Table of Contents

1 Equipment design ........................................................................................................................... 2

1.1 Purpose of equipment design ................................................................................................. 2
1.2 Design process ........................................................................................................................ 2
1.3 Step by step procedure of design of equipment .................................................................... 3
2 Flange ratings .................................................................................................................................. 4
3 Piping and instrumentation diagram .............................................................................................. 5
3.1 Symbols of chemical apparatus and equipment ..................................................................... 5
3.2 Purpose ................................................................................................................................... 6
3.3 P&ID support documents ........................................................................................................ 7
3.3.1 Process flow drawings (PFDs) ......................................................................................... 7
3.3.2 Piping material specifications (PMS) ............................................................................... 7
3.3.3 Equipment and instrumentation specifications (EIS)...................................................... 7
3.3.4 Functional Requirement Specification (FRS) ................................................................... 7
3.4 Piping and Instrumentation Diagram Documentation Criteria ............................................... 7
3.5 How to create a P&ID? ............................................................................................................ 8
3.6 Applications............................................................................................................................. 8
3.7 Limitations of P&ID ................................................................................................................. 9
4 Equipment Support ....................................................................................................................... 10
4.1 Vertical pressure vessel ........................................................................................................ 10
4.1.1 Skirt support .................................................................................................................. 10
4.1.2 Leg support ................................................................................................................... 10
4.1.3 Lug support ................................................................................................................... 11
4.1.4 Brackets Support ........................................................................................................... 11
4.2 Horizontal pressure vessel .................................................................................................... 12
4.2.1 Saddle support .............................................................................................................. 12
4.2.2 Leg support ................................................................................................................... 13
5 Order base equipment and Project base equipment ................................................................... 14
5.1 Flow chart of process of order base equipment and project base equipment .................... 14
5.2 Difference between order base equipment and project base equipment ........................... 14
1 Equipment design
Equipment design can define as the use of scientific principles, technical information
and imagination in the description of equipment to perform specific functions with maximum
economy and efficiency.

1.1 Purpose of equipment design

1) To select proper materials and best suited shapes,
2) To calculate the dimensions based on the loads on machines and strength of the
material,
3) Specify the manufacturing process for the manufacture of the designed component
of the machine or the whole machine.

1.2 Design process

Study alternate
Define specifications mechanism and
Market surway
of product select optimum from
them

Prepare general
Prepare assemebly Design individual
layout of
and detail drawing component
configuration

Modification based
Testing
on testing results

Fig. 1.1 Steps of machine design

The basic procedure of machine design consists of a step by step approach from given
specifications about the functional requirement of a product to the complete description in the
form of drawing of final product. A logical sequence of steps, usually common to all design
projects, is illustrated in fig. 1.1.
1.3 Step by step procedure of design of equipment

Select suitable
Specify function of Determine force
material for
equipment acting on equipment
equipment

Modify dimensions Determine geometric

Determine failure
for assembly and dimensions of
mode of equipment
manufacturing equipment

Prepare working
Modification based drawing of elements
Testing
on testing results

Fig. 1.2 Step by step procedure of design of equipment

Design of machine element is the most important step in the entire process of machine
design. In order to ensure the basic requirements of machine elements, calculations are carried
out to find out the dimensions of the machine elements. The basic procedure of design of
machine elements is illustrated in fig. 1.2.
2 Flange ratings
The concept of flange ratings likes clearly. A Class 300 flange can handle more
pressure than a Class 150 flange, because a Class 300 flange are constructed with more metal
and can withstand more pressure. However, there are a number of factors that can impact the
pressure capability of a flange.
The Pressure Class or Rating for flanges will be given in pounds. Different names are
used to indicate a Pressure Class.
For example: 150 Lb or 150 Lbs or 150# or Class 150, all are means the same.
Example of Pressure Rating
Flanges can withstand different pressures at different temperatures. As temperature
increases, the pressure rating of the flange decreases. For example, a Class 150 flange is rated
to approximately 270 PSIG at ambient conditions, 180 PSIG at approximately 400°F, 150
PSIG at approximately 600°F, and 75 PSIG at approximately 800°F.
In other words, when the pressure goes down, the temperature goes up and vice versa.
Additional factors are that flanges can be constructed from different materials, such as
stainless steel, cast and ductile iron, carbon steel etc. Each material has different pressure
ratings, which we can get from ASME standard B16.

Fig. 2.1 Different flange ratings

3 Piping and instrumentation diagram

A piping and instrumentation diagram (P&ID) illustrates the piping processes and
interactions with other installed equipment and instrumentation. It indicates the more general
flow of plant processes and equipment.
Piping and instrumentation diagram plays a crucial role in the design and engineering
of process plants and piping systems, by showing the interaction of process used to control the
process. P&ID is a schematic illustration of functional relationship of piping, instrumentation
and system equipment components. They are typically created by engineers who are designing
a manufacturing process for a physical plant.

Piping and instrumentation diagram contains following things:

 Key piping and instrument details

 Control and shutdown schemes
 Safety and regulatory requirements
 Basic start up and operational information

3.1 Symbols of chemical apparatus and equipment

Thermall
Cooled
y Jacketed
Pipe or heated
insulated pipe
pipe
pipe
Jacketed
Pressuriz Pressuriz
mixing Half pipe
ed ed
vessel mixing
horizonta vertical
(autoclav vessel
l vessel vessel
e)
Vacuum
pump or Gas
Pump Bag
compress bottle
or

Axial
Radial
Fan fan, MK, Dryer
fan
,
 Packed Tray Cooling
Furnace
column column tower

Plate &
Heat Heat frame
exchang exchange Cooler heat
er r exchange
r
Fixed
U shaped
Double straight Spiral
tubes
pipe heat tubes heat
heat
exchang heat exchange
exchange
er exchange r
r
r

Covered Curved (Air)

Funnel
gas vent gas vent filter

Pressure
Steam Viewing Flexible
reducing
trap glass pipe
valve

Back
Control Manual
Valve draft
valve valve
damper

Back
Butterfly Diaphrag Ball
draft
valve m valve valve
damper

3.2 Purpose

These facilities usually require complex chemical or mechanical steps that are mapped
out with P&IDs to construct a plant and also to maintain plant safety. If something does go
wrong, reviewing the P&ID is usually a good place to start. P&IDs are invaluable documents
to keep on hand, whether they’re used to streamline an existing process, replace a piece of
equipment, or guide the design and implementation of a new facility. With the help of P & ID
changes can be planned safely and effectively using Management of Change (MOC).
 P&IDs are used by field techs, engineers, and operators to better understand the process
and how the instrumentation is interconnected. They can also be useful in training workers and
contractors.

3.3 P&ID support documents

3.3.1 Process flow drawings (PFDs)

P&IDs originate from PFDs. A PFD is a picture of the separate steps of a
process in sequential order. Elements that may be included are: sequence of actions,
materials or services entering or leaving the process (inputs and outputs), decisions that
must be made, people who become involved, time involved at each step and/or process
measurements.

3.3.2 Piping material specifications (PMS)

Here’s where you find details about materials of construction, gaskets, bolts,
fitting.

3.3.3 Equipment and instrumentation specifications (EIS)

Standards and details too extensive to fit into the P&ID are included in the EIS
including Scope, Standards, Codes and Specifications, Definitions and Terminology,
Materials of Construction, Design Basis, Mechanical/Fabrication, Guarantees, Testing
and Inspection, Documentation and Shipping.

3.3.4 Functional Requirement Specification (FRS)

How the plant or system operates is detailed in the FRS. It includes the
Functional Description, Communication, and Scope Definition of the process.

3.4 Piping and Instrumentation Diagram Documentation Criteria

While there are no exact standards for the way P&IDs should be drawn, there have been
standards suggested by the Process Industry Practice (PIP), a consortium of process industry
owners and engineering construction contractors who serve the industry.
Piping and Instrumentation Diagram Documentation Criteria details about what a P&ID
should contain:

 Mechanical equipment with names and numbers

 All valves and their identifications
 Process piping, sizes and identification
 Miscellaneous - vents, drains, special fittings, sampling lines, reducers, increasers
 Permanent start-up and flush lines
 Flow directions
  Interconnections reference
 Control inputs and outputs, interlock
 Seismic category
 Interfaces for class changes
 Quality level
 Annunciation inputs
 Computer control system input
 Vendor and contractor interfaces
 Identification of components and subsystems delivered by others
 Intended physical sequence of the equipment
 Equipment rating or capacity

We should also know that What should a P&ID not include?

 Instrument root valves

 Control relays
 Manual switches
 Primary instrument tubing and valves
 Pressure temperature and flow data
 Elbow, tees and similar standard fitting
 Extensive explanatory notes

3.5 How to create a P&ID?

If you use software to create your P&IDs, there are some basic steps to follow:
1. Create and check an equipment list. Use the symbols within the library after you’re sure
of your list.
2. Connect pipes and equipment, then review the details with a trusted colleague. Walk
through the process several times and search for inefficiencies.
3. Share with collaborators.

3.6 Applications
 Evaluate construction processes
 Serve as a basis for control programming
 Develop guidelines and standards for facility operation
 Produce documents that explain how the process works
 Provide a common language for discussing plant operations
 Create and implement philosophies for safety and control
 Design a conceptual layout of a chemical or manufacturing plant
 Form recommendations for cost estimates, equipment design, and pipe design
 3.7 Limitations of P&ID
 They can’t be relied on as real models, because they aren’t necessarily drawn to scale or
geometrically accurate.
 There’s also no generally accepted universal standard for them, so they may look different from
company to company—or even within the same company.
4 Equipment Support
The selection of the type of support for a pressure vessel depends on various parameters
like the vessel elevation from the ground, materials of construction, wall thickness, operating
temperature, external loads (such as wind loads, seismic condition etc.).

4.1 Vertical pressure vessel

Supports for The vertical pressure vessels units are supported generally by
1) skirt supports,
2) leg supports and
3) lug supports.
4) brackets support.

4.1.1 Skirt support

Tall vertical cylindrical pressure vessels are typically supported by skirts. A support skirt
is a cylindrical shell section that is welded either to the lower portion of the vessel shell or to
the bottom head. The skirt id normally long enough to provide enough flexibility so that radial
thermal expansion of the shell does not cause high thermal stress at its junction with the skirt.

Fig. 4.1 Skirt support

4.1.2 Leg support

Small vertical drums are typically supported on legs that are welded to the lower portion
of the shell. The max. ratio of support leg length to drum diameter is 2:1. The number of legs
depends on the drum size and loads to be carried.
 Fig. 4.2 Leg support

4.1.3 Lug support

Vertical pressure vessel may also be supported by lugs. The use of lugs is typically
limited to pressure vessels of small and medium diameter (1 to 10 ft.). Also moderate height
to diameter ratios in the range of 2:1 to 5:1. The lugs are bolted to horizontal structural
members in order to provide stability against overturning loads.

Fig. 4.3 Lug support

4.1.4 Brackets Support

Small vertical drums are typically supported on legs that are welded to the lower portion
of the shell. The maximum ratio of support leg length to drum diameter is typically 2:1.
Support legs are also typically used for spherical pressurized storage vessels. The support
legs for small vertical drums and spherical pressurized storage vessels may be made from
structural steel columns or pipe sections, whichever provides a more efficient design.
Cross bracing between the legs is typically used to help absorb wind or earthquake loads.
 Fig. 4.4 Side brackets

4.2 Horizontal pressure vessel

Whereas, the horizontal pressure vessels are supported by
1). saddle supports,
2). leg supports and,

4.2.1 Saddle support

Horizontal drums are typically supported at two locations by saddle support. It
spreads over large area of the shell to prevent an excessive local stress in the shell at support.
One saddle is anchored whereas the other is free to permit unstrained longitudinal thermal
expansion of the drum.

Fig. 4.5 Saddle support

4.2.2 Leg support
The connection in this type of support creates a severe local stress and is only suitable
for small equipment. It suitable for vessel length less than or equal to 5m.

Fig. 4.6 Leg support

5 Order base equipment and Project base equipment
5.1 Flow chart of process of order base equipment and project base
equipment

Order from customer

Manufacturing
to marketing Design department
department
department

Quality control and Assembly

Packing
quality assurance department

Supply to customer

5.2 Difference between order base equipment and project base equipment

Sr. no. Order base equipment Project base equipment

1 Each order has to make less design
modifications in order base equipment.
2 Order comes in regular interval.
3 Organization is aware about the type of
problem customers are facing.
4 In case of order base equipment,
delivery time is less.
Each order has to make rigorous design
changes in project base equipment.
Frequency of order is less.
It is new design for company, so that they also
not aware about customer’s problem.
Higher delivery time in case of project base
equipment.