10 Alarm System 38216.10.1 Anatomy of Alarm Systems 38416.10.2 Alarm Requirements 38416.10.3 Alarm System Symbology 38516.10.4 Concept of “Common Alarm” 38616.11 Fire and Gas Detection System 38716.11.1 Manual Alarm 39016.12 Electric Motor Control 39016.12.1 Simple Motor Control 39016.12.2 The Focal Element of Motor Control: MCC 39016.12.3 All About Relationships with Electric Motors 39116.12.4 P&ID Representation of Commands and Responses 39116.12.5 P&ID Representation of the Principal Arrangement for Inspection and Repair 39216.12.6 Examples 394Part IV Utilities 39717 Utilities 39917.1 Utility System Components 39917.2 Developing Piping and Instrumentation Diagrams for Utility Systems 40017.2.1 Identifying the Utility Users 40017.2.2 Utility Distribution and Collection Network Topologies 40017.2.3 Designing Details of a Utility Network 40117.2.4 Placing Priority on Utility Users 40217.2.5 Connection Details of Utility to Process 40317.3 Different Utilities in Plants 40417.4 Air as a Utility in Process Plants 40417.4.1 Instrument Air 40417.4.2 Utility Air or Plant Air 40517.5 Water as a Utility in Process Plants 40517.5.1 Utility Water or Plant Water 40517.5.2 Potable Water 40517.6 Heat Transfer Media 40517.6.1 Steam 40617.7 Condensate Collection Network 40717.8 Fuel as Utility 40717.8.1 Fuel Oil 40817.8.2 Fuel Gas 40817.9 Inert Gas 40817.9.1 Blanket Gas 40817.9.2 Purging Gas 40917.10 Vapor Collection Network 40917.11 Emergency Vapor/Gas Release Collection Network 40917.12 Fire Water 40917.13 Surface Drainage Collection Network or Sewer System 41217.14 Utility Circuits 41417.14.1 Air Circuit 41417.14.2 Steam–Condensate Circuit 41617.14.3 Cooling Water Circuit 41717.14.4 Natural Gas Preparation System 41717.15 Connection Between Distribution and Collecting Networks 41818 Ancillary Systems and Additional Considerations 42118.1 Introduction 42118.2 Safety Issues 42118.2.1 Different Types of Hazards 42118.2.2 Hazards and Injuries 42118.2.3 Mechanical Hazards 42218.2.4 Chemical Hazards 42218.2.5 Energy Hazards 42218.2.5.1 Noise Barrier 42218.2.5.2 Burning Prevention 42318.2.6 Safety Showers and Eye Washers 42318.3 Dealing with the Environment 42418.3.1 Arrangements for Maintaining the Temperature of the Process 42618.3.2 Winterization 42618.3.3 Deciding on the Extent of Insulation 43018.3.4 Summary of Insulation 43118.4 Utility Stations 43118.5 Off-line Monitoring Programs 43418.5.1 The Program Component 43418.5.2 Sampling System 43418.5.3 Sample Extraction Device 43518.5.4 Sample Transferring Tube 43618.5.5 Sample Conditioning System 43618.5.6 Sample Hand-over System 43618.5.7 Waste Sample Collection System 43618.5.8 Sampling Station Structural Frame 43718.5.9 Showing a Sampling System on P&IDs 43718.5.10 Sampling System for Process Analyzers 43818.6 Corrosion Monitoring Program 43818.7 Impact of the Plant Model on the P&ID 43918.8 Design Pressure and Temperature Considerations 44018.8.1 Decision on “Design Pressure @ Design Temperature” Pair 44118.8.1.1 Deciding on “Design Pressure” 44118.8.1.2 Deciding on “Design Temperature” 44118.8.2 Sources of Rebel Pressures 44218.8.3 Sources of Rebel Temperatures 44218.8.4 Design Pressure and Design Temperature of Single Process Elements 44318.8.5 Design Pressure of Connected Items 44318.8.5.1 Design Pressure of Connected Equipment–Equipment 44418.8.5.2 Design Pressure of Connected Equipment–Sensor 445Part V Additional Information and General Procedure 44719 Pre-Piping and Instrumentation Diagrams in Chemical Process Engineering 44919.1 Visual Representation Techniques in Chemical Process Engineering 44919.2 Universal String of Chemical Process Industries 45119.2.1 Beneficiation 45119.2.2 Recovery 45219.2.3 Conversion 45219.2.4 Formulation 45219.2.5 Transfer 45219.2.6 Examples of Chemical Industries Regarding the Five-step Universal String 45219.3 Pre-BFD Stage Development 45319.3.1 Beneficiation 45319.3.2 Recovery 45419.3.3 Conversion 45419.3.4 Formulation 45619.3.5 Transfer 45619.4 BFD Development 45719.5 PFD Development 45919.5.1 Expanding Conversion Units 45919.5.2 Adding Holding Containers 46019.5.3 Adding Fluid Movers 46119.5.3.1 Transferring Liquids 46119.5.3.2 Transferring Gases/Vapors 46119.5.3.3 Transferring Solids 46119.5.3.4 Transferring Two-phase or Three-phase Fluids 46219.5.4 Adding Temperature- and Pressure-adjusting Units 46219.5.4.1 Changing Pressure 46219.5.4.2 Changing Temperature 46219.5.5 Deciding About Utility Systems 46419.5.6 Adding Performance Improver Pipes and Pipe Appurtenances 46419.5.7 Taking Care of Side Streams 46419.5.8 Adding Control Systems 46519.6 PFD Demonstration Rules 46519.7 H&MBT 46619.8 Side-by-Side Comparison 46719.9 Nontraditional Process Drawings 46719.10 Developing PFD Based on Existing P&ID 46819.11 Developing P&ID Based on Existing Process Plant 46920 General Procedures 47120.1 Introduction 47120.2 General Procedure for P&ID Development 47120.2.1 P&ID Development: Piping and Equipment 47120.2.2 P&ID Development: Control and Instruments 47220.3 P&ID Reviewing and Checking 47520.3.1 Format Check 47620.3.2 Demonstration Rules Check 47620.3.3 Technical Check 47720.3.4 Design Check 47920.4 Methods of P&ID Reviewing and Checking 47920.4.1 Systematic Approach 47920.4.2 Scanning Approach 47920.5 Required Quality of P&IDs at Each Stage of Development 48021 Examples 485Index 521