Fundamentals of Process Plant DesignGoals and Objectives Vv VVV WV Understand the basic fundamentals of an EPC role in Process Plant Engineering. Help / Guide you in your job to try and apply some thought, where can you add value to the industry we serve. Presentation where we can learn about Plant Design. Does not cover all aspects of Plant Design. Does not cover all industries Not about making you a Piping DesignerPlant Design Workflow Process Simulations Preliminary GAs Process Flow Diagrams Preliminary P&IDS Preliminary Layouts CAPEX ++/- 30% att Instrument & Electrical Schematics Process and Utility PRIDs Initiate 3D Plant Design Data Sheets HAZOP / Safety Reviews ‘CAPEX +/- 15%Process Plant Activity Model i TS | = Ea Plant | SS ee Es as | i 1 Phaset Phase Ii ‘Phase Itt feed MGM eaten MS commucionProcess department and its role » Process Engineering focuses on Design, Operation, Control and Optimisation of Chemical, Physical and Biological processes » Translate a customer needs into a production facility — Safely & Productive > Block Diagram > FEED (Front End Engineering and Design) > PFD (Process Flow Diagram)PFD (Process Flow Diagram) This figure depicts a small and simplified PFD: System Flow Diagrams should not include: > pipe class » pipe line numbers » minor bypass lines - isolation and shutoff valves » maintenance vents and drains » relief and safety valve » code class information » seismic class information Process Flow Diagram emPFD (Process Flow Diagram) APFD should include: Process Piping Major equipment symbols, names and identification numbers Control, valves and valves that affect operation of the system Interconnection with other systems Major bypass and recirculation lines System ratings and operational values as minimum, normal and maximum flow, temperature and pressure Composition of fluidsP&ID (Piping & Instrumentation Diagram) This figure depicts a very small and simplified P&ID: AP&ID should not include: Instrument root valves > control relays » manual switches » equipment rating or capacity » primary instrument tubing and valves pressure temperature and flow data elbow, tees and similar standard fi fittings extensive explanatory notesP&ID (Piping & Instrumentation Diagram) A P&ID should include: ¥ VvVVWv VVVVVVV VY 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 swaggers Permanent start-up and flush lines Flow directions Interconnections references Interfaces for class changes Computer control system input Vendor and contractor interfaces Identification of components and subsystems delivered by others Intended physical sequence of the equipment; = en pease BP | i]Process and Instrument Shapes (Ie i Centrifugal Centrifugal pump 2 pump 3 Sump pump oy Aes} g Oeia Cc CO tank tank a floating root 75] C5 “Onicntank Centrifugal Centrifugal Centrifugal Centrifugal compressor compressor compressor 2 blower Axial —_Recipracatinn compressor compressorlO alk thoi ES io KS the fee ie fee ule EF BC, LZ fhe ib We ie fe(Gy Instruments: Teer shai Instr Tas ilohe cotrer ian Ee ees ne ‘Baededeaft SPECTACLE BLIND OPEN fh SPECTACLE BUND CLOSED AiR onttce ruavors: £7] rma reciiry ire| : : j i | rP&ID / ISA Symbols and Loop Diagrams Piping and Instrumentation Diagrams or simply “P&IDs” are the “Schematics” used in the field or Instrumentation and Control (Automation). The P&ID is used by the field technicians, engineers and operators to better understand the process and how the instrumentation is interconnected, ensuring the plant is operating efficiently. Most industries have standardised the symbols according to the ISA Standards $5.1 Instrumentation Symbol SpecificationTemperature Process / Loop Diagram Temperature Controller and Recorder Temperature Transmitter Pneumatic Control Valve Heat ExchangerTag Numbers in a Loop Temperature Controller and Recorder Temperature Transmitter Thermometer oof Temperature | Sensing Bulb — +5 oo — Pneumatic Control ValveTag Numbers. TY | temperature Sensing Bulb ve Ce 206the measured variable Pressure Level Flow Temperature The first letter is used to designate vey The succeeding letter(s) are used to designate the function of the component, or to modify the meaning of the first letter. Indicator Recorder Controller TransmitterTemperature Recording Controller Temperature Transmitter — — Temperature Indicator Temperature Sensing BulbNo Line Solid Line No Line The instrument is The instrument is The instrument is mounted in the field mounted in the mounted out of sight near the process, control room (not accessible to the (clase to the operator) (accessible to the operator) operator)Summary of Instrument type & location Accessible to the Mounted in | Not Normally Operator; Primary | the Field Accessible to Location on the Operator, Behind Main Control Panel the Panel Distinct Elements Shared Display Shared Control in Distributed Control System Computer Logic Function Programmable Logic ControlPiping and Connection Symbols Piping and Connection SymbolsInstrument Valve Symbols kp Gate Valve, Hand-operated eed Control Valve ke Globe Valve, Hand-operated Solenoid Valve x a Motor-operated aNF Check Valve Piston-operated 4h Butterfly Valve ke Angle Valve, Hand-operated Safety Valve or Relief Valve Dk. Plug or Cock Valve, Hand-operatedP&ID ExerciseP&ID Exercise (Completed) Flow incicating controler that S equare root Sica (primary focstion) FIC — Flow Indicating Controller Tic Temperature Indicating Cont, Yic PLC Indicating Controller TY Temperature Computer Output FT Flow Transmitter Tt Temperature TransmitterPipeline Naming. 150-PV-20-2002-AD20XS-03-050-N 150 — Line Size Nominal Dia PV — Service Code 20- System 2002 — Sequence Number AD20XS — Pipe Class 03 — Insulation Class 050 — Insulation Thickness N — Heat Tracing0-120120 NB SS LINES Line No 20-MET-05-SS 20-MET-06-SS. 20-MET-07-SS 20-MET-09/10-SS 20-BIO-12-SS, 20-BIO-13-SS. 20-BIO-14-SS. 20-BIO-15-SS, 20-BIO-14-SS(OP) 20-BIO-15-SS(OP) 20-BIO+28-SS(OP) 20-BIO-29-SS(OP) 20-BIO-30-SS(OP) Gate Valves 90 Elbow Pipe 3000 4920 Lists 3208 3000 6260 29570 7860 7545 o54s 9120 S420 S40 3 117500 11 46. mee Be bw awe we ew ee = = 45 Elbow Tee 5 10 = Gasket NutBolt iwi we eR wow no Sw 30 200 CRed 20x15 ‘RedT 20x15 Steam Trap GIobE Valve “Control ¥: ~ Flush Bot Valve ‘Strainer “RedT 20x15 PlugPiping / Mechanical Department and its Role Piping Engineering A Major phase in the life of process plantsElectrical CQ)sstedutina O dient Rotating Equioment() oO Qennserscturot instruments( ) . \ 3 ( )Process systems(_) _ Plant Layout (CQ eomauter Anaictions funace() i O z O , 0. O O Mechanical ric ConstructionPlot Plan Development VVVVVVVVV VV Ww Indicate all Major equipment items Building outlines Battery Limits Area Limits of responsibility Piping Entry and Exit Points Access ways > Roadways Main Structure — Stairways Piperacks > Dimensions kept to a minimum Show all Easting/Northings — Elevations True North Plot Plans supplied by Clients (FEED Specifications)Plot Plan Development — General Information Required Site Plans & Project Design Information — Client Standards > Equipment List > PFD and P&ID & Utility conditions — Cooling Water, Steam, etc > Preferred locations of exit and entry piping points * Electrical Cables entry points » Client / EPC Standards for safely distances > Client / EPC Standards for specific equipment locations > Grade levels of unit area and plant in general » Details of existing roadways, railroad or accessways Plant North * Battery Limits > Firefighting dataPlot Plan Development — General Information Required ) > Storage tanks — diameter and capacity & Heaters — diameter of shell and height > Compressors — size of base plate area — type » Specialist equipment — eg skids, size and area » Towers/Drums- Diameter and tan line minimum heights > Critical elevations for all equipment > Exchangers tube length and diameterPiping - FundamentalsPiping - Fundamentals The Goal of Piping Engineering is: To Ensure a connected Piping is >» Specified and Designed » Fabricated and Erected > Inspected and Tested > Operated and Maintained In other words... To perform reliably and safely in all expected conditions, for its design life.> Pipes are supported at point locations > Weight of the Pipe may change >» Temperature will vary — ambient to operating > Thermal expansion » Connected to equipment » Pipe are welded to components > Different components within a piping system >Piping Standards MAJOR ORGANIZATION FOR STANDARDS ‘Sr. No. County Organization Abbreviation 1. USA American National Standard | ANSI Institute 2. Canada Canadian Standard | CSA Association 3 France Francaise AFNOR 4. United Kingdom British Standards Institute BSI 5 Europe European Community for | CEN standardization 6. Germany Deutsches = Institute for | DIN Normung T Japan Japanese Industrial JIS 8. India Bureau of Indian BIS ‘StandardsPiping - Standards Organization ID Title ASME B31.1__| Power Piping ASME B31.4_| Liquid Petroleum Transportation Piping Systems ASME 831.5 _| Refrigeration Piping ASME 831.8 | Gas Transmission and Distribution Piping Systems ASME B31.9 | Building Services Piping ASME B31.11 | Slurry Transportation Piping Systems ANSWVAGA 2223.1 | National Fuel Gas Code (same as NFPA 54) AWWA C100 _| Cast-Iron Pipe, Fittings AWWA C200 | Steel Pipe AWWA C300 | Concrete Pipe AWWA C400 | Asbestos Cement Pipe AWWA C500 | Valves and Hydrants AWWA C600 | Pipe Laying AWWA C900 _| PVC Pressure Pipe AWWA Mg Concrete Pressure Pipe AWWA M14 Steel Pipe-Guide for Design and Installation NEPA Multiple | Fire Protection SystemsPiping - Standards Acronyms and Definitions The following acronyms and definitions are applicable to this Guide. They may either appear in this Guide, or in various vendor valve catalogues. Understanding of these acronyms and what they mean may be necessary to proper valve selection, > ASME: The American Society of Mechanical Engineers. ly > ANSI: American National Standards Institute. > API: The American Petroleum Institute. Process Pipe Pipe is specified by its Nominal Bore, its outside diameter. Pipe is identified by its Wall Thickness, referred to as “Schedule”, eg Sch 40, 80, XS, etcPiping Specification Revision Control Page Tit Revision Description of Revision 2 3 ‘Glass 150 Carbon Steet 1 PS-102 | Carbon Steal (6163) 1 PS-103 | Class 200 Catbon Steal | 1 PS-104 | Class 400 Carbon Steel 1 ziti saa PS-105 | Class 600 Carbon Stee! ‘Gnginl issue Ps-106 | Rating 1000 psi, Corton Steel | ‘Sniginal issue PS-107 ‘Ciass 1500, Carbon Steet ‘Gnginal issue Ps-108 ‘Ciass 2500, Cerbon Stee ‘Onginal issue P5109 | Vicia Zeto-lex, Caroon Sisal | “Snainal issue PS-200, Class 150 2041 Stainless Stee! Oficial Issue P5201 20 S16L Stamless Steet i —Sngnat issue, Sarna PS-202 Class 200 204L Stainless Stee! Orginal Issue. PS-203, ‘Class 300 3162 Stainless Stee! [“"Fs2207 ‘SOA Stainless Stool tubing PS-205, 3odL Stamigss Steel Tubing PS-206 ‘316L Stainless Stee! Tubing ‘Onainal tse PS-207 ‘3161 Stainless Stee! Tubi I ‘Onoinal issue, [= "Feon Gass 800 S00 Stamioes Steal a npr 5-708, ‘Clsss 600 3041, Stainless Steel Grginal issue PS-210 ‘Rating G00 pei, 30d Seamless Gnginal lesue PS211 | Rating 600 psi, 316 Seamless Onginal Issue PS-212 | Rating 1225 psi, 3041. Seamless | Snginal issue P5715 | Ciess 1500, 3041 Scomiess Griginal issue = PS-214 | Class 2500, 304 Seomiess ‘Original lesa [> Ps-215 | Victaulic Zero-fiex, 316 105 ‘Orginal Issue PS.300 | Class 150 Hastelloy C276 ‘Oniginal tesue PS-201 ‘Glass 300 Hastelloy C276 Gnginal issue PS-202) ‘Class 150 Alloy 20 ‘Onginel issue 5-303 | Class 300 Alloy 20, I Original issue | 1 + T 1 i 1Feng Scheaue Tanes | ASME B26 OM _| ASTM ASS 5 ER — Tye BsSeaTiess Peng ‘Schedde Taties | ASMEBSE10 | ASTM ATOS 5 SearsPiping - Specifications taal Threaded Fittings 4 Sc0Ge S0cos ASME BI6.11 ASTMAIO5 we Use 30008 for PS101-D ‘Socket: Weld Fittings: %-2 Soooe, Sooo ASME B16.11 ASTMATO5 we Use 6000# for PS101-0 Baal Fangs at | Seteaule Tasos [ase Bie | astuaza | wee atid Fngs ‘iat | setmaue Tans | sue ptez0 | astuaza | wee Component. $i Sunda aera Total Grade | Aion Regier Fasten rar AGES | ASTMAGS | STH See Gana 10 mae Bats Sega? | STAs | 2aPiping - Specifications VALVES. Tsien eon Feature Specifications aot CV Code Valve ¢ § 2Bronze, 4. Carbon Steal (1), 5 Stainless Stee! 304(L) (2), 6-Slainless tt 2) Material Steel 316(L) 8) 3 3 3) Pressure Class 1-150, P-Pressure Rated & BH (a) End Connection @) | 1-Flanged, 2-Sockel Wed, 2 Bull Weld, 4 Thweaded Syiypeot Valve Standard Giobe Sil ~ | S)NaNe Size ‘Specified as shown in the Example Valve 1 Number by NPS <2 7) Disc Material 'A-Chromium (11-13%), C-Bronze, D-Stainless Stee! Es t 8) Seat Material ‘A-Chromuum (11-13%), D- Stainless Steel, O.Viion, P-EPDM 253 | 9) StemMatenal ‘A-Chromium (11-13%), B-Carbon Steel, C-Bronze. 0-Siainless Stee! oie 10) Packing Material _| A-Graphite, B-Teflon, D-Nylon, G-Viton, H-EPDM 1) Body Gasket B-Teflon, D-Nylon, G-Viton, H-EPDM NOTES 41)ASTM A216WCB or A105 2)CF3, CFS, F304, or F304L. 3)CF3M, CF8M, F316, F316L_ 4) Non welded end stainless steel valves pressure rating is based on the high carbon (non L) grade.Piping - Specifications Table D-1 Standards for Valves ASME B16.34 | Valves - Flanged, Threaded, and Welding End API594 Wafer Check Valves APIL599 Steel and Ductile Iron Plug Valves API600 Steel Gate Valves, Flanged and Buttwelding Ends API602 Compact Stee! Gate Valves API 603 Class 150 Cast, Corrosion-Resistant, Fianged-End Gate Valves: API 608. Metal Ball valves - Flanged and Buttwelding Ends ‘APIG09 Butterfly Valves, Lug-Type and Wafer-Type AWWA C500. Gate Valves, 3 inch through 48 inch, for Water and Sewage Systems AWWA C504 Rubber Seated Butterfly Valves MSS SP-42 (Note 1) | Class 150 Corrosion Resistant Gate, Globe, Angle and Check Valves with Flanged and Butt Weld Ends MSS SP-67 (Note 1) | Butterfly Valves MSS SP-70 Cast Iron Gate Valves, Flanged and Threaded Ends MSS SP-71 Cast Iron Swing Check Valves, Flanged and Threaded Ends. MSS SP-72 Ball Valves with Flanged or Butt-Welding Ends for general Service MSS SP-80. Bronze Gate, Globe, Angle and Check Valves. P81 Stainless Steel, Bonnetless, Flanged Knife Gate Valves MSS SP-85. Cast Iron Globe & Angle Vaives Flanged and Threaded Ends MSS SP-88 Diaphragm Type Valves Tete “These valves are acceptable even though not Estedin Table 305 1 of ASME 631.3 They are isted in Table 126.1 of ASME Bat 1 The addtional requirements of ASME 831.1 must be mat in that ‘enly valves designed such that the valve stem is retained by an assembly wich functions independientiy of the stem seal retainer shal be used” (eter to paragraph 107.1(D)f ASME 831.1).| Piping - Specifications Contamination Table D-2 Valve Selection Description of Service Control of fluids which may cause contamination buildup, a valve with minimum obstruction to flow is needed Recommended Valve Ball, Gate, Globe, or Pinch High Pressure Control of flow at high pressures - selection of a valve to be used in a high pressure application, particularly pneumatic, should be approached with caution Ball or Globe, Poppet Valves are ‘occasionally used High Temperature Control of flow at high temperatures Ball or Globe, Poppet Valves are ‘occasionally used Low Leakage Contral of flow with very low seat leakage in the closed position Ball, Gate, Globe, or Plug Shutoff Normal on-off control Ball, Gate, Globe, or Plug - Ball and Plug Valves normally operate faster Steam Service Control of steam under pressure Ball or Globe Throttling Control the amount of flow by varying the valve position Globe - Ball and gate valves tend to vibrate under flaw, and erosion is a concem when using gate valvesPiping - Specifications Table D-3 Valve Selection Mode of Flow Regulation Fluid T ‘Solids in Suspension On-Off | Theotting | Diverting Now Abrasive Abrasive Yes Yes Special | Special Yes Special Parallel Gate Wedge Gate_[ With bottom Cavity ‘Without Bottom Cavity (rubber seated) Non-ubricated Lubricated Eccentric PlugPiping — Fittings and Components Screwed stainless steel and butt weld mild steel fittingsPiping — Fittings and Components » Fittings are used in pipe systems to connect straight pipe or where change is direction is required. > Ends are already prepared. > To adapt to different sizes, to branch out or re-direct the process (flow). > To provide a joint if 2 dissimilar materials are used in one system. Fittings for pipe most often made from the same base material as the pipe being connected, e.g., carbon steel, stainless steel, copper or plastic. Any material that is allowed by code may be used, but must be compatible with the other materials in the system, the fluids being transported, and the temperatures and pressures inside and outside of the system. Lines below 50mm NB8 are normally screwed or socket weld. Line 50mm and above are butt welded.Piping - FlangesPiping - Flanges . ny Weld Neck flanges are used in critical applications. These are circumferentially welded onto the system at their necks which means that the integrity of the butt-welded area can easily be examined by X-ray radiography. The bores of both pipe and flange match thus reducing turbulence and erosion. Weld NeckPiping - Flanges Socket Weld ay Socket Weld Flange is counter-bored to accept the pipe, which is then fillet welded. The bore of both the pipe and the flange are the same to ensure good flows.Piping - Flanges Slip-on Flange is slipped over the pipe and then fillet welded. Easy to use in fabricated applications.Piping - Flanges Threaded ie Threaded Pipe a ZP Screwed or Threaded Flange requires no welding and is used to connect other threaded components in low pressure non- critical applications. a“Piping - Flanges “— a # Lap Joint a Stub oe End e - ~ es ZS Lap Flange (or Backing Flange) are used with a stub end which is butt-welded to the pipe with the lap flange acting as a loose collar behind it. Thus the stub end always provides the sealing face. This type of joint is easily assembled and aligned, and it is favoured in low pressure applications.Piping - Flanges Blind Flange or sometimes called a Blanking Flange, this is used for blanking off pipelines, valves and pumps and as an inspection cover.Piping - ValvesPiping - Valves A valve is a mechanical device that controls the flow of fluid and pressure within a system or process. A valve controls system or pracess fluid flow and pressure by performing any of the following functions: 3 Stopping and starting fluid flow. Varying (throttling) the amount of fluid flow. Controlling the direction of fluid flow. Regulating downstream system or process pressure. Relieving component or piping over pressure. There are many valve designs and types that satisfy one or more of the functions identified above. A multitude of valve types and designs safely accommodate a wide variety of process applications. VW Vv Complex control systems will use feedback from an instrument to control these types of valves to regulate pressure, temperature or flowrate depending on the control parameters required.Piping - Valves Types of Valves > Globe > Gate > Plug > Ball > Needle > Butterfly > Diaphragm > Pinch > Check > Safety/relief > ReducingPiping - Valves Classification Isolation Regulation Non-Return Gate Valves Globe Valves Check Valves Ball Valves Needle Valves Plug Valves Butterfly Valves Piston Valves Diaphragm Special Purpose Diaphragm Valves Multi-port Valves Piston Valves Valves Butterfly Valves | | Pinch Valves Float Valves Pinch Valves Blind ValvesRising Stem STEM HANDWHEEL PACKING GLAND BONNET ‘CLOSED OPENED.Non Rising Stem HANDWHEEL PACKING GLAND BONNET CLOSED OPENEDGate ValveGlobe ValveBall Valve vie YU, PY, DKW}Plug Valve = =6) «\ AOR ‘ft iEPiping - Valves Diaphragm Valve OPEN THROTTLING CLOSEDPiping - Valves Reducing Valve IN iSNeedle Valve J G ELLA —Piping - Valves Check Valve - SwingPiping - Valves Check Valve - TiltingPiping - Valves Check Valve - Lift (Tt (T SONNET PLUG (0 PP tH, D SPRelief ValvePiperack configuration ») 2a) 4) @) GY) GO) mess ayy)Piperack configuration = i ? : — Hl _——— GY i |] | mua. i a r RK fi i — H | sae i I | if S| i Fig 1- Typical cross-section for composite piperackCentrifugal PumpPiping — Pump arrangement and piping Typical pump locations - elevation ancosien /Piping — Pump arrangement and piping Typical pump suction and discharge pipingOrientation of handwheels ie 7 (BN HR = ae all (END SUCTION-TOP DISCHARGE)Typical auxiliary pump pipingMaintenance and operation access requirementsPiping — Heat Exchangers, Compressors, Air Coolers, etc Various other equipment HeeiZon TAL VE@TICAL TWEE SIDE SHELL SIDE @. Shell and Tube ExchangerPipe Hangers FO eis eet ruay man —_| = Tunmevenie— — _— = e nop. at aPiping — Pipe supports Anchor, Spring hangers and Guides = 1, CONSTANT LOAD TYPE c Xs pee‘Outputs from the Piping Discipline Overall plot plans showing location of various process units, offsite, package units, roads, piperacks, sleepers, etc. PMS (Piping Material Specifications) & Valve Material Specifications. Equipment general arrangement layouts/drawings indicating the location of all the equipment within a unit, platforms, ladders, overhead crane elevation. Piperack general arrangements drawings & structures for equipment support, Piping general arrangement layouts/drawings showing all the piping and equipment. Piping BOM (Bill of Material). Piping stress analysis reports for critical lines. Drawing showing the vessel cleats location for pipe supports. Layout for underground services. 10. Piping isometrics with bill of material. 11. Pipe support location plan, support schedules, pipe support drawings. 12. Purchase specification for insulation, painting, wrapping and coating.Material Control Piping Material Control The material controller is responsible for all piping material requirement planning. This includes quantity take-off activities, production of bill of material, piping material quantity summaries, piping requisitions, piping order bit tabulation/summaries and technical comparison and required at site date planning. The list of deliverables may include the following. - Bill of material for each piping documents - Bill of material summary - Special take-off summaries (large diameter or long delivery valves) - Piping material procurement request for quote (RFQ) draft - Piping material procurement purchase order (PO)Electrical Electrical engineering Responsible for all of the project power, lighting and communication needs. - Normal and emergency systems - hardware selection such as transformers and switchgear - Aboveground and underground distribution systems - electrical design considerations and electrical code requirementsInstrumentation Instrument engineering Responsible for the ‘nervous’ system of the plant. Input is preliminary data sheet originated by process and complete the definition requirements, including final sizing and vendor selection. Other responsibilities are: - layout of any control room - control system hardware - control system software - local indicators - sensing elements and circuits - defining the physical hardware elements that constitute the in-line and on-line instruments for the project.