Chapter 01 - Process Diagrams - Added by 8 Mar 2017

Chemical Process Diagrams
Chapter 1
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.
1
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.
2
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
3
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
4
The Block Flow Process Diagram
5
The Block Flow Process Diagram
6
The Block Flow Plant Diagram
7
Copyright - R. Turton and J. Shaeiwitz,
8
2012
The Process Flow Diagram (PFD)
• 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
9
The Process Flow Diagram (cont’d)
– 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
• The basic information provided by a PFD can be categorized into one
of the following:
1. Process topology
2. Stream information
3. Equipment information
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Process Equipment General Format XX-YZZ A/B
XX are the identification letters for the equipment classification
Table 1.2 : Conventions Used for Identifying Process Equipment
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
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 13
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2012
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2012
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
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Equipment Numbering (cont’d)
Thus, T-905 is the 5th tower in unit nine hundred

P-301 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
19
Stream Numbering and Drawing
• Number streams from left to right as much as
possible
• Horizontal lines are dominant
yes no no
20
21
Stream Numbering and Drawing (cont’d)
• Add arrows for

– Change in direction
– Inlet of equipment
• Utility streams should use convention given in
Table 1.3, lps, cw, fg, etc.
22
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
23
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
Stream Information - Flags
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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
27
A Portion of Table 1.5
Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (°C) 25 59 25 225 41 600 41 38 654 90
Pressure (bar) 1.90 25.8 25.5 25.2 25.5 25.0 25.5 23.9 24.0 2.6
Vapor Fraction 0.0 0.0 1.00 1.0 1.0 1.0 1.0 1.0 1.0 0.0
Mass Flow (tonne/h) 10.0 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6
Mole Flow (kmol/h) 108.7 144.2 301.0 1204.4 758.8 1204.4 42.6 1100.8 1247.0 142.2
Component Mole Flow (kmol/h)
Hydrogen 0.0 0.0 286.0 735.4 449.4 735.4 25.2 651.9 652.6 0.02
Methane 0.0 0.0 15.0 317.3 302.2 317.3 16.95 438.3 442.3 0.88
Benzene 0.0 1.0 0.0 7.6 6.6 7.6 0.37 9.55 116.0 106.3
Toluene 108.7 143.2 0.0 144.0 0.7 144.0 0.04 1.05 36.0 35.0
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Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved.
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
29
Basic Control
Loops
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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
Bhattacharyya (ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 32
Equipment Information
A Section of Table 1.7: Equipment Summary
Vessel V-101 V-102
Temperature (ºC) 55 38
Pressure (bar) 2.0 24
Orientation Horizontal Vertical
MOC CS CS
Size
Height/Length (m) 5.9 3.5
Diameter (m) 1.9 1.1
Internals s.p. (splash plate)
33
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
34
The Piping and Instrument
Diagram(P&ID)
P&ID – Construction
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
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P&ID
36
P&ID
37
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
38
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
(ISBN-13: 978-0-13-261812-0) Copyright © 2012 Pearson Education, Inc. All rights reserved. 39
Other Common Diagrams
Section of Plot Plan Section of Elevation Diagram
40
Other Common Diagrams (cont’d)
• Piping Isometrics – show piping in 3-

dimensions
• Vessel Sketches – show key dimensions of
equipment and locations of inlet and outlet
nozzles etc.
41
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
42
OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS
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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)
45

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Chemical Process Diagrams

• Block Flow Diagram (BFD)

• Block Flow Process Diagram

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

Thus, T-905 is the 5th tower in unit nine hundred

• Add arrows for

Temperature (°C) 25 59 25 225 41 600 41 38 654 90

Component Mole Flow (kmol/h)

Vessel V-101 V-102

Pressure (bar) 2.0 24

Orientation Horizontal Vertical

Height/Length (m) 5.9 3.5

Diameter (m) 1.9 1.1

Internals s.p. (splash plate)

Contains: plant construction information (piping,

Section of Plot Plan Section of Elevation Diagram

• Piping Isometrics – show piping in 3-

Figure 1.19 An Avatar Can Access Process

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