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    process design intro for chemical engineers

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    8 views7 pages

    Process Degisn Intro To Cad

    Uploaded by

    arun kumar
    process design intro for chemical engineers

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    © All Rights Reserved
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    (. Agun kumne }20)2010002 Back to Basics Designing a Process Flowsheet oneies Piping and instrumentation diagrams belong to a family tee of flowsheets that includes block flow diagrams and process flow diagrams. Technology advances have transformed these resources into intelligent documents, capable of storing layers of digital information. he appearance and form of piping and instrument of diagrams, using standard nomencirs and symbols I ion diagrams (P&IDs) have changed litle over to filly desribe the process, Some regulatory agencies son eene decades of ecology improvements. mandate ther we ring design a Pons oS wellas Cpainenck 60 year agp onthe drawing board, sing, _thrughoutonging operations ne Users SN ink pens on linen sheets, describes process the same way “The main purpose of each documents to convey the ink Pens oie today using modem computer-aided design ight amount of process infOrmalens needed, during the {CAD) software. P&IDs continue to be fundamental refer. various stages of the bidding, engineering, design, procure- ences for any process facility. trent, consiruetion, operation, and decommissioning phases “This article discusses what makes a good P&ID, and. of a facility's lifecyele. tow technology ean improve its quality, usability and effectiveness. Block flow diagrams . “The beauty (and advantage) of a BED iis ability toout- Flowsheets Line the complete process on litle more than a singe sheet. eet Fovshest and odigramareofenwsedin, These diagrams usally een ‘organizational char, Le aay raeeing and design applications. Alihough containing mainly text enclosed Wy Powe interconnecting this terminology is not the most accurate way to describe Tines and the process commodities they transport, and Ow P&IDs, itis suf cient to describe the overall family of process-based diagrams 10 which P&Ds belong. aan "The lock fow dlagram (BFD) (Figure 1) is 8 rea very simple diagram that can condense an entire process ontoas litle asa single sheet. More detailed rs payor Teal Fatormation ean be found in the proces” ‘asc ti diagram (PED), which is considered the precursor nat eee eRCPEID, Tope, the PFD is sed by plant | aPSer A ncsher eS) designers to conduct intial layout studies of — i Sa f plant's process systems and major pipework. Since ll ee eDeuee many ofthe same symbols as PSIDS, ik | | see, | they allow viewers to more easily identify items and i soaks pty ight kis in conto he BFD's cope 181 Peucoas, standard block and line diagram, which emphasizes asses ba the descriptions contained in those blocks. or et fie dczipes_AVHW 1AM Toda emia ena ve CEP Hay 2009 wmnachncriece, 1 Back to Basics arrows to indicate processflow directions. + clear labels illustrating function (since no equipment or ‘A good BED typically contains the following: package numbers appear on this document) ‘large individual pieces of equipment, or equipment + the order of process. ow arranged fiom left to right aspartata combined process, that ae denoted by 2single and, fpesible, with gravity bias, te, ifhydracarbons are symbol, typically a rectangle shown entering a separation process, then gas leaving the ‘process should be shown exiting from the top of the block and condensate from the bottom ~ Fines finking equipment or pro- cesses to show ow direction + wherever more than one line leaves a process, then the processed com- ‘modity in each line should be clearly marked. Process flow diagrams Process ow diagrams (Figure 2) * carry more information than the block ‘ow diagrams from which they are derived, They show more detail about geaensat¢ } major equipment and subsystems and the ow of product between them. EDs include information on the ottshore Platform Offshore Pipeline Onshore A Figure 2. Paces low dagrams lutrate major quipment and subsystems andthe podct How betwen tem. . v-3001 PIG LAUNCHER Ba HGGS_[ SE] PROCESS fe INSTROWENT DIAGRAM Sm iG SPHERE LAUNCHER oe @ ‘A igure 3A piping and nstrmenaton dara sods san imprtanteleence hl is sf at any tage othe rose Meni AS wwnscrecegicen ey2009 CBF pressures and temperatures of feed and product Finest and Fm all major pieces of equipment, such as vessels, tanks, heat exchangers, purnps, et. Also indicated are main head- ‘rs and points of pressure, temperature and ow contol, plus the main shutdown points in te system. ‘For rotating equipment, PFDS carry important informa- tion, uch as pump capacities and pressure heads, and pump fand compressor horsepower For tanks, vessels, columns, eachangers ete design pressures and temperatures are offen shown for clarity "Atypical PED shows the following items: «process piping + process. ow direction ‘tnajor equipment represented by simpli ed symbols + major bypass and recirculation lines + control and process-ritcal valves + processes identi ed by system name + system ratings and operational values + compositions of ids + connections between systems. piping and instrumentation diagrams ‘AD&D (Figure 3) carries a wealth of information that spans engineering disciplines to de ne a process. Its the best way of accurately documenting the operation of @ pro- cess and itis truly a coordinating document. PéelDs ae also required health and safety documents, The US. Dept. of Labor's Occupational Safety and Health ‘Adminisiration (OSHA) mandates that P&UDs be aocurate ‘and Kept up--date throughout the life ofthe plant As a result, P&IDs take center stage in discussions of plant and process operations and product lifecycle : management. ” 'P&IDs take the conceptual aspects of the PED and expand them by adding: + detailed symbols + detailed equipment information * equipment order and process sequence {process and utility (non-provess) piping + process. ow direction + major and minor bypass lines ‘line numbers, pipe speci cations, and pipe sizes + isolation and shutoff valves ‘maintenance vents and drains + relief and safety valves + instrumentation + controls + types of process component connections + vendor and contractor interfaces + skid and package interfaces Tene + lydrostate vents and drains + design requirements for hazardous operations. Standards and rules PAUIDs are prepared according to a set of rules estab- Tished to maximize the documents’ usefulness. Standard symbols that are easly recognized must be used to repre- sent the items on a P&ID. Each line, instrument, pieve of ‘equipment, et, (Figures 4-6), must be labeled using speci ¢ Conventions of nomenclature, These rules may seem strange Sind complicated, but, like-any new language, one learned, they becomes second nature. "To demonstrate the use and importance ofthese rules, let's look at three of the most important named items On atypical P&ID: equipment, process lines, and instrumentation. Equipment designation Equipment numbering allows instant identi cation of ‘equipment by its unique number. For example, an equipment {dent ermay consistofaletierand_ ve numerals 28. 00000. The leter designates the type of equipment, such js: V= vessel, E= heat exchanger, HIE= heater (cecrica), P= pump,andT=tank, The 1st two numerals could be ine system code, for example: 30 ~ process gas, 60 = fuel tos, and 33 ~ gas dehydration The nal three numerals ae Sequential identi cation number, from 001 10999. “Thuis, piece of equipment identi ed as V-30456 isa sescel(V) inthe gas processing service (30), and is uniquely indenti ed with a sequential number of 456. za Sz il Honaona Vessel Pate sump mh Boot scum = Pump et i ) Heat Eenangee tate pe) Exchanger ‘A Figure 4 Sota onsets can bo universally understood, tie equipment configations ‘ive ttn andardzed enupment symbols and numeric means of ierteton. CEP 19/2009 wumacreciyen 17 Back to Basics —fi— eas amo a = ane = eee 7 ‘ ‘Spectacle Blind - Open ici — —k+— 4 % —eR aad ee i B-PG-80467-DIA-P ‘A Figure (op), Wen recess and instrument nes cross, thoy are broken bases on hearty. Figure 6 (mide), Line are broken where inne symbols are inset into aw ine, Figute7 (baton). lstrument loops show instruments working topetier AB vorasicranigicoy Mey2009 CEP Line designation ‘Similar nomenclature rules apply | to process and utility tines (Figure 5), | which are accompanied by an iden- __| i cation number, such as 00°-XX- (00000-XOX-X0". These elds convey ~a-wealth of information ata glance. In this example, the rst elds the ine size (¢g..24). Tis is followed by 10 letters that indicate the process com- ‘modity in the line — for example, VA ent, CU = condensate, PG = process hydrocarbons gas, ete. The third eld is ‘4 ve-digit number, the rsttwoa gas system code (30= process gas, 60 = fuel gas, and 33 = gas dehydration) andthe last three a sequential identi er from 001 to 999. The next segment is an alphanumeric sequence indicating the type fof pipe speci cation (XOX), (ef, Al, BIB, DIA, etc “The last segment designates insulation information, with & letter indicating class (e.g, P= personnel protection, H= heat conservation, and T= tracing, followed by a number indicating thickness (e.1). “Thus, a line labeled 24°-PG-30123-D1A-PI" is a24-in~ pipe carrying gaseous process hydrocarbons (PG) in the process gas syste (30) with a unique ienti cation number 5 123: the line is to be designed to piping speci cation DIA with L-in-thick personnel protection insulation, Instrument lines Instrument fines show both the ow of information betsveen instruments and how that signal is passed from instrament to instrument, Examples of different signal lines include equipment-o-instrument connection lines, electrical, ‘hydraulic, pneumatic, capillary, etc. These use various solid and dashed Iines or have particular modi ers added to them to denote their service. Instrument designations Instrument nomenclature is Very complicated, but once mastered, can become intuitive. Instrument balloons contain two main identi ers: the top indicates the role of the instru- ment (Table 1), and the bottom is a unique identi cation ‘number that could also display the instrument's process service. By looking ata combination of these top and bot- ‘tom strings, one can easily determine the instrument loop to ‘which the instrument belongs. “The instrument nomenclature that appears in the top portion ofan instrument balloon has between two and four letters which de ne its function. The rst letter describes ‘what factor of the process itis measuring or indicating (e.g. pressure, mperature, level, ow, etc). These measuring or indicating factors are denoted by a single letter (in this case, PT, Land F, respectively). ifthe next eter isthe las letter, it typically indicates cither its passive function (.g. indicator), or is ouspat finan (eg, switch), So, Pl represents « pressure indicator, LC level controller, and TS « temperature switch, How ver the second letter isnot always the lst letter, and this is ‘where things get tick. “The sesnd llterean be a modi erofthe rst letter. For instance, Tis a temperaire indicator. To show thatthe indi ator was measuring temperature differentials instead ofthe etal temperature, D is added as a modi er to yield TDI. Modi ers are always placed before the passive or output function, 90 TID would be incorrect. itis possible to have both passive and output funetons ia the same instrument. Fr example, PDIC represents apres sure differential indicating controller. “The letters after the nal pasive or output function can label the ange ofan instrument. LSH denotes a level switch high, whereas LSHH (level switch high high points to @ level switch working ata higher id level than LSH. ‘Sometimes, text may be placed outside the instrument ‘lloon to indicate the range of operation ofan instrument Inthe instrument loop example in Figure 7, PICA (the prs: sue indicating controller alan) operates in both the high tnd low range, indicated by the Hand L placed just outside the instrument balloon, Instrument loops. Since instruments work mostly in ‘eoncert with other instruments, and serve asa vital part of contolling and monitoring facility, its important to identify which process control group each belongs 0. These ‘groupings are kriown as instrument loops. By looking a the combination ofthe top and bottom strings in the instrament designation, one can determine the instrument loop to which the instrument belongs. Instrument loops (Figure 7) are also conveyed on the PAID. The instrument loop nunuber ident es items that ‘work together or ae to be used in concert. Looking a the txamples above, it is tempting to assume that 30302 is the Joop number for both PIC-30302 and LSHEY-303025 this ‘would be a mistake, Both share the same process system code (30) and have the same sequential number (302), but because their measuring and indicating services are differ eat, they cannot be considered to be inthe same loop — PIC-30302 is part ofa pressure loop 30302, whereas LSHH-30302 is part of a level loop 30302. Therefor, it ‘would be more accurate to identify them as loop P-30302 and loop L-30302, respectively. Standard symbols Itis important to use symbols that cleaey identify the equipment lines and inline items that appear on P& IDs. PEE oe Rena aes a eto a1 ee So ee ‘PSX Y ¥ Extra ‘Low et ee St See pe SS ee PC y | Gontrover —— [en eis ee ete ae So" Se ee = eet 2 ie [Although no two companies use exactly the same symbols, they are generally easily recognized. ‘PAID symbols, even those used in CAD systems, are derived from the symbol stencils developed for a 0.125-in, grid and used on the drawing board. These GER Hy 2002 wornatcroorycen 1D Back to Basics symbols, especially frequently drawn inline symbols such as, valves (Figure 8), are usually adltive. For example, gate valve is represented by two triangles with rouching apexes, {bal valve by agate valve symbol with an open circle in the center of the valve; a globe valve by a gate valve with a ‘locked-in cirele ints center, and soon. Modi ers are used extensively in P&IDs to create mohipe symbols without “re-inventng the wheel.” This makes the addition of afew lines oracitele to a standard symbol ove of the easiest ways to differentiate between {wo items on a PRID. Examples of equipment modi ers are the addition of ers, vanes or mist eliminators to ‘eels and the addition of tubes to exchangers. Instrument symbols (Figure 9) make the best (and most extensive) tse of modi ers. When used in concert with nomenclature ‘modi ers, instrument balloons indicate not only an instruments function, but also its type and location, (e.g. Foca, local panel, belinda local panel, control pane, et.) and the type of indication (eg. local lamp or control pane! Jamp, et). pd ate bad VW Diagtag es im Closed ost Local Panel Front {Figure 8 (top). Since F8NDs typically conan iformtion on ipng stems, block ves {et and cont! valves (igh have thelr own standard ses of symbols. Figure 9 (bottom). PIDs depict these commen instrument yes. ZO wnuaiiecwiee May 2000 CEP Computer-aided design ‘Since P&IDs consist mainly offines, ares and standard symbols, CAD systems are ideal for producing them. CAD- produced P&IDs are far more lesible than their hand-drawn counterparts, with the added bene t of being easier to update and maintain, ‘Another bene t of using CAD tools to produce P&IDs isthe ability to automate much of the drafting functional- ity Such functionality includes the ability to automaticaly: break process lines when they cross; remove a section of a process line when a vale is inserted, or close a line when 2 valve is removed: check that a valve is the same sizeas the line into which itis being inserted; make global changes, such as changing the sizeof a line (with a prompt asking if those changes should be applied to al inline components), ‘and change line types without redrawing. Intelligent P&IDs. There are many de nitions of intel Jigent P&IDs (Figure 10), which range from delivering some of the drafting enhancements mentioned above, to P&IDs Tinked to 3-D models. Here we will de ne an intelligent PAID as one whose components carry extra information ‘that cannot be seen by looking at the printed ‘dmwing, For example, looking at valve on a P&ID may reveal its size, tag, and speci ca tions (and its type, due tothe symbol used), ‘but on an intelligent P&ID, the valve could also have additional background informa- tion attached toi, such as vendor name, pat ‘urnber, material of construction, port size, top works, ete. Similarly, operating pressures and temperatures and design pressures and temperatures could be added tothe Fines that represent process piping. : This addition of extra information for each ‘component makes the PID even more valu- ‘able, Intelligent PIDs allow users to store and extract a wealth of information that could be useful throughout the life ofthe project, such a line lists, bills of material, valve counts and equipment and instrument lists. Speci cation-driven P&IDs, One bene t ‘fusing CAD for 3-D plant design is the abil- ity to perform speci cation-driven designs. Once a designer ses the size and piping speci- cation for lie, to ensure accuracy, the CAD system checks the piping specication each time a component is selected for placement into a line. This ensures that someone does not place a carbon steel welded tee in a stan less steel line or use a non-reinforced stub-in branch connection where a welded reducing, tees speci ed Locat Panel ack mura Foue sonves Dateieesie ping Tenge ‘a Figure 10. Inteligen PalDs contin adctora Information that snot accessible or apparent rom apie PED. ‘Although there are many things that do not need to be indicated on & PID, there are still bene ts to having P&IDs that, like 2 3-D model, are speci cation-criven. With speci cation-driven P&IDs, users can set pipe sizes and speci cations, and place items into process lines with the knowledge that these inserted items are correct. With this capability, they know that they are receiving the same be € ts as their downstream colleagues and delivering more- accurate lists and reports much earlier in the engineering and design process. ‘Amore-signi cant bene tof'aspeci cation-driven PAID that uses the same data as a3-D model is that 3-D designers can verify their designs against the P&ID. This allows line checks to be performed mach more quickly. ‘Another bene tof speci cation-driven P&IDs is that, in some systems, the 3-D designer can have both the P&ID and the model displayed on the compater sereen at the same time, and can drag-and-drop a valve or other inline item from the P&LID directly into the model. Doing this ensttes that the designer has the atest information, and thatthe system checks whether the item is in the model. ‘The ability to make these integrity checks at any time during the design process, performed by those creating the design, isa large step toward leveraging the power of P&IDs and all ofthe information associated with them, In closing P&IDs have always been very valuable and useful tools, ‘yet ithas taken modem technology to release their true potential, P&IDs are no longer limited to holding informa- tion that only skilled CAD operators can access. Take a fresh look at your P&ID systems, and you might nd that, for just alittle more effort they can be used to their fll potential in the design process. DN ‘VoRNEL WALKER the mating manages fo COADE (Phan 28) posts; emake waerBroseecom, Website: wnicoade

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