Educational Institute for Equipment and Process Design

Gas Station
Description and PFD-P&ID Development
 Educational Institute for Equipment and Process Design

The purpose of gas station: to remove particles, do flow measurement, and pressure regulation.
Gas station components Filters: simply to remove solid particles in gas
stream.

Flowmeter: since we receive the NG from a

nearby company then we have to pay them.
Hence, the payment is based on cumulative flow
of NG in a period of time. As a result, we need a
flowmeter to measure all flowrates properly.

PCV: we need pressure control valves to control

and regulate the pressure of NG based on
downstream process demands.

So, the first edition of PFD becomes like this:

Now let’s detail it:

1.Flowmeters Since the flow here is of significant importance,

then, it is normal practice in gas station to have
two flowmeters.

On the surface one might think that the they

should be configurated in series. But in gas
stations it is typical to have Z-configuration.

Due to Z-configuration, we should have two runs-

two lines- in a way that, in normal operation, the
gas flows through one line and when we need to
prove the measurement of the flowmeter we use
Z-configuration and direct the gas in other line
and make the gas pass through the second
flowmeter which has not been used. In this way
 Educational Institute for Equipment and Process Design

by second flowmeter we prove that the

measurement of the normal flowmeter is correct
or not.

Based on Day-2 instruction, the best flowmeter

for gas station is ultrasonic flowmeter.

2.Filters Since we need two runs, then we need one filter

for each run.

3.PCV So far it is clear to us that we need to

If we incorporate all above parameters into our PFD, then it would become like this.
 Educational Institute for Equipment and Process Design

P&ID design for gas station

In creation of P&ID, we should take piping, instrumentation and mechanical design aspects into
consideration.

1.Detailed process condition Based on the video for line sizing, we know that
the line size should be 14” but as you can
remember from the video, it was stated that 12”
could be used especially for 3–8-meter length. It
is ok if the pressure drop is a little higher than
that of 14” but since the length of the line is 3-8
meter, that is not a big deal. More importantly,
the lower the size of connecting to equipment,
the lower the size of the equipment itself and as
a result, the lower the cost.

Design condition: since the operating

temperature is 40C, then the design
temperature should be 85C. Maximum
operating pressure is 62 barg. So based on the
design pressure table, due to the fact that the
operating pressure is more than 10 barg, then the
design pressure would be maximum operating
pressure multiplied by 1.1. As a result, the
design pressure becomes like below:

Pd = 62 × 1.1 = 68.2 = 69 barg

2.Piping details Each line in P&ID should have the following

Information:
Educational Institute for Equipment and Process Design

For our case:

1. The line is 14”
2. The fluid is NG
3. We are in first unit which is 100
4. We have high operating pressure and
temperature, so the class 600 or F is
selected.
Educational Institute for Equipment and Process Design

5. Material Selection:
5.1. For services like NG, BFW, CW,
LPS/C, MPS/C, Service Water, Nitrogen,
Plant Air, Methanol we use CS

5.2. For services like DMW, Instrument Air,

Chemicals, Oxygen, Water containing CO2
or H2 we use SS.

So based on the above rule, we use CS.

Since we are supposed to show the
material based on a designation it becomes
24.
6. We don’t need any insulation since we are
in atmospheric condition.

So it becomes like this:

14-NG-100-S1-F24

Two (2) 12” streams originate from the header.

One of them is the “duty” stream, One of them is
the “Stand-by” or “master line”.

Duty Streams
Gas flows through the inlet manual ball valve
(BV-1911). A 2’’ bypass line containing two
isolating ball valves and a globe valve allows
pressurization of the station and/or pressure
equalization across the valve.

Draining
A 2” pipe originating from the dry gas filter is used
to drain any liquid trapped in. A ball valve and
globe valve, connected on the line, are used to
manually control the draining of the stream.
Furthermore a orifice plate (RO-1911) is used for
break pressure drain line.

Gas flows downstream the dry gas filter through

a -10xD of length- straight pipe section, in order
to ensure that the gas enters the ultrasonic flow
meter with a laminar flow.
 Educational Institute for Equipment and Process Design

“Z” Configuration
The duty stream has a 12” branch line
downstream the ultrasonic flowmeter, used for
diverting the flow to master meter stream for
proving purposes. A 12” ball valve (BV-1941) is
used for isolating the branch connection.

N2 Purging
A 3/4” N2 purging connection with a ball and check
valves, are used to injection N2 to purge stream
before maintenance and hot working.

The gas enters the outlet 14” stream through the

12” stream. Three (3) 12” streams originate from
the header. One of them is the “duty” stream, One
of them is the “Stand-by” stream. One of them is
the “Commissioning and maintenance” stream.
You will see that in real P&ID.

3.Instrumentation Symbols

Flowmeter Actuators Valves

Educational Institute for Equipment and Process Design

Functions Alarms
 Educational Institute for Equipment and Process Design

3.Instrumentation-continued Let’s list where we need instrument devices

1. Site operators need to check the

pressure and temperature regularly.

2. We need to monitor filters regularly like

their pressure and pressure drop since the
pressure drop later would be the criteria for
site operators to replace filters with new
ones.

3. We have talked about flowmeter but in

flowmeter it is a common practice to
consider compensation for most
flowmeters specially gas and steam
flowmeters. Check the appendix to learn
about compensation. But for now,
regardless of the type of calculation
performed for compensation, we need
the temperature and pressure of the line
so that the compensation is done.

4. Regarding the flowmeter, we need also

to specify the way data to PLC should
be transferred. As a result, we have to
use instrument functions shown above.

5. A simple note:
The most common way to transfer data

Fieldbus Foundation for the whole plant

Hart for important devices used in ESD

We have different types of packages:

ESD for emergency shut-down system

FCS/DCS for controlling system
PLC for packages like gas station

6. We need to show the open or close

status of control valves and USV-unit
shutdown valves. Check Appendix.

7. Finally site operators and control

operators need to monitor remotely and
locally the pressure and temperature of
 Educational Institute for Equipment and Process Design

the line connecting gas station to

process unit.

After implementing all these changes, then it becomes like this:

 Educational Institute for Equipment and Process Design

Appendix A: Flow compensation

Where stated, pressure, temperature and mole weight compensation of flow is applied after
square root extraction of flow signal with the following algorithm:

Gas and vapor flow measurements based on vortex meters are compensated by one of the
following algorithms

Let’s see how it works:

 Educational Institute for Equipment and Process Design

Appendix B: Valve States

Terminology
CSC: CAR SEALED CLOSED
CSO: CAR SEALED OPENED
FO: FAILURE OPEN
FC: FAILURE CLOSE
FL: FAILURE LOCKED
FLO: FAILURE LOCKED OPEN
FLC: FAILURE LOCKED CLOSED
LO: LOCKED OPEN
LC: LOCKED CLOSE
NO: NORMALLY OPEN
NC: NORMALLY CLOSED

Example 1: FC

Application Valve Status

Valve downstream of a separator FC

Valve inlet to the distillation column FC

Valve controlling the reflux flow FC

and level of the reflux drum

Example 2: FO

Application Valve Status

Valve controlling protection FO

steam added to oxygen line
Note:
1.To get better understanding of example 2, check day 2 example for oxygen line PFD
2. These are typical status, based on process demand it might change.
Educational Institute for Equipment and Process Design

P&ID Development
For Gas Cool Train
 Educational Institute for Equipment and Process Design

Here is a part of PFD that we developed during PFD development:

For today let’s create and develop the P&ID:

1.Air coolers Since they are driven by motor, then we show the
assembly like below in P&ID.

We have headers to distribute the gas to different

air coolers. So in P&ID, we just use

After the air coolers we have condensate, which

means that we need to have the piping with some
slope to direct the mixture to the next equipment.

We need also a temperature transmitter to

monitor its outlet temperature, which is obvious.

2.Water-cooled heat exchanger Each shell and tube heat exchanger needs a vent
and a drain.

CWS-Cooling Water Supply- comes from lower

nozzle and gets heated and exits from upper
nozzle. That’s a rule.
 Educational Institute for Equipment and Process Design

In contrast, the hot Syngas gets cooled, and as a

result, becomes more densed, and exits from
lower part.

Based on detailed design of heat exchanger, we

need TEMA H type for its shell, which means
that we need to divide the Syngas to two lines
connected to the heat exchanger. Since we
have to maintain the mass balance, then we
will have:

Q1 = Q2 + Q3

V1A1 = V2A2 + V3A3

A1 = A2 + A3

D12 = D22 + D32

322 = 2D2, D = 24’’

Finally, as stated before since here we have

condensation process, then we need to slope
the pipe.

We use butterfly valve for manual control of

cooling water.

Near each butterfly valve we need to add a

drain valve

Regardless of the project, we always use a

PSV for hydraulic expansion scenario

3.Separators For separators we have to illustrate the

followings:
1. Inlet type: Half open pipe
2. Mist eliminator if required
3. Vortex breaker
4. Gas outlet line
5. Liquid outlet line
6. Manhole
7. Level gauge
8. Level transmitter
9. Control system
10. Structure
11. Drain
 Educational Institute for Equipment and Process Design

4.Pumps For separators we have to illustrate the

followings:
1. Isolation valve which is gate valve
2. Strainer-Filter
3. Drain between isolation valve and strainer
4. Pump icon and its driver
5. The driver of the mixer is a motor. We need
to have some info about its running status or
any fault in the motor which prevents it from
running. So we have to consider some
instrumentation blocks to show them.
Remember whenever the driver is motor, we
have to do the same, regardless of being the
driver of a pump or mixer
6. Pump drain and vent
7. Pressure gauge at the suction and discharge
8. Check valve
9. Isolation valve which is again gate valve
10. Pressure transmitter
11. Drain valve between isolation valve and
check valve.
12. Control system

5.Control Valve Since we have a separator, we need a control

valve to control the level.

Each control valve has two inlet and outlet

isolation valves which are gate valves.

Between the first isolation valve and control

valve, we need drain valves.

We have to also specify the instrumentation.

Bypass valve size is selected based on following

table, which is developed based on experience.
Notice that it is like this that you size the valve
based on some formula or the way we size a
control valve.
 Educational Institute for Equipment and Process Design

Now, if we incorporate all above parameters into our PFD, then it would become like this:

Notice that here line information is excluded here to help your mind focus on what new is!
 Educational Institute for Equipment and Process Design

Appendix: Interlocks

General information about the trip systems

A number of instruments in the plant are equipped with passive alarms to warn the operators in
the control room against deviating operating conditions, which may lead to dangerous situations
or which may cause damage to the equipment or the catalysts.
Critical parameters such as essential flows, pressures and temperatures are provided with
active alarms connected to the safety interlock trip system. Some of the above passive alarms
are acting as pre-alarms for the active alarms.
These active alarms will initiate automatic safety actions to safely shut down certain process
sections in order to protect the personnel and the equipment of the plant against hazards.
When a trip group has been activated, operators must act to maintain safe operating conditions
in the plant.

Furthermore, there are a number of interlock systems, which activate a shut-down of pumps,
start-up equipment and other equipment if process parameters deviate too much.

Due to a considerable higher cost of IS than DCS hardware, consideration has been given to
define which actions (groups) are to be performed in the IS system and which actions are to be
performed in the DCS. Action performed in the IS are called IS-group (Interlock Safety) and
actions performed in the DCS are called I-group (Interlock). In order to establish guidelines for
the distinction of those actions, the following rules are applied:

Trips in IS groups are generally based on 2-out-of-3 voting.

IS-groups must protect:

• personnel against safety hazards
• critical plant equipment
• unit trips which will result in a significant production loss when initiated

I-groups must protect:

• auto start and stop of motors
• avoidance of PSV relief
• switching of operating mode
 Educational Institute for Equipment and Process Design

P&ID Development for Distillation Column

 Educational Institute for Equipment and Process Design

Here is the PFD we developed in last sessions:

Now let’s work on it and develop a P&ID for it.

1.Feed inlet to the tower The feed to the tower should be measured
and regulated, which is obvious. It means
we need an orifice flowmeter and a globe
control valve to serve the purposes.

Each control valve has two inlet and outlet

isolation valves which are gate valves.

Between the first isolation valve and control

valve, we need drain valves.

We have to also specify the instrumentation.

Bypass valve size is selected based on Appendix

table, which is developed based on experience.
Notice that it is like this that you size the valve
based on some formula or the way we size a
control valve.

2.Distillation Column The following should be shown on P&ID:

1. Trays and their number
2. Instrumentation including LT and LG at bottom,
PT, TT and AP at different stages and control loop
3. Connections namely, feed connection, nitrogen
 Educational Institute for Equipment and Process Design

connection for purging, three connections of

reboilers [ vapor, mixture to reboilers, heavy
component to the bottom].
4. Overhead line and its PSVs [ set pressure +
orifice designation + inlet size + outlet size ]
5. Bottom line

3.Reboilers The following should be shown on P&ID:

1. Vapor line connecting top of the reboilers to the
to towers.
2. Heavy component line connecting lower part
of reboilers to the bottom of the towers.
3. The mixture entrance line from the towers to
the reboilers.
4. The inlet and outlet line of hot medium
5. The line connecting reboilers to each other.
6. LG and LT

4.Condensor As explained in PFD development, the condensers

are generally shell and tube heat exchangers or
air coolers. Since we have talked about air
coolers in the past, just sentences are copy
pasted.

Since they are driven by motor, then we show

assembly like below in P&ID.

We have headers to distribute the gas to different

air coolers. So in P&ID, we just use the circle.

After the air coolers we have condensate, which

means that we need to have the piping with some
slope to direct the mixture to the next equipment.

We need also a temperature transmitter to

monitor its outlet temperature, which is obvious.
 Educational Institute for Equipment and Process Design

5. Drums and separators Again we have talked about that in previous sessions,
so they are copy pasted here.

For separators we have to illustrate the followings:

1. Inlet type
2. Mist eliminator if required
3. Vortex breaker
4. Gas outlet line
5. Liquid outlet line
6. Manhole
7. Level gauge
8. Level transmitter
9. Control system
10. Structure
11. Drain

6.Reflux pump The same happens here.

For pumps we have to illustrate the

followings:
1. Isolation valve which is gate valve
2. Strainer-Filter
3. Drain between isolation valve and strainer
4. Pump icon and its driver
5. Pump drain and vent
6. Pressure gauge at the suction and discharge
7. Check valve
8. Isolation valve which is again gate valve
9. Pressure transmitter
10. Drain valve between isolation valve and
check valve.
11. Control system

After considering the above details, The P&ID is developed and looks like next page. For better
resolution, zooming is recommended. Also you can look at One Note File, which provides a
perfect resolution.
Educational Institute for Equipment and Process Design
 Educational Institute for Equipment and Process Design

Appendix

For a general project.

 Educational Institute for Equipment and Process Design

For this project

1 11/2 2 3 4 6 8 10 12 14 16 18 20 24
2 2 2 2
11/2- 2 2
1
3 3 3 3
2 3 3
4 4 4 4
3 4-3 4
6 6 6 6
4 6-4 6
8 8 8
8-6 8
10 10
10-8
12 12 12
10 12
14 14 14 14
12 10 12
16 16 16
12 16
18 18 18
10 16
20 24
18
24 24
20
Educational Institute for Equipment and Process Design

P&ID Development
Storage Tanks
 Educational Institute for Equipment and Process Design

Here is the PFD-1 we developed for chemical storage tanks:

Now let’s develop P&ID for this PFD:

1.Chemical tanks It is clear that we should demonstrate 3 tanks
itself on the P&ID.

Each tank needs a LT and LG so that the

operator in site can observe the level.
Furthermore, we need level transmitter to
activate an interlock when the level reaches
a low point.

We also need a mixer to do mixing between

the concentrated chemical and DMW to have
a chemical with lower concentration so that
the chocking of pumps is avoided.

The driver of the mixer is a motor. We need

to have some info about its running status or
any fault in the motor which prevents it from
running. So we have to consider some
instrumentation blocks to show them.
Remember whenever the driver is motor, we
have to do the same, regardless of being the
driver of a pump or mixer.

To each chemical tank a DMW valve is

 Educational Institute for Equipment and Process Design

connected.

2.Pumps As stated before, reciprocating type is

used.

Like other designs, we need to have two

pumps, one in service, another one in
standby.

We need to have isolation valve at the

suction and discharge of the pumps.

We also need to consider a strainer before

the suction of the pumps.

We have to consider a PSV at discharge of

the reciprocating pumps. It is a must.

Calibration test: It is used just for

reciprocating pump to check their flowrate
and how the chemicals are injected.

The motor is the driver of the pumps. So

we have to take into account the
instrumentation blocks to check its
running and fault status.

After taking into account all of the parameters, then the developed P&ID becomes like this:
Educational Institute for Equipment and Process Design
 Educational Institute for Equipment and Process Design

Here is the guideline for P&ID development for product storage tanks:

Product Storage tank The references are API-650, API-2000, API-

2003.

Two manholes, one above and one on the

wall for inspection.

Instrumentation:
1. We need a radar level transmitter to
measure the level.
2. We need a TT to check the temperature.
3. We need pressure transmitter to check
the pressure regularly. The most
important parameter in storage tanks
since the pressure inside is atmospheric,
there is always the possibility of vacuum
or over-pressurization. To avoid all of
this we introduce nitrogen PCV which
can regulate the pressure. But what if it
does not function well? Then we need to
add PVRV into our design. If the
pressure goes down then it takes air in
from the atmosphere but if pressure
goes up it relieves some vapor to the
atmosphere. In some designs we also
have ERM or emergency relief manhole
if the pressure reaches a very high value.

If the tank is designed with a fixed roof, then

we use Inlet dip pipe with open-ended top.
But if the tank is designed with a floating
roof, then there is no need to connect it from
above. Simply the line is connected to the
tank in “zero” height.
 Educational Institute for Equipment and Process Design

For the floating roof tanks, it is like this that

at first we have an expansion rubbery pipe
which absorbs all movement, so that no
turbulence occurs in tank. Then we would
have a check valve and a gate valve. In fixed
roof design we don’t need to have the check
valve, which is obvious but for floating type,
we need to have it to prevent the backflow of
product to the inlet line.

So, the P&ID becomes like this:

 Educational Institute for Equipment and Process Design

Here is the guideline for P&ID development for water storage tanks:

DMW storage tank We use a fixed roof type.

Since it is fixed roof type, then we use Inlet

dip pipe with open-ended top.

For water storage tank, it is customary to

use a vent which breathe in and out the
atmospheric air.

Instrumentation:
1. A pressure transmitter for
measurement of the pressure is used.
2. A level transmitter should be used.
Remember for last example we used
radar level transmitter since it was
product which is valuable but for this
since it is water and the density is fixed
we can use a simple level transmitter
which works based on the height of the
water.

Also, we have to consider the drain in our

design.