CL 306 - Process Engineering and

Economics

Lecture 1: Overview of the course

Resmi Suresh (Assistant Professor, IIT Guwahati) 5th JAN 2020

Overview

▪ The course is about the engineering and economics related to chemical

processes
▪ Design course – Design of individual units
▪ This course – Design of an entire chemical plant
▫ Requires the engineering strategies and analysis of economics
▪ Background - Reaction Engineering, Process Control, Thermodynamics,
Heat and Mass transfer, Economics, Equipment design etc.
▪ The procedure of solving design problem are always under-defined, as
there are many factors need to be balanced to take a decision.
2
Decision making

How do I
chose the
best phone? ▪ Even when you buy a phone, lots of options
available and we need to chose from them
based on our requirements
▪ Think about how many decisions one need to
make to build a large-scale chemical plant

3
In almost every case encountered by a chemical engineer there are several alternative
4
methods which can be used for any given process or operation.
Questions we have to ask before project implementation

▪ What to produce?
Requires an extensive foresight and market knowledge
▪ How much to produce?
Depends on market analysis and economic plant capacity

▪ How to produce?
Selection of technology, optimal flowsheet, safety compliance, energy
conservation, project cost, working capital

▪ Will the project survive long enough to grow?

▪ Is this project going to be profitable after implementation? 5
Process engineering
▪ The term process engineering is used in connection with economic evaluation
and general economic analysis of industrial process while process design refers to
actual design of the equipment.
▪ Project engineering is associated with successful implementation of a project
▪ Example: Consider the case where a process engineer is commissioning a Heat
exchanger in a process industry, the role is not only to calculate effective heat
transfer area by material balances, but also to calculate the operating cost, rate
of return and profitability to the owner.
▪ There are two broad type of researches for the development of a process
▫ Basic Research – no commercial value
▫ Applied Research - has the definite goal to solve practical problem arises in industries,
if any change in product composition or quality, market demand, competitors, etc 6
Course objective

Novel
To help you understand Idea

▪ various steps involved in building

processes/ sub-processes
▪ how to find the best flow sheet
▪ how to estimate optimal operating
conditions
▪ how to do a cost analysis
…… 7
Optimal design

▪ Involves both optimal process/operation design and optimal economic

design
Example:
▪ Formaldehyde can be produced by
a. Oxidation of methanol
b. Oxidation of methane
c. Direct reaction between CO and H2
▪ Which process to choose for the industrial productions?
▪ Once you choose a process, what operating conditions should you use?
8
Optimal process design

▪ Many alternatives involving variables such as gas mixture composition,

temperature, pressure and choice of catalyst
▪ The role of chemical engineer is to find the best process which yields best
result (high yield or purity etc.) with process constraints
▪ The process which has higher yield may not be economically feasible!!

9
Optimal Economic Design

▪ Lowest cost among the alternatives

▪ The process which has lowest cost may have very low yield!!
▪ If there are two or more methods for obtaining exactly equivalent final
results, the preferred method would be the one involving the least total
cost. This is the basis of an optimum economic design.

Cannot usually separate optimal process and economic designs!!

Simultaneous optimization of cost and yield may be needed.
10
Example
▪ Consider an example of an optimum economic design to determine the pipe diameter
when pumping a given amount of fluid from one point to another (assume same fluid
between two given points)
▪ The optimal single diameter based on pressure difference may not be available industrially
▪ We may use multiple smaller length pipes combined or a single pipe of sub-optimal
diameter for the whole length
▪ It might be more economic to purchase a single pipe, but in terms of the process and
operational cost, it might be optimal to use multiple pipes
▪ Among all possibilities, we need to find how many parts is the best choice and what should
be the best diameter for each part
Role of optimization!!
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Design steps in process industries

12
General Overall Design Considerations

▪ Basic aspects of process design

▪ Selection of process equipment and utilities
▪ Plant location, layout and site layout
▪ Engineering Economics
▪ Synthesis of heat exchanger, reactor and separation system
▪ Chemical process safety
▪ Optimum design and production scheduling

13
Hierarchical Approach: “Divide-and-Conquer”

PLANT LEVEL

SUBSYSTEM
LEVEL
14
 Syllabus for the course

Module Topics Lectures Tutorial

1 Introduction to design steps, flowsheets, recycle structure of flowsheet 4 1

Introduction to project economic concepts, plant utilities, layout and

2 3 0
heuristics in process synthesis and design

3 Capital investment, method of capital cost estimation, total product cost 2 1

4 Type of interest, cash flow, profitability standard and analysis 4 1

5 Optimization techniques, MILP / MINLP studies (MATLAB / PYTHON) 3 1

6 Introduction to process synthesis, Hierarchical approach 3 0

7 Reactor synthesis by attainable region, reactor design 2 1

Selection criteria for separation process, design of distillation column, energy
8 3 1
integration
9 Composite curves, cost and heat exchanger design 3 1

10 Cost diagram, process alternatives and process retrofitting 3 1

15
Text Books
1. Timmerhaus, Plant Design and Economics for chemical engineers, 5th edition McGraw Hill 2011
2. Smith, Chemical process design and Integration 8th edition, Wiley 2006

Reference Books
1. T. Beiger, I.E Grossman, A.W. Westerberg Systematic methods of chemical process design, Prentice Hall,
International series 1997
2. Douglas, Conceptual Design of Chemical Process, McGraw Hill 1989
3. E. Ludwig, Applied Project Engineering, 2nd Edition, Gulf publishing company, 1988.

Evaluation type Marks

Tutorial 20
Assignment 30
Quiz 20
Final Project 30 16
 Teaching Assistants
TA name Contact email ID

Shanmugam V shanmugam.v@iitg.ac.in
Abhishek Bansal abhishek.bansal@iitg.ac.in
Durlov Pait d.pait@iitg.ac.in
Aakash Rajpoot arajpoot@iitg.ac.in

Class Hours
Day Time

Monday 4-4:55 PM
Tuesday 4-4:55 PM
Friday 3-3:55 PM
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Thanks!
Any questions?
You can find me at:
▪ resmis@iitg.ac.in

18
Lecture 2: Introduction to typical design
steps and input information

Resmi Suresh

Jan 8th, 2021

1
 Design steps

8-Jan-2021 2
 Design Steps of Chemical Process

1. Recognize a societal or engineering need Source of new ideas?

◦ Research (Applied / Basic)
◦ Sales department – as a result of customer request or to meet a competing
product
◦ Engineering department may originate a new process or retrofit
◦ Someone in plant operation may recognize a solution to the problem they
are facing
◦ Accidental discovery (eg: Teflon by Roy. J. Plunkett at the DuPont in 1938)

Example
◦ Electric vehicle
We have been using IC engine vehicles for a long time. It resulted in huge amount of
pollution.
There was a need for alternate technology. This resulted in electric vehicles.
◦ Haber-Bosch process
Nitrogen plays a crucial role in the biochemistry of our lives.
Due to low reactivity of nitrogen, plants and animals were not able to extract
nitrogen from air. This was a major limiting factor in agriculture.
In 1910, German chemists Fritz Haber and Carl Bosch changed all this when they
combined atmospheric nitrogen and hydrogen into ammonia. This in turn can be
used as crop fertiliser, eventually filtering up the food chain to us.
8-Jan-2021 3
 Design Steps of Chemical Process

1. Recognize a societal or engineering need.

2. Create one or more potential solutions to meet this need

o Make a literature survey and patent search (Expired patents can provide helpful information in the design of second generation processes )

o Identify the preliminary data required

o Select a process from several alternatives

3. Undertake preliminary process synthesis of these solutions – Process creation

o Determine reactions, separations, their operating conditions

o Involves synthesis or various configurations of processing operations with the help of prior knowledge and simulation studies

o Recognize environmental safety and health concerns

4. Asses profitability of preliminary process or processes

o If negative, reject process and create new alternatives

8-Jan-2021 4
 Design Steps of Chemical Process
5. Refine required design data
o Establish property data with appropriate software

o Verify experimentally, if necessary, key unknowns in the process

6. Prepare detailed engineering design

o Develop base case (if economic comparison is required)

o Prepare flowsheet

o Integrate and optimize process

o Check process controllability

o Size equipment

o Estimate capital cost

7. Reassess the economic viability of the process

o If negative, either modify the process or investigate other process alternatives

8. Revisit the process again for environment factors and provide a written process design report
8-Jan-2021 5
 Design Steps of Chemical Process

9. Complete the final engineering design

o Determine equipment layout and specifications

o Develop piping and instrumentation diagrams

o Prepare bids for the equipment or the process plant

10. Procure equipment

11. Installation

12. Commissioning of the plant and initiation of production

8-Jan-2021 6
 Levels of Design Accuracy
Depending on the accuracy and detail required, design engineers classify
process designs in the following 5 levels
Increasing accuracy and detail

◦ Order-of-magnitude designs No actual process design involved

Used to determine quickly the level of investment required
◦ Study or factored designs Identify raw materials, products and utilities

Approximate process methods and cost estimates are

◦ Preliminary designs prepared spending minimum time
Cost-and-profit potential of the process is
◦ Detailed-estimate designs determined although exact specifications of
equipment are not provided
◦ Final process designs
Undertaken if detailed-estimate design indicates commercial success
Complete specifications for all components, accurate cost and profit analysis
8-Jan-2021 Detailed documentation for immediate construction of project 7
 Input information
1. The reactions and reaction conditions
2. The desired production rate
3. The product purity or some information about price versus purity
4. The raw materials
5. Information about the rate of the reaction and the rate of catalyst deactivation
6. Any processing constraints
7. Other plant and site data
8. Physical properties of all the components
9. Information concerning the safety, toxicity and environmental impact of the material
involved in the process
10. Cost data for by-products, equipment and utilities

8-Jan-2021 8
 Input information
1. Reaction Information
➢The stoichiometry of all reactions that take place

➢The range of temperature and pressure for the reactions

➢The phases of the reaction system

➢Information on product distribution versus conversion

➢Information on conversion versus space velocity or residence time

If catalyst is used,

➢Information on the state of catalyst ( whether homogenous, slurry, powder etc)

➢Information on deactivation rate and regeneration of the catalyst

8-Jan-2021 9
 Input information
1. Reaction Information
Side reactions
▪ Any side reaction in the process could potentially affect the conversion of the main reaction.
▪ Even if only a trace amount of by-product us formed, it might build-up to large levels due to recycling
▪ Overlooking side reaction has been a common mistake, and it almost always leads to paying the large
economic penalties

Maximum Yield
▪ Many processes are designed to operate at maximum yield, but this
operation need not give optimal economic conversion

▪ Consider the reaction A → B → C, of which B is the desired product and

C has only fuel value. The concentration of A,B and C versus time in a
batch reactor is shown in below graph

▪ When B takes on its maximum concentration at point P, a considerable

amount of undesired C is formed and large amount of A is converted.
8-Jan-2021 10
 Input information
1. Reaction Information
▪ If we consider operating at point Q, only a small amount of C is formed. But, we will have a large amount of unreacted A, thus
operating at Q will require larger recycle flows and higher recycle cost. But we lose less of our expensive raw material A that could
have converted to C.

Selectivity = Moles of B produced / Moles of A converted

▪ Conversion of A to C is selectivity loss. Normally raw material costs and selectivity losses are the dominant factors in the design of
petrochemical process.

▪ The optimum economic conversion is normally fixed by an economic trade off between large
selectivity losses and large reactor costs at high conversions balanced against larger recycle
costs at low conversions.

▪ The graph shows that the optimum economic conversion is less than the conversion
corresponding to the maximum yield.
8-Jan-2021 11
 Input information
2. Production rate
Production rate is directly proportional to the plant capacity and it is fixed by maximum size of one or more pieces of
equipment
The production rate specified for the plant might change during a design as the market condition are constantly
changing we must be responsive to these changes.

3. Product purity
The product purity is fixed by the marketing considerations, it might be possible to produce a range of product purities
at different prices. It is essential that designer inform the marketing department about the cost associated with
producing high purity products, that does not raise customer expectations to unrealistic levels.

4. Raw Materials

During purchasing of raw materials need to gather information from marketing team about raw material price versus
purity. This will help to decide whether to include purification facility as a part of the design.

We must work with chemist to see whether the impurities in the raw materials are inert or will affect the reaction.
Particular trace amount of impurities can build up to large values in recycle loops

8-Jan-2021 12
 Input information
5. Catalyst Deactivation

Life time of catalyst is one of the major pre-requisite of early stages in design which enable us to determine
the deactivation period, hence it will put into regeneration or replacement after its appropriate usage.

6. Constraints

➢ There have been large number of serious plant explosion throughout the history chemical industry hence
safety precautions against ignitions must be incorporated.

➢ Some materials might polymerise and foul heat exchanger surface and also in the process of coking it will
form coke and deactivate catalysts. Toxic or highly corrosive materials also affect the way in which we
approach a design problem.

8-Jan-2021 13
 Input information
7. Physical property
The information we normally need are molecular weights, boiling points, vapour pressures, heat capacities, heat of
vaporisation, liquid densities, fugacity coefficients etc.

For new compounds, these properties may not be available and so, we will have to rely up on experimental studies or
simulation tools like ASPEN
8. Other plant and site data
If we are going to build our new process on an existing site, then we must design the process compatible with the
facilities that already exist on that site.

1. Utilities

a. Feed supply b. Levels of steam pressure c. Cooling water inlet and outlet temperature

d. Refrigeration level e. Electric power

2. Water Disposal facilities

8-Jan-2021 14
 Input information for the Haber process of Ammonia

To understand the basic input information, let us consider the case study of ammonia production in Madras Fertilizer Limited.

This plant was commissioned in the year 1966 producing ammonia, urea and NPK complex located in North Chennai, Tamil nadu.

a. Reaction

N2 + 3H2 ֞ 2NH3

Reaction condition:

Reactants are gas phase and catalyst is solid, hence it is heterogeneous reaction

Catalyst Iron, supported by promoter molybdenum

Reaction temperature 400-450 degC and pressure close to 200 atm.

b. Production rate
Plant has the daily rated capacity of 750 Metric tonnes

8-Jan-2021 15
 Input information for the Haber process of Ammonia
c. Raw materials

Naphtha from Chennai petroleum corporation limited (CPCL) was initially the feedstock for producing hydrogen in the reforming
unit. Later regularised to meet environmental standard requirements, there was a shift from naphtha to Natural gas. Hydrogen
produced from secondary reforming unit from natural gas along with air will be the feedstock to produce ammonia.

d. Catalyst deactivation

Iron is the catalyst and the active life period would be 5-10 years, further the catalyst will be taken for either regeneration or
replacement.

e. Processing Constraints

This is highly reversible reaction and it is thermodynamically favourable with high pressure as the number of moles decreases in the
product side and also requires decreasing temperature profile as it highly exothermic reaction. Failure of cooling water supply will
disturb the equilibrium production.

f. Plant and site data

This fertilizer plant commissioned with the agreement between Government of India and American chemical and oil company in the
year 1966 located at Chennai, Tamil nadu
8-Jan-2021 16
 Input information for the Haber process of Ammonia

g. Safety toxicity and environmental impact

➢ Effluent treatment systems and hydrolyser stripper for treating ammonia in place as a part of environment
protection.

➢ Cooling water blow down has been commissioned for recycling water

h. Cost data for by-products, equipment and utilities

➢ Carbon dioxide evolved during burning of natural gas will be absorbed using ethanolamine in the column,
will be utilized for urea production which saves considerable cost for further production

➢ Water treatment plants and Reverse osmosis plant are functioning effectively to meet the water demand.
Also receives secondary treated sewage water from Chennai metropolitan water supply and sewerage
board.

8-Jan-2021 17
 References
◦ Conceptual design of chemical process by James Douglas

◦ NPTEL video by Prof. Debasis Sarkar

◦ NPTEL video by Prof. Moholkar

◦ Images from google

8-Jan-2021 18
 CL 306
Process Engineering and Economics

Flowsheet Synthesis
Lecture-03

Flow Diagrams
Mass & Energy Balances

Dr. Resmi Suresh

Department of Chemical Engineering

January 11, 2021 | Slide 1

Picture or text?
Toluene is taken into the vessel V-101. It is pressurized,
mixed with hydrogen heated up in the furnace to raise the
temperature. The temperature maybe around 600 to 700
degree Celsius at which this reaction takes place.
And then fed to the packed bed reactor represented by
number R-101. So in this packed bed reactor toluene and
hydrogen reacts to produce benzene and methane. Now
there are two separators V-102, V-103. So the first one
separates the hydrogen, methane gas. So methane gas and
some unreacted hydrogen.
So whatever hydrogen is recovered it will be recycled back
and mostly methane and little bit of unrecovered hydrogen
will be released as flow gas. The separator V-103, this takes
the liquid stream, which is separated into benzene and
toluene in the distillation column T-101. The benzene is
taken out as product. The toluene is recycled back.
 FLOW DIAGRAMS

❖ Pictorial representations of a chemical process

❖ Flow Diagrams offer a very effective way of communicating information about a process
❖ A flow diagram is a diagrammatic model of the process that simplifies the visualization of
manufacturing procedure, i.e., it shows

✓ The sequence of the equipment and unit operations involved in the process.
✓ The stream connections, stream flow rates and compositions
✓ Energy flow in the process
✓ The operating conditions
✓ All necessary auxiliary equipment such as pumps, compressors, turbines, etc.

January 11, 2021 | Slide 3

 FLOW DIAGRAMS

▪ Depending on the information contained, flow diagrams may be divided into three general types:

Qualitative Quantitative Combined-detail

Indicates: A quantitative flow The combined-detail type

✓ The flow of materials diagram shows the of diagram shows the
✓ Unit operations involved quantities or materials qualitative flow pattern
✓ Equipment necessary and required for the and also equipment
✓ Special information on process operations specification, quantitative
operating temperatures data and sample
and pressures calculations.

January 11, 2021 | Slide 4

 Flow Diagrams: Classification

❖ Depending on the level of detail required several types of flow diagrams are used:

1. Block Flow Diagram (BFD) ✓ Simplified representation of the process

✓ A process is represented in terms of blocks

2. Process Flow Diagram (PFD)

✓ Pictorially represent the chemical process
✓ Equipment are drawn in a stylized pictorial form
✓ Contain much more detailed information than BFD
3. Piping and Instrumentation Diagram (P&ID)

❑ Piping and instrumentation diagram is very important for control system design and safety analysis.
❑ Commonly known as P&ID diagram also known as Engineering flow-sheet or Mechanical flow sheet.

January 11, 2021 | Slide 5

 Distillation
Block Flow Diagram Reactor
column

➢ Use of functional blocks - Simplest form of flow diagram used in industry

➢ Used to simplify and understand the basic structure of the system

➢ Block flow process diagram will concentrate on a particular sector/area of a chemical plant

➢ Each block can represent a single piece of equipment or a complete stage in a process or even the complete
process

➢ The simplest form of BFD, the input/output diagram provides the material streams entering and exiting the
process
Input Output
Process

January 11, 2021 | Slide 6

 Block Flow
Block Diagram:
Flow Hydrodealkylation
Diagram: Production ofofBenzene
Toluene for the production of Benzene

January 11, 2021 | Slide 7

 Block Flow Diagram

➢ Block flow plant diagram is used to explain the general material flows throughout an entire plant and would
help orient workers to the products and important operation zones of a chemical facility

➢ Stream flow rates, compositions and operating conditions can be shown

➢ Limited use for complex processes as it will be very difficult to use a large number of blocks to represent the
process
➢ We can use a single block for several units combined, but we will lose the detail of the process

January 11, 2021 | Slide 8

 Process Flow Diagram (PFD) or Process Flow-Sheet

➢ Graphical representation of a chemical engineering process that shows the preliminary process flow
path

➢ It does not show the minor details of the process rather it focus on the equipment used, control valves
and other instruments that are present.

➢ It helps to illustrate how the major components of a process plant interact with each other to bring the
desired effect

➢ It is also effectively used in other sectors such as business administration to understand how different
sections of a company can work efficiently in order to achieve their specific targets

January 11, 2021 | Slide 9

 Process Flow Diagram (PFD)

➢ Process flow diagrams may not show the working of the whole plant. It may be used to represent different
sections of a plant

➢ This would help us to understand in detail about each specific operation that is being carried out such as raw
material storage, reaction, separation, purification, recovery and product storage

➢ Sequence of the equipment and unit operation involved in the process, the stream connections and stream flow
rates, operating conditions and all necessary auxiliary equipment

➢ PFD symbols are a set of diagram that show how different parts of the process are interconnected to each other

➢ The symbols also depict the instrumentation devices that are used in the process. Examples of symbols include
valves, pumps, compressor etc.

January 11, 2021 | Slide 10

 PFD of Entire Crude Oil Distillation

Missing equipment and line numbers

January 11, 2021 | Slide 11
PFD of Hydrodealkylation (HDA) of Toluene
 Main features of Process Flow Diagram

➢ Major process streams and major instruments and controls are only shown

➢ Process streams are numbered and their flow directions will be represented.

➢ Equipment tag numbers are shown with their rated capacity, overall dimensions, design pressures and
design temperatures

➢ Legend of all equipment’s and instruments are shown either on same sheet or on a separate common sheet
depending on the size and complexity of the project.

➢ PFD forms the basis for developing the plot plans as piping studies for all major lines can be carried out on
its basis.

January 11, 2021 | Slide 13

 Main features of Process Flow Diagram
For each stream, temperature, pressure, composition etc. will be mentioned either in the
figure itself or as a separate table

January 11, 2021 | Slide 14

 Commonly used symbols in PFD for storage tanks and operating vessels

January 11, 2021 | Slide 15

 Symbols for Heat Exchangers and Fired Heaters

January 11, 2021 | Slide 16

 Symbols for Pumps, Compressors and Expanders

January 11, 2021 | Slide 17

 Basic overview of reading PFD

➢ Diamond symbol located on the lines represents the stream number, any number of streams can enter and go
out of the process that will be identified by unique numerical value.

➢ Flow arrows represent the direction of flow.

➢ Representation of equipment tag numbers will be XX-YZZ A/B.

XX or X denotes the equipment classification as mentioned below

T- Tower TK- Storage Tank P- Pump R- Reactor E- Heat Exchanger etc.

Y- Process area within the plant

ZZ – Number designation for each item in an equipment class

A/B – parallel units or back up spare

January 11, 2021 | Slide 18

 Hydrogenation of Palm oil

Area code
400

Area code 100

Area code Area code

200 300

January 11, 2021 | Slide 19

 Hydrogenation of Palm oil

▪ P101A/B
P – Pump
100 – Process area in the plant
01 – Pump number
A/B – Running and back up pump

4
V – Pressure control valve
Stream Number 100 – Process area in the plant
01 – Control valve number
January 11, 2021 | Slide 20
 Piping and Instrumentation Diagram

➢ A piping and instrumentation diagram is a schematic illustration of functional relationship of piping,

instrumentation and system equipment components

➢ PID shows all of piping including the physical sequences of branches, reducers, valves, equipment,
instrumentation and control interlocks.

➢ It is used for design, installation and day to day maintenance of the control system and also crucial for plant
operator to go through how the valves are used in the control of the process.

January 11, 2021 | Slide 21

 Essential components of PID

➢ Instrumentation and Identification

➢ Mechanical equipment with names and numbers

➢ All valves and their identification

➢ Process piping, sizes and identification

➢ Permanent start up and flush lines

➢ Flow directions and interconnection references

➢ Control inputs and outputs, interlocks

➢ Valves Cv, stream trap with hot and cold insulation are marked.

➢ Pump with suitable code number.

January 11, 2021 | Slide 22

 Pipe Symbols

➢ There are two methods to illustrate when pipes cross on drawings but are not physically connected. Either a small
hump to show one going over the other or break one of the lines very near the other to show it going under it.
➢ This is not a physical representation of the actual pipes. It is merely a method to keep the lines separate when they
must cross in the drawing

January 11, 2021 | Slide 23

 ❑ PID emphasis on process control and the below figure shows a typical feedback control system
representation in PID for maintaining the level in the tank

Electrical signal

Pneumatic signal

Pneumatic control valve

January 11, 2021 | Slide 24

 PID Tagging philosophy
• Letters and numbers are used to designate the property being measured (such as flow rate, pressure,
temperature or level) and the function performed with that measurement.

• Typical functions are display, record, transmit and control. These instruments are identified by up to five
letter and minimum of two

✓ 1st letter is the property being measured

F= flow rate, P= pressure, T= Temperature, L = Level

✓ 2nd letter is a modifier

D= Differential, F = ratio (omit if no modifiers apply)

✓ 3rd letter indicates passive/readout function (omit if doesn’t apply)

A = Alarm, R = Record, I = Indicator, G = Gauge

January 11, 2021 | Slide 25
 PID Tagging philosophy
✓ 4th letter is active/output function

C = Controller, T = Transmit, S = Switch, V = Valve

✓ 5th letter is the function modifier (Omit if no modifiers apply)

H = High, L = Low, O = Open, C = Closed

FIC045 – Flow indicating controller in the loop 045

PC045 – Pressure controller in the same loop
PT045 – Pressure transmitter in the same loop

January 11, 2021 | Slide 26

January 11, 2021 | Slide 27
 Symbols Used in PID

➢ There are standard symbols used to represent the component in these diagrams. It is important to note that
these symbols are NOT to scale and are NOT dimensionally accurate.

➢ These symbols are also labelled with words, letters and numbers to further identify and specify the
components that they are representing.
➢ Symbols used could vary from company to company

➢ PID do not represent the physical locations and proximity of the each component

➢ The purpose is not to serve as a floor plan or map of the system, it is to illustrate the process of the system

January 11, 2021 | Slide 28

 Valve Symbols

January 11, 2021 | Slide 29

 Actuator

End connection

January 11, 2021 | Slide 30

 Vessels

Pump and Fan

January 11, 2021 | Slide 31

 ❑ All of these bubble types are further defined by horizontal line and lines. These lines define where the
instrument is located and whether or not it is accessible to the operator

January 11, 2021 | Slide 32

January 11, 2021 | Slide 33
 Line number representation
Every line in the PID should have unique tag number representation with information like schedule, line size, length, Nominal Diameter and
sometimes whether it is insulated or not. This will help to trace the connecting PID as well as take the necessary action in case of failure in any of the
connected equipment.

Examples:

• Example 1: 3’’-P-12007-A11A-H30

3 inch, fluid service, unit/facility no 12, serial no. 007, piping service class A11A, Hot insulation of thickness 30 units

A- rating, 11-piping material, A- a suffix qualifying the piping material

• Example 1: 2”AARX-304S/S-1”F

2” dia., Type 304 stainless steel pipe in acetic acid reactor discharge service, insulated with 1” of fiberglass insulation

January 11, 2021 | Slide 34

 Separation of benzene and toluene

January 11, 2021 | Slide 35