Process Drawings

(KIL1002 Chemical Process Principles 1)

Dr. Faidzul Hakim Adnan

faidzulhakim.adnan@um.edu.my

DEPARTMENT OF CHEMICAL ENGINEERING

UNIVERSITI MALAYA
Learning outcomes
At the end of this class, you should be able to

❖ explainthe key uses and features of the 4 major

process drawings:
▪ Block diagrams
These are the focus of this course
▪ PFD (Process Flow Diagrams)
▪ P&ID (Piping & Instrumentation Diagrams)
▪ GA (General Arrangement) drawings

❖ prepare PFDs

2
3
 1. Conceptual design
What happens if a large
pump suddenly stops (e.g.
no power)?
This oscillatory flow creates
large pressure waves that hit
the piping bends and the
pump

Creates low pressure Flow reverses later

upstream because the due to this suction,
liquid inside still and the whole cycle
rushes ahead could repeat

4
continued …
To protect the pump and the
system, we normally install
Inflow and outflow of
pressurized air
❖ a non-return valve (check valve)
-
airin is not airoutis

at the pump delivery, to block back

m.
at

- ChingaPressure)
flow
-
a non-return->
value.
I
❖ a surge tank to supply or to
absorb the surging liquid

This tank must be

pressurized to resist Here we use the familiar
overflow block diagram

5
2. Preliminary design
We have to complete the
mass (and energy) balance No flow normally
6.5 barg
70 m3/h
25 SCMH max both ways
How to report the results?

❖ on the lines?

Not always practical for 70 m3/h

complicated systems

No flow normally
❖ the industry standard: use 10 m3/h max either way
Process Flow Diagrams (PFDs) Values here are for illustration only …
the calculations are too advanced!

6
 Process Flow Diagram (PFD)
Reports essential mass and
4 5
energy balance results 2

3
Tabulates stream data,
typically the steady state 1
❖ temperature
❖ pressure 1 2 3 4 5
❖ total mass flow rate T (oC) 35 35 --- 35 35
❖ individual species flow rates P (barg) 0.5 6.5 --- 6.5 6.5
H2O (te/h) 70 70 10* 0 0
Sometimes a PFD includes Air (SCMH) 0 0 0 25# 25#
❖ physical properties * Max, normally zero Rev Date By
# Max, normally zero
1 22-11-2015 YHK

7
 3. Detailed process design
With flow rates, we can find Then we worry about how
pipe sizes to run, monitor and control
the system, e.g.

❖ how will the operator know

if the surge tank is not empty?
We should also decide the
materials and the thickness ❖ how can the compressed air
of the piping, e.g. flow be automated?

❖ to withstand the pressure We need another drawing

❖ to avoid corrosion to show all these details

nominal value of parameter

value
Set at optimal
condition.
8
Piping & Instrumentation Diagram❖ Level switch OPEN when LOW
❖ Normally close
❖ Why low? Cause too much is
❖ Level switch OPEN when HIGH
deliver
of the
ide pumped in already emptying the
surge tank. Air pressure comes in
n
❖ Normally close to

❖ Why high? Pump failure. Water get

sent into surge pump due to back awae to put back into regulated pressure.
❖ Low level can also be due the
flow or pump overflow. LAHH backflow into the pilot. Adjusting
the pressure by opening the valve
LSH will avoid this.
Valve position switch: reports
valve is open (H) or close (L) indicator it's
LSN
ZSHL when LSL ZSHL

-snowigh witha
5
position

levelelement,
value
Switch
w
whether LALL
is
it open/close.
additional protection
DN25
L
LE DN25
Pressure relief valve E Slightly
DN25
DN25
simplified,

en
DN25
DN600 surge tank only
decoratio dPI
L
dPT
Surge Vessel por Sight
glass
①
E
DN600
exc DN25 DN25

DN200
From / To the pilot 9
Valve to refill or empty
the tank
 E

4. Constructing the plant

We need to know the dimensions, and how things are arranged in 3D
General Arrangement (GA)
drawing
O
Top view (or plan view)
of the surge vessel

10
continued …

Can you find

·O
Side view (or elevation view)
of the surge vessel

the items in the

P&ID?

11
12
Key features of each drawing?
Key Features BD PFD P&ID GA
Major unit operations shown v ~v v

Major connecting streams shown vvv -

Flows generally from left to right v v v X

All minor streams shown X X v v

Streams labelled
stream
details
numbers codebel rarely

Mass and energy balance results given X

V X X

Piping details shown X X v v

Control loops shown X x v x

Drawn to scale, with multiple views X X X V

Ownership & revision tracking X V v ~

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 What are these mostly used for?
BD PFD
-
conceptual understanding -

production calculations

-disclosure
to external parties, benchmark for process

performance
-

P&ID GA
construction
-
understanding control

-modification, maintanance
philosophy.
review
-trouble-shooting
-

safety
-costing.
-
modification, maintanance.
review
-
safety
-
costing.

14
Test yourselves …
Which drawing(s) to use if you wish to …

Activity Drawing
Know what happens inside every stream PFD

List down what to buy to build the plant PnIb

Have an idea of the process BD

Check if there is space for a plant modification GA

Design the supporting structure for equipment GA

Examine if the equipment or part can be maintained EA, AnIb

Find out the expected performance of the plant PAT

Check if the plant can be operated properly -A /

Pu ID.

15
Further reading
❖ “Diagrams for Understanding Chemical Processes”, Debangsu
Bhattacharyya, Joseph A. Shaeiwitz, Richard Turton, Wallace B.
Whiting, 2012, Prentice-Hall,
http://www.informit.com/articles/article.aspx?p=1915161

❖ ISO 10628-1, “Diagrams for the Chemical and Petrochemical

Industry- Part 1: Specification of Diagrams”

❖ ISO 10628-2, “Diagrams for the Chemical and Petrochemical

Industry- Part 2: Graphical Symbols”
All available now
in the library

16
17
 A cooling tower
A cooling tower cools down the returning warm water by contacting
it with a stream of air. Water lost by evaporation into the air is
replenished with the make-up water. The cooled water is then
pumped back to the processes.
Air, 40oC
Fan
Cooling water return, 45oC Processes that
Cooling generate heat
Make-up tower and need
water Cooling water supply, 39oC cooling

Air 35oC
Pump, 30 m3/h

18
 PFD for the cooling tower
air (3) absorbs heat
x out hot (4)
from hotwater (i) water comes

3 in ctc with the operation (4)

I
W

Processes that
5 generate heat
Cooling
1 tower 4 and need
- cooling

↑
(I) to
water make up
account for the solubility

ofwater in air.
2 Fair is inert 4atm (4) after pump
(s
but coming outlower

Stream: 1 2 3 4 5
T (oC) 34 35 40 39 45
P (atm abs.) 1 1 1.03 4 2.5

H2O (kg/s) 0.060 0.185 (v) 0.245 (v) 8.33 8.33

PFD-1123
N2 (kg/s) 0 4.25 4.25 --- --- 1 YHK 31/07/2014
O2 (kg/s) 0 1.29 1.29 --- --- Rev By Date

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Extracting information from a PFD
Based on the cooling tower PFD,

❖ What is the expected ambient temperature?

34 -
35°

❖ What is the design pressure drop in the cooling water circuit?

*P4-
1. 5a =

❖ Are the solubilities of air in water considered?

Yes, air contains
inlet 0.185kg/s 120 and outlet contains 0.245kg/s.

❖ Is the water balance correct?

H2O soluble in air.
make water of 0.06kg/s accounting for
up

❖ What is the design cooling load of the tower?

constant:1.88 kgls -

① in ctec ↑
A not
cooling
Qunfer=inH0.Cp. AT
=

20
water
water ↳ 45 -
39

Cheat loss (