PFD and P& ID Preparation in Visio

Process Flow Diagram (PFD) and Piping and Instrumentation diagram (P& ID) can be prepared with the help of this software easily. The available tools for creating the diagram is customized and made available as icons under the topics Equipments – General, Heat Exchangers, Pumps, Vessels, Instruments, Pipelines, valves & Fittings. Once can also use the search box to find out the needed equipment. Other simple customizations can be done like any other MS – Office software like Changing the color, Font size and Inserting symbols which is helpful in creating colorful PFD/ P& ID’s for presentation purpose. It is possible to save the diagrams as VISIO files or simple images. The other use is we can simply copy the equipments from VISIO and paste it as image wherever we need.

Other Applications of VISIO

Organization charts for the department or for an Industry can also be effectively created with the help of VISIO. Gantt Charts can be created by using MS – VISIO to schedule project tasks and communicate them visually to team members. Program Evaluation and Review Technique (PERT) chart can be prepared which is a useful tool for Project managers. Brainstorming diagrams available in MS-VISIO Swill help to conduct a brainstorming session in effectively capturing and organizing the ideas.

It also helps to prepare Plant layout and site layout. Cause and effect diagrams which is also known as fishbone or Ishikawa diagrams can be made using VISIO. This will Show factors and causal relationships in a given situation. Fault tree analysis diagrams show and analyzes faults in processes. Basic electrical diagrams, Circuits and logic diagrams, Industrial control systems diagrams will be helpful for creation of circuit diagrams and other Interlock diagrams. These will be very useful for Electrical engineers and Instruments Engineers also.

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The task of writing chemical plant manual categorized into two. One is for new plants and the other is for plants that already running. For old plants there are already established systems and procedures and for the modifications or revamps additional information has to be added, which is a simple task. But writing the operating manual for new chemical plant is a challenging task though already similar plants are running around the world. Let us will see how to write operation manual for new plants here.

Data Collection and Brainstorming

This is the preliminary task of a process engineer who is involved in preparation of Chemical Plant operation manual. PFD, P& ID, Control System, Process description from Technology provider, Equipment supplier manuals, HAZOP study recommendations, Details of legal/ regulatory requirements, Design Material & Heat balance of Process streams are to be collected before proceeding further. Then a brainstorming session is to be arranged with the colleagues/ superiors to discuss the various activities associated with the task and set Specific Measurable Attainable Relevant Time bound goal to bring up the better manual.

Contents of Chemical Plant Operating Manual

The content of a chemical plant operation manual is simplified into the following topics and the details may be added into appropriate section based on the specific requirements of the plant.
Abbreviations
Design Basis
Overview of the Process
Process Description
Procedures
Safety, Health & Environment Section
Utility and Other Systems
Appendix

Abbreviations

Abbreviations used in the manual are to be consolidated and added in this section for better understanding for beginners.

Design Basis

Design basis of the plant including Plant Capacity, Technology used, Site Climatic Data, Raw Materials, Utility & Product Specifications forms this section in the chemical plant operation manual.

Overview of the Process

Overview of the Manufacturing process with the major equipments or sections involved in sequential manner to be described to get the overall understanding of the chemical plant. Process Flow Diagram (PFD) helps in preparing this section.

Process Description

The detailed process description with Equipments and Control valves associated including tag no’s used with the design parameters and compositions at various streams in a sequential manner forms this section. Process control philosophy for various parameters in the plant like pressure, flow, level & temperature and description of various controllers and control loops available for the process control. Various Trips and Interlocks and reasons for having it along with Emergency Shutdown (ESD) system available in that section is elaborated. Piping & Instrumentation Diagram (P& ID) and Process description from Technology provider will be useful in bringing effective process description of units in the chemical plant.

Procedures

Standard operating Procedures for individual equipment and sections in plant for Normal Operation, Start up and Shutdown and then for total plant are to be established and produced in this section. Procedure for safe isolation of equipment for maintenance jobs shall also be included. This section shall also include Trouble shooting guide for various upsets. Routine schedule with incorporation of lubrication schedule, trial run of equipment, availability check of systems etc. Equipment supplier Manuals, HAZOP study recommendations will help the process engineer for preparing this important section of Chemical Plant Operating manual.

Safety, Health & Environment Section

Safety section provides overview of installed Safety Systems, Fire Fighting Facility and available safety procedures in the chemical plant. It also provides details on Zone classification, Emergency Actions, Hazards. Applicable Work permit systems related to plant like Hot Work, Confined Space Entry and procedure for issuing and authorizing the permits are to be listed for the entrants to understand the systems. Types of Personal Protective Equipment (PPE) available, issue and usage details are to be provided in this section and proper sign boards are also to be made available in plant premises.

Toxicological information of chemicals used in the manufacturing process is to be provided in the chemical plant operation manual. Chemical handling & storage and their first air measures also need to be listed for better understanding of chemical hazards.

Environment section of the Chemical Plant operation manual must contain industry specific disposal limits for various effluents generated in the plant and details on applicable laws & governing bodies.

Utility and Other Systems

Description of various other associated facilities in Chemical Plant like Water Treatment facility, Cooling Towers, Cooling Water system, Deaerators, Boiler & Steam System, Compressed Air System, Inert Gas generation & distribution systems, Effluent treatment facilities, Flare system, Electrical Power Distribution and ESD system is to be prepared and written under this section.

Appendix in Chemical Plant Operation Manual

This section contains the supporting information for better understanding of the Chemical plant operating manual. Normally it contains PFD, P& ID, Alarm & Trip set points, MSDS of Chemicals Handled, Equipment Data sheets & Curves, Further Reading – Vendor Document List etc.

Process engineer can add additional resources in this section based on specific need. One can also create his own structure based on the needs and prepare a better chemical plant operation manual.

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