KH 8X ft g jgae D> § 253®OOOO prensure Taree ‘S) ‘Terporsture Bement © a i ®OGOOOOO @ (6s) tewicune © veer recon covate; (an) Aen Toren QC. Ccomatioop Gracimeutc) aha cere pore Figure 12:1b Process and Insrunent Symbols (continued) uring thet na training period, Knowing and recognizing these symiols is important fora new technician. The chemical processing Industry has as signed a symbol foreach type of valve, pump, compressor, steam turbine, heat exchanger, cooling tower, basic instrumentation, reactor, distillation Column, furnace, and boiler (Figure 12.1). There are symbols to represent ‘major and minor process Ines and pneumatic, hycraulic, or electric lines, ‘and there is @ wide variety of electrical symbol, Flow Diagrams New technicians are required to study a simple flow diagram of their as- signed operating system, Process flow diagrams typically include the major equipment and piping path the process takes through the unit, As operators learn more about symbols and diagrams, they graduate to the much more ‘complex P&IDs.Figure 12.2 Process Flow Diagram (PFD) ‘Some symbols are common among plans; others dif from plant to plant ‘Some standardization of process symivols and diagrams is taking place. “The symbols used in this chapter reflect a wide variety of petrochemical and refinery operations. Figure 12.2 is @ PFD that shows the basic relationships and flow paths: found in a process unt. ts easier to undarstand a simple low diagram it |s broken down into sections: feed, preheating, the process, and the final products, This simple left-right approach allows a technician to identiiy ‘where the process starts and where i wil eventually end.The feed section Includes the feed tanks, mixers, piping, and valves. nthe second step, the process tow is gradually heated for processing, This secton includes heat ‘exchangers and furnaces. n the tid section, the process is included, Typ- ical examples found in the process section could insiude distillation ‘columns or reactors. The process area is a complex collacion of equipment that works togethe: to produce products that wil be sent tothe final sectionChapter 12. Process Diagrams 86 Process and Instrument Drawings [A PAID Is a complex representation of the various units found in a plant (Figure 12.3). tis used by people ina varity of crafts. The primary users. ‘ofthe document after plant startup are process technicians and instrument land electrical, mechanical, safety, and engineering pe'sonnel In order to read a P&ID, the technician needs an understanding of the ‘equipment, instrumentation, and technology. The next step in using a PAID is to memorize your plant's process symbol ist. Ths information can be found on the process legend. Process and instrument drawings have a va- Fle of elements, incising flow giagrams, equipment locations, elevation plans, electrical layouts, loop dlagrams, tie blocks and legends, and foun- {ation drawings. The entire PaID provides a three-dimensional look atthe vatious operating units ina plant. Process Legend ‘The process legend (Figure 12.4) provides the informstion needed to inter pret andiread the PAlD. Process legends are found at he front ofthe PAID. ‘The legend includes information about piping, instrument and equioment t = g a 1“ oe f We Figure 12.3 Process and Instument Diagram (P&ID)Proces and lnstrument Drawings ‘VALVE SYMBOLS EQUIPMENT CONT, LINE SYMBOLS. DISTILLATION UNIT ABBREVIATIONS Figure 124 Process Legend asChapter 12, Process Diagrams 2 Figure 125. Fowndavion symbols, abbreviations, unit name, drawing number, revision number, ‘pprovale, and company prefixes. Because symbol and diagram stardard- ization is nat complete, many companies use their own symbols 1 unit drawings. Unique and unusual equipment wil also require a modified sym= bois fle Foundation Drawing “The conotnuoton crow pouring the footere, beame, and foundation uss foundation drawings (Figure 12.5). Concrete and steel specifications are ‘designed te support equipment, integrate underground piping, and provide ‘support for exterior and interior walls. Process technicians do not typically Use foundation drawings, but these drawings are useful when questions arise about piping that disappears under the ground and when new equip ‘ment is being added. Elevation Drawing Elevation drawings (Figure 12.6) show the location of process equipment in relation t existing stuctures and ground level. In a multistory structure, the elevation drawing provides the technician with information abouti A pol Le rie 38 ‘equipment location. Tis information Is Important for making rounds, check: ing equipment, developing checklists, catching samples, and performing startups and shutdowns. Electrical Drawing Electrical drawings (Figure 12.7) include symbols and diagrams that de- pict an electrical system. Electrical drawings show unit electricians where Power transmission tines run and places where powers stepped cown oF up for operational purposes. ‘A process technician typically traces power tothe uni from a motor contro! ‘center (MCC). The primary components of an electrical system are the MCC, motors, transformers, breakers, fuses, switchgears, starters, and ‘switches. Specific safety rules are attached to the operation of electrical systems. The primary safety system is the isolation of hazardous energy “Iock-out, tag-out” Process technicians are requited to have taining inthis area. Figure 12.7 shows the basic symbols and flow path associated with {an eleetical drawing, Electrical lines are typically tun in cable trays to hitches, motors, ammeters, substations, and control rooms. ‘A transformer is @ device used by industry to convert high voltage to low voltage, The electric department always handles problems with transform= es. Electric breakers are designed to interrupt current flow if design cond liane are exceeded, Breakers are not ruitches and should not ba turned on Figure 12.6 Elevation Drawing Process and Instrument Drawings 29300 vote {40V BUS HAN POWER DISTRISUTION ELECTRIC POWER PLANT 3 ewe I) ‘Motor B Fane [MCC Motor Corio Carter [(@) vette meres vase at Se @ wv ner a (A) smrmenc reasons sete crent | [Aa] Amt snten term owes tar | ke pata ners Smet ‘weap Onin toy | lpn nase tn ‘A Cheater atin eee = ‘ Secon. sec comen Figure 12.7 Electrical Drawingor of. a tripping problem occurs, the technician should call for an elect- cian. Fuses are devices designed to protect equipment from excess cur- ent A thin stip of metal wil met if design specticatons are exceeded. During operational rounds, technicians check the ammeters inside the MCC for current flow to their electrical systems. Volimeters, electrical dovices used to monitor voltage in an electrical system, are also checked {uring routine rounds. Equipment Location Drawing Equipment location drawings (plot plans) show the exact location of {equipment in relation tothe plant’ physical boundaries (Figure 12.8). One ‘of the most dificult concepts to explain to a new process technician isthe ‘scope and size of modern chemical processing. Most chemical plants and refineries closely resemble small cites; they have well-defined blocks and ‘areas connected by a highway of piping and equipment. Equipment loca tion drawings provide information about the neighborhood. Loop Diagrams ‘A loop diagram traces ll instrument connections between the field instru ‘ment and the contol room panel. This includes instrument ai tines, wining ‘connections at field junction boxes, and control room panels and front ‘connections. Electrical One-Line Diagrams. Like the piping in process systems, the wiring ina unt flows a path Elet- ‘cal diagrams show a low path for dstibuting power throughout the unt ang ee % PoE] neo Rlee Process and Instrument Drawings Figure 12.8 Equipment Location 261Chapter 12. Process Diggrams Figure 12.9 Pipisg Symbols to all electrical equipment. These diagrams show the diferent oiage levels Inthe unt, electrical equipment suchas transformers, ccuitbreakers, uses, {and motors and horsepower required It also includes star'stop switches, femergency circuits, and motor contol centers. Process tectncians can use these diagrams to trace a system from the power source tothe load Review of Basic and Specialized Symbols Piping and Valves Each plant will have a standardized file for their piping symbols. Process. technicians should caretully review the piping symbo's for major and minor flows; electric, pneumatic, capillary, and hydraulic elements; and future ‘equipment (Figure 12.8).The major low path through a unit ilustrates the aera = ae ees ‘Gt peemmme CD een oe TH eawe TBD detonation Amesior A veer Cover (LED Flame Arestor 5 nine Miner — ty Omen aan 1QI run vie Fea ta io ne io =eReview of Basic and Specialized Symbols critical areas a new technician should concentrate on. A varity of other symbols are included on the piping, These include valves (Figure 12.10), stramers iiers, tanges, spool pieces, insulation, piping size, pressure ing, material codes, and steam taps. Pumps and Tanks Pumps and tanks come ina variety of designs and shapes. Common pump ‘and tank symbols are shown on Figure 12.11 ‘Compressors, Steam Turbines, and Motors Because compressors and pumps share a common set of operating prin- ciples and are classified as dynamic or posite dlsplacement, the Sym bbols for compressors may closely resemble those for pumps (compare ee Fare p ees Ly gee 240 == i = “e- = Sar ar eR EET 4 o£ $= 263Chapter 129, Process Diagrams 164 CENTRIFUGAL PONS POSTIVE DBPLAGENENT PONDS ee eee ae te Ay svrone CHEE Soe SOQ SE Figure 12.11 Pumps and Tanks Figures 12.11 and 12.12) In most cases, the compressor symbolis slighty larger than the pump symbol Inthe mutistage, centetugal compressors, the narrowing ofthe symbol from lett right denotes compression ofthe gas belore it is released. This isin sharp contrast othe steam turbine symbol, whichilustrates the opposite fect as the steam expands while passing over tne rotor. Modern PalDs show the motor symbol connected tothe driven equipment. This equipment may bbe a pump, compressor, mixer, or generator Figure 12.12 liustrates the standardized symbols fr compressors, steam turbines, and motors, Heat Exchangers and Cooling Towers. Heat exchangers and cooling towers are two types of industrial equipment ‘hat share a unique relationship. A heat exchanger Is a device used toReview of Basic and Specialized Symbols ees aren Cente : H Ub §¥ I] wm Figure 1212 Compressors, Steam Turbines, and Motors transfer heat energy between two process flows. The cooling tower per- forms a similar function, but cooling towers and heat exchangers use ai ferent scientific principles 1 operate, Heat exchangers transfer heat energy ‘through conductive and convective heat transfer, whereas cooling towers twansier heat energy tothe autside alr tough the princioe ot evaporation, Figures 12.13 and 12.14 illustrate the standard symbols used for heat ‘exchangers and cooling towers, The symbol for @ heat exchanger clearly illustrates the flows through the device. I is important for a process technician to be able to recog- ‘ize the shell inlet and outlet and the tube inlet and outlet flow paths. A hheat exchanger with an arrow drawn through the body illustrates whether the tubeside flow is being used to heat or cool the shellside {uid The downward sraction indioatas hanting: the upward direction i lustrates coating.Review of Base and Specialized Symbols ) . Fumace and Boiler “The symbol fora cooling tower is designed to resemble the actual device inthe process unit. Cooled product ows out of the bottom of re tower and to the processing units. Hot water returns to a point located above the fl “The symbol wll not show all ofthe various components ofthe c>oing ower system, butt will provide a technician with a good foundation in cooling tower operation and enough information to clealy see the process. Furnaces and Boilers ‘The standard symbols file for furnaces and boilers is shown in Fig- ture 12.18. Ifa proprietary process includes several types of equipment not typically ound on a standard symbol fle, the designer wil draw the device ait visually appears in the unit Distillation Columns Distilation columns come in two basic designs, plate and gacked (Fig lure 12.16). Flow arrangements vary from process to process. The sym: bois aliow the technician to identify primary and secondary flow paths. Distilation is a process designed to separate the various components in ‘a mixture by their boing points. (See Chapter 15.) distillation column is the central component of a much larger system. This system typically in- Cludes all of the equipment symbols foundlin this chapter. Plato distilation. Columns include sieve trays, valve trays, and bubble-cap trays. Packed columns are filed with packing material, rings, saddles, sulzer, and rosette, Reactors Feeactors (Figure 12.17) are stationary vessels and can be dassiied as batch, semibatch, or continuous. A reactor is designed to éllow cher cals to mix together under specific conditions to make chemical bonds, break chemieal bonds, or make and break chemical bonds 'o Torm new producto, 267Figure 12.16 Distilarion Symbols mies, Sve, vive ga ing ur Rote oe Denier © fle Sources of Information for Process Technicians Information used by process technicans comes from a variety of sources, Some ofthese sources ae * Operating taining manuals * Process descriptions Process contro manuals Equipment summaries Safely, heath, and environment regulations Operating procedures fet ane Shutdown proceduresocc totentaeson ce ee ee 4, fii Emergency procedures Process diagrams Tecnnical data books: Detaled equipment vendor information Summary Process flow diagrams (PFOs) and process and instrument drawings (P&IDs) are used to outtne or explain the complex flows, equipment, in- strumentation, electronics, elevations, and foundations that exist in a process unit. A PFD is a simple flow diagram that describes the primary flow path through a unit. A P&ID is complex representation of the v Unita found in a plant. Standardized symb: ‘developed for most pieces of industrial equipment, process flows, and instrumentation, Summary Figure 12.17 Reactor SymbolsChapter 129. Progess Diagra ¥ Review Questions Describe a process flow diagram and a process and instrument crewing Draw the symiols for a gate, globe, and automatic valve. Draw the symbols for a centritugal pump and positive displacement pump. Daw the symbols for a blower and a reciprocating comeressor. Draw the symbols for a steam turbine and centrifugal compressor Draw the symbols for @ heat exchanger and a cooling tower Draw the symbols for @ packed cistilation column and pate distillation column. Draw the symbols for @ furnace and a boiler. 8. Draw a simple process flow diagram using the symbols ‘rom questions 2-8, 410. What information is abtained from a loop diagram? 111. What information s avaiable on electical onesine diagrams? 12, What information is contained on a plot plan drawing? mm