Guide For Instrumenting The P&I / Flow Diagram: Tata Consulting Engineers

TATA CONSULTING ENGINEERS SECTION: TITLE
TCE. M6-IC-580-001 SHEET 1 OF 1
GUIDE FOR INSTRUMENTING

THE P&I / FLOW DIAGRAM
TATA CONSULTING ENGINEERS

414, Veer Savarkar Marg
Prabhadevi
MUMBAI 400 025
FLOPPY NO : TCE-971-IC-FP-004
FILE NAME : M6580001.DOC
REV.NO R0 R1 R2 ISSUE
INITIALS SIGN INITIALS SIGN INITIALS SIGN INITIALS SIGN
PPD.BY MKG sd/- As per Memo SVB

MKG TCE-921-IC(W)-
CEC-97/31
CKD.BY VK sd/- VK Dated 1997.05.05 ISR R2
APP.BY KGS/KG sd/- RKC

KGS/KG
DATE 1994-03-29 2000-03-22
FORM NO. 020R2

TATA CONSULTING ENGINEERS SECTION: WRITE UP
GUIDE FOR INSTRUMENTING THE
P&ID/FLOW DIAGRAM
1.0 SCOPE
Purpose of this guide is to prepare P&I/Flow diagram for a process or

a system. This will not be applicable where P&I diagram is provided
by the client or his collaborator as a part of process design package.
2.0 REFERENCE DOCUMENTS
(i) Legends and symbols for P&I diagram.
(ii) Similar P&I diagram exhibited for previous projects.
(iii) Drawings for typical instrumentation to be provided for

different type of equipments.
(iv) Standard flow diagrams.
(v) Vendor flow diagram.
(vi) Performance Guarantee Test scheme given by Vendor.
3.0 Refer Annexure-VII enclosed with this guide for instrumenting the
P&I / Flow diagram.
4.0 Instrument the P&I /Flow diagram considering the instruments

required for each type of equipment as per the reference documents of
S1 . No. (ii) to (v) and Annexure-1 enclosed with this guide.
Functional usage of all instruments viz. control. display/recording,
annunciation etc. are to be indicated.
5.0 Follow the legends and symbols as per ‘PCS’ for marking the
instruments on P&I /Flow diagram.
6.0 Indicate the performance guarantee (P.G) test points (pressure,

temperature, flow etc. ) for all equipment/ systems as per the P.G test
code adopted. Collect the relevant P.G test scheme from project
group.
7.0 Indelicate root valve (s) for all pressure, differential pressure, level,
flow measuring instruments, sampling system instruments (steam and
water analysers) and pressure test points including P.G test points.
8.0 Indicate no. and size of roof valve(s) for all instruments and pressure
test points in 6.0 above, with respect to service conditions as per
Annexure-II enclosed with this guide.
9.0 For all 25 NB size root valves for pressure and differential pressure
and flow measuring instruments and pressure test points indicate 25
NB/15 NB size reducer after root valve(s). ISSUE
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FORM NO. 120 R1

P&ID/FLOW DIAGRAM
10.0 Indicate reducer for P.G test pressure points as applicable.
11.0 Tag all the instruments as per “ Tagging procedure for I&C system”
12.0 Indicate scope of supply for all tap point stubs, root valve(s), reduce
and instruments in P&I/ Flow diagram as per reference document at
Sl. No. (ii). (v) & (vi). Generally the scope of supply shall be as
under:
12.1 Tapping point stubs for all types of measurements & test points-
respective piping/equipment vendor.
12.2 Root valve(s)
a) Tapping point on process pipe.
--Valve vendor (or pipe vendor where pipe & valve is by;
same vendor) check with piping group.
b) Tapping point on flow element assembly
--Flow element vendor
c) Tapping point from stand pipe
--Standpipe vendor
d) Tapping point on equipment/vessel
--Equipment/vessel vendor.
12.3 Reducer
a) For test points
--Same as root valve vendor
b) For measurement
--Instrument vendor.
12.4 Instruments – as per Annexure -III enclosed with this guide.
13.0 Indicate maximum parameter (pressure, temperature, flow etc.) values

at different stages of process in P&I diagram.
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FORM NO. 120 R1

P&ID/FLOW DIAGRAM
14.0 Ensure that pipe sizes are indicated in P&I/Flow diagram in co-
ordination with PJ/piping group.
15.0 Indicate the following operational details for all the drives auxillaries
and valves /dampers).
a) Type of drive- electric, pneumatic, hydraulic, electro

hydraulic, solenoid operated.
b) Type of service for valve/damper(s)
--open/close by o/c
--regulating by %
--inching by standard legend
c) Interlock requirement for all interlocked drives by I symbol

(s). with brief description of interlock condition(s) applicable
for the subject interlocked drive. For interlock requirement of
any drive refer reference document at S1. Nos. (ii) to (v).
Consider general guideline for deciding the interlock
requirement for a drive as per Annexure-IV enclosed with this
guide.
d) The symbols H,L,HH or LL for the state of process conditions

high, low, high high or low low respectively, required to be
used as an interlock condition for a drive or for alarm
annunciation.
e) Reference control system (description of control loop or logic

control system) controlling the drive. e.g. for a regulating
control element indicate the control loop through which the
valve is controlled, or for pump/fan or open/ close type
valve/damper indicate the respective equipment logic control
system.
f) Details of operation/status feedback display hardware

alongwith their mounting location. e.g. CRT/keyboard, on
illuminated lamp push button/control tile on operating
panel(s), console insert etc.
g) Valve /damper accessories like
(i) Position transmitters- for regulating type

valve/damper(s) and inching type valve(s).
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FORM NO. 120 R1

P&ID/FLOW DIAGRAM
(ii) Limit switches- for electric and pneumatic valve/reduce

space dampers.
(iii) Torque switches – for motorised valve/ damper (s).
(iv) I/P converter and air lock relay – for regulating

valve/damper (s) with pneumatic actuators.
(v) Scope of supply of drive control system and operation/

status feedback display system.
16.0 Indicate separate legend for unit control panel (UCP) and local control
panel (LCP) mounted instruments.
17.0 For panel mounted instruments, operational hardware, drive status

feedback display devices and annunciation windows mounted on local
control panel (LCP), identify the LCP by indicating its designation.
Also, provide ‘NOTES’ in P&I / Flow diagram indicating that, all
panel mounted items referred above are mounted on unit control panel
(UCP) unless specified otherwise.
18.0 Type of temperature elements (TEs) shall be identified with the

subscript R or T/ C for RTD and thermocouple respectively.
19.0 Indicate the following connections for all control valve(s):
a) One (1) no. pressure test point both at inlet and outlet.
b) One (1) no. drain connection both at inlet and outlet.
20.0 Indicate flow measuring devices for different applications as follows

or as per Annexure-V.
a) Orifice plate with flange connection – for all low pressure, low
temperature water services ( pressure <= 30 kg / cm2 ,
temperature <=100 0 c ) and for all steam services where pipe
size is <3”
b) Flow nozzle – for all steam services where pipe sizes are >3”
and for all high pressure water services.
c) Pitot tube or Annubar – for condenser cooling water system

having large pipe size.
d) Air foil – for all air services in ducts.
21.0 Indicate no. of tapings for flow elements (FE’s) as per Annexure- VI
enclosed with this guide or as per ‘Standard Basic Study for I&C
System. ISSUE
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FORM NO. 120 R1

P&ID/FLOW DIAGRAM
22.0 Indicate arrangement of tapping points for different flow elements on

P&I / Flow diagram as follows:
a) For orifice plate with flange tapping – tapping points on flange.
b) Orifice plate with D&D/2 tapping – tapping points on pipe line.
c) Flow nozzle / venturi – flow nozzle / venturi assembly

alongwith D&D/2 tapings on flow nozzle / venturyiassembly.
23.0 Flow elements located on rubber lined pipes ( where no welding is

possible), shall have separate SS assembly with flange connections.
e.g. flow element on make-up water line to hotwell.
24.0 If flow element (FE) is used for performance guarantee test then the
flow element shall have a spool piece.
25.0 For compressible fluids, if density change, due to variation in pressure,

temperature or both pressure and temperature, affects the desired
accuracy of flow measurement (used for control) then provide pressure
and temperature instruments ( as the case may be ) for compensation
of flow value. e.g. HP bypass steam flow measurements in feed water
flow control or secondary air flow measurement in air flow control.
26.0 For high pressure, high temperature compressible fluids, if density

change due to high pressure variation affects the desired accuracy of
level ( differential pressure) measurement, then provide pressure
instruments for compensation of DP value. e.g. Boiler drum level
measurement.
27.0 For incompressible fluids, if density; change due to high temperature

variation affects the desired accuracy of flow measurement, then
. provide temperature instrument for compensation of flow value e.g.
feed water flow measurement in Boiler drum level control.
28.0 Variable area type flow measuring instruments shall be of following

types with respect to pipe size :
a) Bypass type with orifice assembly – for pipe size >4”
b) Online type – for pipe size <4”.
29.0 All flow gauge (FG), flow switch (FS) and flow indicators (FI) shall be
at the outlet of the equipment.
30.0 All drain piping from Instruments/ Instrument racks shall be in the LP
( low pressure) piping Vendor’s scope of supply. Mark the scope
accordingly, or otherwise add a ‘Note’ to this effect.
ISSUE
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FORM NO. 120 R1

P&ID/FLOW DIAGRAM
31.0 Indicate following details in P&I /Flow diagram
a) Legends and symbols.
b) Notes of following types :
i) All information required for piping engineering.
ii) All information connected with operation process.
c) Engineering reference drawing :
i) TCE drawings.
ii) Vendor drawing.
32.0 Indicate all legends and symbols used in; P&I / Flow diagram or the
reference drawing no. for the same.
33.0 Following ‘NOTES’ are suggested for incorporating under ‘Notes’ in

P&I /Flow diagram; the ‘Notes’ as applicable shall be selected :
i) NOTE 1 : “ For service conditions >=62 bar OR 425 degree

C, pressure tap point shall be 25 NB and two (2) root valves
shall be supplied. For service conditions < 62 bar and 425
degree C. Pressure tap point shall be NB 15 and One (1) NB
15 root valve shall be supplied”
ii) NOTE 2 : “ Temperature stubs for all temperature instruments

shall be M33 x 2 size : height of temperature stub is as per
‘Piping standard drawing’ - indicate the ‘Piping standard
drawing no. as applicable.
iii) NOTE : 3 “ For all thermowells supplied by others ( indicate

the vendor) size. height of temperature stubs and type of
connection of thermowells are as per drawing no ( indicate
relevant vendor drawing nos. as applicable).
iv) NOTE : 4 “ For all thermowells supplied by vendor ( indicate

the vendor) required to be seal welded, welding is done by
thermowell vendor.
v) NOTES :5 “ Tapping point, root valve size and connection

type for different types of level instruments and stand pipe are
as follows :
Level gauge : 25 NB, SW
Level switch : 25 NB, SW ISSUE

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FORM NO. 120 R1

P&ID/FLOW DIAGRAM
Level transmitter : 40 NB, SW

(displacement type)
Level transmitter (diff. : Indicate as per Note 1

pressure type) above
Standpipe : 80 NB”
vi) NOTE 6 : “ Drain connection from level instruments/

transmitter rack are connected to nearest plant drain".
vii) NOTE 7 : “All flow gauges and flow switches on pipes upto
50 NB size are provided with screwed connection. All flow
gauges and flow switches on pipes of 50 NB and above size,
are provided with flange connection alongwith the counter
flange.
viii) NOTE 8 : “ Straight length required for the flow elements are
as follows : ( Indicate for all flow elements)
ix) NOTE 9 : “ For P.G test temperature points, size and height
of stubs and thermowells are as per drawing no. ( indicate
relevant vendor drawing no.)
x) NOTE : 10 “ All high pressure high temperature sampling

are through sampling well. Sampling well is as per ASME
standard. All sampling wells are welded into pipe line and is
in piping vendors scope of supply. For all other sampling
connections stub and root valve size is 25 NB with two (2)
root valves for pressure >=62 bar or 425C and one (1) no. of
pressure <62 bar and temperature <425 degree C.
xi) NOTE 11 : “ All flow indicators ( FIs) , flow switches (FS)

and flow gauges (FG) mounted on vertical pipes, are mounted
on vertical pipe line with upward flow.
xii) NOTE 13 : “ All operator hardware and panel mounted

instruments will be mounted on unit control panel (UCP),
unless otherwise specifically indicated”.
xiv) NOTE 14 : “ All unidirectional motor drives will have start /

stop operation from local push button (LPB). All bi-
directional motor drives will have open/ close / stop operation
from LPB”. Local push buttons are not indicated in this P&I /
Flow diagram.
xv) NOTE 15 : “ All annunciation points indicated are for

‘Hardwired Annunciation System’ ( HAS)”.
ISSUE
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FORM NO. 120 R1

P&ID/FLOW DIAGRAM
xvi) NOTE 16 : “ All unidirectional motor trip, and causes of trip

of equipment/system are connected to sequence of Events
Records (SER)”.
xvii) NOTE 17 : “ All temperature elements are of duplex type”.
xviii) NOTE 18 : “ Performances Guarantee test of equipments /

systems (indicate the equipment/ system) will be as per
standard ( indicate the standard applicable) in consultation
with systems group.
xix) NOTE 19 : “ For test points numbers indicated inside the

circle, are the tag nos. as indicated in vendor’s ( indicate the
vendor) performance guarantee test scheme no. ( indicate
relevant drawing no. )”.
xx) NOTE 20 : “ Process parameters indicated are for 100%

MCR condition. Flow Q in Ton / hour. pressure P in kg. /
cm2 (2) and Temperature . T in degree C”.
xxi) NOTE 21 “ All erection hardware viz. impulse piping and

fittings for instruments will be supplied and erected by
respective instruments vendor”.
xxii) NOTE 22 : “ For all reference drawings indicated in this P&I

/ Flow diagram. only the latest revision shall be referred”.
34.0 Indicate following types of engineering reference drawings in P&I/

Flow diagram along with the details indicated below :
a) TCE drawings with title and drawing no. for following:
i) Input / Output List
ii) Drive List
iii) Annunciation Schedule
iv) SER Schedule
v) List of Panels
vi) Instrument source connection details.
b) Vendor drawings with drawing title, vendor drawing no. and

TCE drawing no. for drawings related to followings items /
details :
i) Closed loop control system ISSUE

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FORM NO. 120 R1

P&ID/FLOW DIAGRAM
ii) Logic diagrams
iii) Measurement and Instrumentation Schedule
iv) Motor list
v) Valve list.
35.0 List of Annexure to this document :
Annexure- I : General guidelines for deciding

Instrumentation requirement for different
equipment.
Annexure-II : General guideline for selecting size of

tapping point stub no. and size of root
valves for different type of measurements.
Annexure-III : General guideline for deciding scope of

supply of instruments.
Annexure-IV : General guideline for deciding a drive as

interlocked drive.
Annexure-V : General guideline for selecting type of

flow element for different applications.
Annexure-VI : General guideline for deciding no. of

tapping points on flow elements for different
applications.
Annexure-VII : Representation of Instrumentation in P&I/

Flow Diagrams.
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 10 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I
GENERAL GUIDE LINES FOR DECIDING INSTRUMENTATION
REQUIREMENT FOR DIFFERENT EQUIPMENT
1.0 Instruments required to be provided for monitoring and control of

different equipment and its associated auxiliary systems are as follows :
SL.NO. EQUIPMENT INSTRUMENTS/ FUNCTION QTY/ REMARKS

EQUIPMENT EQPT.
1.1 For large sized (critical) fans and its drive motor (6.6kV)
i) Each fan TI Local Indication 1

bearing
TS Alarm 1
TS Interlock 1
TE Remote display 1
VX Remote 2 1 no. each in

display/Alarm ‘X’ & ‘Y’
/Interlock direction at 900
apart.
ii) Each fan TI Local indication 1

drive motor
bearing
TS Alarm 1
TS Interlock 1
TE Remote display 1
VX Remote 2 1 no. each in

display/Alarm/ ‘X’ & ‘Y’
Interlock direction at 900
apart
iii) Fan drive TE Remote display 6 Two per phase

motor Interlock / Alarm shall be
winding provided
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 11 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I
SL. EQUIPMENT INSTRUMENTS/ FUNCTION QTY/ REMARKS

NO. EQUIPMENT EQPT.
1.2 For forced lube oil and control oil systems of fans
i) Oil tank LI Local Indication 1
TI Local Indication 1
LS Alarm 1 For low level

condition
ii) Oil system TI Local Indication 2 1 no. each

piping before & after
oil cooler
PI Local Indication 1 For common

pipe at lube oil
pump
discharge
PI Local Indication 2 1 no. each for

lube oil &
control oil
systems
PI Local Indication 1 Across the oil

line filter
dPS Alarm 1
PS Interlock 1 For lube oil

pumps auto-
changeover
PS Interlock 4 2 nos. each for

lube & control
oil system
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 12 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I

NO. EQUIPMENT EQPT.
1.3 Air pre-heater ( rotary type) and it’s lube oil system
i) Air preheater TE Remote 6 For fire

detection
system
LS Alarm 1 Vane operated

limit switch for
rotor stoppage
alarm
ii) Air preheater TE Remote display / 1

bearing tank Alarm
TS Interlock 1
iii) Air preheater PI Local Indication 2 1 no. at each

oil system lube oil pump
pipe discharge
TI Local Indication 2 1 no. for each

oil line
FS Alarm 1
iv) Air heater FS Alarm / Interlock 2 1 no. for each

lube oil lube oil cooler
cooler
cooling water
1.4 For furnace and windbox
i) Furnace PS Alarm 2 1 no. each for

high & low
conditions
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 13 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I

NO. EQUIPMENT EQPT.
PS Interlock 6 3 nos. each for

high-high and
low-low
conditions for
2 out of 3 logic
PX Control/Remote 3 3 nos. for

display & ‘Median value
Recording Auto
(narrow range) Selection’.
PX Remote display/ 1
Recording ( wide
range)
ii) TE Control/ Remote

display
/Recording
iii) windbox PX Remote display
iv) Furnace & dPS Interlock

Windbox
dPX Control
dPX Remote display
1.5 Large size pump and its drive motor (6.6kV)
1.5.1 Boiler feed pump and its drive motor (6.6 kV)
i) BFP booster TE Remote display 2

pump bearing
ii) BFP bearing TI Local Indication 1
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 14 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I

NO. EQUIPMENT EQPT.
TS Alarm 1
TS Interlock 1
TE Remote display 1
VX Remote 2 1 No. each at ‘X’

display/Alarm/ & ‘Y’ direction at
Interlock 90° agent
iii) BFP drive TI Local Indication 1

motor bearing
TS Alarm 1
TS Interlock 1
TE Remote display 1
VX Display/ Alarm/ 2 1 no. each at ‘X’ &

Interlock ‘Y’ direction at
90o apart
iv) BFP drive TE Remote display/ 6 2 nos. per phase

motor motor Alarm/ shall be provided
winding Interlock
v) BFP hydraulic TI Local Indication 1

coupling
bearing
TS Alarm 1
TE Remote display 1
1.5.2 Condensate Extraction pump and its drive motor.
i) Each CEP TI Local Indication 1

thrust
bearing
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 15 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I

NO. EQUIPMENT EQPT.
TS Alarm 1
TS Interlock 1
TE Remote display 1
VX Display/ 2 1 no. each in ‘X’

Recording & ‘Y’ direction at
Alarm/ 90o apart
Interlock
ii) Each CEP PI Local Indication 2 1 no. each at pump

suction &
discharge
TI Local Indication 1 For pump suction
PS Interlock 2
iii) Each CEP TI Local Indication 1

drive motor
TS Alarm 1
TS Interlock 1
TE Remote display 1
VX Display/ 2 1 no. each in ‘X’

Recording/ & ‘Y’ direction at
Alarm/ 90o apart
Interlock
iv) Each CEP TE Remote display/ 6 2 No. per phase

drive motor Alarm/Interlock shall be provided
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 16 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I
SL. NO. EQUIPMENT INSTRUMENTS/ FUNCTION QTY/ REMARKS

EQUIPMENT EQPT.
1.5.3 CW Pump
and its Drive
motor
i) CW pump TI Local Indication 1

thrust
bearing
TS Alarm 1
TS Interlock 1
TE Remote display 2 1 no. each for

each half of
bearing
VX Display/ 2 1 no. each in

Recording/ ‘X’ & ‘Y’
Alarm/Interlock direction at 90o
apart
ii) CW pump drive TI Local Indication 1

motor bearing
TS Alarm 1
TS Interlock 1
TE Remote display 1
VX Display/ Recording/ 2 1 no. each in ‘X’

Alarm/Interlock & ‘Y’ direction at
90o apart
iii) CWP drive TE Remote Display / 6 2 nos. per phase

motor Alarm / Interlock shall be provided
iv) CW Pump PI Local Indication 1 At pump

discharge
PI Local Indication 1 At pump gland

sealing and brg.
lubrication line. ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 17 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I
SL. NO. EQUIPMENT INSTRUMENTS/ FUNCTION QTY/ REMARKS

EQUIPMENT EQPT.
FS Interlock 1 - do -
FS Interlock 1 At pump pre-

lubrication line
1.5.4 For small PI Local Indication 2 1 no. at suction &

centrifugal discharge
sumps and
positive
displacement
pumps
PS Interlock / Alarm 2
1.6 Tanks and

Vessels
i) Boiler Drum PI Local Indication 1
LI Local Indication / 2 1 no. for each side

Fireman’s floor of boiler drum
indication
LX Control/Remote 3 For feed water

display/Recording flow control
PX Control/Remote 3 For compensation

display/ Recording of drum level for
FW control
LI Remote display 2 Conductivity type

/Alarm/ Interlock level indicator, 1
no. for each side
of boiler drums
KX Remote display/ 1 For specific

Recording conductivity
measurement of
boiler drum steam
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 18 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I

NO. EQUIPMENT EQPT.
KX Remote display/ 1 For specific

measurement of
boiler drum blow
down water
phx Remote display/ 1 For specific

measurement of
boiler drum blow
down water.
ii) Hotwell LI Local Indication 2 1 no. for each end

of Hotwell
LS Alarm 2 1 no. for high &

low conditions
LS Interlock/ Alarm 4 3 nos. for low –

low condition for
2 out of 3 logic
and 1 no. for
normal level
condition
LX Control/ Recording 2 Displacement type

LX (Narrow
range)
LX Remote display/ 1 DP type LX (full

display in BFP local range)
panel
iii) Deaerator LI Local Indication 2 1 no. for each side

of deaerator
PI Local Indication 1
TI Local indication 1
LS Alarm 2 1 no. each for

high and low
conditions
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 19 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE -- I
SL. EQUIPMENT INSTRUMENTS FUNCTION QTY/ REMARKS

NO. / EQUIPMENT EQPT.
LS Interlock /Alarm 5 2 nos. for high – high

3 nos. for low – low
conditions
LS Interlock 3 1 no. each for normal

water level, high level
for over flow valve
open & low level for
over flow valve close
condition.
LX Control/ Recording 2 Displacement type LX

(narrow range)
LX Remote display/ 1 DP type LX (full

display in BFP local range)
panel
PX Control 2
TE Remote display 1
iv) CBD tank PI Local Indication 1
LI Local Indication 1
LS Alarm 2 1 no. each for high &

low level conditions.
LX Remote display 1
LC Control 1 Local pneumatic

controller
v) IBD tank TI Local indication 1
LI Local indication 1
vi) Condensate LI Local indication 1 Pressure guage

storage tank calibrated in terms of
level
LS Alarm 1 For high-high level

condition
LS Interlock 2
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 20 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - I
SL EQUIPMENT INSTRUMENTS FUNCTION QTY/ REMARKS

LS Interlock/ Area 1
vii) Aux. cooling LI Local 2 or 3 Qty. shall be suitable to

water O/H tank Indication cover entire tank level.
LS Alarm 2 1 no. each for high –

high and low – low level
conditions
LS Interlock 2 1 no. each for high &

low level conditions
viii) Service water LI Local 2 1 no. for each

O/H tank Indication compartment of the tank
LS Alarm 2 1 no. for each

compartment of the tank
for low level condition
ix) Potable water LI Local 1

storage tank Indication
LS Inter lock / 2 1 no. each for high &

Alarm low level conditions
1.7 Sump/ponds
i) CW pump sump LS Interlock/Alarm 2 1 no. each for sump level

low & adequate
conditions
LS Interlock/Alarm 2 1 no. each for sump level

low & adequate
conditions
Required if sump make

up water line is provided
with motorised valve.
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 21 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - I

ii) Raw water pond LS Interlock/ 2 1 no. each for high &
/ sump Alarm low level conditions for
such raw water pump
iii) Clear well sump LS Alarm 2 1 no. each for high &
low level conditions
LS Interlock 2 1 no. each for high-high

& low-low level
conditions
1.8 Heat exchanger
i) For all HP PI Local 1 For heater shell pressure

heaters Indication measurement
LI Local 1
Indication
LS Alarm 2 1 no. each high & low

conditions
LS Interlock / 2 For high - high condition

Alarm
For LP heater
ii) PI Local 1 For shell pressure
no. 1
Indication measurement
TI Local 1 For shell temperature

TI Local 2 At inlet & outlet of

Indication heater on secondary fluid
path
LI Local 1
Indication

low conditions
ISSUE
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 22 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - I

LS Interlock/ 1 For high-high condition

Alarm
LX Control/Remote 2
display
iii) For LP heaters P1 Local 1 For shell pressure

2&3 Indication measurement
TI Local 1 For shell temperature

TI Local 2 At inlet & outlet of

Indication heater on secondary fluid
path
LI Local 1
Indication

low conditions
LS Interlock/ 2 For high-high condition

Alarm
LX Control/Remote 2
display
iv) For small size TI Local 2 1 no. each at inlet and

Indication outlet of heat exchange
on primary fluid path
TI Local 2 1 no. each at inlet and

Indication outlet of heat exchanger
on secondary fluid path
FI Local 1 At heat exchanger outlet

Indication on primary fluid path.
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 23 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE – II
General Guidelines for selecting size of Tapping point stub. No. and size of Root Valves
for different type of measurement.
1.0 Size of tapping point stub, no. and size of root valve(s) for different type of measurements are as
follows :
Sl. Quantity of root valves Size of stub and root valve Service Condition
No.
A. Pressure and differential pressure measurement
(i) 2 25 NB >=62 bar or 425 degree C
(ii) 1 15 NB <62 bar and 425 degree C
B. Level measurement
a) Level Gauge & Switch
b) Level transmitter (displacement type)
c) Stand pipe for level measurement instrument
C. Flow measurement
(a) 2 25 NB >=62 bar or 425 degree C
(b) 1 25 NB <62 bar and 425 degree C
D. Sampling system measurement (steam & water service)
(a) 2 25 NB >=62 bar or 425 degree C
(b) 1 25 NB <62 bar and 425 degree C
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 24 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE – III
General Guidelines For deciding Scope of Supply of Instruments
SR. NO. TYPE OF INSTRUMENT SCOPE OF SUPPLY REMARKS
1.0 Local Gauge
i) Pipe line mounted gauges (with the Main equipment/process vendor e.g.
terminal point of scope of supply SH outlet pressure & temperature
of pipe line of main gauge on main steam line.
equipment/process)
ii) Pipe line mounted gauge (where Instrumentation & Control (I&C)
pipe line/process equipment is system vendor e.g. temperature
outside the terminal point of scope gauge at inlet & outlet of BFF lube
of supply of main equipment) oil cooler on aux. cooling water line
iii) Equipment mounted local gauges Respective equipment vendor e.g.

(pressure, temperature gauge) Boiler drum pressure gauge by Boiler
drum vendor; Deaerator pressure
gauge by deaerator vendor
iv) Equipment mounted level gauge I&C system vendor e.g. deaerator
level gauge
2.0 Transmitter
i) Transmitter for monitoring Respective instrument vendor

providing monitoring system
ii) Transmitter for control Respective instrument vendor

providing control system
3.0 Sensors/Switches for control/annunciation
i) Pipe mounted sensor/switches Respective instrument vendor

providing annunciation/control
system
ii) Equipment mounted Respective equipment vendor

sensor/switches
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 25 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE – III
General Guidelines For deciding Scope of Supply of Instruments
SR. NO. TYPE OF INSTRUMENT SCOPE OF SUPPLY REMARKS
4.0 Temperature element
i) Pipe/duct mounted for process I&C System vendor

fluid
ii) Equipment bearing/equipment Respective equipment vendor

drive motor bearing mounted
iii) For boiler tube metal/boiler drum Boiler vendor

skin metal
5.0 Control valve I & C system vendor
6.0 Control damper Air/Flue gas duct vendor
7.0 Flow element
a) Pipe mounted I & C system vendor
b) Duct mounted Air duct vendor
8.0 Analyser I & C system vendor
9.0 Receiver Instrument (Indicator / Recorder) I & C system vendor
10.0 Operational hardwares of control systems Respective instrument vendor

providing control system
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 26 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - IV
General Guideline for Deciding A Drive As Interlocked Drive
1.0 A drive is called an interlocked drive if the operation (either start/stop or open/close) of the drive is
dependent on any interlock (permissive/protection) condition(s).
1.1 Interlock requirement for an drive can be of following types :-
a) Interlock condition(s) based on process requirement.
b) Interlock condition(s) based on equipment safety criteria.
c) Interlock condition(s) based on both process and equipment safety requirements.
2.0 Example of categories of drive(s) requiring interlocked operation for each of the cases of point no.
1.1 referred above are as follows :
2.1 Based on process requirement.
2.1.1 Starting of a standby pump automatically (Auto standby feature) on failure of a running pump or on
an inadequate discharge pressure etc.) to maintain process parameter value or cater to process load
e.g.
Sl. No. Drives Purpose
(i) Fuel oil supply pumps To maintain pump discharge pressure above set
value
(ii) Hotwell makeup pumps - do -
(iii) H2 cooler aux. cooling water booster pumps To maintain generator hydrogen temperature
below set valve to maintain generator load
2.1.2 Drives provided for automatic catering of process functions e.g.
(i) Pumps feeding into a tank Based on low/high tank level pump starts/stops.
e.g. Potable water pump feeding into service &

potable water tank
(ii) Valves on inlet line feeding a tank Based on low/high tank level inlet valve opens
or closes
e.g. Isolating valve on DM water inlet line to

condensate storage tank
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 27 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - IV
Sl. No. Drives Reasons
(iii) Valves on inlet, outlet and bypass paths of On high drip level in heaters and also for
primary process fluid (being heated) and inlet isolating the heat exchanger from process
valve on secondary process fluid (heating
medium) path of a heat exchanger
e.g. inlet, outlet & bypass valves on feed water

and condensate lines for HP & LP heaters
respectively and steam inlet valves to both HP &
LP heaters.
2.1.3 Drives requiring fulfilment of prestart permissives based on process safety criteria e.g.
(i) Coal mills Ignition energy available
2.2 Based on equipment safety criteria
2.2.1 Drives requiring pre-start permissive e.g.
Sl. NO. Type of Drive Permissive Requiirement
(i) All centrifugal pumps Flooded suction i.e. either suction valve open or
suction pressure adequate
e.g. a) Boiler feed pumps
b) CW pumps
c) Hotwell makeup pumps
d) Boiler aux. cooling water pumps
e) Turbine lube oil cooler booster pumps
f) H2 cooler booster pumps
(ii) All positive displacement pumps Flooded suction i.e. either suction valve open or
suction pressure adequate
e.g a) Fuel oil supply pumps
b) Turbine lube oil supply pumps
(iii) Drives with forced bearing lubrication system Lubricating system O.K. i.e. lubricating medium
(oil or water) pressure/flow adequate.
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 28 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - IV
e.g. FD/PA fans, Air pre-heater (rotary type),

BFP, CW pumps etc.
(iv) Drives requiring satisfactory MCC (i) Breaker in service

status conditions
e.g All 6.6 KV equipments (ii) Breaker in remote
(iii) Breaker not in test
(iv) Breaker lockout relay reset
(v) Breaker gas pressure low (for

SF6 type breakers only)
(v) Critical equipments for which bearing Equipment bearing temperature shall be
condition is monitored continuously below set value.
e.g. All 6.6 kv equipments
(vi) Valves with integral bypass valve Main valve can open after integral
bypass valve is open
(vii) Equipments with discharge Discharge valve/damper shall be closed

valve/damper provided with powered to prevent equipment overloading while
drives starting for a short duration.
e.g ID,FD,PA fans CW & CEP pumps
(viii) Discharge valve/damper of equipment. Shall open automatically when the main
If provided with powered drive equipment is in service
e.g. Discharge dampers of ID, FD & PA

fans, discharge valves of BFP, CEP
(ix) Pumps requiring NPSH Inlet feeding reservoir/vessel shall be

adequate
e.g. BFP, CEP, CWP
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 29 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - IV
2.2.2 Starting of a standby auxiliary to enable main equipment running when the main
auxiliary of that equipment fails. e.g.
Sl. No. Service Purpose
(i) PD/PA fans bearing lube oil pumps When the running pump fails or the
pressure is inadequate, the standby
pump starts automatically
(ii) Air preheater (rotary type) bearing lube When the running pump fails or the
oil pumps pressure is inadequate, the standby
(iii) Turbine oil cooler booster pumps When the running pump fails or the
pressure is inadequate, the standby
(iv) Air preheater main & standby motor When the running motor fails, the
drives standby motor runs to keep the Air-
heater in service
(v) Air preheater air motor When the electrical drives of Air heater
fans, the air heater in rotation of a lower
speed by plant air to protect airheater
elements.
2.2.3 Drives requiring protection trip while on service based on equipment safety criteria.
These are as follows :
Sl. No. Drives Reason
(i) All centrifugal pumps Suction pressure falls below set value
(ii) All 6.6 kV equipment Bearing temperature & Vibration above

set value
(iii) Drives in upstream of process flow path If downstream equipment trips
e.g. Coal feeder trips if running coal

mill trips
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 30 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - IV
Sl. No. Drives Reason
2.2.4 Pumps requiring NPSH for operation NPSH falls below set value
e.g BFP, CWP, CEP
2.3 Based on process/equipment safety criteria.
2.3.1 Drives which can be operated only if other equipments in the process are in service.
e.g. (i) FD fan can run if ID fan is in service.
(ii) Coal feeders can run if coal mill is in service
(iii) Only specific no. of mills can operate in relation to no. of PA fans in
service/primary air pressure available.
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 31 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - V
General Guideline for Selecting Type of Flow Element for Different

Applications
SL. NO. TYPE OF FLOW FLUID PRESSURE PIPE SIZES APPLCATION

ELEMENT MEDIUM TEMPERATUR SUITABLE (EXAMPLES)
WHERE E OF FLUID FOR FE
USED SUITABLE
1. Orifice plate Water (Feed Pressure <= For all sizes i) RH spray
water, 30 Kg/cm2 except very water flow
condensate and large dia.pipe
DM water) Temperature
<= 1000 C
ii) CEP
discharge
flow
iii) Condensate
at Deaerator
inlet
iv) Make-up
flow to
Hotwell
v) DM water
flow to CST
2. Orifice plate Water Pressure >30 All pipe sizes SH spray water
Kg/cm2 flow
Or
Temperature
>100o C
3. Orifice plate Steam For any <3” Soot blowing

conditions steam flow
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 32 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - V

Applications
SL. NO. TYPE OF FLOW FLUID PRESSURE PIPE SIZES APPLCATION

ELEMENT MEDIUM TEMPERATUR SUITABLE (EXAMPLES)
WHERE E OF FLUID FOR FE
USED SUITABLE
4. Flow Nozzle Water Pressure >30 For all pipe (i) BFP
Kg/cm2 sizes except suction
very large flow
dia pipe
Or (ii) FW flow to
boiler drum
Temperature
>100o C
5. Flow Nozzle Steam - do - >3” (i) HP bypass

steam flow
(ii) Aux. Steam

flow
6. Pitot tube or Water Pressure <=30 >1 metre Condenser

Annubar (Condenser kg/cm2 and pipe cooling water
cooling Temperature flow
water) <=100o C
7. Air foil Air - do - All duct sizes (i) Primary

Air flow
(ii) Secondary
Air flow
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 33 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - VI

Applications
Sl. No. SERVICE APPLICATION PREFERENCE
A. NO. OF PAIR TAPPING : 3 (FOR MORE CRITICAL SERVICES)
1. HP Bypass steam flow Drum level Control Standard Flow Element

Data Sheet
2. Feed water flow to boiler Drum Level Control Standared Flow Element
drum Data Sheet
3. Feed water flow at BFP BFP minimum Standard Flow Element

suction Recirculation flow control Data Sheet
4. Condensate pumps CEP Minimum Standard Flow Element

discharge flow (after Recirculation flow control Data Sheet
GSC)
5. Condensate flow at Deaerator Level Control Standard Flow Element

Deaerator inlet Data Sheet
6. Primary Air Flow to coal (i) Mill Air Flow/Mill Standard Flow Element
mill Outlet Temperature Data Sheet
Control (for Bowl mills)
(ii) Fuel flow control (for

tube mills)
7. Secondary Air flow (to Air flow control Standard Flow Element
furnace) Data Sheet
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 34 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - VI

Applications
Sl. No. SERVICE APPLICATION PREFERENCE
B. NO. OF PAIR TAPPING : 2 (FOR LESS CRITICAL SERVICES)
1. Spray Water flow to SH (i) Steam Temperature Standard Flow Element

Desuperheater Control (for 2 stage Data Sheet
de-superheating
boiler)
(ii) Monitoring (for 1 Standard Flow Element

stage Data Sheet
desuperheating
boiler
2. Spray Water flow to RH Monitoring Standard Flow Element

Desupherheater Data Sheet
3. Maker-up water flow to Monitoring Standard Flow Element

Hotwell Data Sheet
C. NO. OF PAIR TAPPING : 1 (FOR NON-CRITICAL SERVICES)
1. Auxiliary Steam flow Monitoring Standard Flow Element

after Aux. PRDS Data Sheet
2. DM water flow to Monitoring Standard Flow Element

condensate storage tank Data Sheet
(CST)
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FORM NO. 120 R1

TCE. M6-IC-580-001 SHEET 35 OF 35
P&ID/FLOW DIAGRAM
ANNEXURE - VII
REPRESENTATION OF INSTRUMENTATION IN P 7 I / FLOW DIAGRAM
1.0 GENERAL NOTES
1.1 TYPICAL EXAMPLES OF REPRESENTING INSTRUMENTATION IN P 7 I

DIAGRAMS/FLOW DIAGRAMS ARE SHOWN.
1.2 SOME OF THESE EXAMPLES SHOW A GROUP OF SECONDARY

INSTRUMENTS SUCH AS PY, PR CONNECTED TO A SINGLE
TRANSMITTER FOR THE PURPOSE OF ILLUSTRATION ONLY. THE
SECONDARY INSTRUMENTS SHALL BE SHOWN AS APPLICABLE,
WHETHER ONLY PY OR PR OR BOTH AS THE CAE MAY BE.
1.3 TAG NO. IS SHOWN ONLY FOR PRIMARY INSTRUMENTS FOR

ILLUSTRATION PURPOSE ONLY. SECONDARY INSTRUMENTS TAG NO.
SHALL BE ENTERED SIMILARLY.
1.4 ALARM ANNUNCIATION/INTEERLOCK STATE i.e. HIGH-HIGH, LOW,

LOW-LOW IS INDICATED AS FOLLOWS :
A) HIGH ALARM/HIGH INTERLOCK
B) HIGH-HIGH ALARM/HIGH-HIGH INTERLOCK
C) LOW ALARM/LOW INTERLOCK
D) LOW-LOW ALARM/LOW-LOW INTERLOCK
1.5 PANEL DESIGNATION FOR ALARM ANNUNCIATION WINDOW

LOCATION 9APPLICABLE FOR LOCAL PANELS ONLY) IS INDICATED AS
FOLLOWS :
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FORM NO. 120 R1

Guide For Instrumenting The P&I / Flow Diagram: Tata Consulting Engineers

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Guide For Instrumenting The P&I / Flow Diagram: Tata Consulting Engineers

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TATA CONSULTING ENGINEERS SECTION: TITLE

TCE. M6-IC-580-001 SHEET 1 OF 1

GUIDE FOR INSTRUMENTING

TATA CONSULTING ENGINEERS

INITIALS SIGN INITIALS SIGN INITIALS SIGN INITIALS SIGN

PPD.BY MKG sd/- As per Memo SVB

APP.BY KGS/KG sd/- RKC

DATE 1994-03-29 2000-03-22

FORM NO. 020R2

Purpose of this guide is to prepare P&I/Flow diagram for a process or

2.0 REFERENCE DOCUMENTS

(i) Legends and symbols for P&I diagram.

(ii) Similar P&I diagram exhibited for previous projects.

(iii) Drawings for typical instrumentation to be provided for

(iv) Standard flow diagrams.

(v) Vendor flow diagram.

(vi) Performance Guarantee Test scheme given by Vendor.

4.0 Instrument the P&I /Flow diagram considering the instruments

6.0 Indicate the performance guarantee (P.G) test points (pressure,

FORM NO. 120 R1

10.0 Indicate reducer for P.G test pressure points as applicable.

12.2 Root valve(s)

a) Tapping point on process pipe.

b) Tapping point on flow element assembly

--Flow element vendor

c) Tapping point from stand pipe

d) Tapping point on equipment/vessel

a) For test points

--Same as root valve vendor

12.4 Instruments – as per Annexure -III enclosed with this guide.

13.0 Indicate maximum parameter (pressure, temperature, flow etc.) values

FORM NO. 120 R1

a) Type of drive- electric, pneumatic, hydraulic, electro

b) Type of service for valve/damper(s)

--inching by standard legend

c) Interlock requirement for all interlocked drives by I symbol

d) The symbols H,L,HH or LL for the state of process conditions

e) Reference control system (description of control loop or logic

f) Details of operation/status feedback display hardware

g) Valve /damper accessories like

(i) Position transmitters- for regulating type

FORM NO. 120 R1

(ii) Limit switches- for electric and pneumatic valve/reduce

(iii) Torque switches – for motorised valve/ damper (s).

(iv) I/P converter and air lock relay – for regulating

(v) Scope of supply of drive control system and operation/

17.0 For panel mounted instruments, operational hardware, drive status

18.0 Type of temperature elements (TEs) shall be identified with the

19.0 Indicate the following connections for all control valve(s):

b) One (1) no. drain connection both at inlet and outlet.

20.0 Indicate flow measuring devices for different applications as follows

c) Pitot tube or Annubar – for condenser cooling water system

d) Air foil – for all air services in ducts.

FORM NO. 120 R1

22.0 Indicate arrangement of tapping points for different flow elements on

a) For orifice plate with flange tapping – tapping points on flange.

b) Orifice plate with D&D/2 tapping – tapping points on pipe line.

c) Flow nozzle / venturi – flow nozzle / venturi assembly

23.0 Flow elements located on rubber lined pipes ( where no welding is

25.0 For compressible fluids, if density change, due to variation in pressure,

26.0 For high pressure, high temperature compressible fluids, if density

27.0 For incompressible fluids, if density; change due to high temperature

28.0 Variable area type flow measuring instruments shall be of following

a) Bypass type with orifice assembly – for pipe size >4”

b) Online type – for pipe size <4”.

FORM NO. 120 R1

31.0 Indicate following details in P&I /Flow diagram

a) Legends and symbols.

b) Notes of following types :

i) All information required for piping engineering.

ii) All information connected with operation process.

c) Engineering reference drawing :

ii) Vendor drawing.

33.0 Following ‘NOTES’ are suggested for incorporating under ‘Notes’ in

i) NOTE 1 : “ For service conditions >=62 bar OR 425 degree

ii) NOTE 2 : “ Temperature stubs for all temperature instruments