National Institute of Technology of Mexico

Tianguistenco Institute of Advanced Studies

Mechatronics Engineering Division

Tianguistenco Higher Technological Institute of Studies

National Technological Institute of Mexico

Mechatronics Engineering Division

Subject:
Instrumentation

Teaching:
Hugo Yáñez Badillo

Students:
González Moreno Axel Salvador
Quintero Solano Jeshua Hassan
Urbina García Dan Isaías.
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Laboratory Practice Manual

Instrumentation
Mechatronics Engineering Division

Practice 1. P&ID diagrams (Temperature System)

Objective.

Introduction
A piping and instrumentation diagram (P&ID) is a schematic layout of a plant that shows the
units to be used, the piping connecting these units, and the sensors and control valves.
Standard structures located on a P&ID include storage tanks, surge tanks, pumps, heat
exchangers, reactors, and distillation columns. These last three comprise the majority of
single-unit control problems in the chemical process industry.

P&IDs have a number of important uses in the successful design and operation of chemical
process plants. Once a process flow diagram is made, P&IDs help engineers develop control
strategies that ensure production goals are met and all environmental standards are met.
These diagrams are also very important for locating valves and process components during
maintenance and troubleshooting.[2]

Each page of a P&ID should be easy to read and correspond to a specific plant action. In
addition, the symbols used in the P&ID are uniform throughout. The diagrams for heat
exchangers, continuously stirred tank reactors (CSTRs), and distillation columns shown in
later sections of this wiki represent a small sample of standard symbols for these structures.
For a list and explanation of symbols related to standard controls, see PID standard notation.

Basic Definitions:
• General Strategies for Implementing Good Control Systems
There are several guidelines to follow when designing P&IDs for a plant. The first
consideration is stable plant operation so that all safety and environmental regulations are
met. Maintaining product quality should also be a primary design goal. In addition, systems
should be designed to respond quickly to rapid changes in product rate and quality. Control
systems should typically be run in automatic mode so that the system corrects itself, as
opposed to a manual mode, which requires operator supervision.[2]

When setting up a control system, it is helpful to first focus on mass balance control, which
can be monitored by level and pressure control loops using gas or liquid flow rates.
Additionally, a product control structure should be established to ensure efficient process
operation. To prevent controls from conflicting with each other, a final examination of the
controlled streams should be performed. Additional instrumentation can then be installed to
prevent conflicts between controllers. Finally, proper tolerances must be established for
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controllers that directly affect the action of other controllers. Determining optimal control
placement is essential for successful plant operation.

• Standard Structures and Location of Control Features

As mentioned above, control of heat exchangers, reactors, and distillation columns accounts
for the majority of single-unit control problems. The control schemes derived in the following
examples are summarized in the following Table 1. The most common control schemes are
listed in the following table.[3]

Table 1 Overview of common P&ID structures [3]

For most equipment, a degree of freedom analysis is performed first and then a control
scheme is designed based on the degrees of freedom.

• Heat Exchanger
To monitor the performance of a heat exchanger, the product stream is important. Typically,
the product stream must be within some temperature range before continuing to the
downstream process units. The outlet temperature of this stream can be used to calculate heat
transfer. Steam is controlled in order to obtain the desired temperature of the product stream.
One way to influence the product temperature is by controlling the flow of the heated steam.
This flow-based control may take some time to implement and therefore cause fluctuations
in the process.[4]

Depending on the process, these fluctuations may or may not be acceptable. Instead of
monitoring the flow rate, steam pressure can be monitored, achieving tighter temperature
control. A change in pressure is much easier to monitor and directly correlates to a change in
steam temperature. This offers an effective way to control process temperatures. Pressure
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control also allows for monitoring the physical condition of the piping as pressure changes
occur as fouling progresses. Pressure, combined with the flow rate and temperature of the
heated steam, can be used to calculate this fouling occurring within a piece of equipment. It
is important to remember that steam should always be controlled on the inlet side of the heat
exchanger for better pressure control and safety reasons, as shown in Figure 1 below.

Heat exchanger with pressure control at the steam inlet and temperature control on the
product stream.

• Control Schemes
As discussed above, a valve can be placed on the coolant inlet stream to ensure proper control
of reactor temperature. By controlling the coolant stream based on the inlet conditions of the
reactant streams, the control can respond quickly. But, if the coolant is controlled based on
the exit conditions of the product stream, there is a delay in response, but it is easy to monitor
heat transfer performance.[5]

Figure 1 Jacketed CSTR with coolant control based on exit temperature conditions [5].
To translate this example into an endothermic reaction, the coolant flow would simply be
translated into vapor flow in order to provide heat to the reaction through the CSTR jacket.

• Liquid-Liquid Extractors
In liquid-liquid extractors, the interface level and pressure are the controlled variables.
Disturbances in the flow rate of the incoming stream can affect the interface level and prevent
complete separation of the heavy and light components. From this, it is obvious that there
must be valve controls on both exit streams. The best control scheme depends on the process
operation. When the heavy phase is continuous (light phase flows up through the heavy
phase), changes in interface level must be controlled by adjusting the light product flow rate,
while pressure is controlled by adjusting the heavy product flow rate out of the column.
Figure A is a representation of what occurs in a single-stage extractor.[6]

Single-stage extractors are typically used in chemical laboratories, where as multi-stage

extractors they are used in industry. A multi-stage extractor uses the immiscible liquid stream
from the previous stage as feed into the next stage. Figure 2 represents the control scheme
described above.
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Figure 2 Liquid-liquid extractor control scheme with interface level and pressure control
[7].
When the light phase is continuous, the control system must be configured in the opposite
manner. Figure C is again a representation of what occurs in a single-stage extractor. Figure
D is a representation of a control scheme that could be implemented. This is the opposite of
the control scheme in Figure 2.

Figure 3 Liquid-liquid extractor control scheme with light phase control [7].
These representations are just two possibilities for basic control schemes that can be
implemented in a process as there are several controllers and aspects of the specific processes
that may need to be controlled or monitored.

• Compressors
Compressors are another valuable component in process design. They allow for the reduction
of the volume of an incoming stream by increasing the pressure at which the stream is
maintained. They can also be used to pump liquids through the process, as liquids are highly
incompressible compressors cannot be used for volume reduction. For this, a specific control
system must be in place to prevent adverse effects due to extremely high or low pressures.
There are several types of compressors including: dynamic, axial and rotary [1] to name a
few. Because the pressure increase is governed by the ideal gas law, there is most often and
temperature increase as well. This can be left as is, or sent to a heat exchanger for temperature
reduction. Heat exchangers were discussed above.[7]

One such example is the use of a centrifugal compressor to reduce the volume of a fuel stream
for storage. Using a compressor will allow for volume reduction as the gases are easily
compressed, this is also economically friendly as it reduces the size of the tank needed to
store the fuel stream. The tank should also be equipped with a pressure reducing valve, to
return the stream to the desired pressure, depending on the process. A diagram of this scheme
is as follows:
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Figure 4 Compressor control scheme with pressure control [7].

The pressure controller on the compressor controls the valve on the incoming fuel stream.

This ensures that if there is a pressure build-up, the flow into the system will be stopped in
time. In addition, a pressure controller should be placed on the storage tank. This is controlled
by the pressure reducing valve mentioned above.

• Selecting Controls and Their Locations for a Multi-Unit Process

1. The following steps should be followed when setting up controls for multi-unit
processes. For more detailed descriptions, see the Step-by-Step Method for
Describing Controls and Their Purpose.

2. Determine process objectives, taking into consideration product specifications,

economic constraints, environmental and safety regulations, etc.

3. Identify limits to normal operation. These may be based on equipment limitations,

safety concerns, environmental regulations, and the economic objectives of the
processes.

4. Identify units and streams in the process that are susceptible to significant
disturbances. These disturbances commonly occur in feed streams, product streams,
and reactor vessels, but may be present anywhere temperature or pressure or other
variables are changing.

5. Select sensor types and locations to properly measure and monitor critical process
variables.

6. Determine appropriate types and locations for control valves in order to properly
adjust process variables so that they remain within normal operating limits. Controls
should be established to minimize the response time between detecting a change and
taking corrective action. The ideal location for any given control depends on the
process unit or units it affects.
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7. Perform a degree of freedom analysis.

8. Energy Considerations. An energy balance must be performed for the process. This
step involves transporting energy to and from process units. This may include
removing heat generated by a reactor and using it elsewhere in the process. Control
valves will help regulate the flow of such streams.[7]

9. Control the process throughput rate and other operating parameters. Adjusting
process inputs, such as reactant feed rates, can alter other variables in the process.
Process controls must be able to respond to these adjustments to keep the system
within operating limits.

10. Configure the control system to handle disturbances and minimize their effects. (See
Chemical Process Controls > PID Control ) Monitor Component Balances. Buildup
of materials within a system is undesirable and can lead to process inefficiency or
catastrophic failure.

11. Control operations of individual units. Each unit in a multi-unit process needs to be
controlled individually so that control of the entire system is possible.

12. Optimize the process. If the system has degrees of freedom, process variables can be
manipulated to create product more efficiently or economically.

Equipment and materials

• Computer with electrical software
• P&ID piping study
• Diagrams
• Books

Safety standards
All personnel who enter the laboratories to carry out practices must comply with the
following policies:

1. The user must deliver the laboratory voucher approximately 5 business days prior
to the practice.
2. The teacher and the student must present a valid official identification to receive.
3. The teacher and the student will have 15 minutes of tolerance for the delivery-
reception of material, otherwise the laboratory technician will issue the
corresponding report.
4. The laboratories must be entered with the safety equipment, according to the
practice to be developed and the equipment and machinery that will be used.
5. Before entering the laboratory, personal materials and backpacks must be placed
in the drawers located inside.
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6. It is prohibited to enter and eat food inside the laboratory.

7. The facilities and laboratory equipment must be used with due caution and safety
in handling, taking care not to exceed the capacity of the equipment and to
maintain order.
8. Users must report any anomaly in the equipment to the corresponding teacher.
9. Development

Development
The fluid process temperature of a heat exchanger shall be regulated.
The controlled temperature system used is a controlled system with self-regulation (PT1-
controlled system). Because the conversion of energy happens slowly these comtrolled
system has a big time constant (of time delay).

Figure 5 Temperature sensor [1]

The on/off switching period of the heating element E104, which is the manipulated variable,
determines the heat output of the heat exchanger. For controlling system a two-point element
can be used (see also EMCS block diagrams). For disturbance is it possible to use cold fluid
or (f.g. ice cubes) or mix with water from the upper tank. The resistance of the temperature
sensor is connected to the measuring transformer A3. The transformer changes the resistance
into a standard voltage signal 0 to 10 V. The standard voltage signal is connected to the analog
terminal X2 (UE4). The heating is controlled by a internal relay. With a digital ouput (O1 at
XMA1) the relay can be switched on/off.[1]
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Figure 6 Controlled temperature system – reactor container B101 with temperatur sensor
B104 (measuring point ‘TIC B104’)[1]

Figure 7 Flow chart of the close loop temperature control System [1]
The water in the reactor container B101 of the heat exchanger E104 is heated by means of a
heating element and is recirculated by means of the pump P101. A PT100 sensor B104 (2) is
used for measuring the system temperature at measuring point ‘TIC B104’ in the form of an
actual value. The actual value should be kept on a certain temperature also if disturbances or
set point changes occur.
To carry out this practice we must take into account that we must have the following software
(Lucidchard) to be able to support us in making the P&ID diagram and the following steps
must be taken:
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1. Are the components that were used

Figure 8 Components to use [8]

2. To integrate the engineering library, press the button for more figures and there is the
process engineering that creates DTI diagrams

Figure 9 Lucidchart software starter template [8]

3. Components that make up the library

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Figure 10 Library components [8]

4. Pipes that integrate the program

Figure 11 Library pipes [8]

5. Library containers
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Figure 12 Capacitors from the library [8]

6. Heat exchangers

Figure 13 Heat exchangers [8]

7. Various bombs that integrate the library

Figure 14 Diversity of valves [8]

8. Instruments that make up the library.

Figure 15 Measuring instruments [8]

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9. Finally the valves that make up the library

Figure 16 Different valves [8]

10. To add line types in the toolbar there is the option of lines

Figure 17 Types of lines in the toolbar [8]

Results and interpretation

The temperature controlled system used is a self-regulating controlled system (PT1
controlled system). Because the energy conversion occurs slowly, these controlled systems
have a long time constant (time delay).
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Figure 18 Instrument panel [2]

In the temperature diagram shown, we can see that it is a closed-loop temperature control
system. This means that it will be regulated according to the temperature digitized in the TIC
B104 instrument, since this means a controller, temperature indicator, which means that
depending on the case, the temperature is automatically regulated.

We see the container, which in this case is represented with the following format B101, in
which the liquid is contained and certain conditions are met that occur in the level switch LS-
(B117), which measures when the level is low and when it exceeds a certain limit the level
switch LS+ (B114), if it happens that this level is exceeded, an alarm is activated with the
LA+ (S111) instrument. First of all, remember that E104 represents a section of pipes used
to heat the liquid that is operating.
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Figure 19 Flow chart of the close loop temperature control System

We see a pipe that then splits into two parts, one that goes to a valve (V105) that represents
the outlet of the hot liquid and the other that goes to a pump (P101) that passes through a
valve (V104) which means that it will feed back said circuit and the TIC temperature
controller and indicator (B104) will be activated again and this will keep the liquid at the
ideal temperature

Conclusions
Piping and Instrumentation Diagrams (P&ID) are essential tools in the design, operation and
maintenance of industrial facilities. They provide a detailed visual representation of piping
systems, equipment and instruments, allowing engineers and operators to understand the
interconnection and functionality of each component.

Standardizing symbols and including critical technical information facilitates communication

and collaboration between different disciplines, improving safety and efficiency in processes.
In addition, P&IDs are essential for documentation and training of personnel, contributing to
more effective operation and management of the life cycle of facilities.

In short, P&ID diagrams are not only a design tool, but also a vital resource for the safe and
efficient operation of complex industrial systems

An instrument identification system might include the following components:

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1. Label numbers to define the foundation in the process and the location of the
instrument.
2. Symbols to identify pneumatic, hydraulic, capital, electronic, sonic or radioactive
process control signals.
3. Symbols to represent primary and final control devices that govern flow, level,
and temperature.

Four types of drawings are used in process control systems.

1. The P&I (Piping and Instrumentation) as the basis of any process design.
2. Layout drawings to indicate the position of installed instruments and
equipment.
3. Installation drawings to provide details of parts and instrument locations.
4. Control loop diagrams for calibration and troubleshooting.

Questionnaire
1. What does a P&ID diagram represent?
A P&ID diagram represents the layout of piping, equipment, instruments, and controls in a
processing system. It is an essential tool for the design and operation of industrial facilities.

2. What is the function of instrument symbols in a P&ID?

Instrument symbols on a P&ID indicate the presence and function of measurement and
control devices, such as valves, pressure gauges, temperature sensors, and controllers,
providing an understanding of how processes are monitored and regulated.

3. What additional information can be included on a P&ID diagram besides symbols?

In addition to symbols, a P&ID may include information about technical specifications, line
numbers, fluid types, operating conditions, and references to operating or maintenance
procedures.

4. How is a P&ID different from a flow chart (FDS)?

A P&ID focuses on the detailed representation of the equipment, piping, and instruments in
a system, while a flow diagram (FDS) focuses on the flow of materials and the sequence of
operations without detailing specific components.

5. Why is standardization important in the symbols used in a P&ID?

Standardizing symbols on a P&ID is crucial to ensure clear understanding and
communication between engineers, operators, and maintenance personnel. It makes diagrams
easier to interpret and prevents confusion during system design and operation.

Sources of reference
[1] Bequette, W. B. Process Control Modeling Design and Simulation. , New Jersey:
Prentice Hall, pp 466-477
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[2] Luyben, W.L. Plant-Wide Process Control. , New York: McGraw-Hill, pp 53-69, pp
201-203, pp 235-247
[3] Module 3.1: Distillation Column Control. The ECOSSE IGDS Controls
HyperCourse. University of Edinburgh, Scotland.
[4] Ogunnaike, Babatunde A. Process Dynamics, Modeling and Control , New York:
Oxford University Press 1994, pp 1149-1153
[5] Riggs, James B. Chemical and Bioprocess Control. , Ferret Publishing, pp 491-504
[6] Turton, Richard. Analysis, synthesis, and design of a chemical process , New Jersey:
Prentice Hall, pp 408-409
[7] U.S. Chemical Safety and Hazard Investigation Board; “Morton International
Explosion.” www.csb.gov/completed_investigations/docs/mortondigest.pdf. Last
updated 07/17/2003.
[8] Tompkins, Bill. “Reaction and Action.” www.ehponline.org/members/2004/112-
6/focus.html. Last updated 09/09/2007