MICROSOFT VISIO

1
INTRODUCTION
The design of complex chemical plants
requires the integration of very large amounts
of diverse information.
Process designers make use of standardized
sets of graphical representations to assist in
the development and transfer of these
information sets.
HOW to develop the information sets?
2
HOW?
3
P&ID
PFD BFD
GENERIC
DIAGRAM
INPUT/
OUTPUT
DIAGRAM
a crude block flow
diagram in which only
feed and product streams
are identified.
Break the process into its basic
elements such as reaction
and separation, and recycle sections
Include the material
balance calculations
complete mass and
energy balance and
preliminary equipment
specs
includes the mechanical
and instrumentation
details
4
LEVELS
OF
DIAGRAM
BLOCK FLOW
DIAGRAM
(BFD)
PROCESS
FLOW
DIAGRAM
(PFD)
Piping and
Instrumentation
Diagram
(P&ID)
often referred
to as Mechanical Flow Diagram
COMPARISON
5
6
Block Flow Diagram
Group of connected blocks of process units
Lines with arrows connect blocks and represent process
streams
Raw materials enter on the left
Products exit on the right
4 kinds of process units:
Mixers
Reactors
Splitters
Separators
Process
Products
Raw Materials
7
Mixer
butter
C
12
H
22
O
11
flour
eggs
NaCl
NaHCO
3
Chocolate chips

Raw chocolate chip
Cookie dough
Baked chocolate chip
Cookies
Reactor (Oven)
Raw chocolate chip
Cookie dough
8
Splitter
4 dozen cookies
75% choc chip
25% peanut butter
3 dozen cookies
75% choc chip
25% peanut butter
1 dozen cookies
75% choc chip
25% peanut butter
Separator
4 dozen cookies
75% choc chip
25% peanut butter
3 dozen cookies
97.5% choc chip
2.8% peanut butter
1 dozen cookies
8.3% choc chip
91.7% peanut butter
BFD
9
10
Flowsheets
The first step in any process design or analysis is
the construction of a flowsheet that shows the
major material flows and processing steps.
common flowsheet symbols
common abbreviations
The flow sheet allows for better visualization and
quantification of the process.
A picture is worth a thousand words.
A process flow sheet is comprised of units,
represented by simple shapes like circles or
rectangles.
11
Some common flowsheet symbols
Pumps are used to increase a fluids pressure so the fluid will flow from high
pressure to low pressure, or used to condense a fluid or increase the speed of
a chemical reaction.
Gas compressor a different unit description is used as the fluid responds
differently than liquid in a pump (ie increase in pressure causes gas to condense)



Gas expander or turbine is similar but with flows reversed.
Valves are needed to control flows between various units.

12
Combiner and splitter:


Avoid crossing streams. If streams must cross,
you need to indicate whether they mix or not.
streams cross
without mixing
Ambiguous
streams combine
and split
13
Example
14
tabulate process
design values for
the components in
different
operating modes,
typical minimum,
normal and
maximum.
PFD
PFD Should NOT include:
15
pipe classes pipe line numbers
minor bypass
lines
isolation and shutoff
valves
maintenance
vents and
drains
relief and safety valves
code class information
SYMBOLS FOR DRAWING PFD
16
PFD 17
18
P&ID
A family of functional one-line diagrams showing hull,
mechanical and electrical (HM&E) systems like piping,
and cable block diagrams.
Show the interconnection of process equipment and
the instrumentation used to control the process.
They are the primary schematic drawings used for
laying out a process control installation in a factory or
plant.
A standard set of symbols may be used to prepare
drawings of processes, for instance the instrument
symbols used may be based on Instrument Society of
America (ISA) Standard S5.1.

19
A P&ID should not include :
Instrument
root valves
control relays
manual
switches
equipment rating
or capacity
primary
instrument
tubing and valves
pressure
temperature and
flow data
elbow, tees and
similar standard
fittings
extensive
explanatory
notes
20
P&ID
21
The P&ID mixes pneumatic / hydraulic elements, electrical
elements and instruments on the same diagram
It uses a set of symbols defined in the ISA S5.1 standard.
Examples of pneumatic / hydraulic symbols:
pipe
valve
binary (or solenoid) valve (on/off)
350 kW
heater
vessel / reactor
pump, also
heat exchanger
analog valve (continuous)
one-way valve (diode)
22
P&ID
23
24
INSTRUMENTATION IDENTIFICATION
V1528
FIC
S
tag name of the
corresponding
variable
function
(here: valve)
mover
(here: solenoid)
The first letter defines the measured or initiating variables such as Analysis (A), Flow (F),
Temperature (T), etc. with succeeding letters defining readout, passive, or output functions such
as Indicator (I), Record (R), Transmit (T), and so forth. *(C for control)
INTRODUCTION TO VISIO
25
10/16/2014
26
10/16/2014
27
General Equipment & Details
10/16/2014
28
Vessel, Pump & Others
EXERCISE 1 : PFD
29
30
Draw a PFD from the following simplified
description of the synthesis of ammonia:

A mixture of hydrogen and nitrogen is fed to a
catalytic reactor where some of the hydrogen and
nitrogen is converted to ammonia. The reactor
effluent is sent to a condenser where all of the
ammonia is condensed. The condensed ammonia is
sent to product storage. The uncondensed hydrogen
and nitrogen are recycled by being mixed with a
fresh feed of the same composition. The resulting
mixture is fed to the reactor.
31
Type of process?
Reactor and condenser are continuous
Storage tank is semi-continuous
Reaction: N
2
+ 3H
2
2NH
3


32
A mixture of hydrogen and nitrogen is fed to a catalytic
reactor where some of the hydrogen and nitrogen is
converted to ammonia. The reactor effluent is sent to a
condenser where all of the ammonia is condensed. The
condensed ammonia is sent to product storage. The
uncondensed hydrogen and nitrogen are recycled by being
mixed with a fresh feed of the same composition. The
resulting mixture is fed to the reactor.

Step 1 is the feed to the reactor:
reactor
feed
N
2
H
2
effluent
NH
3
N
2
H
2

33
A mixture of hydrogen and nitrogen is fed to a catalytic reactor
where some of the hydrogen and nitrogen is converted to
ammonia. The reactor effluent is sent to a condenser where all
of the ammonia is condensed. The condensed ammonia is sent
to product storage. The uncondensed hydrogen and nitrogen
are recycled by being mixed with a fresh feed of the same
composition. The resulting mixture is fed to the reactor.

Step 2 is to purify the product:
reactor
feed
N
2
H
2
effluent
NH
3
N
2
H
2

condenser
NH
3
liquid
34
A mixture of hydrogen and nitrogen is fed to a catalytic reactor
where some of the hydrogen and nitrogen is converted to
ammonia. The reactor effluent is sent to a condenser where all
of the ammonia is condensed. The condensed ammonia is sent
to product storage. The uncondensed hydrogen and nitrogen
are recycled by being mixed with a fresh feed of the same
composition. The resulting mixture is fed to the reactor.

Step 3 is to send product to storage:
reactor
feed
N
2
H
2
effluent
NH
3
N
2
H
2

condenser
NH
3
liquid
Storage
tank
35
A mixture of hydrogen and nitrogen is fed to a catalytic reactor
where some of the hydrogen and nitrogen is converted to
ammonia. The reactor effluent is sent to a condenser where all
of the ammonia is condensed. The condensed ammonia is sent
to product storage. The uncondensed hydrogen and nitrogen
are recycled by being mixed with a fresh feed of the same
composition. The resulting mixture is fed to the reactor.

Step 4 is to recycle unreacted feeds:
reactor
feed
N
2
H
2
effluent
NH
3
N
2
H
2

condenser
NH
3
liquid
Storage
tank
N
2
, H
2
recycle
purge
EXERCISE 2: CREATING A P&ID
37
38
Instrumentation and Control
Instruments are used to sense process variables and
drive control valves.
These are denoted on P&IDs by circles with letters:

Valves are connected by solid lines to the point where
variables are measured, and by dotted lines to the
equipment they control


LC FRC
FRC
39
As 1st letter As 2
nd
letter As 3
rd

letter
A analyzer Alarm Alarm
C - controller controller
F flow - -
I - indicator -
L Level/liquid level -
P Pressure - -
R - Recorder -
T Temperature - -
V - - Valve
D Differential Differential -
r ratio ratio -
Instrumentation symbols
40
First letter describes the variable sensed by the
instrument: Pressure (P), Temperature (T), Flow (F), level
or liquid level (L or LL), composition (A)
The second and third letters describe the action taken:
Record ( R), Indicate (I), Sound an alarm (A), or Control
(C )
Explain the symbols:

LC FRC
41
42 Description
Main pieces of equipment are the column (C1),
accumulator drum (D1), reboiler (E2) and condenser
(E1).
The distillation column (C1) separates the feed stream
according to volatility into overhead and bottoms
products.
The heat exchangers (E1) and (E2) condense the
overhead vapours and partially vaporize the liquid from
the bottom of the column.
The drum (D1) accumulates the condensed liquid and
also accommodates surges in overhead product rate.
Control elements are shown by circles and dashed lines.
43 Control elements
The rate of bottoms withdrawal is controlled by the liquid level in the
bottom of the column. When the level rises the valve is opened to increase
the withdrawal rate and thus lower the level.
The net bottoms flow is controlled by an analyzer (with recorder) which sets
the flow controller on the steam to the reboiler to maintain the bottoms
composition within specified limits.
The net overhead is withdrawn from the drum on level control (ie when the
level in D1 rises the valve is opened). This keeps the level in the tank within
a preset upper and lower limits.
The rate at which reflux is returned to the column is controlled by the
Temperature at a particular point in the column, when this temperature rises
the valve is opened and more reflux flows to the column. This instrument is
an indicator as well as a controller so it sends a signal proportional to the
temperature to a readout instrument in the control room.
The column is feed controlled by an FRC.