Understanding

Process Diagrams
 Flowsheeting
Flowsheets are the pictorial representation of the process.

Goal:
Transmit the most
E-1
CWS amount of
F-1
information with the
least amount of effort
P-1A/B
T-1
on the part of the
reader!

CWS E-3
STM
E-2
F-2

STM

E-4
 Flowsheet
Is a diagrammatic model of the process
• Shows the arrangement of equipment selected to carry our the
process
• Includes
stream connections, names of streams, stream flow rates
compositions and operating conditions (temp., Pressure)
instruments
optional details of streams molar compositions
physical data (ρ, η),code no. of streams, Enthalpies of streams
Brief description of stream
Type of Diagrams
• Block Diagram
• Material Flow Sheet
• Energy Flow Sheet
• Process Flow Diagram
• Information Flow Diagram
• Piping & Instrumentation Diagram
 Type of Flowsheets

Block

Process 6 7

FCV
218

Piping and Instrumentation

 Block Diagram
Conveys what is achieved in a given step, not how it is achieved

• Particularly useful in initial studies

• Useful for conveying information to management

• Useful to show inter-relation of streams

• Useful in conveying global, not detailed, material balance

Feed 1 Product 1
Feed 2 Process Product 2
Feed 3 Product 3

This particular block flow could be used to obtain (assist) in the

development of an initial material balance for streams crossing the
battery limits. You might use it in your input/output structure
development during synthesis.
 Block Flow Diagram
Example:
Byproduct to
Refinery
Refinery Product
Gas Low Temp Reaction &
Compression
Clean-up Cooling
Purge

Air Recycle
Separation
Compression

Oxygen

Major steps are conveyed but no equipment details. Sometimes the

blocks may be process flow diagram symbols. Sometimes steps
may include equipment if it is particularly important to the
communication.
 Block Flow Diagram
I find block flows to be particularly useful for setting up (identifying) the key
streams to solve the material balance around the major blocks. I subsequently
solve the material balance inside each block.
113 128

104 T-102 114 T-103

134

T-101
101
153
F-105

F-101 147
103 106
140
150

T-104 T-105 151

108 109

111
159
146

105 160
 Material Flow Sheet
 Is drawn with standard symbols and labeled
and include all data obtained
 If no space available to label equipment, a
equipment key can be drawn at the bottom
of the flow sheet
 Following data should be shown on the flow
sheet in deferent ways
 flow rate of each component
 total stream flow rate
 percentage composition
 N Component Flow rate T
P

C
1 R2

N Component Flow rate T

Equipment key P
C1 Column
R2 Reactor

Simplest method suitable for simple processes with few

equipments: tabulate the data in blocks alongside the process stream
Better method applicable for all complex processes: stream line is
numbered and the data tabulated at the top or bottom of the sheet
 Energy Flowsheet

 Energy balance is to determine the energy

requirement of the process
 In energy flow sheet Inlet and outlet energy flow
rates should be shown separately for each piece
of equipment. Include:
 energy of each component in all (inlet and
outlet) streams
 process conditions of all (inlet and outlet)
streams
 process conditions of the specific equipment
Energy Balance Sheet
 Information Flow Diagram (IFD)
 Is used in simulation programs
 Is presented by blocks
 Each block represents a calculation module in the
simulation program, usually a process unit or part of a unit
 units in which no change of composition or temperature
or pressure occurs are omitted from IFD
 But other operations not shown on the process flow
diagram as actual pieces of equipment, but which can
cause changes in the stream composition must be shown.
 Flow of information should be shown with lines and arrow
Process Flow Diagrams
 Process Flow Diagram
Conveys the major processing steps represented by the equipment

• Useful for conveying the heat and material balances

• Useful for conveying major pieces of equipment

• Useful for conveying processing conditions

• Useful for conveying utilities

There are no hard and fast rules but Howat Standards include
• essentially every major piece of equipment
• every flow
• every temperature
• every pressure
• auxiliary services (utility flows)
• equipment sizes
• process control
 Standard symbols
BS 8888 ; BS 1553

Heat exchange
Reactor Sealed tank

Fluid
Tray column contacting
column
Material Flow Sheet
• Is drawn with standard symbols and labeled and include all data obtained
If no space available to label equipment, a equipment key can be drawn at
the bottom of the flow sheet
Following data should be shown on the flow sheet in deferent ways
flow rate of each component
total stream flow rate
percentage composition

Simplest method suitable for simple processes with few equipments,

tabulate the data in blocks alongside the process stream Slide 14
Better method applicable for all complex processes,
stream line is numbered and the data tabulated at the top or bottom of
the sheet (above and below the equipment layout) Slide 15
 Process Flow Diagram
The following diagrams are examples of class and commercial
process flow diagrams (PFD’s). The content depends on the goals
for the communication.

Unless there are reasons to the contrary, the standard is:

• All major equipment

• All major process lines
• All major utility lines involving material flow
• All stream numbers, temperatures, pressures, flows
• All major process controls and valves
• All equipment sizes with relevant MEB information as required
• All equipment names and numbers
 Process Flow Diagram
The goal is to present the most amount of information with the least
amount of effort on the part of the reader.

• The flowsheet should generally flow from left to right.

• The flowsheet should not be cluttered - use multiple sheets.
• The flowsheet should be in landscape with the bound edge at top.
• The equipment should be drawn in approximately relative size, e.g.
towers larger than drums, exchangers larger than pumps etc.
• The major towers and reactors are generally on one, or nearly one,
level.
• The reader should be able to follow it with his or her eye.
• The streams should have the minimum of direction changes.
• The streams that enter across the battery limits should be on the left.
• The streams that leave across the battery limits should be on the
right.
• The streams that move to the next sheet should leave on the right.
• The streams that recycle to earlier sheets should leave on the left.
 153
Flowsheeting
140 The process flowsheet shown below is one
possible expansion of the block flow for T-104.
109 T-104 When this PFD was drawn, the process was not
complete as is evident by the missing equipment
sizes, pump discharge pressures etc. In this case,
the process control scheme was not included. It
146
generally is, however.
105 160
Process Flow Diagram
The following process flow is an approximate
rendition of a refinery alkylation unit. This is
however not as complete as it is required in
industry practice
Note that equipment sizing is not included.
The material balance grid is included. Many
companies require the material balance to
be imposed on the diagram. In those cases,
the stream numbering may not be as
extensive as we typically use in design. Or,
only a limited number of streams are
included in the material balance grid.
Process Flow Diagram
Another example from design. This includes the equipment sizing and material balance
block. Note the symbol key is included. This is frequently necessary when client
standards differ.
Process Flow Diagram

The following two sheets are examples of a commercial PFD

developed prior to construction. Note that the content is, yet again,
different. In this case, the control scheme is included as is the legend
key. There are some differences. Note that there are three different
feed points shown on the diagram. It is typical to have multiple feed
points for a column but unusual to show them on the PFD. They were
shown here because it was critical for discussing different feedstocks
in the process design report. The process description which
accompanied the PFD described the reason for the multiple feeds.
On the second diagram, you will note the pressure control. This is a
split range controller with the primary control being a flooded
condenser and the secondary control being a vent. Note that the
pumps show operating and design conditions.
The process description
will sometimes dictate
the content of the
process flow diagram.
For most purposes, the
process control scheme
will be included in our
work. Multiple feed
points or side stream
points will not be shown
unless it is critical to the
process. We will
typically not be showing
the future equipment
such as the reboiler
shown on the left of the
column.

When you examine the

flowsheet, you should
be able to deduce the
type of equipment.

Tower type?
Repoiler type?
Pump type?
This is the other part of
the previous flowsheet.
Because of scan
limitations, I’ve broken
the flowsheet into two
parts. However, the
original is all one
flowsheet drawn in
landscape.

In this flowsheet, you

will not the original
reboiler is on flow
control reset by
temperature. The
primary measured
variable is steam flow,
the manipulated
variable is steam flow
and the controlled
variable is steam flow.
The secondary
measured variable is
temperature. What is
the temperature
indicative of? Why
above the bottom?
Process Flow Diagram
This process flow diagram is another commercial example. This client
standard had two PFD’s per page, each shown in landscape, one on
top of the other on the same page. I have taken the top PFD and split
in two. (This is the basis for the following EFD’s.)

This was a revamp. Shaded equipment is new, unshaded equipment

is existing. Note that the control scheme is included. There are
additional symbols which indicate that the controls are connected to a
digital distributed control system. The tags at the edge of the page
indicate connections to other PFD’s.
This is an extractive distillation tower. There are additional reboilers here (type?) that are in
place for heat recovery. The shaded equipment is new. The unshaded equipment was
existing. The equipment might be in a new service, however. We will generally not show
instrument connections to the DCS (distributed control system). The instruments will be
shown but the connection will be implied.
This is the overhead system for the extractive distillation column. Note that there is a vent
condenser from F-204. Why might we add a vent condenser? What is the purpose? Note
that the F-204 Reflux Drum has a ‘boot’. What might that be for? The circle symbol in the
center bottom is a professional stamp of a licensed engineer. He/she is signifying that the
engineering integrity of the process.
Process Flow Diagram

Unless stated otherwise, the target content for

PFD’s is:

All major process equipment

All major process and utility streams – all
numbered
All major process controls necessary to
operate the process
All operating temperatures
All operating pressures
All operating flows
All equipment sizes
 Piping and
Instrumentation
Diagram
Piping and Instrumentation Diagram

 Similarly to electrical schemas, the control industry

(especially the chemical and process industry) describes
its plants and their instrumentation by a
 P&ID (pronounce P.N.I.D.) (Piping and Instrumentation
Diagram), sometimes called P&WD (Piping and wiring
diagrams)
 The P&ID shows the flows in a plant (in the chemical or
process industry) and the corresponding sensors or actors.
 At the same time, the P&ID gives a name ("tag") to each
sensor and actor, along with additional parameters.
 This tag identifies a "point" not only on the screens and
controllers, but also on the objects in the field.
Piping & Instrumentation Diagram (P & I)
 P & I should be included with
 All process equipment identified by equipment number
 All pipes identified by a line number. Pipe size and
material of construction should be shown (material
may include as a part of the identification number)
 All valves with an identification no. along with their type
& size should be shown
 Ancillary fittings that are part of piping system such as
inline sight glasses, strainers and stream traps with an
identification no.
 Pumps identified by a suitable code no.
 All control loops and instruments with identification
Instrument Identification

Measured Variable Type of Conditioner Type of Component

F = Flow R = Recorder T = Transmitter
L = Level I = Indicator M = Modifier
P = Pressure C = Controller E = Element
Q = Quantity A = Alarm
T = Temperature
P&ID
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
350 kW heater
valve

one-way valve (diode) vessel / reactor

binary (or solenoid) valve (on/off)

analog valve (continuous)

heat exchanger
pump, also
Instrumentation identification
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

FIC
V1528

tag name of the

mover corresponding
(here: solenoid) variable

function
(here: valve)
ISA S5.1 General instrument or function symbols
Primary location Auxiliary location
accessible to Field mounted accessible to
operator operator

Discrete
instruments

Shared
display,
shared
control

Computer
function

Programmabl
e logic control

1. Symbol size may vary according to the user's needs and the type of document.
2. Abbreviations of the user's choice may be used when necessary to specify location.
3. Inaccessible (behind the panel) devices may be depicted using the same symbol but with a
dashed horizontal bar.
Source: Control Engineering with data from ISA S5.1 standard
Example of P&ID
The output of FIC 101 is an electrical signal to TY 101
located in an inaccessible or behind-the-panel-board location.

TIC 101’s output is

connected via an internal
Square root extraction of the software or data link (line
input signal is part of FIC with bubbles) to the setpoint
101’s functionality. (SP) of FIC 101 to form a
cascade control strategy
FT101 is a field-mounted flow
transmitter connected via
electrical signals (dotted line)
to flow indicating controller TT 101 and TIC 101 are
FIC 101 located in a shared similar to FT 101 and FIC
control/display device 101
but are measuring,
The output signal from TY indicating, and controlling
101 is a pneumatic signal temperature
(line with double forward
slash marks)
making TY 101 an I/P (current
to pneumatic transducer)
The ISA code for instrument type
First letter
Measured or initiating variable Modifier
A Analysis
B Burner, combustion
C User's choice
D User's choice Differential
E Voltage
F Flow rate Ration (fraction)
G User's choice
H Hand
I Current (electrical)
J Power Scan
K Time, time schedule Time rate of change
L Level
M User's choice Momentary
N User's choice
O User's choice
P Pressure, vacuum
Q Quantity Integrate, totalizer
R Radiation
S Speed, frequency Safety
T Temperature
U Multivariable
V Vibration, mechanical analysis
W Weight, force
X Unclassified X axis
Y Event, state, or presence Y axis
Z Position, dimension Z axis
Common connecting lines
Connection to process, or
instrument supply
Pneumatic signal

Electric signal
Capillary tubing (filled
system)
Hydraulic signal
Electromagnetic or sonic
signal (guided)
Internal system link
(software or data link)
Source: Control Engineering with data from ISA S5.1
standard
Many Standards
 DIN
 ISA
 etc