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Process Diagrams and P&IDs for Typical FGD Plant

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  • Process Diagrams and P&IDs

    for Typical FGD Plant

  • 0. Engineering Milestones

    1. General

    2. Process Diagrams2.1 Block Flow Diagrams2.2 Process Flow Diagram (PFD)

    3. P&IDs

    Overview

  • 0. System Engineering Milestones

  • The process industry describes its plants and their instrumentation by a P&ID (pronounce P.N.I.D.)

    (Piping and Instrumentation Diagram), sometimes called

    (Process and Instrumentation Diagram)German name: R&ID

    (Rohr and Instrument Diagrams)

    P&ID is one of the 3 major types of process diagrams.

    The process industry describes its plants and their instrumentation by a P&ID (pronounce P.N.I.D.)

    (Piping and Instrumentation Diagram), sometimes called

    (Process and Instrumentation Diagram)German name: R&ID

    (Rohr and Instrument Diagrams)

    P&ID is one of the 3 major types of process diagrams.

    1. General1. General

  • 2. Process Diagrams

    Block Flow Diagram(BFD)

    Process Flow Diagram(PFD)

    Piping and Instrumentation Diagram(P&ID)

    to convert the physical reality

    or design concept to

    something we can analyze: Three major types of process diagrams.

  • 2.1 Block Flow Diagrams

    Block flow diagrams show linear flow of materials in process

    Give a clear overview of a process

    Starting point for PFDs

    Useful in presentations

  • 2.1.1 Typical FGD Plant

    FIGURE 1: TYPICAL WET FLUE GAS DESULFURIZATION PLANT

  • 2.1.1 FGD Block Diagram

    Typical FGD Plant is composed of the following 5 sections:---- Flue Gas and GGHFlue Gas and GGHFlue Gas and GGHFlue Gas and GGH

    ---- Limestone Slurry PreparationLimestone Slurry PreparationLimestone Slurry PreparationLimestone Slurry Preparation---- SOSOSOSO2

    22

    2

    RemovalRemovalRemovalRemoval---- Gypsum DewateringGypsum DewateringGypsum DewateringGypsum Dewatering &

    - Utility section

  • Block Flow Diagram is Basic P&ID

    2.1.2 Block Flow Diagram - Example

  • 2.2 Process Flow Diagram (PFD)

    >PFD is a schematic illustration of the system and more complex than a BFD.

    > Standard symbols are used to identify units.

  • 2.2.1Process Flow Diagram - Example

  • - PFD's shows the relationships between the major components in the system.

    - PFD also tabulate process design values for the components in different operating modes, typical minimum, normal and maximum.

    - PFD's do not show minor components, piping systems, piping ratings and designations.

    2.2.2 PFD's

  • 3. P&IDs3. P&IDs

    3.1 General

    3.2 Identification

    3.3 Importance & Responsibilities

    3.5 Revisions and Standards

    3.5 Wet - FGD P&IDs

    3.1 General

    3.2 Identification

    3.3 Importance & Responsibilities

    3.5 Revisions and Standards

    3.5 Wet - FGD P&IDs

  • 3.1 General3.1 General

    P&ID, is a schematic illustration of functionalrelationship of piping, instrumentation and process equipments.

    P & IDs represent the last step in process design Requires completed process flow diagrams (PFDs)P&ID represents the basis for plant construction,

    and with system descriptions, means by which the plant is started up, operated and shut down.

  • 3.1.1 Piping, Instrumentation and Equipments

    Gate Valves;

  • 3.1.2 P&ID Example

  • The P&IDs will contain sufficient information to enable:

    } communication between Company, Contractor and Authorities

    } preparation of data sheets.

    } communication with the project departments to ensure a consistent design.

    3.1 P & ID Function:

  • 3.1.3 P&ID Design

    P&ID should include all: Mechanical equipment with names and

    numbers Valves and their identifications Process piping, sizes and identification Miscellaneous - vents, drains, special fittings,

    sampling lines, reducers and increasers Flow directions Interconnections Instrumentation

    Control inputs, outputs and interlocks

    Standard symbols & Identification names are used for identification.

  • 3.2 P&I Identification3.2 P&I Identification

    The P&ID defines a name (Tag") for each instrument, along with additional parameters.

    This Tag identifies a "point" not only on the DCS screens and controllers, but also for the objects in the field.

  • 3.2.1 Instrumentation identification

    V1528FIC

    S

    tag name of the corresponding

    variable

    function (here: valve)

    mover(here: solenoid)

    The first letter defines the measured or initiating variables such as Analysis (A), Flow (F), Temperature (T), etc. with succeeding letters defining readout, passive, or output functions such as Indicator (I), Record (R), Transmit (T), and so forth

    P&ID mixes pneumatic / hydraulic elements, electrical elements and instruments on the same diagram

  • 3.2.2 P&I Identification3.2.2 P&I Identification

    ISA S5.1 - Instrumentation symbols and identification standard defines how each symbol is constructed using:

    - graphical elements, - alpha and numeric identification codes,- abbreviations, - function blocks, and - connecting lines.

    (ISAThe Instrumentation, Systems, and Automation Society)

    P&ID uses symbols and names defined in ISA standard!

  • 3.2.3 Instrument graphical symbols

    Primary location accessible to

    operatorField mounted

    Auxiliary location accessible to

    operator

    Discrete instruments

    Shared display, shared control

    Computer function

    Programmable logic control

    1. Symbol size may vary according to the user's needs and the type of document.2. Abbreviations of the user's choice may be used when necessary to specify location.3. Inaccessible (behind the panel) devices may be depicted using the same symbol but with a dashed horizontal bar.

  • 3.2.4 ISA S5.1- Instrument Identification3.2.4 ISA S5.1- Instrument Identification

    ISA standard defines:> Graphical elements:

    - discrete instruments, - shared control/display, - computer function, and - programmable logic controller

    and

    > location categories:- primary location (control room), - auxiliary location (local control panel), and - field mounted.

  • 3.2.5 ISA S5.1- Instrument Identification3.2.5 ISA S5.1- Instrument Identification

    Single horizontal bar across graphical elements indicates the function resides in the primary

    (control room) location.

    Double line indicates auxiliary (local control) location,

    No line: Device or function in the field

    Devices located in some other inaccessible location (e.g.switchgear) are shown with a dashed horizontal line.

  • 3.2.6 ISA S5.1- Instrument Identification3.2.6 ISA S5.1- Instrument IdentificationLetter combinations appear inside graphical element are defined by the ISA standard:

    First letter: - measured or - initiating variables (Analysis (A), Flow (F), Temperature (T), )

    Succeeding letters define:- readout, - passive, or output functions (Indicator (I), Record (R), Transmitter (T) )

  • Identification lettersFirst letter Succeeding letters

    Measured or initiating variable Modifier Readout or passive function Output function Modifier

    A Analysis Alarm

    B Burner, combustion User's choice User's choice User's choice

    C User's choice Control

    D User's choice Differential

    E Voltage Sensor (primary element)F Flow rate Ration (fraction)G User's choice Glass, viewing device

    H Hand High

    I Current (electrical) IndicationJ Power Scan

    K Time, time schedule Time rate of change Control station

    L Level Light Low

    M User's choice Momentary Middle, intermediate

    N User's choice User's choice User's choice User's choice

    O User's choice Orifice, restriction

    P Pressure, vacuum Point (test connection)Q Quantity Integrate, totalizerR Radiation Record

    S Speed, frequency Safety Switch

    T Temperature Transmit

    U Multivariable Multifunction Multifunction Multifunction

    V Vibration, mechanical analysis Valve, damper, louver

    W Weight, force Well

    X Unclassified X axis Unclassified Unclassified Unclassified

    Y Event, state, or presence Y axis Relay, compute, convert

    Z Position, dimension Z axis Driver, actuator

  • 3.2.8 Instrument Identification - Examples3.2.8 Instrument Identification - Examples

    Transmitters/sensing elements: FT flow transmitter LE level element

    Indicators: FI flow indicator AI analytical indicator LI level indicator PAH pressure alarm high

    Controllers: TIC temp indicating controller

    Controlled devices: FCV flow control valve PV pressure valve

  • 3.2.9 Instrument Identification - Examples3.2.9 Instrument Identification - Examples

    Pressure &Temperature:

  • 3.2.10 P&ID Valve Symbols

  • F.O Failed open F.C Failed close F.P - Failed in place

  • 3.2.11 Common connecting linesConnection to process, or instrument supplyPneumatic signal

    Electric signalCapillary tubing (filled system)Hydraulic signalElectromagnetic or sonic signal Internal system link (software or data link)Source: ISA S5.1 standard

  • 3.2.12 Example of P&ID

    FT101 is a field-mounted flow transmitter connected via electrical signals (dotted line) to flow indicating controller FIC 101 located in a shared control/display device

    Square root extraction of the input signal is part of FIC 101s functionality.

    The output of FIC 101 is an electrical signal to TY 101located in an inaccessible or behind-the-panel-board location.

    The output signal from TY 101 is a pneumatic signal (line with double forward slash marks) making TY 101 an I/P (current to pneumatic transducer)

    TT 101 and TIC 101 are similar to FT 101 and FIC 101but are measuring,

    indicating, and controlling temperature

    TIC 101s output is connected via an internal software or data link (line with bubbles) to the setpoint (SP) of FIC 101 to form a cascade control strategy

  • 3.2.13 Referring to the (DCS) Example P&ID

    FT-101 is field-mounted flow transmitter connected (via electrical signals - dotted line) to FIC-101 - flow indicating controller located in a shared control/display device.A square root extraction of the input signal is applied as part of FIC-101's functionality.

    FIC-101 output of is an electrical signal to TY-101 located in an inaccessible location.

    TY-101 output signal is a pneumatic signal (line with double forward slash marks) making TY-101 an I/P (current to pneumatic transducer).TIC 101's output is connected via a data link (line with bubbles) to the setpoint (SP) of FIC 101 to form a cascade control strategy.

  • 3.2.14 Referring to the (PLC) Example P&ID

    Typical YIC indicates an on/off valve.

    YIC is controlled by a solenoid valve and is fitted with limit switches to indicate open (ZSH) and closed (ZSL) positions.

    All inputs and outputs are wired to a PLC that's accessible to the operator (diamond in a square with a solid horizontal line).

    'Y - letter indicates an event, state, or presence. 'I' - letter depicts indication is provided, and 'C - letter means control takes place in this device.

  • 3.3 Importance of P&IDs

    The P&ID is the last stage of process design and serves as a guide by those who will be responsible for the final design and construction. Based on the P&ID:

    Mechanical and civil engineers will design and install equipments.

    Instrument engineers will specify, install, and check control systems

    Piping engineers will develop plant layout and elevation drawings.

    Project engineers will develop plant and construction schedules.

  • 3.4 Responsibilities Process Dept.:

  • 3.4.1 Responsibilities Instrument Dept.:

  • 3.4.2 Responsibilities Electrical /Mechanic Dept.:

  • 3.4.3 Responsibilities Safety / Piping Dept.:

  • P&ID revisions

    P&IDs revisions shall be performed at the same time for all drawings, and in such a manner that a given revision number reflects the same status for all P&IDs issued.

    Standards

    Design of P&ID shall comply to engineering standards &rules and company internal regulations.

    4. Revision & Standards:

  • 5. Wet FGD P&IDs:

    - Flue Gas- Booster Fan- Gas-Gas Heater (GGH)- Limestone- Limestone silo & fluid. air fans- Absorber & Limestone Slurry

  • 5.1 Wet FGD P&IDs cont.:

    - Absorber & Gypsum Slurry- Oxidation Air Fans- Process Water & Filtrate Tank- Emergency Storage Sump- Hydrocyclone Station- Belt Filter - Gypsum Storage

  • 01 Flow sheet02 Symbols and legends03 Flue gas path 04 Booster fan 05 GGH 06 Limestone slurry preparation 07 Fluidizing air system08 /09 Absorber system: Limestone slurry pipe

    & Gypsum slurry pipe10 Oxidation air fans 11 Process water system12 Emergency storage system13 Gypsum slurry dewatering (Hydrocyclone Station)14 Belt filter 16 Gypsum storage

    5.2 Typical P&I Diagrams List

  • FYI