Chapter 29: Process Design Documentation

29.1 Introduction 4
29.1.1 Related References 4
29.2 Process Engineers Role 4
29.2.1 Process Engineering Activities 4
29.2.2 Overview of Key Process Engineering Documents 4
29.3 Process Basis Of Design (BOD) 7
29.4 Process Simulation Report 17
29.5 Equipment List 18
29.6 Block Flow Diagram (BFD) 20
29.7 Process Flow Diagrams (PFD) and Utility Flow Diagram (UFD) 22
29.8 Process Description 24
29.9 Process Philosophy Documents 25
29.10 Material Selection Report / Diagrams 28
29.11 Fluid List 33
29.12 Process Safeguarding Flow Diagrams (PSFD) 40
29.13 Piping & Instrumentation Diagrams (P&ID) 42
29.13.1 Introduction 42
29.13.2 Stages for P&IDs in Project 43
29.13.2.1 IFR – Issued For Review 43
29.13.2.2 IFH – Issued For Hazop 46
29.13.2.3 IFD Issue – Issued For Design 46
29.13.2.4 IFC – Issued For Construction 47
29.13.2.5 As Built P&IDs 47
29.13.3 Softwares used in P&IDs 62
29.13.4 Licensor P&IDs 62
29.13.5 Vendor P&IDs 63
29.13.6 Engineering guidelines for information in P&IDs 63
29.13.7 Representation of Equipments in P&ID 74
29.13.7.1 Pressure Vessels (Including Reactors and Columns) 74
29.13.7.2 Shell and Tube Heat Exchangers 78
29.13.7.3 Air-Cooled Heat Exchangers 82
29.13.7.4 Pumps 85
29.13.7.5 Fired Heaters, Boilers, Incinerators 93
29.13.7.6 Compressors and Blowers 94
29.13.7.7 Steam and Gas Turbine Drivers 94
29.13.7.8 Miscellaneous Equipment 94
29.13.8 Isolation 95
29.13.9 Instrumentation 101
29.13.10 Process Control 102
29.13.11 Electrical 103
29.13.12 Insulation, Tracing and Jacketing 103
29.13.13 Utility Connections 103
29.13.14 Unit Battery Limit Isolation 105
29.13.15 Symbols Normally used in P&IDs 105
29.13.16 Instrumentation Simplified and Detailed representation on P&IDs 120
29.13.17 Pressure relief Valves 122
29.13.18 Piping 123
29.13.19 Equipments Symbols 141
29.13.20 Typical Pump piping 165
29.13.21 Typical P&ID Representations 174
29.13.22 Piping Spec Breaks Typical Representations 201
29.13.23 Simplified and detail representation in P&IDs of motors 202
29.13.24 Representation of sample collectors in P&IDs 218
29.14 Equipment sizing calculations (static & rotating) 223
29.15 Process data sheets (PDS) 224
29.16 Instrumentation process data sheet (IPDS) 234
29.17 Relief and depressurising load summary 236
29.18 control narrative 238
29.19 A) Shutdown Logic Diagram 242
B) Cause and Effect Diagram 242
29.20 Utility summary / catalyst and chemical summary 244
29.21 Effluent and emissions summary 246
29.22 Line List 247
29.23 Tie-In List 249
29.24 Special Piping Item List (SPI List) 250
29.25 Operation and Maintenance (O&M) Manual 251
29.26 DP-DT diagram (Design Pressure – Design temperature) 255

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