BCWWA

34rd Annual Conference and Exhibition April 29 May 1, 2006

Process & Instrumentation Diagrams for Municipal Treatment Plants An Overview

Howard Dallimore, P.Eng. Dayton & Knight Ltd.

Presentation Summary
Process Process & & Instrumentation Instrumentation Diagrams Diagrams
Definition Definition Standards Standards Examples Examples The The Big Big Picture Picture Task Task Summary Summary Cost Cost Considerations Considerations

Treatment Treatment Plant Plant Development Development

P P& & ID ID Development Development Hazard Hazard & & Operability Operability Studies Studies Functional Functional Description Description Detailed Detailed Design Design Phase Phase Treatment Treatment Plant Plant Construction Construction Treatment Treatment Plant Plant Commissioning Commissioning and and Operation Operation

Process and Instrumentation Diagrams

Definition
A Process and Instrumentation Diagram (P&ID) is a detailed graphical representation of a process including the hardware and software (eg. piping, equipment and instrumentation) necessary to design, construct and operate the facility. In Other Words: P&IDs are the foundation on which the successful design, construction and operation of a treatment plant will depend.

Process and Instrumentation Diagrams

Standards
A standard set of symbols is used to prepare drawings of processes. The instrument symbols used in these drawings are generally based on ISA*35.1 Although ISA-35.1 is an excellent flexible document to define symbolism there is no universal standard for the development of P&IDs Every organization has to develop an unique standard. Dayton & Knight uses 2 legend sheets for this purpose: P1 - Standard tags and abbreviations P2 - Standard symbols
* The Instrumentation, Systems and Automation Society

P1

Process and Instrumentation Diagrams

P1

Process and Instrumentation Diagrams

P1

Process and Instrumentation Diagrams

P1

Process and Instrumentation Diagrams

P2

Process and Instrumentation Diagrams

P2

Process and Instrumentation Diagrams

P2

Process and Instrumentation Diagrams

Example of a Typical Dayton & Knight P&ID

Example of a Typical Dayton & Knight P&ID

Example of a Typical Dayton & Knight P&ID

Treatment Plant Development

The Big Picture

Pre-implementation Phase Implementation Phase

Pre-design

Detailed Design Tendering and Award Construction Commissioning Operation

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The Cloud of Unknowing

Operating Treatment Plant

Instruction to Proceed with Detailed Design

Treatment Plant Development

Task Summary
Pre-implementation Phase Implementation Phase

Objectives Finalized

Design Options

Design Parameters

Process Diagrams

P&IDs

Design Documents

Construction & Commissioning

Operation

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The Cloud of Unknowing

Operating Treatment Plant

Treatment Plant Development

Cost Considerations
Pre-implementation Phase Implementation Phase

Free Thinking Phase

Focused Thinking Phase

Costs Relatively Low

Costs Higher and Escalate as Project Progresses P&IDs Developed, Frozen & Approved at an Early Stage in order to Control Costs & Avoid Delays

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The Cloud of Unknowing Operating Treatment Plant

P&ID Development
Pilot Studies

Preliminary Design Parameters

Final Design Parameters

Freeze!

Process Diagrams

Preliminary P&IDs

HAZOPS

Final P&IDs

Design Documents

Key Steps

Functional Description

HAZOPS- Hazard and Operability Studies

Been Been in in use use and and developed developed over over approximately approximately four four decades decades Examines Examines deviations deviations from from design design intent intent Team Team approach approach
Designers Designers Other Other Consultant Consultant Engineers Engineers & & Technicians Technicians Owners Owners representatives representatives Engineers Engineers & & Technicians; Technicians; Operating Operating Personnel Personnel

Method Method
Questioning Questioning & & systematic systematic analysis analysis using using keywords keywords to to focus focus attention attention of of team team upon upon deviations, deviations, their their possible possible causes causes and and effects. effects.

Keywords Keywords Divided Divided into into two two subsets subsets
Primary Primary Keywords Keywords focus focus attention attention on on a a particular particular aspect aspect of of the the design design intent intent Secondary Secondary Keywords, Keywords, which which (when (when combined combined with with a a Primary Primary Keyword) Keyword) suggest suggest possible possible deviations deviations

HAZOPS (contd)
Examples Examples of of Primary Primary Keywords: Keywords:
Flow, Flow, Pressure, Pressure, Temperature, Temperature, Level Level

Examples Examples of of Secondary Secondary Keywords Keywords

No, No, Less, Less, More, More, Reverse, Reverse, Also Also

Method Method
P&IDs P&IDs are are divided divided into into subsystems subsystems and and each each is is examined examined using using primary primary and and secondary secondary keywords. keywords. The The process process is is guided guided by by a a facilitator facilitator who who frequently frequently uses uses software software to to record record the the proceedings proceedings and and produce produce a a final final report. report. The The input input of of all all participants participants is is encouraged. encouraged. Results Results are are recorded recorded in in a a columnar columnar format format similar similar to to the the following following example: example: Deviation Cause Consequence Action

The The final final report report will will recommend recommend changes changes to to be be made made to to the the P&IDs P&IDs to to eliminate eliminate hazards hazards and and improve improve operability. operability.

HAZOPS (contd)
Examples of Sustainability Provisions:
Results Results are are recorded recorded in in a a columnar columnar format format similar similar to to the the following following example: example:
Deviation Energy Use Rates of NON Renewable Resources Creation of nonbiodegradables Degradation of environement Quality of life Cause Consequence Action

HAZOPS (contd)
Following receipt of the HAZOPS Report, to the greatest extent possible, Finalize & Sign off the P&IDs.

This is a key step in bringing the project in on time and under budget.

The Functional Description

Purpose:
Allows Allows the the Process Process Designer Designer to to communicate communicate with with the the Control Control System System Designer Designer in in an an unambiguous unambiguous way. way.

Method:
The The process process is is broken broken into into discrete discrete systems, systems, each each of of which which is is described described in in a a systematic systematic manner. manner. Flexibility Flexibility is is not not permitted. permitted. Headings Headings such such as as the the following following are are used: used:
System Overview Subsystem A
Subsystem Abstract Equipment Abstract Technical Description Interfaces SCADA Interface Initialisation Alarms

Subsystem B
etc.

Functional Description Sample

Sump Sump and and Sump Sump Pump Pump
Subsystem Subsystem Abstract Abstract The The purpose purpose of of the the sump sump is is to to collect collect water water used used to to wash wash down down chemical chemical spills spills and and to to collect collect water water from from the the operation operation of of the the emergency emergency shower shower and and eyewash. eyewash. Equipment Equipment Abstract Abstract The The sump sump includes includes a a single single submersible submersible pump pump which which pumps pumps water water collected collected in in the the sump sump to to an an existing existing drain. drain. Two Two float float switches switches control control its its operation. operation. Technical Technical Description Description Local Local Station Station (LCS): (LCS): Pump Pump controlled controlled locally locally (ON/OFF) (ON/OFF) from from LCS LCS Pump Pump will will RUN RUN when when high high level level float float switch switch is is activated activated and and will will STOP STOP when when the the level level falls falls below below low low level level float float switch. switch. Interfaces Interfaces The The following following instruments instruments are are associated associated with with this this equipment equipment LS_and LS_and LS_ LS_ SCADA SCADA Interface Interface There There is is no no connection connection with with the the SCADA SCADA panel. panel.

Detailed Design Phase

The Design Process is based on the production of a comprehensive and accurate set of P&IDs. Late changes to the P&IDs can result in extensive rework.
Equipment Lists Pipeline & Valve Lists Site, Building & Mechanical Layouts Piping Drawings Electrical Drawings Specifications and Construction Contract Tender Documents

P&IDs

Single Line Diagrams

Control System Design and Programming SCADA System Design

Treatment Plant Construction

P&IDs are Essential for the Construction of: Pipework Electrical & Control Systems SCADA Systems

Treatment Plant Commissioning & Operation

P & IDs

Pre-commissioning Planning

Commissioning

Operation

Debugging