ChE

522: Diagrams for Understanding Chemical Processes

PROCESS FLOWSHEETS for CHEMICAL PROCESSES

The most effective way of communicating information about a process is through the use of flow diagrams.

KEY TERMS:
Electrical drawings: symbols and diagrams that depict an electrical process.
Elevation drawings: a graphical representation that shows the location of process equipment inrelation to existing
structures and ground level.
Equipment location drawings: show the exact floor plan for location of equipment in relation tothe plan’s physical
boundaries.
Flow diagram: a simplified sketch that uses symbols to identify instruments and vessels and todescribe the primary flow
path through a unit.
Foundation drawings: concrete, wire mesh, and steel specifications that identify width, depth,and thickness of footings,
support beams, and foundation.
Legends: a document used to define symbols, abbreviations, prefixes, and specialized equipment.
Process and instrument drawing (P&ID):a complex diagram that uses process symbols todescribe a process unit; also
called piping and instrumentation drawing.

Types of Process Diagrams
Process diagrams can be broken down into two major categories: flow diagrams and process andinstrument drawings
(P&IDs),sometimes called piping and instrumentation drawings.

I. FLOW DIAGRAMS
A. BLOCK FLOW DIAGRAM
• Series of blocks representing different equipment or unit operations that were connected by input and output
streams.
• Important information such as operating temperatures, pressures, conversions, and yield was included on the
diagram along with flowrates and some chemical compositions.
• However, the diagram did not include any details of equipment within any of the blocks.
• Effective for conceptualizing a new process or a PFD.

Conventions and Format Recommended for Laying Out a Block Flow Process Diagram
1. Operations shown by blocks.
2. Major flow lines shown with arrows giving direction of flow.
3. Flow goes from left to right whenever possible.
4. Light stream (gases) toward top with heavy stream (liquids and solids) toward bottom.
5. Critical information unique to process supplied.
6. If lines cross, then the horizontal line is continuous and the vertical line is broken

TYPES OF BLOCK FLOW DIAGRAM
1. Block Flow Process Diagram
• gives a clear overview of the production, unobstructed by the many details related to the process.
• Each block in the diagram represents a process function and may, in reality, consist of several pieces of
equipment.
• Although much information is missing, it is very useful for “getting a feel” for the process.
• Block flow process diagrams often form the starting point for developing a PFD.

dcleal 1
ChE 522: Diagrams for Understanding Chemical Processes
Block Flow Process Diagram for the Production of Benzene









2. Block Flow Plant Diagram
• This allows us to get a complete picture of what a plant does and how all the different processes interact.
• Each block in this diagram represents a complete chemical process
• On the other hand, in order to keep the diagram relatively uncluttered, only limited information is available
about each process unit.
• The conventions for drawing block flow plant diagrams are similar to block flow process diagram

Block Flow Plant Diagram of a Coal to Higher Alcohol Fuels Process

B. PROCESS FLOW DIAGRAM (PFD)

• Represents a quantum step up from the BFD in terms of the amount of information that it contains.
• The PFD contains the bulk of the chemical engineering data necessary for the design of a chemical process.
• No universally accepted standards.
• The PFD from one company will probably contain slightly different information than the PFD for the same
process from another company.

Process flow diagram mainly defines:
1. A schematic representation of the sequence of all relevant operations occurring during a process and includes
information considered desirable foranalysis.
2. The process presenting events which occur to the material(s) to convert thefeedstock(s) to the specified products.
3. An operation occurring when an object (or material) is intentionally changed in any of its physical or chemical
characteristics, is assembled or disassembledfrom another object or is arranged or prepared for another
operation,transportation, inspection or storage.
dcleal 2
ChE 522: Diagrams for Understanding Chemical Processes

PURPOSE OF PFD
1. Plant design basis
• PFD shows the plant design basis indicating feedstock, product and main streams flow rates and operating
conditions.
2. Scope of process
• PFD serves to identify the scope of the process.
3. Equipment configuration
• PFD shows graphically the arrangement of major equipment, process lines and main control loops.
4. Required utilities
• PFD shows utilities which are used continuously in the process.

Contents of a Typical PFD
1. All the major pieces of equipment in the process will be represented on the diagram along with a description of
the equipment. Each piece of equipment will have assigned a unique equipment number and a descriptive
name.
2. Operating conditions around major equipment.
3. All process flow streams will be shown and identified by a number. A description of the process conditions and
chemical composition of each stream will be included. These data will be either displayed directly on the PFD or
included in an accompanying flow summary table.
4. All process lines, utilities and operating conditions essential for material balance and heat and material balance.
5. All utility streams supplied to major equipment that provides a process function will be shown.
6. Simplified control instrumentation pertaining to control valves and the likes to be involved in process flows.

Not Inclusive
The following items are generally not be shown on PFD, except in special cases:
1. Minor process lines which are not usually used in normal operation and minor equipment, such as block valves,
safety/relief valves, etc.
2. Elevation of equipment.
3. All spare equipment.
4. Heat transfer equipment, pumps, compressor, etc., to be operated in parallel or in series shall be shown as one
unit.
5. Piping information such as size, orifice plates, strainers, and classification into hot or cold insulated of jacket
piping.
6. Instrumentation not related to automatic control.
7. Instrumentation of trip system, (because it cannot be decided at the PFD preparation stage).
8. Drivers of rotating machinery except where they are important for control line of the process conditions.
9. Any dimensional information on equipment, such as internal diameter, height, length, and volume. Internals of
equipment shall be shown only if required fora clear understanding of the working of the equipment.

GENERAL DRAFTING INSTRUCTIONS
1. Scale
PFDs should not be drafted to scale. However, their size should be compatible with that of equipment drawings.
2. Flow Direction
As a rule, PFDs should be drawn from the left to the right in accordance with process flows.

dcleal 3
ChE 522: Diagrams for Understanding Chemical Processes
3. Process and Utility Lines in General
• The main process flow shall be accentuated by heavy lines.
• Process utility lines shall be shown only where they enter or leave the main equipment.
• Pipe lines shall not be identified by numbers.
• Valves, vents, drains, by-passes, sample connections, automatic or manual control systems, instrumentation,
electrical systems, etc. shall be omitted from the schemes.
• The direction of the flow shall be indicated for each line.

4. Kind of Lines
As a rule, Process lines, utility lines, and loop lines for instrument should be drawn as follows:
a. Main process line; thickness = 0.8 mm

b. Secondary process lines and utility line; thickness = 0.5 mm

c. All electrical, computer, and instrument signals; thickness = 0.3 mm

5. Line Crossover: horizontal line should be drawn as a continuous line in all cases. This shall not apply to loop lines
for instruments.

Denotation of Lines at Tie-In Points

Often PFDs are drawn on large sheets of paper and several connected sheets may be required for a complex process.

1. Process lines
From Item No. and/ or Dwg. No.To Item No. and/ or Dwg. No.

Where a PFD consists of two or more divided sheets, drawing numbers should be indicated

2. Utility lines

Cooling Water
Names of fluids should be given in parentheses above the utility lines.

3. Direction of Flow
The direction of flow should be indicated by arrows. In principle all flow lines should be denoted by arrows
located at the inlet of equipment, at merging points, and at the corners of the lines. Where a process line is long,
however, the process flow may be denoted by arrows located at intermediate points.
The number of arrows used to denote one process flow line is not restricted. However, care should be taken
not to clutter the drawing with excessive arrows. Arrows at corners may be suitably omitted.

dcleal 4
ChE 522: Diagrams for Understanding Chemical Processes
4. Division of PFD
Where a PFD must be divided into two or more sheets, it should be divided at portions where division is easiest
from the process standpoint and each divided section should be drawn on a separate sheet.
5. Title
The title should be given in the title block at the lower right-hand corner of the PFD.
6. Legend
The legend may be given in separate schematic drawing to which reference shall be made if necessary.
7. Size
The size of PFD should normally be A1 (594 mm × 841 mm).

CONTENTS OF A PROCESS FLOW DIAGRAM

The basic information provided by a PFD can be categorized into one of the following:
A. Process topology
B. Stream information
C. Equipment information
A. PROCESS TOPOLOGY

• Illustrates the location of the major pieces of equipment and the connections that the process streams make
between equipment
• Equipment is represented symbolically by “icons” that identify specific unit operations.
• A list of the equipment numbers along with a brief descriptive name for the equipment is printed along the top
of the diagram. The location of these equipment numbers and names roughly corresponds to the horizontal
location of the corresponding piece of equipment.

Basic Instrument Symbols
Process technicians use P&IDs to identify all of the equipment, instruments, and piping foundin their units.

FIGURE 1.Process/Instrument Symbols

dcleal 5
ChE 522: Diagrams for Understanding Chemical Processes

Conventions Used for Identifying Process Equipment

Process Equipment General Format XX-YZZ A/B

XX are the identification letters for the equipment classification

C - Compressor or Turbine R - Reactor

E - Heat Exchanger T - Tower
H - Fired Heater TK – Storage Tank

P - Pump V - vessel
Y designates an area within the plant

ZZ is the number designation for each item in an equipment class

A/B identifies parallel units or backup units not shown on a PFD
Supplemental Information Additional description of equipment given on top of PFD

PFD for the Production of Benzene via the Hydrodealkylation of Toluene (with Process Topology)

Note: Along the top of the PFD, each piece of process equipment is assigned a descriptive name.
Ex. Pump P-101 is called the “toluene feed pump.”

Conventions Used for Identifying Process Equipment:
General Format XX-YZZ A/B
Example: P-101A/B
P-101A/B identifies the equipment as a pump.
P-101A/B indicates that the pump is located in area 100 of the plant.
P-101A/B indicates that this specific pump is number 01 in unit 100.
P-101A/B indicates that a backup pump is installed. Thus, there are two identical pumps P-101A and P-101B. One pump
will be operating while the other is idle.

dcleal 6
ChE 522: Diagrams for Understanding Chemical Processes
B. Stream Information

• Each of the process streams is identified by a number in a diamond box located on the stream
• The direction of the stream is identified by one or more arrowheads.
• The process stream numbers are used to identify streams on the PFD
• Utility streams are included (electricity, compressed air, cooling water, refrigerated water, steam, condensate
return, inert gas for blanketing, chemical sewer, waste water treatment, and flares)

Conventions for Identifying Process Streams
• All conventions for block flow diagram apply.
• Diamond symbol located in flow lines.
• Numerical identification (unique for that stream) inserted in diamond.
• Flow direction shown by arrows on flow lines.

Conventions for Identifying Utilities Streams
lps Low-Pressure Steam: 3–5 barg (sat)
mps Medium-Pressure Steam: 10–15 barg (sat)
hps High-Pressure Steam: 40–50 barg (sat)
htm Heat Transfer Media (Organic): to 400°C
cw Cooling Water: From Cooling Tower 30°C Returned at Less Than 45°C
wr River Water: From River 25°C Returned at Less Than 35°C
rw Refrigerated Water: In at 5°C Returned at Less Than 15°C
rb Refrigerated Brine: In at −45°C Returned at Less Than 0°C
cs Chemical Waste Water with High COD
ss Sanitary Waste Water with High BOD, etc.
el Electric Heat (Specify 220, 440, 660V Service)
ng Natural Gas
fg Fuel Gas
fo Fuel Oil
fw Fire Water
As an example, the notation, cw, associated with the nonprocess stream flowing into E-102 indicates that cooling water
is used as a coolant (see example PFD given)


Process Flow Diagram: STREAM INFORMATION
• For small diagrams containing only a few operations, the characteristics of the streams such as temperatures,
pressures, compositions, and flowrates can be shown directly on the figure, adjacent to the stream.
• This is not practical for a more complex diagram.
• In this case, only the stream number is provided on the diagram.
• This indexes the stream to information on a flow summary or stream table, which is often provided below the
process flow diagram. In this text the flow summary table is provided as a separate attachment to the PFD.

dcleal 7
ChE 522: Diagrams for Understanding Chemical Processes
Information Provided in a Flow Summary
Required Information Optional Information

Stream Number Component Mole Fractions

Temperature (°C) Component Mass Fractions

Pressure (bar) Individual Component Flowrates (kg/h)

3
Vapor Fraction Volumetric Flowrates (m /h)

Total Mass Flowrate (kg/h) Significant Physical Properties

Density, Viscosity, Other
Total Mole Flowrate (kmol/h) Thermodynamic Data
Heat Capacity
Individual Component Flowrates (kmol/h) Stream Name
Stream Enthalpy
K-values
Process Flow Diagram: STREAM INFORMATION

Stream information is added to the diagram
by attaching “information flags.”

Symbols for Stream Identification

Sample of Section of PFD with Flags

dcleal 8
ChE 522: Diagrams for Understanding Chemical Processes

PFD for the Production of Benzene via the Hydrodealkylation of Toluene (with Process Topology and Stream
Information)

Flow Summary Tablefor the Benzene Process Shown

dcleal 9
ChE 522: Diagrams for Understanding Chemical Processes

C. Equipment Information
• Provides the information necessary to estimate the costs of equipment and furnish the basis for the detailed
design of equipment.

Equipment Descriptions for PFD and PIDs

Equipment Type Description of Equipment

Towers Size (height & diameter), Pressure, Temperature
Number and Type of Trays
Height and Type of Packing
Materials of Construction

Heat Exchangers Type: Gas-Gas, Gas-Liquid, Liquid-Liquid, Condenser, Vaporizer

Process: Duty, Area, Temperature, and Pressure for both streams
Number of Shell and Tube Passes
Materials of Construction: Tubes and Shell

Tanks and Vessels Height, Diameter, Orientation, Pressure, Temperature, Materials of

Construction

Pumps Flow, Discharge Pressure, Temperature, ΔP, Driver Type, Shaft Power,
Materials of Construction

Compressors Actual Inlet Flowrate, Temperature, Pressure, Driver Type, Shaft Power,
Materials of Construction

Heaters (Fired) Type, Tube Pressure, Tube Temperature, Duty, Fuel, Material of Construction

Other Provide Critical Information

Example: Equipment Summary for Toluene Hydrodealkylation PFD (HEAT EXCHANGER)

dcleal 10
ChE 522: Diagrams for Understanding Chemical Processes
Example: Equipment Summary for Toluene Hydrodealkylation PFD (VESSELS/TOWERS/REACTORS)

Combining Topology, Stream Data, and Control Strategy to Give a PFD

Process Flow Diagram (PFD) for the Production of Benzene via the Hydroalkylation of Toluene

Piping and Instrumentation Diagram (P&ID)
• The piping and instrumentation diagram (P&ID), also known as mechanical flow diagram (MFD), provides
information needed by engineers to begin planning for the construction of the plant.
• The P&ID includes every mechanical aspect of the plant EXCEPT the following information:
• Operating Conditions T, P ● Equipment Locations
• Stream Flow ● Pipe Routing
• Pipe Length ● Pipe Fittings ● Supports, Structures, and Foundations

dcleal 11
ChE 522: Diagrams for Understanding Chemical Processes

Conventions Used for Identifying Instrumentation on P&IDs

Location of Instrumentation

Instrument Located in Plant

Instrument Located on Front of Panel in Control Room

Instrument Located on Back of Panel in Control Room

Conventions Used for Identifying Instrumentation on P&IDs

Meanings of Identification Letters

Meanings of Identification Letters

First Letter (X) Second or Third Letter (Y) First Letter (X) Second or Third Letter (Y)
A Analysis Alarm M Moisture or Humidity Middle or Intermediate
B Burner Flame O Orifice
C Conductivity Control P Pressure or Vacuum Point
D Density or Specific Q Quantity or Event
Gravity
E Voltage Element R Radioactivity or Ratio Record or print
F Flowrate S Speed or Frequency Switch
H Hand (Manually High T Temperature Transmit
Initiated)
I Current Indicate V Viscosity Valve, Damper, or Louver

J Power W Weight Well

K Time or Time Schedule Control Station Y Relay or Compute
L Level Light or Low Z Position Drive

Symbols for instrument

1. The symbol for an instrument is a circle which shall be connected to the line which is nearest the point of
measurement.

2. Where the instrument is a controller, a dotted line representing the control impulse shall connect the instrument
circle to the controller valve.

3. The denotation of such functional symbols as "R" for recorder, "I" for indicator, and "A" for alarm, etc. should be
omitted except for the functional symbol "C” for control.

dcleal 12
ChE 522: Diagrams for Understanding Chemical Processes
Functional symbols for control

The following symbols are shown inside the circle representing the instrument.
Flow Controlling FC
Flow Ratio Controlling FRC
Level Controlling LC
Pressure Controlling PC
Pressure Differential Controlling PDC
Temperature Controlling TC
Temperature Differential Controlling TDC
Speed Controlling SC
Example: Piping and Instrumentation Diagram for Benzene Distillation

Conventions in Constructing Piping and Instrumentation Diagrams
For Equipment—Show Every Piece Including For Instruments—Identify
Spare Units Indicators
Parallel Units Recorders
Summary Details of Each Unit Controllers
Show Instrument Lines
For Piping—Include All Lines Including Drains and Sample Connections, For Utilities—Identify
and Specify Entrance Utilities
Size (Use Standard Sizes) Exit Utilities
Schedule (Thickness) Exit to Waste Treatment
Materials of Construction , Insulation (Thickness and Type) Facilities
NOTE: The final control element in nearly all chemical process control loops is a valve.

Example: Consider the benzene product line leaving the right-hand side of the P&ID given. The flowrate of this stream is
controlled by a control valve that receives a signal from a level measuring element placed on V-102.

dcleal 13
ChE 522: Diagrams for Understanding Chemical Processes

The sequence of instrumentation is as follows:

A level sensing element (LE) is located on the reflux drum V-102. A level transmitter (LT) also located on V-104 sends an
electrical signal (designated by a dashed line) to a level indicator and controller (LIC). This LIC is located in the control
room on the control panel or console (as indicated by the horizontal line under LIC) and can be observed by the
operators. From the LIC, an electrical signal is sent to an instrument (LY) that computes the correct valve position and in
turn sends a pneumatic signal (designated by a solid line with cross hatching) to activate the control valve (LCV). In
order to warn operators of potential problems, two alarms are placed in the control room. These are a high-level alarm
(LAH) and a low-level alarm (LAL), and they receive the same signal from the level transmitter as does the controller.

Recommended Minimum Spacing (in Feet)

between Process Equipment

Reasons for Elevating Equipment

dcleal 14
ChE 522: Diagrams for Understanding Chemical Processes
Problems:

1. Figure below is a portion of a PI&D. Find at least six errors in it. All errors are actually shown on the drawing.

Errors include:
1. LI on pump discharge should be PI.
2. Direction of arrowheads should be reversed.
3. TCV on control valve should be labeled FCV.
4. LAH on control loop should be FAH (Since no level signal is
shown)
5. Add isolation valve to the left of the control valve.
6. Add a bleed valve between control valve and isolation
valve.
7. Suction piping should be larger than discharge piping,
switch 4”with 8”
8. Label insulation.
9. Pumps should be labeled P-102 A and P-102B.


Corrected Diagram

2. Draw a proper P&ID diagram of the following process: A storage tank is filled with condensed products formed via a
CSTR. The tank contains a level controller at a set point on the top of the tank. If this tank were to fill, materials would
get clogged up in the reactor. Therefore, if the tank reaches 90% of its total capacity, the level controller will send an
electric signal, which opens an emergency drainage line located at the bottom of the tank. The level controller will also
activate an alarm alerting plant engineers that there is a problem with the storage tank. Finally, the level controller will
also close the inlet valve to the storage tank.

Solution:

dcleal 15