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.

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 TwöPhase Flow in Pipes 92

6.9.1 Liquid-Gas TwöPhase Flow 92

6.9.2 Gas-Liquid TwöPhase Flow 94

6.9.3 Solid-Liquid TwöPhase 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...