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Control System Training

Classification: Restricted
Agenda:
• Feed documents overview
• PFD and P&ID
• Process flow diagram
• Piping and instrumentation diagram

FEED DOCUMENTS OVERVIEW
Whether it is the process of construction of a new industry or facility expansion
of existing industry the following main design stages are followed.
• Conceptual Design
• Basic Engineering Design
• Front End Engineering Design
• Detail Engineering Design

CONCEPTUAL DESIGN :The conceptual design is a study phase in which ideas
and possibilities are evaluated. This phase results in a basic process concept, a
preliminary schedule and a rough cost estimate. At this stage the process is
evaluated to assess its technical feasibility and economic viability for
developing project scope as well as providing a well defined starting point for a
more detailed process design.
Concept designing covers:
• Literature Survey
• Development of an Idea from scratch
• Concept development
• Conceptualization of Process Schemes
• Concept refinement
• Preliminary Process Flow Diagram (PFD)
• Overall Heat and Material Balance (HMB)
• Conceptual Layout
• Order of Magnitude Cost

BASIC ENGINEERING: The basic engineering consists of core documentation of
projects like control & operational philosophy, basic equipment sizing,
equipment specifications, conceptual equipment layout, etc.
Basic engineering covers:
• Conceptual process studies (material balances, process flow-sheets,…)
• Preliminary plot plan.
• Freezing the Master Layout of the Plant.
• Definition and sizing of main equipment resulting in process
specifications.
• Preliminary Piping and Instrument Diagrams.
• Utility consumption figures.
• Schematic drawing of equipments on each floor.
• Definition of control and safety devices.
• Analysis and sizing of Safety Valve.
• Control valve hydraulics & process specifications.

FRONT END ENGINEERING DESIGN (FEED): FEED reflects all technical specific
requirements and avoid any significant changes during execution of the same.
FFED covers
• Basis of Design.
• Feasibility Study.
• Preparation of the specification.
• Mechanical data sheets of the main equipment, starting from the process
specifications issued during the BED and incorporating the specific
requirements of codes and standards to be applied to the project.
• Development of process and utility Piping and Instrument Diagrams
released for detail engineering.
• Preparation of tender packages for the main equipment.
• Development of detailed plot plans and hazardous areas.
• Elaboration of the main piping, instrument, electrical and civil works
layouts.
• Carrying out all the studies to be performed before ordering the main
equipment.

DETAIL ENGINEERING: Detail engineering includes the extraction of all the
essential information from all the basic engineering drawings and calculations
to provide the exact drawings in detail for all production, fabrication & erection
items and in turn the details of entire project along with the precise bill of
quantities and specifications for each of the equipment.
Detail engineering covers:
• Purchasing of equipment, main and bulk.
• Thermal rating of heat exchangers.
• Development of Piping and Instrument Diagrams released for construction.
• Development of detailed piping drawings, including isometrics and stress
calculations.
• Development of detailed drawings related to instrumentation, electrical
facilities and civil works.
• Management of vendor drawings.
• Cost and schedule control.
• Start-up procedures.

Front-End Engineering Design plays a critical role in preparing projects for
success.
FEED comprises a thorough project scope, complete project budget, total cost
of ownership, implementation timeline and initial risk assessment.
All of these factors combine to help reduce risk and uncertainty during the
detailed engineering and commissioning phases, and can help create value
lasting throughout the production lifecycle.
Through FEED the following can be achieved :
• Lower lifecycle costs
• Reduced project technical, schedule and cost risks
• Faster time to achieve plant startup and turnover
• Reduced EHS and compliance risks
• Improved risk identification and mitigation

The procedure followed to develop a FEED are,
• Survey – Begins with a project kick-off meeting to review the technical and
commercial objectives so that all stakeholders are clear on the expectations
of the FEED.
• Following the kick-off, it is ensured that all the appropriate project
information are in order to efficiently commence the preliminary design
work.
• This will include gathering any previously completed design documentation
and may involve an on-site survey for projects.

• Resourcing & Execution – It contains an experienced and dedicated project
team composed of engineers with an engineering background and industry
expertise specific to application.
• Typical activities that will be perform in collaboration with team including
developing the basis of design, specifying the scope of supply and developing
project schedule.
• A project strategy that is tailored to the needs will be developed once
analysis and understanding of schedule, cost, resource, and other project and
business constraints are understood.

DELIVERABLE FROM A FEED
Automation FEED may include key design deliverables such as:
• Requirements specifications, Package specifications
• MCC, panel Designs
• Advanced control and optimization specifications
• Migration strategy
• PFD, P&ID electrical diagrams
• Equipment general arrangements
• Utility loads
• HAZID reports
• Basis of design
• Lists including equipment lists, instrument lists, motor lists, I/O lists
• Control narratives, Control, safety and operational procedures
• Network architectures,
• Validation strategy

USE OF DELIVERABLES
• Overall project cost estimate,
• ROI justification
• Procurement scenarios
• Project schedule / Gannt chart
FEED CAPABILITIES PROCESS
• Generation of Process Flow Diagrams (PFD) and P&IDs
• Process modeling
• Technical specification and basis of design development
• Equipment specification and sizing
• Safety device sizing and selection
• Full hydraulic calculations
• PFD review, estimate and report of process performance with MPC system

SAFETY
• Hot safety system migration strategies
• Risk analysis, HAZID studies
• Safety system design and documentation
• Preparation of safety philosophy / narratives
• SIL target determination and analysis
• ATEX (Hazardous Area Classification compliance)
• Machine safety assessments

MECHANICAL
• Development of modular process solutions
• Layouts
• Process and utility piping systems
POWER/ELECTRICAL
• Power system load studies
• Electrical design diagrams
• Electrical load list
• Equipment specifications & design (LV/MV Switchgear, MCC, etc.)
• Electrical heat trace
• Cable sizing

CONTROL & NETWORK
• Preparation of system architecture
• Preparation of operation and control philosophy
• Preparation of control narratives
• Advanced process control reviews
• Hardware specifications
• I/O lists, drawings
• Installed base assessment and obsolescence study
• Network design, security assessment
• IT infrastructure assessment

INSTRUMENTATION
• Instrument specifications and selection
• Preparation of instrument indexes and I/O lists
• Preparation of Instrument data sheets
• Cable block diagrams
• P&ID review of instruments required for unit or plant-wide model predictive
control (MPC)
• Gap analysis report on optimization instruments

QUALITY
• GMP risk assessment
• Gap analysis vs current regulation study
• Quality documentation (quality plan, validation master plan, etc.)
PACKAGED EQUIPMENT
• Site-wide standards and specifications for packaged equipment
• Package equipment upgrade specifications
• Packaged equipment integration

PFD and P&ID
BASIC INTRODUCTION
• The term flow sheet and flow diagram is often used in the context of
engineering and design applications.
• The following are some of the flow diagrams that are used in process
industries.
• Block flow diagram: It’s the simplest diagram which can condense the
entire process on to a single block sheet.
• Process Flow Diagram: It is the precursor to the Piping and Instrument
Diagram(P&ID).They show details about the major equipment and
subsystems and the flow of product between them.
• Piping and Instrument Diagram: It gives the most detailed explanations
about the process using standard nomenclature and symbols.

PROCESS FLOW DIAGRAM
OVERVIEW OF PFD
• A process flow diagram provides a quick snapshot of the operating unit. Flow
diagrams include all primary equipment and flows.
• A technician can use this document to trace the primary flow of chemicals
through the unit.
• Secondary or minor flows are not included. Complex control loops and
instrumentation are not included.
• The flow diagram is used for visitor information and new employee training.

OVERVIEW OF PFD
• PFD contains information on pressure and temperature of feed and product
lines to and from all major pieces of equipment, such as vessels, tanks, heat
exchanger, pumps etc.
• It also indicated the main headers and points of pressure, temperature and
flow control, plus the main shutdown points in the system.
• For rotating equipment PFDs contain important information such as pump
capacity and pressure heads, and pump and compressor horse power.
• For tanks, vessels, columns, exchangers etc. design pressures and
temperatures are often shown.

OVERVIEW OF PFD
A typical PFD contains,
• Process piping
• Process flow direction
• Major equipment represented by simplified symbols
• Major bypass and recirculation lines
• Control and process critical valves
• System ratings and operational valves
• Composition of fluids
• Connection between systems

• This simple left-to-right approach allows a technician to identify where the
process starts and where it will eventually end.
• The feed section includes the feed tanks, mixers, piping, and valves.
• In the second step, the process flow is gradually heated for processing. This
section includes heat exchangers and furnaces.
• In the third section, the process is included. Typical examples found in the
process section could include distillation columns or reactors.
• The process area is a complex collection of equipment that works together to
produce products that will be sent to the final section.

PIPING AND INSTRUMENTATION DIAGRAM
OVERVIEW OF P&ID
• P&ID is known by many names as Process and Instrumentation Diagram or
Engineering Flow Diagrams or Mechanical Flow Diagrams.
• P&IDs are often used in the process industry to show the process flow and
other installed equipment and instruments.
• They show the interconnection of process equipment and the
instrumentation used to control the process.
• Piping and Instrumentation Diagrams play a crucial role in the design and
engineering of process plants and piping systems.

OVERVIEW OF P&ID
• Process and instrument drawings have a variety of elements, including flow
diagrams, equipment locations, elevation plans, electrical layouts, loop
diagrams, title blocks and legends, and foundation drawings. The entire P&ID
provides a three- dimensional look at the operating units in a plant.
• P&IDs are schematic diagrams that contain engineering and design details of
the process plants. It is a pictorial representation of:
• Key Piping and Instrument Details
• Control and Shutdown Schemes
• Safety and regulatory requirements and
• Basic Start‐up and Operational Information

OVERVIEW OF P&ID
• Process legends are found at the front of the P&ID. The legend includes
information about piping, instrument and equipment symbols, abbreviations,
unit name, drawing number, revision number, approvals, and company
prefixes.
• Because symbol and diagram standardization is not complete, many
companies use their own symbols in unit drawings. Unique and unusual
equipment will also require a modified symbols file.

SAMPLE P&ID DIAGRAM FOR HEAT EXCHANGER

The Heat Exchanger Process
• The heat exchanger is a process unit in which steam is used to heat up a
liquid material. The material, called feedstock, is pumped at a specific flow
rate into the pipes passing through the heat exchanger’s chamber (called the
tube) where heat is transferred from steam to the liquid material in the pipe.
• It is desired to regulate the temperature of the outlet flow irrespective of the
change in the demand (flow rate) of the feed stock or change in the inlet
temperature of the feed stock.
• The regulation of the outlet temperature is achieved by automatic control of
the steam flow rate to the heat exchanger.

• A look at the above diagram shows that the various equipments in the field
are represented by certain symbol names.
• A description about the symbols are as follows,
• PT103, FT103,TT103 these represent the pressure, flow, temperature
transmitters respectively at steam inlet.
• HV102, TCV102 represent the hand valve and the temperature control
valve for the steam inlet.
• P101, E101, FT101,FCV101 represent the pump, exchanger, flow
transmitter, and self actuated flow control valve at the feed inlet.
• TT102 represents the temperature transmitter at the hot feed outlet.
• Apart form the above mentioned few equipments a lot more detailed
explanation can be derived from the P&ID diagram.

• In this P&ID, there are two sets of instrument bubbles used: plain circle
bubble and a circle bubble with a solid line across it.
• The plain circle bubbles represent field mounted instruments while circle
bubbles with a solid line across represent control room mounted
instruments.
• Two kinds of signals are represented on the P&ID. They are:
• Electrical signals
• Pneumatic signals
• Electrical signals are represented by the dashed lines with red colour on the
P&ID.
• The pneumatic signals are represented by solid lines with double strip across.
• To know more details about the symbols please refer to the ISA Standard 5.1
Instrumentation symbols and Identification.

• A P&ID is a working document that is used by every discipline involved in the
design, engineering and construction of process plants. It is used as a Process
Plant Layout and Piping Design reference for checking engineering and design
documents and drawings associated with a project.
• P&IDs are used in material take‐off, in generating a “Bill of Materials” for
procurement and construction.
• P&IDs typically contain the following information:
• All the equipment and their specifications, usually presented in the form
of a table.
• All piping and line specifications.
• All piping system components such as fittings, flanges and valves with
their specifications.
• All instrumentation and control components Flow directions.
• Information on process variables such as pressure and temperature.

• Material Specifications Specialty Items such as strainers.
• Control Input and Output, Interlocks and Alarm System Interconnections
References.
• Computer Control System input
• Identification of Components and Subsystems Delivered To and By Others
• P&IDs play very important roles in plant maintenance and modification in
that.

Basic and Specialized Symbols-Piping and Valves

Basic and Specialized Symbols- Valves

Basic and Specialized Symbols-Pumps and Tanks

Basic and Specialized Symbols-Heat exchanger

Basic and Specialized Symbols- Cooling towers

Thank you!

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