04 basic piping

8/21/2019 04 Basic Piping

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Design of PipingSystem


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Piping System Design - What is that?Concept Layout Development

Piping Components & their access requirement.

Straight length requirements.

Orientation of various tapings components etc.Piping Drains & !ents

"nsulation.

#aterial & Si$ing

Critical piping system consi%eration.Pipe Stress nalysis.

Pipe Supports

Pipe 'a(rication


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Let us first Discuss a(out W)* "S P"P+,

"t is a *u(ular item ma%e of metal plastic glass etc.

meant for conveying Liqui% as or any thing that

flos."t is a very important component for any in%ustrial

plant. n% it/s engineering plays a ma0or part in overall

engineering of a Plant.

"n ne1t fe pages e shall try to familiari$e a(out pipe

an% it/s components.

Piping 'un%amentals 2


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In any plant various fluids flow through pipes

from one end to other.

Now let us start with a plant where we see three

tanks.

Tank-1, Tank-2 and Tank-3

We have to transfer the ontent of Tank no. 1 to

the other two tanks.

We will need to onnet pipes to transfer the

fluids from Tank-1 to Tank-2 and Tank-3

!"T #$ %&IN' T(" )I)"$.


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We have *ust +rought the pipes, now we

need to solve some more pro+lems.

)ipes are all straight piees.

We need some

+ranh

onnetions

We need some +end

onnetions

" v e n s o m

e p i p e

s a r e

o f d i f

f e r e n t s i ,

e s -

To solve these

pro+lems we need the

pipe omponents,

whih are alled

)I)" ITTIN'$


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These are the pipe fittings,

There are various types of fittings for various

purposes, some ommon types are -

"l+ows/%ends, Tees/%ranhes,

&eduers/"0panders, ouplings, lets, et.

nyway, the pipes and

fittings are in plae, +ut the

ends are yet to +e *oined withthe Tank noles.

We now have to omplete theend onnetions.

These, in piping term, we all

T"&4IN! NN"TIN$.

http://basic%20piping%20fittings.ppt/


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These are flanged *oints

This is a welded *oint

$o far this is a nie arrangement.

%ut there is no ontrol over the flow from Tank-1

to other tanks.

We need some arrangement to stop the

flow if needed

To ontrol the flow in a pipe line weneed to fit a speial omponent.

That is alled - 5!5"

http://basic%20piping%20fittings.ppt/


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There are many types of valves, ategoried

+ased on their onstrution and funtionality,

Those are - 'ate, 'lo+e, hek, %utterfly, et.

ther than valves another important

line omponent of pipe line is a filter,

whih leans out der+ies from theflowing fluid. This is alled a

$T&IN"&


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(ere we see a more or less funtional piping

system, with valves and strainer installed.

!et us now investigate some aspets of pipe

fle0i+ility.

If this tank nole

e0pands, when

the tank is hot.

In suh ase we need to fit a fle0i+le

pipe omponent at that loation,

whih is alled an "6)N$IN

7INT


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When some fluid is flowing in a pipe we may

also like know the parameters like, pressure,

temperature, flow rate et. of the fluid.

To know these information we need

to install IN$T"NT$ in thepipeline.


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There are various types instruments to measure various

parameters. lso there are speifi riteria for installation

of various pipe line instruments.Ne0t we shall look

into how to

$#))&T thepipe/and it8s

omponents.


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(ere are some of the pipe supporting arrangements.

There an +e numerous variants. ll depend on piping

designer8s preferene and *udgement.

!et us see some T("& types of supports


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We have *ust ompleted a pipe line design.

We shall rewind and hek how it is really done in pratie.

irst the flow sheme is planned,

19 What, 29 rom what point, 39 To whih point

)ipe sies are seleted, pipe material and pipe wall thikness are seleted.

Types of 5alves are planned

lso the types of instruments re:uired are planned

We represent the whole thing in a drawing whih is alled )iping andInstrumentation ;rawing, in short )


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*his is screen picture of P&"D ma%e (y SPP&"D

"f e clic3 on any line it ill sho the Data em(e%%e%.


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fter the )


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While arrying out pipe routing we also need to onsider the following

5alves, strainers, instruments on the pipe should +e easily aessi+le.

If needed separate "$$ )!T&4$ to +e provided to failitate these.

;esired loation and orientation of valves / instruments and other pipeomponents are to +e heked and maintained, like some valves or strainers

an only +e installed in horiontal position.

$peifi re:uirements for instrument installation to +e heked, like

temperature gauge an not +e installed in pipe whih is less than = inh in sie.

$peifi re:uirements of $T&I'(T !"N'T( of pipe for some omponents to

+e maintained, like for flow orifie we need to provide 1> times diameter

straight pipe length at upstream of orifie and > times diameter straight at down

stream of orifie.

"0ample of $traight length re:uirement for low rifie


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lso arrangement is kept in the

pipeline so that li:uid an +e

drained out if re:uired.

To ahieve this a ;&IN onnetion

with 5alve is provided at the lowest

point of the pipeline )ipes are also slopped towards low

points.

or )ipeline whih shall arry li:uid, we have to make sure that all air is

allowed to vent out of the line when the line is filled with li:uid.

To ahieve this a 5"NT onnetion with 5alve is provided at the top most point

of the pipeline.

!et us look

into typial5ent and

;rain

arrangement

in a pipeline


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!et us have a look into a piping model done +y );$ 3;

This is a 3; model

of eed water linealong with pumps

and other

aessories


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NSULAT ON

- When hot or old fluid flows through pipe then generally pipe is

insulated ?(ot@ or ?old@ insulation respetively.

There are two primary reasons for insulating the pipe arrying hot fluid.

ontaining the heat inside the pipe. Insulation preserves the heat of the fluid. Itis alled (ot Insulation

)ersonnel safety, so that people do not get +urn in*ury +y touhing hot surfae

of pipe. It is alled )ersonnel )rotetion Insulation

old pipes are also insulated

old or hilled fluid arrying pipes are insulated to prevent heating of old fluidfrom outside. It is alled old Insulation.

$ome times old pipes are insulated to prevent ondensation of atmospheri

water vapor on pipe surfae. It is alled nti-$weat Insulation.

ther types of Insulation

When gas flows through pipes at high veloity, it reates noise. In suh asespipes are insulated to redue noise. It is alled ousti Insulation.

$ome times pipe and it8s ontent are heated from outside, +y heat traing

element. In that ase pipe along with heat traing element are insulated to

onserve the heat of the traer. It is alled (eat Traing Insulation.


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IN$#!TIN 4T"&I! - The insulating material should +e +ad ondutor of heat.

There are two +asi ategories

19 i+rous 4aterial, whih has large voids full of air +etween fi+ers - ork, 'lass Wool

4ineral Wool, rgani i+ers. Note stagnant air is a +ad ondutor.

29 ellular 4aterial, whih has losed void ells full or air - alium $iliate, ellular

'lass Aoam 'lass9, )olyurethane oam A)#9, )olystyrene AThermool9, et.

$ome times ast material like ement )laster or )laster of )aris are also used.

IN$#!TIN !;;IN' - Insulation materials are generally soft or fragile. $o the

outer surfae of insulation are proteted with luminum, $tainless $teel or 'I

sheet ladding.

Have a look at how

pipes are insulated,

and general

components ofinsulation

)ipe 4aterial $eletion - to selet appropriate pipe material +ased on flowing fluid property.


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)ipe $iing alulation - to selet re:uired pipe diameter +ased on veloity and pressure drop.

Find outFlow volume

per second

Check Velocity Allowable per

second

Calc. flow arearequired and

ipe si!e

Calc. ress."rop for that

ipe si!e

Check ress."rop meets

ress. #udget

ipe$i!e

%&

'($

)ncrease

ipe $i!e

*%

p pp p p p g p p y

Find out type

of Fluidflowing

Check ipe

life(+pectancy

$elect suitable

aterial perpractice -*ote/0

Check at.

1isted in"esign Code

ipe

aterial%&

'($

$ee *ote/

*%Note-1 B 4aterial is seleted per past e0periene with ost in

mind and per material listed in design ode. If material isnot listed in ode we may selet ne0t suita+le material

listed.

Find out

Fluid 2emp.3 ressure

)ipe Thikness $eletion - to selet appropriate pipe thikness +ased on flowing fluid property.

$elect at.

3 "iameteras above

"ecide on

Corrosionallowance

Calc. ipe

2hickness perCode

Find out

Fluid 2emp.3 ressure


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In )ower plant there are some piping whih arries steam at high pressure and

temperature. nd also there are piping whih arries water at (igh pressure.

These pipes arries the main yle steam and water of the steam power plant.

These pipelines are all the &ITI! )I)IN'.

5ery speial are are taken for design of these piping.

irst the pipe material seletion for suh piping is very important as it has to

withstand the high pressure and may +e also high temperature.

s these pipes arry the main system fluid of the power plant, they are given

the right of way, and routed at +eginning of the overall plant layout.

$team pipes run at very high temperature and the hot pipes e0pand. We have to+uilt in fle0i+ility in the high temperature pipe routing so that the e0pansion

fore is a+sor+ed within the piping.

lso there should +e enough fle0i+ility in these pipe routing so that high loads

are not transferred to the noles of Tur+ine or )umps

There are many reognied international odes whih lay down guide lines andmandatory re:uirements for design of suh piping.

The most important odes used +y power plant piping engineers are

$4" N$I %31.1- )ower )iping ode < I%& - the Indian %oiler &egulation

)ipe $tress nalysis


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)ipe $tress nalysis

We have already seen that some of the pipes are su+*eted to high pressure

and high temperature. lso pipes arry the load of the flowing fluid.

We need to hek and onfirm the pipe is not going to fail with these loading.

This proess of heking the stress developed in the piping due to variousloading is alled )ipe $tress nalysis/le0i+ility analysis.

In the proess of nalysis we apply various postulated loading on the pipe and

find out the stress resulted from these loading.

Then we hek with governing odes if those stresses generated are

aepta+le or not. We hek support load < movement for various loading ondition.

We also hek out the terminal point loading generated from pipe to the

e:uipment onneted to the pipe. This loading are to +e within aepta+le

limits of the e:uipment suggested +y the vendors.

We also find out the pipe growth due to hange in temperature and need to

keep the movement of pipe within aepta+le limits.

)ipe $tress nalysis is an Interative and Iterative proess. "ah step is

heked

If a hek fails we have to go +ak, modify the layout and restart the analysis.

)I)" $T&"$$ N!C$I$


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)I)" $T&"$$ N!C$I$

Inputs

'eometri layout of )ipe

)ipe supporting onfiguration

)ipe ;iameter and Thikness

)ressure inside )ipe

old and (ot temperatures of )ipe

Weight of )ipe and insulation

Weight of arrying luid

)ipe material )roperty ACoung8s 4odulus,

Thermal "0pansion oeffiient9

Thrust on pipe due to +lowing wind.

Thrust on pipe due to earth:uake

!oad of $now on pipe

ny transient loading like $team (ammer

load

ny other load on the piping

Tools we use

)I)$C$ - is an integrated pipe stress

analysis module of )!;"$ 2DDD

"$"& - ommerial )iping analysissoftware

There are many other ommerial software

availa+le

utputs

$tress of the pipe at various loadingonditions

!oad at various supports and restrains.

4ovement of pipe at support loations

)ipe terminal point loading.

odes and $tandards In general )ower )lant )iping have to

omply stipulations of $4" N$I %31.1

In India )ower yle )iping to omply I%&

ode re:uirements.

Types of )ipe $upports


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Types of )ipe $upports

)n the beginning of this discussion we

talked about various types of pipe

supports. Here is some elaboration

There are three general types

&igid type Ano fle0i+ility in the

diretion of restrain9

$pring type Allows pipe

movement in diretion of loading9

;ynami $upport A;egree of

restrain depends on aeleration

of load9

There are two types of spring

support

5aria+le load type, here support

load hanges as the pipe moves.

onstant load support, the load

remains onstant within some

range of movement.

onstant !oad $pring

5aria+le $pring

& i g i d

( a n g e r

& i g i d

$ u p p o r t

;ynami $upport,

$nu++er

&igid $upport

$ome $peial onsiderations for )iping


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$ome $peial onsiderations for )iping

When pipes are routed #N;"& '&#N; A%uried9 following points to +e kept in mind4

4inimum pipe sie to +e routed under ground shall +e not less than1 inh.

void flange *oint in #/' piping.

Eeep in mind if pipe leaks #/', it will +e diffiult to detet, so avoid #/' routing of pipe

arrying haardous fluid.

)ipe to +e laid +elow rost Fone at areas where am+ient temperature goes +elow freeing.

#/', %uried piping should +e properly proteted from orrosion.

)ipe may +e properly wrapped and oated to prevent orrosion.

r #/' piping +e proteted +y using athodi protetion.

reee )rotetion of outdoor )iping4

In the areas where the am+ient temperature goes +elow freeing there is a possi+ility that

the li:uid ontent of pipe may freee while the plant is under shut down.

or similar ase pipes are wrapped with heat traing elements to maintain the ontent

temperature a+ove freeing Aaround = deg. 9 even when the am+ient temp. is +elowfreeing.

"letri (eat traing is done +y wrapping eletri oil around pipe, whih turns on as the

am+ient temperature goes down. )ipes are insulated over the heat traing oils.

(eat traing an also +e done +y winding $team tu+es around main pipes.

SPOOL


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n assem(ly of fittings flanges an% pipe that may (e

pre-fa(ricate%.

"t %oes not inclu%e4

• 5olts

• as3ets

• !alves

• "nstruments

$pool si!e is limited by transportation

SPOOL


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Piping 'a(rication

http://pipe%20fabrication%2Cerection%26testing%28r%29.ppt/


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Drawing/Documents for Pipe

Work

PURPOSE


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T(" 4IN )#&)$" ;&WIN'

I$ T 44#NIT" IN&4TIN

IN $I4)!" N; "6)!IIT WC

PURPOSE

STAGES OF DRAWINGS


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STAGES OF DRAWINGS

Issued for information II

Issued for review I&

Issued for approval I

Issued for onstrution I

Issued for as +uilt I%

DRAWINGS/DOCUMENTS FOR PIPE WORK


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DRAWINGS/DOCUMENTS FOR PIPE WORK

verall )lot )lan

Eey )lan

$hemati diagrams

low diagrams

A)roess or servie9

Isometri drawings

!ine identifiation

)roess and Instrumentation

;iagrams A)I;9


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• "sometric s3etches 6"SOS78spool %raings

• Cutting Plan

• 'iel% routing %raings for small (ore piping

• eneral rrangement %raings

• *est Pac3s

• s (uilt %raings

• Process 'lo Diagram 6Optional7G.ontd


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• Pipe Supports Sche%ule

• Pro0ect Specifications for 'a(rication Wel%ing an%

+rection

• Pro0ect 9uality Plan 6P9P789uality "nspection Plans

69"Ps7

• #aterial Specifications

• Stress :elieving Stan%ar%s


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OVERALL PLOT PLAN

INFORMATION ON AN OVERALL PLOTPLAN


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PLAN

• 5attery limit of overall Plot of the Pro0ect

• Location of Pro0ect Site ith reference to any other

3non8esta(lishe% facilities

• Plant ;orth actual north in% %irection.

*his information help in erecting the plant

equipment

• eneral gra%e level ith reference to a 3non level

for e1ample mean sea level

INFORMATION ON AN OVERALLPLOT PLAN


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PLOT PLAN

• Layout of various units8sections of a pro0ectin%icating roa%s an% other facilities ithin the site

• "t also gives the layout of plant equipment ithin

various units8section of Plant

• "t also gives equipment list in various units of the

Pro0ect their elevation


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KEY PLAN

INFORMATION ON A KEY PLAN


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INFORMATION ON A KEY PLAN

"n a%%ition to the information given in PlotPlan


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$hows )ath of flow +y single lines

)roess e:uipment shown +y simple

figures Aretangle, irle. s:uare et.9

)roess notes inluded

;iagram is not to sale

+ut&elationships +etween e:uipment, piping, proess is shown

FLOW DIAGRAM


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#n saled drawing ;esri+ing the proess

Aflow sheet9

$tate materials to +e onveyed

$peify their flow rates and information

like temperature, pressure et.


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ISOMETRIC DRAWINGS

ISOMETRIC DRAWINGS


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5 The purpose of an isometri drawing is to show a

three-dimensional piture in one drawing

5 It resem+les a piture without the artisti details

5 The isometri drawing om+ines the floor plan

and the elevation

5 It learly shows the details and the relationship of

the pipes in a piping installation

5 The isometri drawing follows ertain rules or

onventions to show three dimensions on a flat

surfae

ORTHOGRAPHIC AND ISOMETRIC DRAWINGS


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INFORMATION ON AN ISOMETRIC DRAWING


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• "SO ;um(er & :evision

• Orientation 2 :eference to Pro0ect Site 2 6;orth7.

• Coor%inates of


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• #*Os

• Piping class an% line num(er

• *est pressure

• *est me%ia

• Line to (e heat trace% or not

• P&"D referenceG..ontd.

INFORMATION ON AN ISOMETRIC DRAWING


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• "nsulation requirement

• "n line instruments & valve num(ers si$e type

• Painting requirement

• Wel% positions 6spool (8% to mar3 'W&SW7

• Wel%ing specifications

• Operating & %esign temperature & pressure

ISOMETRIC DRAWINGS


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LINE IDENTIFICATION

INFORMATION ON A LINE IDENTIFICATIONDIAGRAM


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• Si$e

• Plant num(er8area

• 'lui% 2 piping service

• #aterial class

• Coating8"nsulation category

• Line sequence num(er

EXAMPLE OF AN ISOMETRICDRAWING NUMBER


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H= / %F / /=12 / 23-2)lant/rea

luid

Nominal )ipe $ie

I$Num+er

4aterial$peifiation

!ine Num+er

- $poolNum+er


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PROCESS AND

INSTRUMENT DIAGRAM(P&ID)

*ypes of Process Diagrams


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• Process diagrams can be broken down into two major categories:

=. process flo %iagrams 6P'Ds7 an%

>. process an% instrument %raings 6P&"Ds7sometimes called piping and instrumentation drawings.

)roess low ;iagrams A);s9


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• flo %iagram is a simple illustration to

%escri(e the primary flo path through a

unit.

• process flo %iagram provi%es a quic3

snapshot of the operating unit.

Process Flow Diagram (PFD)


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Interpretation of Process Flow Diagram


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• Previous Figure is a PFD that shows the basic relationshipsand flow paths found in a process unit. It is easier to

understand a simple flow diagram if it is broken down into

sections: feed, preheating, the process, and the final products.

his simple left!to!right approach identif"• where the process starts and where it will eventuall" end. he

feed section includes the feed tanks, mi#ers, piping, and

valves.

ontdG


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• In the second step, the process flow is graduall"

heated for processing. his section includes heate#changers and furnaces. In the third section, the

process is included."pical e#amples found in the

process section could include distillation

columns or reactors. he process area is a comple#

collection of e$uipment that works together to

produce products that will be sent to the final

section.

)roess nd Instrument ;rawings A)


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• % process and instrument drawing is more comple#. heP&ID includes a graphic representation of the e$uipment, piping, and instrumentation. 'odern process control can beclearl" inserted into the drawing to provide a processtechnician with a complete picture of electronic and

instrument s"stems. Process operators can look at their process and see how the engineering department hasautomated the unit. Pressure, temperature, flow, and levelcontrol loops are all included on the unit P&ID.

A 9

Process and Instrument Diagram (P&ID)


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Interpretation of P&IDs


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• In order to read a P&ID, one needs an understanding of thee$uipment, instrumentation, and technolog". he ne#t step inusing a P&ID is to memori(e "our plant)s process s"mbollist. his information can be found on the process legend.Process and instrument drawings have a variet" of elements,

including flow diagrams, e$uipment locations, elevation plans, electrical la"outs, loop diagrams, title blocks andlegen%s and foun%ation %raings. he entire P&ID

provides a three!dimensional look at the various operatingunits in a plant.

Process *egends


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INFORMATION ON P&ID


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• Process flo 2 %irection of flo

• Line num(ers *heir terminal points inclu%ing

equipment connections

• "%entification of 'iel% "nstruments

• "n line instruments8ven%or items

• Simple Depiction of Control Strategy

• Design8Operating parameters


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SYMBOLS


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or e0ample, when two steel plates are *oined together into a T shape,

welding may +e done on either side of the stem of the T.

The weld sym+ol distinguishes +etween the two sides of a *oint +y using

the arrow and the spaes a+ove and +elow the referene line.

The side of the *oint to whih the arrow points is known as the arrow side,

and its weld is made aording to the instrutions given +elow the referene line.

The other side of the *oint is known as the other side, and its weld is made

aording to the instrutions given a+ove the referene line.

The below=arrow and above=other rules apply regardless of the arrowJs

diretion.


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