PROCESS DIAGRAMS

OUTLINES
TYPES of piping and
instrumentation symbols.
How to CHOOSE the suitable
symbols in control system?
How to DEVELOP the piping
systems and the specification of the
process instrumentation,
equipment, piping, valves, fittings.
The ARRANGEMENT in P&ID
for the bioprocess plant design.
 Block Flow Process Flow
Diagram (BFD) Diagram (PFD)

PROCESS
DIAGRAMS

Piping and
Instrumentation
Diagram (P&ID)
 Block Flow Process Flow
Diagram (BFD) Diagram (PFD)

PROCESS
DIAGRAMS

Piping and
Instrumentation
Diagram (P&ID)
 BLOCK FLOW DIAGRAM (BFD)
simplest flowsheet.
Proses di desain dengan diagram blok
Diagram input-output tidak sangat rinci tetapi yang
paling berguna dalam tahap awal proses
pembangunan .
Aliran bahan baku dan produk dapat disertakan pada
BFD . Proses yang dijelaskan di BFD, kemudian dipecah
menjadi elemen fungsional dasar seperti reaksi dan
pemisahan bagian .
Juga mengidentifikasi aliran recycle dan operasi unit
tambahan untuk mencapai kondisi operasi yang
diinginkan
 BLOCK FLOW DIAGRAM (BFD)
Example 1:
Mixed Gas
Toluene, C7H8 2610 kg/hr
10,000 kg/hr

Reactor Gas Separator Benzene,

C6 H 6
C6H6 8,210
CH4 kg/hr
Hydrogen
H2 820 kg/hr C7 H 8
Mixed
Liquid

75% Conversion
of Toluene

Reaction : C7H8 + H2 C6H6 + CH4

Figure 1: Block Flow Diagram for the Production of Benzene

Example 2:
Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of Acid Sulphuric
catalyzer to produce ethylene. Distillation process then will be
applied to separate ethylene-H 2O mixture. Ethylene as a top product
is then condensate with condenser to perform liquid ethylene.
Hydrogenation of ethylene with presence of Nickel catalyzer to
produce ethane as a final product. Develop BFD for these processes.

CH3CH2O H2SO4 CH2=CH2 +

H2=CH2 +
CH H2O
CH3CH3
Ni
H2
Answe Hot
r: water
Ethylene liq.
Ethylene, out
CH2CH2 (g) CH2CH2 (l)

Ethanol,

C 2 H5 Cold Ethane,
CH2C
Reactor 1 water Reactor 2 CH3CH3
OHSO
H HH
2 2O Distillati Hydroge
2 4 in
on n, H2Ni
column
H2
O
 Block Flow Process Flow
Diagram (BFD) Diagram (PFD)

PROCESS
DIAGRAMS

Process equipments Piping and

symbol and Instrumentation
numbering Diagram (P&ID)
 PROCESS FLOW DIAGRAM (PFD)

Proses flow Diagram umumnya mencakup

Informasi sebagai berikut;
a) Composition streams.
b) Operating conditions of each stream such as
pressure , temperature, concentration, etc.
c) Heat added or removed in a particular equipment.
d) Flows of utilities such as stream, cooling water,
hot oil, chilled water, etc.
e) Simbol peralatan utama , nama dan identifikasi ..
f) Any specific information which is useful in
understanding the process. For example, symbolic
presentation of a hazard, safety precautions,
sequence of flow, etc.
1. Major Pieces Of 2. Utility
Equipment Streams

PFD

4. Basic 3. Process
Control Loops Flow Streams
PROCESS FLOW DIAGRAM (PFD)
1. Major Pieces Of 2. Utility
Equipment Streams

PFD

4. Basic 3. Process
Control Loops Flow Streams
 PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology
Symbol Descriptio
n
Heat exchanger

H2O Water cooler

S Steam heater

Cooling coil
 PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology
Symbol Descriptio
n
Heater coil

Centrifugal pump

Turbine type
compressor

Pressure gauge
 PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology

Symbol Name Description

Stripper A separator unit used

commonly to liquid
mixture into gas phase.

Absorber A separator unit used

commonly to extract
mixture gas into liquid
phase.
 PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology

Symbol Name Description

Distillation A separator unit used

commonly to crack liquid
column contains miscellaneous
component fractions.

Liquid mixer A process unit that used

or
to mix several
components of liquid.
 PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology

Symbol Name Description

Reaction A process unit where

chemical process
chamber reaction occurs

Horizontal A unit to store liquid or

tank gas.
or cylinder
 PROCESS FLOW DIAGRAM (PFD)
Process Unit Symbology

Symbol Name Description

Boiler A unit for heating.

Centrifuge A separator unit that to

physically separated
liquid mixture. (exp: oil-
liquid)
 PROCESS FLOW DIAGRAM (PFD)
Valve Symbology

Symbol Name

Gate Valve

Globe
Valve

Ball Valve

Check Valve

Butterfly
Valve
 PROCESS FLOW DIAGRAM (PFD)
Valve Symbology

Symbol Name

Relief Valve

Needle Valve

3-Way
Valve

Angle Valve

Butterfly
Valve
Example 4

Production of Ethane from Ethanol

Ethanol is feed to continuous reactor with presence of Acid Sulphuric

catalyzer to produce ethylene. Distillation process then will be applied to
separate ethylene-H2O mixture. Ethylene as a top product is then
condensate with condenser to perform liquid ethylene. Hydrogenation of
ethylene applies in another reactor with presence of Nickel catalyzer to
produce ethane as a final product. Develop PFD for these processes.
CH3CH2OH H2SO4 CH2=CH2 + H2O
CH2=CH2 + H2 CH3CH3
Ni
R-100 P-100 T-100 E-100 P-101 R-101
Reactor Pump Distillation Condenser Pump Reactor
Column

Hot water out

Ethylen
E- Ethylene
e 100
V- liq.
Cold water 104
in V-
CV-100 T-
CV-101 106
100
Ethanol V-
105
V- V- V- Hydrog
H2SO4 100 101 102
R-
V- V- enNi
100
103 107
R- Ethane
P- 101
100 H2 P-
 PROCESS FLOW DIAGRAM (PFD)
Process Unit Tagging and Numbering

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
1. Major Pieces Of 2. Utility
Equipment Streams

PFD

4. Basic 3. Process
Control Loops Flow Streams
 PROCESS FLOW DIAGRAM (PFD)

Stream Information
-Since diagrams are small not much stream information
can be included.
-Include important data around reactors and towers, etc.
Flags are used
Full stream data
 PROCESS FLOW DIAGRAM (PFD)
Stream Information - Flag

600 Temperatur
300 e

3 8 24 Pressure
9
6 7 Mass
10.3
1 10 Flowrate

108 Molar
600
Flowrate
24

2 5 12 Gas
Flowrate

4 11 Liquid
Flowrate
24
13
 Example 4- cont

R-100 P-100 T-100 E-100 P-101 R-101

Reactor Pump Distillation Condenser Pump Reactor
Column

Hot water
out

Ethylene E- Ethylene liq.

100
6
V-
104
Cold
T-100
water CV-101 V-
25
28 CV-100 in 106

V-
Ethanol 5 105
1 V- V- 38 20
H2SO4 4 101 102 Hydroge
V-
100 V- V-
n Ni 9
R-
103 107
100 Ethane
R-
3 8
2 35
31.0
101
10
H 2O
32.235 7 P-
101
P-
100
 PROCESS FLOW DIAGRAM (PFD)

Stream Information - Full stream data:

Stream 1 2 3 4 5 6 7 8 9 10
Number
Temperature 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54.0 45.1
(oC)
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39.0 2.6

Vapor fraction

Mass flow 10.3 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6
(tonne/hr)
Mole flow 108 114.2 301.0 1204.0 758.8 1204.4 42.6 1100.8 142.2 244.0
(kmol/hr)
Example 4- cont
R-100 P-100 T-100 E-100 P-101 R-101
Reactor Pump Distillation Condense Pump Reactor
Column r

Hot water
out

Ethylene E- Ethylene liq.

100
6
V-
104
Cold
water in V-
25
28 CV-100
T-
100 CV- 106
101
V-
Ethanol 5 105
20
H2SO4 1 V- V-
4 101 102 38 Hydroge
V-
100 V- V- n Ni 9
R-
103 107
100 Ethane
3 8
R-
2 35
31.0 101 10
32.2 35 7 H2O
P-
101
P-
100
Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC) 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54 45.1
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39 2.6
Vapor fraction

Mass flow (tonne/hr) 10.3 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6
Mole flow (kmol/hr) 108 114.2 301.0 1204.0 758.8 1204.4 42.6 1100.8 142.2 244.0
 Block Flow Process Flow
Diagram (BFD) Diagram (PFD)

PROCESS
DIAGRAMS

Process equipments Piping and

symbol and Instrumentation
numbering Diagram (P&ID)
 PIPING AND INSTRUMENTATION
DIAGRAM (P&ID)

skema dari ,jalur pipa, equipment, instrumentasi,

control system,dari suatu sistem proses yang terdapat
di Oil Refinery, Chemical Plant, Paper Mill, Cement
Plant, dll.
PIPING AND INSTRUMENTATION DIAGRAM (P&ID)

PFD
PIPING AND INSTRUMENTATION DIAGRAM (P&ID)
EXERCISE

P&ID
 Exercise

R-100 P-100 T-100 E-100 P-101 R-101

Reactor Pump Distillation Condenser Pump Reactor
Column

Hot
water
out
Ethylene E- Ethylene liq.
100
6
V-
104
Cold
T-100
water inCV-101 V-
CV-100 106

V-
Ethanol 5 105
1 V- V-
H2SO4
4 101 102 Hydroge
V-
n Ni 9
100 V- V-
R-
103 107
100 Ethane
R-
3 8 101
2 10
H 2O
7
P-
101
P-
100


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