Petrochemical Plants Primary Documents for Engineering Contractor

Petrochemical Plants Primary Documents for Engineering Contractor

The initial version of the following primary documents may be issued, as necessary, by EPC Company to the ENGINEERING CONTRACTOR for overall scope definition and the EC’s overall understanding of the project. The content of these primary documents is described briefly here. Some of these documents may be completed by EPC Company as the project progresses. Alternatively, the EC’s scope of work may include completion of the primary documents. The ENGINEERING CONTRACTOR shall refer to the contract scope to confirm who is responsible for completion.

2  Facility Arrangement Drawing (Plot Plan)

The facility arrangement drawing provides a plan view of the overall plot and the equipment layout for a plant. The initial issue of the drawing will be provided by EPC Company and will be updated when detailed design is completed. It will show major equipment, structures, roads, North arrow, N and E coordinates, plan scale, a list of all equipment items with their tag numbers, a tie-in list, and other information as appropriate for the contract scope. The arrangement can change throughout execution because of government regulations, supplier information, availability of and location of utilities, customer changes, etc.

3      Unit Operations Key Plan

1. This drawing shows the arrangement and boundaries of individual unit operations in the plant.
2. It will also show the EC’s scope of work limits when the scope of work is less than the entire plant.

4   Piping and Instrumentation Diagram (P&ID)

1. The piping and instrumentation diagram (P&ID) is the key document that defines the plant process. This schematic-type document is the basis of all piping and instrument engineering and design required to control and operate the plant. The P&ID shows all piping, valves, equipment, instruments, in-line piping items, line sizes, line numbers, flow directions, insulation, heat tracing, piping classification specifications, scope breaks, supplier-furnished equipment interface points, and line designators for system design conditions. Key letters that refer to pressure and temperature tables on the P&ID are used. In addition, it lists the tag numbers for all valves, controls, instruments, equipment; valve normally open or closed positions; valve locked open or closed positions; PSV and PCV setpoints; critical safety circuits; and other appropriate information.
2. Any relevant EPC Company standards or specifications applicable to the project-specific P&ID will be listed in the contract scope appendix.
3. Changes to the P&ID to incorporate operability, reliability, safety, supplier data, and related information are made routinely during development of the project scope. Specific changes to individual sheets of the P&ID, without an overall revision, are controlled and approved as a P&ID change note (P&ID CN). These change notes will be issued to the ENGINEERING CONTRACTOR for detailed design.
4. The P&ID will identify the scope breaks between the work of the ENGINEERING CONTRACTOR and others. The P&ID may show piping, instruments, and equipment that are not part of the scope of detailed design by the EC. These items are either totally contained within Air Products-supplied systems or within parts of the plant for which detailed design is by EPC Company or by others, including vendor packages.
5. The ENGINEERING CONTRACTOR is responsible for maintaining a master copy of the P&ID that incorporates all P&ID CNs. The ENGINEERING CONTRACTOR must obtain Air Products’ approval of any changes they wish to make to the P&ID. The ENGINEERING CONTRACTOR shall use a P&ID change control procedure that is based on the EPC Company P&ID CN procedure. Essentially the same documentation shall be used whether the change is initialed by EPC Company or the EC. EPC Company will provide an example of this procedure.

5  Manual Valve List

The manual valve list provides information about all manual valves depicted on the P&ID.

Manual valves that will be furnished as part of a packaged system are indicated accordingly on the manual valve list. The manual valve list will include the process line number (for example, 40 mm-N-2104-WSC020_E) and P&ID sheet number on which the manual valve is located (for example, sheet 220) and the location of the manual valve on the P&ID sheet (for example, 1B). This list will be updated by EPC Company with dimensional and weight information for manual valves that are specified by Air Products. Valve tag numbers will be given on the P&ID. Any additional tag numbers needed will be given in the contract scope.

6  Instrument and Control Valves Summary

1. The instrument and control valves summary lists all of the instruments and control valves depicted on the P&ID. The instruments and control valves that will be furnished as part of a packaged system are indicated accordingly on the instrument and control valves summary. Instrument and control valve tag numbers will be given on the P&ID. Any additional tag numbers needed will be given in the contract scope.
2. The instrument and control valves summary will include the location of each instrument and control valve on the P&ID. EPC Company will update the instrument and control valves summary to include the instrument and control valve specification number for the specifications that are prepared by Air Products. Instrument and control valve specifications will be provided to the ENGINEERING CONTRACTOR when completed.
3. EPC Company will provide dimensional and weight information for instruments and control valves that are specified by EPC Company after the instruments and control valves are specified and ordered.
4. The instrument summary and control valve summary for a given plant may be separate documents if agreed upon by EPC Company and the EC.

7  High Voltage and Low Voltage Electrical Single Line Diagrams

1. The electrical single line diagrams show the incoming feeds, the substation, and the power distribution systems. These drawings show the fundamental requirements of the main power arrangement and the boundaries of responsibility.
2. Completed electrical single line diagrams will identify the switching, interconnection, inter- tripping, interlocking, protection, alarms, and metering requirements in accordance with the “final” supplied/”as-built” equipment.
3. Electrical single line diagrams may initially be prepared by EPC Company and then updated and finalized by the EC.

8  Utilities Summaries

2.8.1   These summaries list the various utilities needed to supply a given plant. The preliminary lists are developed by Company. The ENGINEERING CONTRACTOR will expand and refine the lists in accordance with the detailed design information about the plant utilities as it becomes available.

2.8.2   Electrical Load List

• • This list includes all of the high voltage (typically 380 volts and above) electrical loads and their quantities that will be fed from the plant main power supply.

2.8.3   Cooling Water Load List

• • This list includes all of the plant’s equipment that requires cooling water. In addition, the quantity of cooling water needed by each user and the total cooling water flow needed to feed the cooling water system are provided.

2.8.4   Instrument Air/Nitrogen Load List (when required by the job contract)

• • This list includes all of the plant’s instrument air/nitrogen users. It also provides the quantities of instrument air and nitrogen that will be fed from the plant main instrument air/nitrogen header to the plant.

2.8.5   Potable Water Load List

• • This list includes all of the plant’s potable water users. It also provides the quantities of potable water that will be fed from the plant main potable water supply line to the plant.

2.8.6   Other Load Lists

• • Other utility load lists may be needed depending upon the requirements and design of a given plant.

9  Piping Line List

1. The piping line list provides a listing of all lines in the plant that are within the EC’s scope of responsibility.
2. The piping line list is in numerical order by line number itself. It ignores identifying information that may precede or follow the line number. For example, P&ID line 2-N-2003- BB/WSC020 would be listed as line 2003.
3. The piping line list contains the following information on each line at a minimum.
   • Pipeline data – includes line size, fluid contained, material of construction, and identification information.
   • Normal operating conditions – pressure and temperature.
   • Design conditions – min/max pressures and temperatures.
   • Test conditions – pressure and media to use.
   • Insulation and heat tracing requirements.

10  Stress Analysis Line List

1. The stress analysis line list is a listing of all lines in the plant that require stress analysis.
2. The stress analysis line list is arranged by line number as noted above for the piping line list.
3. The stress analysis line list contains the following information about each line at a minimum.
   • Line identification information.
   • Pressure and temperature data – includes upset conditions.
   • Piping data – includes size, wall thickness, and material.
   • Stress analysis requirements – includes critical, safety sensitive, fatigue, high wind, and any special considerations.
4. The stress analysis line list may be combined with the piping line list for some projects. EPC Company will determine if a combined list is to be used on a project-specific basis.

11    Oxidizer Piping Record (when relevant)

1. The oxidizer piping record lists all lines in the plant that contain an oxidizer fluid.
2. The intent of the oxidizer piping record is to ensure that the correct piping materials and components are used for all process lines containing fluids that are oxidizers.
3. The record will be arranged by line number. Information such as the following will appear in the record.
   • Line function                                         •    Design operating flow rate
   • P&ID sheet number                               •    Operating pressure
   • Line size                                               •    Operating temperature
   • Fluid composition
4. The oxidizer piping record will be started and partially completed by Air Products. The EC must complete the record as their engineering and design work progress.