PIPING ENGINEERING

Flow diagrams & Instrumentation

Introduction
Flow diagrams describe, in a schematic drawing
format, the sequential flow of liquids, gases, and
vapours as they enter, flow through, and exit the
process facility. By using simplified drawing
symbols, to represent various pieces of
mechanical equipment, valves, and
instrumentation, and specific notes, callouts,
and abbreviations, the flow diagram provides
the piping designer with an overall view of the
operation of a facility.
The flow diagrams presented are representative
of the types used by many engineering and
design companies. While actual symbols may
vary slightly from company to company, the
general appearance of flow diagrams is the
same throughout the piping industry.
Types of Flow Diagram
The Process Flow Diagram:
The Process flow diagram is the first flow diagram developed during the design process. The Process flow diagram will
include the following: 1. Major mechanical equipment 2. Main piping 3. Direction of commodity flow 4. Operating
pressures and temperatures of the facility components 5. Major controlling instrumentation
The Process flow diagram will denote the following:
• Conditions to be used for the design of various pieces of mechanical equipment required for facility operation,
that is, fractionation columns, pumps, heaters, etc.
• The operating and design conditions (pressures and temperatures) of which a particular piece of mechanical
equipment will function. Design conditions establish the limits that certain components such as gaskets and valve
seats used in the facility can withstand. Design pressure is calculated to be at least 10% above the maximum
operating pressure or 25# greater (whichever is largest). The design temperature will be at least the maximum
operating temperature, but should be at least 25 degrees above the normal operating temperature.
• Composition of the commodities used in the refining or treatment process sequence as they enter and leave the
unit.
Purpose of PFD
1.Plant design basis- The PFD shows the plant design basis indicating feedstock, product, and
mainstream flow rates and operating conditions.
2. Scope of process-The PFD serves to identify the scope of the process.
3.Equipment configuration-The PFD shows graphically the arrangement of major
equipment, process lines and main control loops.
4. Required utilities- The PFD shows utilities that are used continuously in the process.
The Process Flow Diagram:
Process & Instrumentation Diagram (P & ID)
• From the Process flow diagram, the mechanical group develops the Mechanical flow diagram. The
Mechanical flow diagram provides much more detailed data than the process flow diagram. Many
companies refer to the Process & Instrumentation diagram as Mechanical flow diagram also. Often referred
to as the “bible” of the design process, this drawing provides the pipe drafter with specific design criteria.
• P & ID includes the following: 1. Pipe line numbers with direction of commodity flow 2. Pipe specifications
and line sizes 3. All mechanical equipment 4. All operating and isolating valves 5. All controlling
instrumentation with transmitting devices.
• Mechanical flow diagrams define the exact sequence in which all mechanical equipment, valves,
instrumentation, connections, etc. are to be made on each process pipe routed through the facility.
• P & ID shows, from the point of view of the process, different measures such as pressure, flow, level, etc. and
their respective control schemes in relation to the elements of the plant and its interconnection pipes. These
elements (mechanical equipment, piping, piping components, valves, equipment drivers and
instrumentation and controls) are represented by symbols and labels. A standard set of symbols is used to
prepare drawings of control systems and processes. Symbols have been developed to represent all of the
components used in industrial processing, and have been standardized by ANSI
Process & Instrumentation Diagram (P & ID)
Importance of P & ID
Pre EPC phase - P&ID is used to derive the Project capital cost estimates. It is also used to develop EPC contract
specifications. Plot plant is developed considering various inputs from P&ID and physical site location.
EPC phase - P&ID is used to develop the individual unit layout. It used to identify hazardous areas classification,
preparing data sheets of equipment, valves, and instrument.
P&ID is used to develop the piping layout and preparing bulk material take-off for piping, electrical,
instrumentation and civil. It is key documents for various reviews such as HAZOP (Hazard & Operability Analysis)
, SIL(Safety Integrity Level) and operability review.
Operation phase - In this phase, you have to maintain P&ID in such a condition that it will show actual plant
conditions at any time. It should be updated when any physical change is made so that the unit will remain
compliant with codes, standards, and specification, and can be operated safely under the defined process
conditions.
What information does P&ID provide?
•All the equipment, including installed spares, and associated piping including drain and vent line.
•Insulation or jacketing requirements.
•Instrumentation
•Heat tracing and insulation detail
•Piping components including their size, class and tag Number
•A slope of the line
•Minimum straight lengths after instruments
What is not included in a P&ID?
•Process conditions and physical data
•Equipment locations
•Pipe routing, length, and fittings
•Support and structural details
The Utility Flow Diagram
The Utility flow diagram includes all pipes, valves, and instrumentation of the facility utilities. Utilities are
services that are essential to the proper function of the facility. Although the facility is not being constructed
to make condensate, condensate will be present in the facility and must be dealt with. Similarly, the facility is
not being designed to gather and use rainwater but the collection, treatment, and disposing of rainwater
must be incorporated into the facility’s design. Some utilities found in a petrochemical facility correspond to
those found in a typical house, such as water, gas, heating oil, and sewer drains.
Others are specific to industrial applications, such as compressed air for pneumatic tools and steam for high-
pressure cleaning. Some of the common plant utilities are the following: l Steam l Fuel oil l Instrument air l
Drainage systems l Condensate l Utility air l Cooling water l Flare system Flow.
Once flow diagrams have been finalized, they will be stamped for “release” by a registered professional
engineer, approving them for construction by the engineering group. The flow diagram is a dynamic
document. They may be revised and updated during the project’s design phase to reflect the client
changes or modifications imposed by governmental regulations. Continual review of relevant flow diagrams
must occur on a regular basis.
The Utility Flow Diagram
Flow Diagram Instruments
To ensure the safe and efficient operation of a facility controlling instrumentation is an absolute necessity.
Controlling instruments function by sensing conditional changes in the commodities they monitor, either in pipes
or mechanical equipment. These conditional changes comprise the four basic instrument groups; they are the
following:
Flow (F)
Level (L)
Pressure (P)
Temperature (T)
Within these four instrument groups are uniquely designed instruments that carry out the sensing, controlling, and
monitoring of the commodity. These instruments can be one or a combination of the following five specific types:
Controller (C)
Indicator (I)
Gauge (G)
Alarm (A)
Recorder (R)
By learning the combination of these nine instrument groups and types, you will be able to interpret most of the
instrumentation symbols present on a P & ID.
The first letter in the symbol typically indicates the instrument
group, while the second and/or third letters indicate(s) the
instrument type.
To respond to a change in, or to control the flow, level,
pressure, or temperature of a commodity, an instrument
must first sense a change in a particular variable. Once a
change has been detected, the instrument then transmits
this information, via mechanical, electronic, or pneumatic
means, to a control panel where it can be observed,
recorded, and responded to. At the same time, the
instrument may activate other devices that will affect and
change process conditions elsewhere in the facility. Some
instruments are read in the plant at the instrument’s actual
location; others are displayed on a control panel located in
the operator’s control room.
Instrument Types
Gauges - instruments that measure the liquid level inside a vessel or the temperature
and/or pressure in the piping system. Level, temperature, or pressure gauges can be
locally mounted to enable plant operators to obtain a visual reading.
Controllers - devices used to maintain a specified liquid level, temperature, pressure, or
flow inside a vessel or piping system. Controllers can activate a control valve, which
regulates the level, temperature, pressure, or flow of the commodity coming into or out
of a vessel.
Alarms - instruments that send a signal via lights, horns, or sirens indicate the liquid level,
temperature, or pressure inside a vessel is too high or too low or that there is no flow or
reverse flow.
Indicators—devices used to indicate the liquid level, temperature, pressure, or flow rate
inside a piping system.
Recorders - electronic devices used to record the liquid level, temperature, pressure,
and flow rate inside a vessel or piping system throughout a certain shift or period of
time.
Although they are often installed independently, multi-type instruments are engineered
to perform various functions simultaneously. If there are the need to record and control
the level of a commodity in a vessel, one would install a level recording controller
(LRC). The LRC would not only record the level of the commodity in the vessel but also
send a signal to a control valve that opens or closes to adjust the commodity level
inside the vessel
Flow Diagram Drawing Symbols

Mechanical Equipment Symbols

Flow Plan Arrangements
The flow plan, or sequence of flow, should be arranged in a
logical order of commodity flow. Even with a brief examination
of the flow diagram, the primary flow of commodity through the
facility should be obvious. Use the following checklist as an aid
when developing a flow diagram.
• Avoid crossing lines where possible.
• Space mechanical equipment to avoid overcrowding.
• Add notes to symbols where necessary for clarity.
• Use arrows to show commodity flow direction.
• Show equipment numbers when it is necessary to identify
mechanical equipment.
• Show control systems on the sketch. The control scheme is
frequently the most important part of a flow diagram.
• Show important valves, orifice flanges, and control valves.
• Show commodity flow directions through exchangers with
arrows.
• Do not run lines diagonally across the drawing.
• Label feed lines entering the unit from the field where the line
enters the unit. Label product lines leaving the unit by name.
• Do not draw lines any closer together than necessary