Process flow diagram
Process flow diagram Drawing that shows the general process flow between major pieces of equipment
of a plant and the expected operating conditions at the target production rate. Since the purpose of the
process flow diagram is to document the basic process design and assumptions, such as the operating
pressure and temperature of a reactor at normal production rates, it does not include many details
concerning piping and field instrumentation.
In some cases, however, the process engineer may include in the PFD an overview of key
measurements and control loops that are needed to achieve and maintain the design operating
conditions. The process engineer then documents the design in a process flow diagram (PFD).
The process flow diagram typically identifies the major pieces of equipment, the flow paths through the
process, and the design operating conditions—that is, the flow rates, pressures, and temperatures at
normal operating conditions and the target production rate.
A
process
flow
diagram
(PFD)
is a
diagram
commonly used in power plant engineering to indicate the general flow of plant processes and
equipment. The PFD displays the relationship between major equipment of a plant facility and does not
show minor details such as piping details and designations. Another commonly used term for a PFD is
a flowsheet.
Typically, process flow diagrams of a single unit process will include the following:
Process piping
Major equipment items
Control valves and other major valves
Connections with other systems
Major bypass and recirculation streams
Operational data (temperature, pressure, mass flow rate, density, etc.), often by stream
references to a mass balance.
Process stream names
Process flow diagrams generally do not include:
Pipe classes or piping line numbers
Process control instrumentation (sensors and final elements)
Minor bypass lines
Isolation and shutoff valves
Maintenance vents and drains
Relief and safety valves
Flanges
Process flow diagrams of multiple process units within a large industrial plant will usually
contain less detail and may be called block flow diagrams or schematic flow diagrams
Piping and Instrumentation (P&ID)
A
piping
and
instrumentation diagram is similar to a process flow diagram in that it includes an illustration of the
major equipment. However, the P&ID includes much more detail about the piping associated with the
process, to include manually operated blocking valves.
A piping and instrumentation diagram/drawing (P&ID) is a diagram in the power plant industry which
shows the piping of the process flow together with the installed equipment and instrumentation.
A piping and instrumentation diagram/drawing (P&ID) is defined by the Institute of Instrumentation
and Control as follows:
A diagram which shows the interconnection of process equipment and the instrumentation used to
control the process. In the process industry, a standard set of symbols is used to prepare drawings of
processes.
The primary schematic drawing used for laying out a process control installation.
P&IDs play a significant role in the maintenance and modification of the process that it
describes. It is critical to demonstrate the physical sequence of equipment and systems, as well as how
these systems connect. During the design stage, the diagram also provides the basis for the
development of system control schemes, allowing for further safety and operational investigations,
such as a Hazard and operability study commonly pronounced as HAZOP.
For processing facilities, it is a pictorial representation of
Key piping and instrument details
Control and shutdown schemes
Safety and regulatory requirements
Basic start up and operational information
List of P&ID items
Instrumentation and designations
Mechanical equipment with names and numbers
All valves and their identifications
Process piping, sizes and identification
Miscellanea - vents, drains, special fittings, sampling lines, reducers, increasers and swaggers
Permanent start-up and flush lines
Flow directions
Interconnections references
Control inputs and outputs, interlocks
Interfaces for class changes
Computer control system
Identification of components and subsystems delivered by
Mass Balance Diagram (MBD)
A mass balance, also called a material balance, is an application of conservation of mass to the analysis
of physical systems. By accounting for material entering and leaving a system, mass flows can be
identified which might have been unknown, or difficult to measure without this technique. The exact
conservation law used in the analysis of the system depends on the context of the problem, but all
revolve around mass conservation, i.e. that matter cannot disappear or be created spontaneously.
The general form quoted for a mass balance is The mass that enters a system must, by conservation of
mass, either leave the system or accumulate within the system.
A mass
balance can also be taken differentially. The concept is the same as for a large mass balance, but it is
performed in the context of a limiting system (for example, one can consider the limiting case in time
or, more commonly, volume). A differential mass balance is used to generate differential equations that
can provide an effective tool for modelling and understanding the target system.
The differential mass balance is usually solved in two steps: first, a set of governing differential
equations must be obtained, and then these equations must be solved, either analytically or, for less
tractable problems, numerically.
Guidelines of factories Act.
The Factories Act,1948 serves to assist in formulating national policies on occupational safety and
health in factories and docks in India. It deals with various problems concerning safety, health,
efficiency and well-being of the persons at work places.
The Act is administered by the Ministry of Labour and Employment in India through its Directorate
General Factory Advice Service & Labour Institutes (DGFASLI) and by the State Governments
through their factory inspectorates. DGFASLI advices the Central and State Governments on
administration of the Factories Act and coordinating the factory inspection services in the States[1].
The Act is applicable to factory whereon ten or more workers are working, or were working on any day
of the preceding twelve months, and in any part of which a manufacturing process is being carried on
with the aid of power, or is ordinarily so carried on, or whereon twenty or more workers are working,
or were working on any day of the preceding twelve months, and in any part of which a manufacturing
process is being carried on without the aid of power, or is ordinarily so carried on; but this does not
include a mine , or a mobile unit belonging to the armed forces of the union, a railway running shed or
a hotel, restaurant or eating place.
