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THIẾT KẾ P & ID

CHƯƠNG 1. GIỚI THIỆU


TS. Nguyễn Thành Duy Quang
Giảng viên bộ môn Chế biến dầu khí

Phòng 109B2.
Office hour: Sáng thứ 4 hàng tuần (8h30-11h30)

E-mail1: ntdquang@hcmut.edu.vn
E-mail2: ntdquang@gmail.com
Giới thiệu về môn học
Môn học trình bày các kiến thức cần thiết để tạo ra một
bản vẻ thiết kế đường ống & thiết bị (Piping and
Instrumentation Diagram - P & ID diagram) cho một thiết
bị / cụm thiết bị trong nhà máy hóa chất. Cụ thể hơn, 3
nhóm kiến thức được trình bày trong môn học:
1. Kiến thức để phát triển / tạo ra bản vẻ P & ID thỏa
mãn các yêu cầu đặt ra về vận hành và điều khiển thiết
bị và yêu cầu về an toàn
2. Kiến thức liên quan đến cách thức thể hiện các thông
tin trên bản vẻ P & ID
3. Kiến thức để vẻ ra bản vẻ P & ID

Ngày nay, việc vẻ bản vẻ P & ID thường được thực hiện


bằng phần mềm nên môn học này tập trung vào nhóm
kiến thức thứ nhất và thứ hai
Tài liệu tham khảo

1. Moe Toghraei. (2019). “Piping and Instrumentation Diagram


Development”, Wiley.
2. Ray Sinnott and Gavin Towler. (2019). Chapter 5 "PIPING AND
INSTRUMENTATION" in the book “Chemical Engineering Design”,
Elsevier.
3. Turton, Bailie, Whiting, and Shaeiwitz. (2012). Chapter 1
“Diagrams for Understanding Chemical Processes” in the book
“Analysis, Synthesis and Design of Chemical Processes, Fourth
Edition”, Prentice Hall.
4. Charles E. Thomas. (2015). Chapter 11 and Chapter 12 in the book
“Process Technology Equipment and Systems, 4th Edition”, Cengage
Learning
Điểm đánh giá

•Kiểm tra / Bài tập: 25%

•Đồ án: 25%

•Thi: 50%
Giới thiệu về quy trình thiết kế

Determine Set Design


Customer Needs Specifications
Build Performance
Models
Generate Design
R&D if Needed
Concepts
Predict Fitness
For Service

Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction

Common to all design problems in all industries


Đội ngũ thiết kế

Project Business
Sponsor Input

Project
Manager

Process Technical Control


Cost Engineer Consultants
Engineer(s) Specialists Engineer

R&D Mechanical Civil


Contractors
Specialists Engineer(s) Engineers
Chuyên môn hóa trong công tác thiết kế
và vận hành quy trình

Operating Companies
• Own plants Technology Vendors
• Produce chemicals • Own patents
• High sales revenue
• Margins & return on assets • Sell catalysts, enzymes,
(ROA) vary by sector equipment, licenses
• Sales volume low
• Margins, ROA usually high

Engineering & Construction Companies


• Experienced project managers
• Highly competitive & cost effective
• Medium sales volume, low margins
Long ago (<1980s) most projects were done “in house”

Operating
Company Project Business
Sponsor Input

Project
Manager

Process Technical Control


Cost Engineer Consultants
Engineer(s) Specialists Engineer

R&D Mechanical Civil


Contractors
Specialists Engineer(s) Engineers

E&C
Technology Company
Vendor
Nowadays
(For most companies, most sectors)

Project Business
Operating Sponsor Input
Company

Project
Manager

Process Technical Control


Cost Engineer Consultants
Engineer(s) Specialists Engineer

R&D Mechanical Civil


Contractors
Specialists Engineer(s) Engineers

Technology E&C
Vendor Company
Cơ sở của thiết kế
Determine Set Design
Customer Needs Specifications
Build Performance
Models
Generate Design
R&D if Needed
Concepts Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction

Chúng ta cần phải biết:


• Đang thiết kế cái gì? Sản lượng bao nhiêu?
• Vị trí nhà máy ở đâu? Điều kiện môi trường ở vị trí nhà máy?
Cơ sở của thiết kế
Project Name
Company Name Project Number Sheet 1
Address

DESIGN BASIS
REV DATE BY APVD REV DATE BY APVD

• Ghi chép thành văn bản các yêu cầu


Form XXXXX-YY-ZZ

thiết kế, các giả định thiết kế và điều


1 General Information

Owners Name

Process Unit Name

kiện môi trường là rất quan trọng


Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

English Metric
• Các văn bản này rất quan trọng trong
việc trao đổi thông tin giữa chủ đầu tư,
3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)

nhà cung cấp bản quyền công nghệ và


D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve

4 Primary Products

nhà thầu xây lắp (EPC)


Product Name
Product Grade
MSDS Form Number

Production Rate
Tons per year
Tons per day
Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
Feedstock name
Feedstock grade
MSDS form number

Feedstock availability
Tons per year
Tons per day
Other units

Feedstock price ($/lb)


(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw

Additional specifications

6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements
Thông tin nào trong văn bản
Project Name
“Cơ sở thiết kế”?
Company Name Project Number Sheet 1
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS

Form XXXXX-YY-ZZ
1 General Information

Owners Name

Process Unit Name

Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

English Metric

Project Name
3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve

Project Number Sheet 1


4 Primary Products

Product Name
Product Grade
MSDS Form Number

Production Rate
Tons per year
Tons per day

REV DATE BY APVD REV DATE BY APVD


Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
Feedstock name
Feedstock grade
MSDS form number

Feedstock availability
Tons per year
Tons per day
Other units

Feedstock price ($/lb)


(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw

Additional specifications

6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements

Project information and revision tabs


• To allow retrieval of documentation
• To ensure that revisions are properly documented and make sure that the engineers
aren’t working from the wrong version
• To document review and approval of the design basis
Thông tin nào trong văn bản
Project Name
“Cơ sở thiết kế”?
Company Name Project Number Sheet 1
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS

Form XXXXX-YY-ZZ
1 General Information

Owners Name

Process Unit Name

Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

English Metric

3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve

4 Primary Products

Product Name
Product Grade
MSDS Form Number

Production Rate
Tons per year
Tons per day
Other units

Product Purity (wt%)

Product shipment mode


1 General Information
Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
Owners Name
Feedstock name
Feedstock grade
MSDS form number

Feedstock availability
Tons per year
Tons per day
Other units
Process Unit Name
Feedstock price ($/lb)
(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw
Plant Location

Correspondance Contacts
Additional specifications

6 Site Information Address


Low ambient temperature (F)
High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Telephone / Fax
E-mail
Other site design requirements

Contact information
• Company name
• Process unit name
• Who to contact & where to reach them
Thông tin nào trong văn bản
Company Name
Address

DESIGN BASIS
Project Name
Project Number
REV DATE BY APVD REV
Sheet
DATE BY
1
APVD
“Cơ sở thiết kế”?
Form XXXXX-YY-ZZ
1 General Information

Owners Name

Process Unit Name

Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

English Metric

3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve

4 Primary Products

Product Name
Product Grade

2 Measurement System
MSDS Form Number

Production Rate
Tons per year
Tons per day
Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

English Metric
5 Primary Raw Materials
(Attach additional sheets if needed)
Feedstock name
Feedstock grade
MSDS form number

3 Equipment Numbering System


Feedstock availability
Tons per year
Tons per day
Other units

Feedstock price ($/lb)


(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
Additional specifications

6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements

D Dryer ME Miscellaneous equipment


First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve

Conventions followed
• Units of measurement
– Customer specific and may also depend on location
– Design engineers have to be able to work with both metric and English units
• Equipment labeling convention
• Sometimes other conventions and codes, e.g. design codes
Thông tin nào trong văn bản
“Cơ sở thiết kế”?
Company Name
Address
Project Name
Project Number
REV DATE BY APVD REV
Sheet
DATE BY
1
APVD
Product Name
Product Grade
DESIGN BASIS

Form XXXXX-YY-ZZ
1 General Information

MSDS Form Number


Owners Name

Process Unit Name

Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

3 Equipment Numbering System

Equipment will be identified by alphabetic


English

AC Air cooler
Metric

G Grinder, mill R Reactor


Production Rate
Tons per year
prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve

Tons per day


4 Primary Products

Product Name
Product Grade
MSDS Form Number

Other units
Production Rate
Tons per year
Tons per day
Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
Feedstock name
Feedstock grade
MSDS form number

Feedstock availability
Tons per year
Tons per day
Other units

Feedstock price ($/lb)


(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw
Product Purity (wt%)

Additional specifications

Product shipment mode


6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)

Additional Specifications
Maximum wind loading (mph)
Other site design requirements

Product information for primary products


• Product grades desired
• Safety data sheet reference number
• Production rate, purity, shipment details
Thông tin nào trong văn bản
“Cơ sở thiết kế”? Feedstock name
Company Name
Project Name
Project Number Sheet 1
Feedstock grade
MSDS form number
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS

Form XXXXX-YY-ZZ
1 General Information

Owners Name

Process Unit Name

Feedstock availability
Plant Location

Correspondance Contacts
Address
Telephone / Fax
E-mail

2 Measurement System

English Metric
Tons per year
Tons per day
3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)

Other units
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve

4 Primary Products

Product Name
Product Grade
MSDS Form Number

Production Rate
Tons per year
Tons per day
Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
Feedstock name
Feedstock price ($/lb)
(Default: open market price)
Feedstock grade
MSDS form number

Feedstock availability
Tons per year
Tons per day
Other units

Feedstock price ($/lb)


(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw

Known feedstock impurities Name ppmw


Additional specifications

6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements

Information for primary raw materials Additional specifications

• Feedstock grades
• Safety information
• Availability and pricing
• Feed impurities and their concentrations
Thông tin nào trong văn bản
“Cơ sở thiết kế”?
Project Name
Company Name Project Number Sheet 1
Address REV DATE BY APVD REV DATE BY APVD

DESIGN BASIS

Form XXXXX-YY-ZZ

Low ambient temperature (F)


1 General Information

Owners Name

Process Unit Name

Plant Location

High ambient temperature (F)


Correspondance Contacts
Address
Telephone / Fax
E-mail

Hight ambient relative humidity (%)


2 Measurement System

English Metric

3 Equipment Numbering System

Equipment will be identified by alphabetic AC Air cooler G Grinder, mill R Reactor

Site elevation (ft)


prefix as defined here, followed by three- B Boiler H Heater (fired or electric) SP Sample point
digit serial number unless otherwise C Compressor, blower, fan J Ejector, jet, turboexpander T Storage tank
indicated CT Cooling tower M Mixer V Vessel (including columns)
D Dryer ME Miscellaneous equipment
First digit - process section E Exchanger P Pump
Second & third digits - equipment count F Filter, classifier PRV Pressure relief valve

4 Primary Products

Product Name
Product Grade
MSDS Form Number

Production Rate
Tons per year
Maximum wind loading (mph)
Other site design requirements
Tons per day
Other units

Product Purity (wt%)

Product shipment mode

Additional Specifications

5 Primary Raw Materials


(Attach additional sheets if needed)
Feedstock name
Feedstock grade
MSDS form number

Feedstock availability
Tons per year
Tons per day
Other units

Feedstock price ($/lb)


(Default: open market price)

Known feedstock impurities Name ppmw Name ppmw Name ppmw Name ppmw

Additional specifications

6 Site Information

Low ambient temperature (F)


High ambient temperature (F)
Hight ambient relative humidity (%)
Site elevation (ft)
Maximum wind loading (mph)
Other site design requirements

Site information
• Ambient conditions needed for design of insulation, air coolers, etc.
• Special conditions such as wind loads, hurricane and earthquake conditions
that are needed for mechanical and civil engineering design
Thông tin nào trong văn bản
“Cơ sở thiết kế”?
Project Name
Company Name Project Number Sheet 2
Address REV DATE BY APVD REV DATE BY APVD

Form XXXXX-YY-ZZ
DESIGN BASIS
Sheet 2 of the Design Basis has
utility information
7 Utility Information

Fuel Gas
Gas source or operation mode Nat Gas
Supply header temperature (F)
Supply header pressure (psia)
Net calorific value (BTU/lb)
Marginal availability (lb/h)
Marginal fuel cost ($/MMBTU)
Sulfur content (wppm)
Nitrogen content (wppm)
• Fuel gases
• Fuel oils
Chlorine content (wppm)
Gas composition (vol%)
H2O
O2
N2
CO
CO2
H2S
H2
CH4
C2H4
• Steam levels
C2H6
C3H6
C3H8
C4H8
iC4H10
nC4H10
• Coolants
• Process water
C5H10
C5+

Fuel Oil
Fuel source or operation mode #2 Heating Oil
Supply header temperature (F)
Supply headder pressure (psia)
Net calorific value (BTU/lb)
Marginal availability (lb/h)
Marginal fuel cost ($/MMBTU)
Fuel viscosity at F
• Electricity
Fuel viscosity at F
Flash point (F)
Pour point (F)
Sulfur content (wppm)
Nitrogen content (wppm)
Ash content (wt %)
• Process Air
Steam
Steam header classification
Operating pressure (psia)
Operating temperature (F)
Mechanical design pressure (psia)
VHP HP MP LP
Conditions, availability, price, etc.
Mechanical design temperature (F)
Marginal availability (lb/h)
Marginal cost ($/Mlb)

Coolants
Coolant classification Cooling Tower Water Once-Through Water Chilled Water
Operating pressure (psia)
Supply temperature (F)
Maximum return temperature (F)
Marginal availability (lb/h)
Marginal cost ($)
Marginal cost units

Process Water Feeds


Water feed stream Raw Water Process Water Boiler Feed Water Condensate
Supply pressure (psia)
Supply temperature (F)
Marginal availability (lb/h)
Marginal cost ($/1000 gal)
Total dissolved solids (wt%)
Hardness as CaCO3 (ppmw)
Chloride as Cl (ppmw)
Metallurgy

Electric power
Power range (kW)
Voltage (V)
Phase
Frequency (Hz)
Marginal availability (kW)
Marginal cost ($/kWh)

Plant air streams


Air stream Plant Air Instrument Air Plant Nitrogen
Header pressure (psia)
Header temperature (F)
Moisture (ppmw)
Marginal availability (lb/h)
Marginal cost ($/Mscf)
Các tiêu chuẩn thiết kế (Codes & Standards)
• Các phương pháp và quy tắc thiết kế quy trình / thiết bị được miêu tả
trong các tiêu chuẩn thiết kế (design codes of practice)
• Các tiêu chuẩn này được đặt ra bởi các tổ chức hiệp hội (e.g.,
ISO, ASME, API, ISA) hay công ty (Shell, Exxon, BP…)
• Các tiêu chuẩn này được xem xét lại và cập nhật phiên bản mới
thường xuyên
• Các tiêu chuẩn này chỉ rõ cách thực hành công việc thiết kế, lắp
đặt, kiểm tra và vận hành thiết bị và quy trình, nhằm đạt được
một thiết kế hợp lỳ và an toàn, dựa trên kinh nghiệm của ủy ban
đề ra bộ quy tắc này
• Thiết kế tuân theo một tiêu chuẩn nào đó thường được yêu cầu
bởi công ty, hoặc bởi luật pháp
• Kích cỡ / công suất tiêu chuẩn cho đường ống, van, thiết bị (bơm, máy
nén,…) cũng được miêu tả trong các tiêu chuẩn thiết kế
• Luôn luôn tham khảo tiêu chuẩn thiết kế mới nhất

• Thiết kế P & ID có thể cần tuân theo một tiêu chuẩn thiết kế (tiêu chuẩn
riêng của công ty thiết kế)
Tiêu chuẩn thiết kế: Hệ số an toàn (Design
Factors or Design Margins)
• Thiết bị thường được thiết kế vượt hơn kích cỡ cần thiết tương
ứng với lưu lượng thiết kế
– Bù trừ cho sai số trong phương pháp và dữ liệu thiết kế
– Để dành cho khả năng tăng công suất nhà máy trong tương
lai
– Bảo đảm nhà máy có thể hoạt động ở công suất thiết kế
• Các công ty thiết kế thường quy định rõ về hệ số an toàn
– Thông thường, xác định kích cỡ thiết bị tương ứng với
110% lưu lượng thiết kế
– Cần cẩn thận, thêm hệ số an toàn chỉ một lần
Ghi chép tài liệu thiết kế
Determine Set Design
Customer Needs Specifications
Build Performance
Models
Generate Design
R&D if Needed
Concepts Predict Fitness
For Service
Evaluate Economics
& Select Design
Customer
Approval
Detailed Design & Procurement
Begin Operation
Equipment Selection & Construction

Thông tin thiết kế cần được ghi chép rõ để:


• So sánh đúng đắn giữa các phương án thiết kế đối lập nhau
• Truyền tải thông tin giữa các bên liên quan (chủ đầu tư, công ty cung cấp công
nghệ, công ty EPC)
• Phát triển sổ tay hướng dẫn (vận hành, bảo trì,,,)
Ghi chép tài liệu thiết kế
Tài liệu thiết kế cho một quy trình thường bao gồm ít nhất 10 loại tài liệu sau:

1. Miêu tả cơ sở thiết kế
2. Miêu tả quy trình
3. Bản vẻ process flow diagram (PFD)
4. Cân bằng vật chất và năng lượng
5. Chỉ tiêu chất lượng và tính chất sản phẩm
6. Một danh sách các thiết bị chính
7. Tờ ghi chỉ tiêu về hiệu năng (specifications) của các thiết bị chính
8. Bản vẻ piping and instrumentation diagram (P & ID)
9. Ước lượng chi phí của quy trình
10.Thông tin về sức khỏe, an toàn và môi trường HSE (e.g., HAZAN, HAZOP,
MSDS forms)
Các thông tin khác như phân tích kinh tế kỹ thuật, thông tin về thị trường, thông tin về
công nghệ cạnh tranh hay các phương án công nghệ khác cũng có thể được miêu tả nếu
nằm trong phạm vi dự án
Cách hiệu quả nhất để trình bày kết quả thiết kế quy
trình CNHH là thông qua sơ đồ quy trình

• Block Flow Diagram (BFD) Tính khái quát


Mức độ hóa (cho toàn
chi tiết • Process Flow Diagram (PFD)
thể quy trình)
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• Piping and Instrumentation
Diagram (P&ID) (allo called
Mechanical Flow Diagram)
Toluene Mixed Gas
(10,000 kg/h) Reactor (2,610 kg/h)
Gas
Separator
Benzene
Hydrogen (8,210 kg/h)
(820 kg/h) Conversion Mixed Liquids
75% Toluene

Toluene

Reaction : C7H8 + H2 = C6H6 + CH4

Figure 1.1 Block flow process diagram for the production of benzene
Toluene and hydrogen are converted in a reactor to produce benzene and methane.The
reaction does not go to completion, and excess toluene is required. The noncondensable
gases are separated and discharged. The benzene product and the unreacted toluene are
then separated by distillation. The toluene is then recycled back to the reactor and the
benzene removed in the product stream.
Table 1.1 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.
7. Simplified material balance provided.
Process Flow Diagram (PFD)

A PFD includes the following items:

1. major equipments;
2. principal flow route and control involved from raw
material feed to final product;
3. key temperature and pressure corresponding to
anticipated normal operation;
4. material flow rates and compositions;
5. design duties and sizes of major equipments.
Table 1.2 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
E - Heat Exchanger
H - Fired Heater
P - Pump
R - Reactor
T - Tower
TK - Storage Tank
V - Vessel
Y designates an area within the plant
ZZ are 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
Table 1.3 Conventions for Identifying Process and Utility Streams
Process Streams
All conventions shown in Table 1.1 apply.
Diamond (square) symbol located in flow lines.
Numerical identification (unique for that stream) inserted in diamond (square).
Flow direction shown by arrows on flow lines.
Utility 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 Fuel Water

These pressure are set during the preliminary design stages and typical values vary within the ranges
shown.
+
Above 45C, significant scaling occurs.
Table 1.4 Information Provided in a Flow Summary
Essential Information
Stream Number
Temperature (C)
Pressure (bar)
Vapor Fraction
Total Mass Flow Rate (kg/h)
Total Mole Flow Rate (kmol/h)
Individual Component Flow Rates (kmol/s)
Optional Information
Component Mole Fractions
Component Mass Fractions
Individual Component Flow Rates (kg/h)
Volumetric Flow Rates (m3/h)
Significant Physical Properties
Density
Viscosity
Other
Thermodynamic Data
Heat Capacity
Stream Enthalpy
K-values
Stream Name
Table 1.5 Equipment Descriptions for PFD and P&IDs
Equipment Type
Description of Equipment
Towers
Size (height and diameter), Pressure, Temperature
Number and Type of Trays
Height and Type of Packing
Materials of Constructions
Heat Exchangers
Type: Gas-Gas, Gas-Liquid, Liquid-Liquid, Condenser, Vaporizer
Process: Duty, Area, Temperature, and Pressure for both streams.
No. of shell and Tube Passes
Materials of Construction: Tubes and Shell
Tanks
See vessels
Vessels
Hight, Diameter, Orientation, Pressure, Temperature, Materials of Construction
Pumps
Flow, Discharge Pressure, Temperature, P, Driver Type, Shaft Power, Materials of Construction
Compressors
Actual Inlet Flow Rate, Temperature, Pressure, DrverType, Shaft Power,
Materials of Construction
Heaters (fired)
Type, Tube Pressure, Tube Temperature, Duty, Fuel, Material of Construction
Others
Provide Critical Information
Piping and Instrumentation Diagram
(P&ID)
1. All process equipments and pipings required for start-up, shut-down, emergency and
normal operation of the plant, including valves, blinds, etc.
2. An id number, an identifier of the material of construction, diameter and insulation
requirements for each line.
3. Direction of flow.
4. Identification of main process and start-up lines.
5. All instrumentation, control and interlock facilities with indication of action on
instrument air failure.
6. Key dimensions or duties of all equipments.
7. Operating and design pressures and temperatures for vessels and reactors.
8. Equipment elevations.
9. Set pressure for relief valves.
10.Drainage requirements.
11.Special notes on piping configuration as necessary, e.g. “gravity drainage.”
Table 1.6. Exclusions from Piping and Instrumentation Diagram

1. Operating conditions T,P


2. Stream flows
3. Equipment locations
4. Pipe routing
a. Pipe lengths
b. Pipe fittings
5. Supports, structures, and foundations
Table 1.7. Conventions in Constructing Piping and Instrumentation Diagrams
For Equipment - Shown Every Piece Including
Spare units
Parallel units
Summary details of each unit
For Piping - Include All Lines Including Drains, Sample Connections and Specify
Size (use standard sizes)
Schedule (thickness)
Materials of construction
Insulation (thickness and type)
For Instruments - Identify
Indicators
Recorders
Controllers
Show instrument lines
For Utility - Indentify
Entrance utilities
Exit utilities
Exit to waste treatment facilities
Piping & Instrumentation Diagrams (P & ID)

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