Mihir’s handbook of Chemical Process Engineering

Excerpt From
Chapter 29:
PROCESS DESIGN
DOCUMENTATION
29.5 TITLE OF DOCUMENT: Equipment List

PURPOSE OF DOCUMENT: Equipment list communicates to rest

of engineering team, all of the equipment and package units
involved in the engineering.

Equipment list is used by other departments for following purpose:

• Based on the equipment list, Planning Department prepares

the detailed schedule / planning using Primavera and it is
further used to monitor the progress.
• Procurement
Department generates procurement status and monitors the p
rogress of procurement on the basis of equipment list.
• Piping, mechanical, civil and electrical engineers also refer to
the equipment list to understand discipline-wise responsibility
of each item and monitor progress of same.

INPUTS REQUIRED (as applicable):

 Mihir’s handbook of Chemical Process Engineering

1. Simulation report
2. Block flow diagram
3. Process Flow Diagrams
4. Basis of Design (BOD)

CONTENTS OF DOCUMENT: It includes all major mechanical

items in the plant. It is prepared unit-wise for each plant which
means all equipment in a particular unit are listed together.
However, it excludes electrical, instrumentation and construction
equipment and all special parts (SPI).

A unique number is given to each and every mechanical item in a

process plant to enable its identification.

Equipment list is one of the most effective tools extensively used

and referred to during basic as well as detailed engineering phase
of the project. It is used for generating field erection data sheets for
process equipment.

Equipment list is made and controlled by process engineer and

used by other engineering disciplines also.

Block flow diagrams & Process flow diagrams form an input for
generating equipment list.

In case of package units, all equipment included within the

package unit are numbered and included in equipment list with an
indication of requirement of E-Motor for each item to enable a fairly
correct estimation of size of MCC with respect to number of feeders.

Following are the specific contents of an Equipment List.

Please refer to Vol III Chapter 42 for template of an equipment

list.

• Equipment Code : Equipment number is indicated here

 Mihir’s handbook of Chemical Process Engineering

• Description: Equipment title or name is indicated here

• P&ID reference number where equipment is shown
• Quantity: Numbers of equipment are indicated. (Column “a” is
for number of operating equipment and Column “b” is for
number of standby equipment.)
• Medium: Fluid handled by equipment is indicated
• Technical Details: Technical data for each equipment is given
under this column

For example; Pumps:

Type: Centrifugal

F: Flow in m³/h

H: Differential Pressure in mlc

Heat Exchangers:

Type: Shell & Tube

Q: Heat Duty in kcal/h

A: Area in m², Length, and OD

For package units, duty parameters are given. For example; for
boilers, capacity in TPH and pressure in kg/cm²g is given.
Technical details of equipment within package unit are furnished
only after order placement.

• Design Pressure
• Design Temperature
• Drive: Requirement of E-Motor, steam turbine, gas turbine or
Electrical Heater
• Material of Construction: Broad material of construction for
major parts of equipment is specified, for example;
• Pumps & Blowers – MOC for Casing & Impeller
 Mihir’s handbook of Chemical Process Engineering

• Heat Exchangers – MOC for shell side, MOC for tube side
• Test Pressure and Medium: For hydro test or pneumatic test
• Source of Supply: Whether the equipment is indigenous (I),
foreign (F) or part of package unit (P) is indicated here.
• Group Responsibility: Different equipment is handled by
different disciplines and are responsible for
procurement/inquiry. In order to identify the responsible
department, following codes are entered:

e.g. Process, Mechanical, Piping, Civil, Electrical, Client

Any additional information which needs to be known is specified

under “Remarks” e.g. if an existing equipment is to be used, the
same is highlighted. Similarly, if an equipment requires emergency
power backup, this is indicated in the remarks column.

29.6 TITLE OF DOCUMENT: BLOCK FLOW DIAGRAM (BFD)

PURPOSE OF DOCUMENT: BFD is prepared in initial stage of

process engineering. The purpose of block diagram in basic
engineering package is to show at one place the material balance in
kg/h or m³/h of all process streams entering and leaving each unit
in the overall process. This communicates the overall scope of
project to the rest of team.

INPUTS REQUIRED:

For the preparation of block flow diagram, the following documents

are required:

• Understanding of process
• Preliminary overall General Arrangement (GA) drawing

Each unit is shown as one rectangular block and all incoming and
outgoing process streams as lines with arrows. The units are also
shown as per the location as per overall GA drawing.
 Mihir’s handbook of Chemical Process Engineering

By the above representation of unit as a block, the total process

plant can be covered under one block diagram. In one block
diagram, all plants in a complex can also be represented.

Similarly, an overall utility block diagram can also be generated, if

required, as per contract; by showing individual utility
consumption for each unit.

While selecting a capacity for utility package, block diagrams are

generally prepared along with concept notes.

Refer to sample BFD attached below for an incinerator project.

29.7 TITLE OF DOCUMENT: PROCESS FLOW DIAGRAMS (PFD)

and UTILITY FLOW DIAGRAM (UFD)

PURPOSE OF DOCUMENT: In a chemical process plant, raw

materials go through a series of unit operations before getting
converted into the finished product. Unit operations could be feed
preparation, reaction, separation, distillation, filtration,
crystallization, centrifugation, drying, etc.

To understand these operations easily a Process Flow Diagram

(PFD) is prepared which shows the flow of chemicals/reactants
through various equipment. Thus a Process Flow Diagram (PFD)
shows all the important pieces of equipment with flow lines and
control systems in a schematic way, along with its process
description, which helps to understand the process very well.

CONTENTS OF DOCUMENTS:

A) Process flow diagram is a fundamental process drawing which

depicts major process related equipment, machines, and process
lines in a simple manner.
 Mihir’s handbook of Chemical Process Engineering

Inputs for generating process flow diagram are as follows:

– Design basis

– Simulation Report

– Thermo-physical property data

i) The contents of process flow sheets are mainly as follows:

– All equipment and machines as per simulation report

– Package units as blocks

– Equipment number (matching later with equipment list)

– Main connecting process lines between the equipment are shown.

However, less important lines like minimum flow lines are not
shown.

– Main control loops with control valves and impulse lines of the
instruments are shown.

– Number for major open loops are shown.

– Operating pressure of the line is shown

– Operating temperature of the line is shown

– Operating pressure of the equipment is shown inside the

equipment.

– Process stream numbers are marked

– Incoming lines enter from the left and leave on the right side.
 Mihir’s handbook of Chemical Process Engineering

– If a process stream is appearing on another sheet also then on

the subsequent sheet the stream number as on the previous
stream is given to identify the stream easily

ii) The minimum information of the process streams is as given

below:

– Stream No.

– Composition

– Operating pressure & temperature

– Density

– Volumetric / mass flow rates

– Viscosity

– Utilities like steam, cooling water, pressurized air, etc. are shown
by a line with the short code for medium

– The heat balance is given in units as per Design Basis units of

measurement.

– The utility consumption is given on each consumer as volume or

mass stream.

– Additional temperature and pressure data is given as required.

– Pressures is given in gauge pressure

– Flow sheets are organized to show correct relative elevations of

equipment and also in relation to other flow sheets.

iii) The PFD and the material balance is the basis for the
following engineering activities:
 Mihir’s handbook of Chemical Process Engineering

– Preparation of P&I Diagrams and to size lines.

– Preparation of list of consumption figures

– Preparation of list of emissions required by statutory bodies

– Preparation of utility summary and concept notes for utility

package units

– Sizing of static and rotating equipment

– Unit equipment plot plans

– Hazid / Envid safety study

iv) Separate process flow diagrams are generated to take care

of:

– Start of run conditions (SOR)

– End of run condition (EOR)

– Runaway condition

v) Also from the same process, different grades of products can

be manufactured, for example, for HDPE plant:

– Extrusion grade HDPE

– Blow moulding grade HDPE

Separate PFD thus is generated for each such grade.

vi) Material balance shown in PFD is corresponding to the

contractual design capacity of the plant.
 Mihir’s handbook of Chemical Process Engineering

vii) It is also a practice to give the heat & material balance

portion in a separate A4 size sheet for large unit PFDs.

B) UTILITY FLOW DIAGRAMS:

Utility flow diagrams are prepared for each utility showing each
consumer as a rectangular block. These are generated mainly for
all process plant consumers.

Pages 28 to 29

29.12 TITLE OF DOCUMENT: PROCESS SAFEGUARDING FLOW

DIAGRAMS (PSFD)

PURPOSE OF DOCUMENT: Process Safeguarding Flow Diagrams

(PSFD) provide an overview of the process safeguards applied to a
process plant. They show the location of pressure relieving devices
based on design pressures of the system. They, therefore, serve as
a starting point for the development of P&IDs.

INPUTS REQUIRED:

(i) BFD

(ii) PFD

CONTENTS OF DOCUMENT:

The following should be shown on the PSFDs:

i) Safeguarding elements:

– Ultimate safeguards (these are trip interlocks e.g. High-high, low-

low):
 Mihir’s handbook of Chemical Process Engineering

– Relief valves will be shown along with relief destination e.g. HP or

LP flare.

– Safety Instrumented Systems (SIS), if used as an ultimate

safeguard.

– Capacity determining components:

• Control valves and by-passes will be shown along with action

on air failure (i.e. spring action fail open/close or stay put).
• Notes should be shown as necessary to state which if any of
downstream relief systems are affected by the capacity (i.e.
CV) of the control valve and restriction orifices where
applicable.

ii) Mitigating systems:

– All mitigating systems such as ESD valves, ROVs installed for an

emergency (e.g. in pump suction lines), check valves etc.

– Emergency depressuring valves along with relief destination.

– Relevant interfaces with upstream and downstream units

Details of penultimate safeguards (i.e. alarms of high and low) do

not need to be shown on PSFDs.

Process Safeguarding Flow Diagrams (PSFD) should be prepared

only for new process units and repeat modified units where the
changes affect the safety integrity of the system.

PSFDs are based on the initial issue of the relevant PFD. The
PSFDs are intended to assist and guide the development of the
P&IDs with regard to identifying safety protective devices including
emergency shutdown valves, relief valves and depressuring
facilities.
 Mihir’s handbook of Chemical Process Engineering

PSFDs should be issued before the issue of P&IDs to ensure that

the required information is transposed on to the P&IDs.

Refer sample PSFD shown below.

Fig 29.4: PSFD of a LPG bullet storage facility

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--- END OF SAMPLE ---

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 Mihir’s handbook of Chemical Process Engineering

Index (Full Version)

Chapter
Vol No. Title No. of Pages
I – Preface, Foreword and Overall Table of 6
Contents
I 1 Introduction 5
I 2 General 138
I 3 Pumps 181
I 4 Compressors 149
I 5 Fans and Blowers 59
I 6 Heat Exchangers 93
I 7 Pressure vessels, Tanks and Bullets 58
I 8 Fractionators and Absorbers 396
I 9 Separators 92
I 10 Fired Heaters 142
I 11 Incinerators 68
I 12 Agitated Vessels 86
I 13 Safety Relief Systems 255
I 14 Line Sizing, Hydraulics 76
I 15 Vacuum systems 90
I 16 Utilities 469
I 17 Dryers 48
I 18 Motors 16
I 19 Evaporators 62
I 20 Pneumatic Conveying 78
I 21 Crystallisers 32
I 22 Steam and Gas Turbines 84
I 23 Leaching and Extraction 77
I 24 Special Process Items 191
I 25 Additional Process Calculations 50
 Mihir’s handbook of Chemical Process Engineering

II 26 Project Types 13
II 27 Engineering Disciplines and Sequence of 60
Engineering
II 28 Overall Engineering Documentation for all 13
Disciplines in a Project
II 29 Process Design Documentation 256
II 30 TBE Guidelines 44
II 31 Safety Studies 15
II 32 Automation and Control 138
II 33 Material of Construction 90
II 34 Cost, Time & Resource Estimation 10
II 35 Inspection and Testing 11
II 36 Precommissioning, Commissioning and 58
Guarantee Run
II 37 Specialised Studies 55
II 38 Heat Exchanger Optimization 156
II 39 Philosophies 28

III 40 Calculation Templates (40

numbers)
III 41 Checklists (25
numbers)
III 42 Datasheets (93
numbers)
III 43 Technical Bid Evaluation Formats (11
numbers)
III 44 Go-By Reference P&IDs (41
numbers)
 Mihir’s handbook of Chemical Process Engineering

Handbook Details
1 No. of Chapters 44
2 No. of Pages 4000
3 Figures 2265
4 Tables 440
5 Calculation Templates 40
6 Datasheets 93
7 TBE Blank Formats 11
8 Checklists 25

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