PROCESS DIAGRAMS

OUTLINES
TYPES of piping and
instrumentation symbols.
How to CHOOSE the suitable
symbols in control system?
How to DEVELOP the piping
systems and the specification of the
process instrumentation,
equipment, piping, valves, fittings.
The ARRANGEMENT in P&ID
for the bioprocess plant design.

Block Flow
Diagram (BFD)

Process Flow
Diagram (PFD)

PROCESS
DIAGRAMS
Piping and
Instrumentation
Diagram (P&ID)

Block Flow
Diagram (BFD)

Process Flow
Diagram (PFD)

PROCESS
DIAGRAMS
Piping and
Instrumentation
Diagram (P&ID)

BLOCK FLOW DIAGRAM (BFD)

simplest flowsheet.
Proses di desain dengan diagram blok
Diagram input-output tidak sangat rinci tetapi yang
paling berguna dalam tahap awal proses
pembangunan .
Aliran bahan baku dan produk dapat disertakan pada
BFD . Proses yang dijelaskan di BFD, kemudian dipecah
menjadi elemen fungsional dasar seperti reaksi dan
pemisahan bagian .
Juga mengidentifikasi aliran recycle dan operasi unit
tambahan untuk mencapai kondisi operasi yang
diinginkan

BLOCK FLOW DIAGRAM (BFD)

Example 1:
Mixed Gas
2610 kg/hr

Toluene, C7H8
10,000 kg/hr
Reactor
Hydrogen
H2 820 kg/hr

C6 H 6

Gas Separator

CH4
C7 H 8

Benzene,
C6H6 8,210
kg/hr

Mixed
Liquid

75% Conversion
of Toluene

Reaction : C7H8 + H2

C6H6 + CH4

Figure 1: Block Flow Diagram for the Production of Benzene

Example 2:
Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of Acid Sulphuric
catalyzer to produce ethylene. Distillation process then will be
applied to separate ethylene-H 2O mixture. Ethylene as a top product
is then condensate with condenser to perform liquid ethylene.
Hydrogenation of ethylene with presence of Nickel catalyzer to
produce ethane as a final product. Develop BFD for these processes.

CH3CH2O
H2=CH2 +
CH
H2

Answe
r:

H2SO4
Ni

Ethylene,
CH2CH2 (g)

CH2=CH2 +
H2O
CH
3CH3
Hot
water
out

Ethylene liq.
CH2CH2 (l)

Ethanol,

C 2 H5
OHSO
H
2

Reactor 1
4

CH2C
HH
2 2O

Cold
water
Distillati
in
on
column

H2
O

Reactor 2

Hydroge
n, H2Ni

Ethane,
CH3CH3

Block Flow
Diagram (BFD)

Process Flow
Diagram (PFD)

PROCESS
DIAGRAMS
Process equipments
symbol and
numbering

Piping and
Instrumentation
Diagram (P&ID)

PROCESS FLOW DIAGRAM (PFD)

Proses flow Diagram umumnya mencakup
Informasi sebagai berikut;
a) Composition streams(komposisi alir/tahapan).
b) Operating conditions of each stream such as
pressure , temperature, concentration, etc.
c) Heat added or removed in a particular equipment.
d) Flows of utilities such as stream, cooling water,
hot oil, chilled water, etc.
e) Simbol peralatan utama , nama dan identifikasi ..
f) Any specific information which is useful in
understanding the process. For example, symbolic
presentation of a hazard, safety precautions,
sequence of flow, etc.

1. Major Pieces Of
Equipment

2. Utility
Streams

PFD

4. Basic
Control Loops

3. Process
Flow Streams

PROCESS FLOW DIAGRAM (PFD)

2. Utility
Streams

1. Major Pieces Of
Equipment

PFD

4. Basic
Control Loops

3. Process
Flow Streams

PROCESS FLOW DIAGRAM (PFD)

Process Unit Symbology
Symbol

Descriptio
n
Penukaran panas

H2O

Water cooler

Steam
heater(pemanas
uap)
Cooling
coil(pendingin
berliku)

PROCESS FLOW DIAGRAM (PFD)

Process Unit Symbology
Symbol

Descriptio
n
Heater
coil(pemanas
berliku)
Centrifugal pump

Turbine type
compressor
Pressure gauge

PROCESS FLOW DIAGRAM (PFD)

Process Unit Symbology
Symbol

Name

Description

Stripper

A separator unit used

commonly
to
liquid
mixture into gas phase.

Absorber

A separator unit used

commonly to extract
mixture gas into liquid
phase.

PROCESS FLOW DIAGRAM (PFD)

Process Unit Symbology
Symbol

Name

Description

Distillation

A separator unit used

commonly to crack liquid
contains
miscellaneous
component fractions.

column

or

Liquid mixer

A process unit that used

to
mix
several
components of liquid.

PROCESS FLOW DIAGRAM (PFD)

Process Unit Symbology
Symbol

Name

Description

Reaction
chamber

A process unit where

chemical
process
reaction occurs

Horizontal
tank

A unit to store liquid or

gas.

or cylinder

PROCESS FLOW DIAGRAM (PFD)

Process Unit Symbology
Symbol

Name

Description

Boiler

A unit for heating.

Centrifuge

A separator unit that to

physically
separated
liquid mixture. (exp: oilliquid)

PROCESS FLOW DIAGRAM (PFD)

Valve Symbology
Symbol

Name
Gate Valve
Globe
Valve
Ball Valve

Check Valve
Butterfly
Valve

PROCESS FLOW DIAGRAM (PFD)

Valve Symbology
Symbol

Name
Relief Valve
Needle Valve
3-Way
Valve
Angle Valve

Butterfly
Valve

Example 4
Production of Ethane from Ethanol
Ethanol is feed to continuous reactor with presence of Acid Sulphuric
catalyzer to produce ethylene. Distillation process then will be applied to
separate ethylene-H2O mixture. Ethylene as a top product is then
condensate with condenser to perform liquid ethylene. Hydrogenation of
ethylene applies in another reactor with presence of Nickel catalyzer to
produce ethane as a final product. Develop PFD for these processes.

H2SO4

CH3CH2OH
CH2=CH2 + H2

CH2=CH2 + H2O
CH3CH3

Ni

R-100

P-100

T-100

E-100

P-101

R-101

Reactor

Pump

Distillation
Column

Condenser

Pump

Reactor

Hot water out

Ethylen
e
CV-100

Ethanol
H2SO4

V100
R100

P100

VV101
102
V103

T100

E100

VCold water 104

in
CV-101
V105
V107

H2

Ethylene
liq.
V106

Hydrog
enNi
P-

R101

Ethane

PROCESS FLOW DIAGRAM (PFD)

Process Unit Tagging and Numbering
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

2. Utility
Streams

1. Major Pieces Of
Equipment

PFD

4. Basic
Control Loops

3. Process
Flow Streams

PROCESS FLOW DIAGRAM (PFD)

Stream Information
-Since diagrams are small not much stream information
can be included.

-Include important data around reactors and towers, etc.

Flags are used
Full stream data

PROCESS FLOW DIAGRAM (PFD)

Stream Information - Flag

600 Temperatur
e

300

8
6

10

600
24

12
11

4
24

Pressure

10.3

Mass
Flowrate

108

Molar
Flowrate

24

13

Gas
Flowrate
Liquid
Flowrate

Example 4- cont
R-100

P-100

T-100

E-100

P-101

R-101

Reactor

Pump

Distillation
Column

Condenser

Pump

Reactor

Hot water
out
Ethylene liq.

Ethylene E100

25

Cold
water
T-100
in

CV-100

28
Ethanol
H2SO4

V100

R100

35

V101

32.2
P100

V102

35

V106

CV-101
V105

20

38

V103

31.0

V104

Hydroge
n Ni

V107

R101

8
7

H 2O
P101

Ethane

10

PROCESS FLOW DIAGRAM (PFD)

Stream Information - Full stream data:

Stream
Number

10

Temperature
(oC)

25.0

35.0

35.0

35.0

35.0

60.3

41

38

54.0

45.1

Pressure (psi)

28

32.2

31.0

31.0

30.2

45.1

31.3

24.0

39.0

2.6

Mass flow
(tonne/hr)

10.3

13.3

0.82

20.5

6.41

20.5

0.36

9.2

20.9

11.6

Mole flow
(kmol/hr)

108

114.2

301.0

1204.0

758.8

1204.4

42.6

1100.8

142.2

244.0

Vapor fraction

Example 4- cont
R-100

P-100

T-100

E-100

P-101

R-101

Reactor

Pump

Distillation
Column

Condense
r

Pump

Reactor

Hot water
out
Ethylene liq.

Ethylene E100

6
25

T100

CV-100

28

V100

R100

35

32.2
Stream Number

V101

P100

V102

Cold
water in

V106

CV101
V105

20

38

V103

Hydroge
n Ni

V107

35

H2O

Ethane

R101

31.0

Ethanol
H2SO4 1

V104

10

P101

10

25.0

35.0

35.0

35.0

35.0

60.3

41

38

54

45.1

28

32.2

31.0

31.0

30.2

45.1

31.3

24.0

39

2.6

Mass flow (tonne/hr)

10.3

13.3

0.82

20.5

6.41

20.5

0.36

9.2

20.9

11.6

Mole flow (kmol/hr)

108

114.2

301.0

1204.0

758.8

1204.4

42.6

1100.8

142.2

244.0

Temperature (oC)
Pressure (psi)
Vapor fraction

Block Flow
Diagram (BFD)

Process Flow
Diagram (PFD)

PROCESS
DIAGRAMS
Process equipments
symbol and
numbering

Piping and
Instrumentation
Diagram (P&ID)

PIPING AND INSTRUMENTATION

DIAGRAM (P&ID)
skema dari ,jalur pipa, equipment, instrumentasi,
control system,dari suatu sistem proses yang terdapat
di Oil Refinery, Chemical Plant, Paper Mill, Cement
Plant, dll.

PIPING AND INSTRUMENTATION DIAGRAM (P&ID)

PFD

PIPING AND INSTRUMENTATION DIAGRAM (P&ID)

EXERCISE

P&ID

Exercise
R-100

P-100

T-100

E-100

P-101

R-101

Reactor

Pump

Distillation
Column

Condenser

Pump

Reactor

Hot
water
out

Ethylene liq.

Ethylene E-

100

V104

Cold
water inCV-101
T-100

CV-100

Ethanol
1
H2SO4
R100

V100

V101

V102

V105

V103

R101

8
7

P100

Hydroge
9
n Ni

V107

V106

H 2O
P101

Ethane

10

Arigatou gozaimas