Len Church Jan, 2011

Process Flow Diagram

Prepared early, 85% complete by completion of DBM

Conveys a basic pictorial definition Process equipment Connecting flow paths Primary control elements. Provides an understanding of the process Pertinent process flow data and Heat and material balances
table within the relevant diagram separate, attached document (preferred).

 Basis for Piping and Instrumentation Diagrams

(P&IDs) development Responsibility of Process engineers Used by various members of the project team:
Customer review, approve, scope of work, operations Project Manager - reviews, preliminary HAZOPs Instrument Engineer - control philosophy, basic

control schemes Mechanical Engineer - major equipment; number, types & sizes, ident. of potential equipment suppliers Electrical Engineer - Preliminary estimate of major motor loads & identification of Variable Frequency Drives (VFDs)

 Used by (contd) Piping Engineer Equipment Layout, plot plans, piping specifications selection Materials Engineer - metallurgy selection Cost Estimator - preliminary cost estimate

 PFD Content Stream Identification:

Feed Products Intermediate By-products Waste

Process piping (mainly)

Major equipment

Symbolically represented Numbered (tagged) Named Sized

 PFD Content (contd) Vessel internals

Trays Baffles Demisters Vortex breakers Etc

HMS

HMR

Valves that affect the operation Control Block Connections with other systems Steam Heat medium Chemical injection required for normal operations

 PFD Content (contd) Major by-pass and recirculation streams Stream references to the heat and material balances

 PFD Content (contd) Process stream names (edge of drawing only)

beside the "drawing continuation arrow boxes beside feed, product or utility streams that enter or leave the process unit (but not to another dwg) with origin or destination

 PFD Content (contd) Control bubbles showing the type of process variable being controlled
Pressure Temperature Level Etc.

 PFD Content (contd) All basic control functions

master/slave arrangements control functions with calculations ratio controllers, etc

Notes for P&ID development

equipment/piping arrangement requirements.

General notes
assist understanding

of the process flow scheme

 PFDs do not include: Pipe classes or piping line numbers or size Process control instrumentation (sensors and final elements) Minor by-pass lines Isolation and shut-off valves Maintenance vents and drains Relief and safety devices Flanges Minimum flow by-passes on pumps Nitrogen/inert gas purge lines or steam-out lines

 PFDs do not include: Block valves

except for alternate flow paths, start-up lines etc

Pressure and temperature indicators and recorders Pipe and equipment cladding Other installed features

 PFD Development Principles: Use customer standard symbols (if available)for:

equipment numbering equipment title terminology

Equipment items reflect

physical characteristics proportion

Display equipment identification

top of the PFD vertically above equipment (if possible)

 PFD Development Principles (contd):

In general, process flows from left to right Divide the process logically between drawings when

more than one PFD is needed PFD drawing number source or destination
shown in boxed arrow source or destination description adjacent

To show different design options being considered

include separate PFDs or separate H&M Balances

 PFD Development Principles (contd): Designate stream numbers (names) for all major process flows
in a logical manner correspond to the H&M Balance stream numbers

Start-up, shutdown, and recycle lines may be shown

but are generally not numbered unless

they are key to the process and have an identified flow in the H&M Balance

Clearly identify exchanger shell-side and tube-side

process streams (otherwise use blank symbol)

 PFD Development Principles (contd): Show all major process lines

in bold with stream direction clearly identified

Other lines essential to understanding process

lighter weight

Licensed technology package indentified with dashed

border Instrumentation shown in a simplified manner

no Tags

Reviewed and checked before formal issue

 Review Tutorial 8 Samples PFDs - standard drawing symbols, example PFDs and P&IDs, mass and energy balance tables PFD controls - Process control depiction on PFDs

 Piping & Instrument Diagram

Convey a detailed graphical definition of: ALL the process & other equipment Piping Control & instrumentation Prepared early (in EDS) other disciplines design

from it Prepared by
Process engineers - accountable and responsible Other engineering disciplines - responsible

 Prepared from the PFD

Prepared in association with the Line Designation

Table (LDT) Types; Process, Utility & Equipment Auxilliary

 P&ID Content PFD content Plus PFD not included items (from above) Plus miscellaneous other items Equipment Tagging
Typically assigned during PFD development All major equipment must have one

Equipment Description

All start with equipment name Pumps & Compressors: rated capacity, head, power Vessels: diameter ID (or OD), length T/T (or S/S), design press & temp, material, insulation

 Equipment Description (contd)

Tanks: diameter & height, nominal capacity, design press & temp, material, insulation Shell & Tube Exchangers: duty, shell design press & temp, tube design press & temp, material, insulation Air Coolers: duty, tube design press & temp, material, insulation Note: equipment descriptions located along top of drawing, rotating equipment along bottom

Instrument Tagging Piping

Identification: size, specification, commodity, number, insulation, heat tracing Specification breaks Slope, no pockets or free draining

 Piping (contd)

spectacle blinds
reducers
Valves required for isolation

block positive isolation, typically gate or ball valves ESD on/off emergency isolation valves Butterfly - low pressure differential, leakage globe throttling needle small diameter, throttling, on/off diaphragm, pinch slurry service check prevent back flow, leakage CSO or CSC, NO or NC Vents & drains

 P&ID Content (contd) Relief valves

required to prevent over pressure on equipment & piping

Control Valves

Generally one size smaller than piping Fail positions indicated: FO, FC consider 1. personnel injury, 2. equipment damage, 3. vessel inventory loss Tight shut off (TSO) Bypasses vs hand jacks Isolation valves & drains upstream & downstream

 P&ID Content (contd) Insulation

Heat conservation Personnel protection Cold insulation Thickness

Heat tracing required for freeze protection, maintaining pour point maintains temperature when flow has stopped piping vessels its not a heater dead legs electric, steam, glycol

 Sparing

Critical equipment Rotating equipment - pumps, compressors Process equipment - filters, adsorbent beds, chemical beds Philosophy required

Flow

Meters: orifice plates, vortex, coriolis, ultrasonic Size provided by instrumentation engineer Generally located upstream of systems control valve Transmitters

Pressure, temperature & level

Gauges Transmitters

 P&IDs do not include complete control logic

located in the Control Narrative and/or Shutdown Key

P&ID Development Principles Generally the principles for PFDs apply except now all details are added Reference to H&M Balances are omitted Its an art!

 Review sample P&IDs

Location: Tutorial 8, more drawing examples