Chemical Process Diagrams Chapter 1

Department of Chemical Engineering West Virginia University

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

3 Levels of Diagram
Block Flow Diagram (BFD) Process Flow Diagram (PFD) Piping and Instrumentation Diagram (P&ID) often referred to as Mechanical Flow Diagram Complexity Conceptual increases understanding Increases As chemical engineers, we are most familiar with BFD and PFD.
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

The Block Flow Diagram (BFD)

BFD shows overall processing picture of a chemical complex
Flow of raw materials and products may be included on a BFD BFD is a superficial view of facility ChE information is missing

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

Definitions of BFD
Block Flow Process Diagram
Figure 1.1 Similar to sketches in material and energy balances

Block Flow Plant Diagram

Figure 1.2 Gives a general view of a large complex plant
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

The Block Flow Process Diagram

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

The Block Flow Plant Diagram

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

The Process Flow Diagram

PFD shows all process engineering information
Diagram developed in junior year design projects (especially the 2nd semester) Often PFD is drawn on large paper textbook breaks down information into 1 diagram and 2 tables

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

The Process Flow Diagram (contd)

The topology of the process showing the connectivity of all the streams and the equipment
Example for toluene HDA Figures 1.3 and 1.5 Tables 1.2 and 1.4 list information that should be on the PFD but cannot fit Use appropriate conventions consistency is important in communication of process information ex. Table 1.2

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

The Process Flow Diagram (contd)

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

The Process Flow Diagram (contd)

Process Equipment Table 1.2 : Conventions Used for Identifying 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 10

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

Equipment Numbering
XX-YZZ A/B/
XX represents a 1- or 2-letter designation for the equipment (P = pump) Y is the 1 or 2 digit unit number (1-99) ZZ designates the equipment number for the unit (1-99) A/B/ represents the presence of spare equipment

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

11

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

12

Equipment Numbering (contd)

Thus, T-905 is the 5th tower in unit nine hundred P301 A/B is the 1st Pump in unit three hundred plus a spare Use unambiguous letters for new equipment
Ex. Turbine use Tb or J not T (for tower) Replace old vessel V-302 with a new one of different design - use V-319 (say) not V-302 since it may be confused with original V-302

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

13

Stream Numbering and Drawing

Number streams from left to right as much as possible Horizontal lines are dominant

yes

no

no

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

14

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

15

Stream Numbering and Drawing (contd)

Add arrows for
Change in direction Inlet of equipment

Utility streams should use convention given in Table 1.3, lps, cw, fg, etc.

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

16

Stream Information
Since diagrams are small, not much stream information can be included Include important data around reactors and towers, etc.
Flags are used see toluene HDA diagram Full stream data, as indicated in Table 1.4, are included in a separate flow summary table see Table 1.5
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

17

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

18

Stream Information - Flags

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

19

The Process Flow Diagram (contd)

Table 1.4: Information 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/h) 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
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

20

10

The Process Flow Diagram (contd)

A Portion of Table 1.5
Stream Number Temperature (C) Pressure (bar) Vapor Fraction Mass Flow (tonne/h) Mole Flow (kmol/h) Component Mole Flow (kmol/h) Hydrogen Methane Benzene Toluene 0.0 0.0 0.0 108.7 0.0 0.0 1.0 143.2 286.0 15.0 0.0 0.0 735.4 317.3 7.6 144.0 449.4 302.2 6.6 0.7 735.4 317.3 7.6 144.0 25.2 16.95 0.37 0.04 651.9 438.3 9.55 1.05 652.6 442.3 116.0 36.0 0.02 0.88 106.3 35.0 1 25 1.90 0.0 10.0 108.7 2 59 25.8 0.0 13.3 144.2 3 25 25.5 1.00 0.82 301.0 4 225 25.2 1.0 20.5 1204.4 5 41 25.5 1.0 6.41 758.8 6 600 25.0 1.0 20.5 1204.4 7 41 25.5 1.0 0.36 42.6 8 38 23.9 1.0 9.2 1100.8 9 654 24.0 1.0 20.9 1247.0 10 90 2.6 0.0 11.6 142.2

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

21

Basic Control Loops

Often the basic control loops (those involving maintaining material balance and reactor controls) are included on the PFD; instrumentation and other control loops are not shown

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

22

11

Basic Control Loops

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

23

Equipment Information
Equipment are identified by number and a label (name) positioned above the equipment on the PFD Basic data such as size and key data are included in a separate table (Equipment Summary Table) Table 1.7 (and Table 1.6) in TBWS

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

24

12

Equipment Information
A Section of Table 1.7: Equipment Summary
Vessel Temperature (C) Pressure (bar) Orientation MOC Size Height/Length (m) Diameter (m) Internals 5.9 1.9 3.5 1.1 s.p. (splash plate)
25

V-101 55 2.0 Horizontal CS

V-102 38 24 Vertical CS

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

PFD Summary
PFD, Equipment Summary Table, and Flow Summary Table represent a true PFD This information is sufficient for a preliminary estimation of capital investment (Chapter 7) and cost of manufacture (Chapter 8) to be made

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

26

13

The Piping and Instrument Diagram(P&ID)

P&ID Construction Bible Contains: plant construction information (piping, process, instrumentation, and other diagrams) P&ID information is explained in Tables 1.8 and 1.9 Conventions for instrumentation are shown in Figure 1.10
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

27

P&ID

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

28

14

Look at V-102 on P&ID

V-102 contains an LE (Level Element) LE senses liquid level in separator and adjusts flow rate leaving LE opens and closes a valve depending on liquid level LE and valve represent a feedback control loop

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

29

Other Common Diagrams

Plot Plans plan or map drawn looking down on plant (drawn to scale with all major equipment identified) Elevation Diagrams show view from side and give information about equipments distance from ground

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

30

15

Other Common Diagrams

Section of Plot Plan

Section of Elevation Diagram

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

31

Other Common Diagrams (contd)

Piping Isometrics show piping in 3dimensions Vessel Sketches show key dimensions of equipment and locations of inlet and outlet nozzles etc.

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

32

16

Scale Models and Virtual Plants

25 years ago physical models were used for review Now virtual or electronic models are generated using software (3-d plant diagrams) Purpose of Models catch errors such as
Piping clashes Misaligned piping Equipment not easily accessed Sample points not easily reached by operators

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

33

OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

34

17

OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS

From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

35

OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS

Figure 1.19 An Avatar Can Access Process trends and Observe Equipment Schematics in AR (Reproduced by Permission of Invensys Systems Inc., Property and Copyright of Invensys plc, UK)
From Analysis, Synthesis, and Design of Chemical Processes, Fourth Edition, by Richard Turton, Richard C. Bailie, Wallace B. Whiting, Joseph Shaeiwitz, and Debangsu Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright 2012 Pearson Education, Inc. All rights reserved.

36

18