Utility Summary
Template (Excel)

A utility summary, also called a utility consumption summary or utility balance, is the consolidated EPC register of every utility consumer on a project (steam HP, MP, LP, cooling water, chilled water, instrument air, plant air, nitrogen, fuel gas, electrical power) with normal, peak, and design consumption per consumer. It is built from the PFDs and P&IDs during FEED and is the basis for utility header sizing, utility generation unit capacity (boilers, cooling towers, air compressors, nitrogen plant), and OSBL design. It is a mandatory FEED and detailed engineering deliverable on every process plant project.

Required columns: utility type, consumer tag, service description, P&ID and PFD references, battery limit conditions (pressure, temperature), normal consumption, peak consumption, design consumption with margin, intermittent or continuous flag, duration of peak, source header reference, return header reference for closed loops, recovery or reuse flag, operating mode (startup, normal, shutdown, emergency), heat duty for steam and cooling water, make-up requirement for cooling tower and DM water systems, utility specification reference (quality, ppm chloride, TDS), vendor package source flag, and plot plan coordinates. The template includes all required columns plus optional CapEx and OpEx allocation columns.

Pathnovo, an engineering document intelligence platform, extracts every utility connection on the P&IDs and PFDs, parses the equipment datasheets and vendor packages for normal and peak utility duties, and consolidates them into the utility summary by utility type. Heat duties are auto-calculated from steam pressure and condensate return conditions, cooling water duties from heat exchanger datasheets. Typical project turnaround is 48 hours for the initial batch with 99.5% contractual accuracy on header totals. See the P&ID extraction workflow for the full pipeline.

The heat and material balance (or HMB, captured in the PFD) covers process streams (feed, intermediates, products) with composition, flow, temperature, pressure, and enthalpy at each tagged stream point. The utility summary covers utility streams (steam, cooling water, air, nitrogen, power) per consumer rather than per stream. The two are complementary: the HMB feeds the utility summary because each heat exchanger duty in the HMB drives a steam or cooling water consumption row in the utility summary. See the PFD reference page and the heat balance template.

Intermittent loads (startup steam to driers, regeneration nitrogen for molecular sieves, dilution steam during upset) are flagged with duration of peak in hours per day. Header sizing uses the diversified peak (sum of coincident peaks across consumers, not arithmetic peak total) because not every consumer peaks simultaneously. A typical instrument air header is sized for the diversified peak plus 30% future margin. The utility summary captures both normal and design consumption per row so the discipline lead can apply the diversification factor at header level rather than re-querying every consumer.

On Indian PSU projects (IOCL, BPCL, HPCL, GAIL, ONGC, NTPC, SAIL) the utility summary is reviewed at FEED gate and IFC gate, and is the basis for the OSBL utility tie-in design at the existing refinery or fertiliser complex. On brownfield revamps the existing utility summary is reconciled against the as-built P&IDs (Pathnovo extracts both sides of the revamp boundary), the delta is the incremental utility demand the existing units must support, and any shortfall drives either utility unit debottlenecking or a new package (additional boiler, cooling tower cell, instrument air compressor). The template includes a Revamp Delta column for brownfield scope.

Downstream consumers: utility generation unit sizing (boiler MCR per HP steam total, cooling tower cell count per CW circulation total, air compressor TPH per instrument air peak, nitrogen plant Nm3/h per N2 average), utility distribution header sizing per pressure drop calculation, equipment datasheet utility tie-in conditions, vendor package utility schedules (for tendering), and operating cost modelling for the economic evaluation. Utility summary is revision-aligned with the line list so every utility header tag on the line list ties back to one or more rows in the utility summary. See the P&ID extraction workflow.