Global A Potential Hub To Deliver Dynamic Professionals. PROCESS DESIGN ENGINEERING COURSE LESSON 07 (PART 01) HOW TO DEVELOP PFD & P&ID ? OMESOL GLOBAL WWW.OMESOLGLOBAL.COM admin@omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. DEVELOPMENT OF PROCESS DESIGN AND ENGINEERING DRAWINGS Introduction The general perception of process design is to perform simulations, sizing and design calculations for various equipment and unit operations; but another important highlight in a process engineer’s career is the development of engineering drawings which brings the design in to reality. During this lessons we deals with the development of process design and engineering drawings which are helpful for the design, engineering and construction of a plant/facility. The process design engineering drawings are prepared in the following sequence. Facility Process Description Block Flow Diagram Process Flow Diagram Piping And Instrumentation Diagram Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. BLOCK FLOW DIAGRAM Block Flow Diagram (BFD) is a schematic representation of the major process of a facility. In a block flow diagram, unit operations are represented, using blocks or rectangles. The blocks are connected by straight lines which represent the process flow streams that flow between the units. The process flow streams may be a mixture of liquids, gases and solids flowing in pipes or duct, or solids being carried on a conveyor belt. In order to prepare clear, easy to understand and unambiguous block flow diagrams a number of rules should be followed: Unit operations such as mixers, separators, reactors, distillation columns, pump etc., are usually denoted by a simple blocks or rectangles. Process flow streams flowing into and out of the blocks are represented by neatly drawn straight lines. These lines should either be horizontal or vertical. The direction of the each process flow stream must be clearly indicated by arrows. Flow streams should be numbers sequentially in a logical order. Unit operations (i.e., blocks) should be labeled. Where possible the diagram should be arranged so that the process material flows from left to right, with upstream units on the left and downstream units on the right. This figure depict a very small and simplified BFD: Overhead Storage Tank T-102 Under Ground Water TanK T-101 Water Transfer Pump P- 201 Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. BLOCK FLOW DIAGRAM EXAMPLE: This diagram explains the operating principle of the whole installation in just a few boxes. The schematic diagram of the N’Kossa site in the Congo is given below. Task: Develop BFD for the process on the basis of given facility description. Production Of Ethane From Ethanol Ethanol is feed in to continuous reactor in the presence of H2SO4 catalyst to produce ethylene. Then distillation process will be applied to separate ethylene and H2O mixture. Top product from the column is then condense by condenser to get liquid ethylene. Which introduced in another reactor for Hydrogenation in presence of Nickel catalyst to produce ethane as a final product. CH3CH2OH CH2=CH2 + H2O (In Presence Of H2SO4 Catalyst) CH2=CH2 + H2 CH3CH3 (In Presence Of Ni Catalyst) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Solution: PROCESS FLOW DIAGRAM Process Flow Diagram (PFD) is a schematic diagram showing the main equipment and controls (Pressure, temperature, flow, level, etc.) of the process in the facility, using symbols. The diagram also shows stream numbers of important / main fluid streams flowing into, through and out of the facility. A summary of the process operating parameter like composition, mass flow rates, energy flow rates, operating pressure, operating temperature and physical properties of the numbered process streams are presented in a tabular form on the PFD or on a separate sheet known as Heat & Material Balance Sheet ( H&MB). Objective: PFD: To give an overview of the process taking place in the facility / plant. H&MB: To provide a summary of the process simulation data for the design of the facility / plant. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Input required for preparation PFD Process description of the facility Block flow diagram of the facility H&MB Stream numbers from PFDs Stream data from simulation Uses: PFD: To correlate the stream numbers with those used in simulations and / or Heat & Mass Balance. Prepare Piping and Instrumentations Diagrams H&MB: Perform equipment sizing calculations Perform line sizing calculations Perform instrument sizing calculations Generate process specification / datasheets for the equipment and instruments Generate line schedule Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. PROCESS FLOW DIAGRAM EXAMPLE: Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. PIPING AND INSTRUMENTATION DIAGRAM (P&ID) The process flow diagram (PFD) is the primary source of information for the development of piping and instrumentation diagram (P&ID). The P&ID is a schematic diagram which shows the interconnection of the process equipment and the instrumentation used to control the process. The P&ID should define piping, equipment and instrumentation well enough for cost estimation and subsequent design, engineering, construction, pre-commissioning, operation, maintenance and modification of the process. During the design and engineering phase of a project, the P&ID provides the basis for the development of system control schemes, allowing for further safety and operational investigation, such as the hazard and operability study (HAZOP). P&IDs are also referred as Engineering Flow Diagrams (EFDs). A P&ID as a minimum should include: Mechanical equipment with names and numbers Instrumentation and designations Process piping, sizes and identification All valves and their identifications Vent, drains, piping specialty fittings, sampling lines, reducers, expanders, etc. Permanent start-up and flush lines Flow directions Interconnections references Control input and output, interlocks Interface for pipe class changes Vendor and contactor interfaces Identification of components and subsystems delivered by others In short, P&ID is just a pictorial representation of Key piping and instrument details Control and shutdown schemes Safety and regulatory requirements Basic start-up and operational information Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. INPUT REQUIRED FOR P&ID PREPARATION Process design basis Process flow diagram Equipment list Process description Operation philosophy Control philosophy Shutdown philosophy Isolation philosophy Symbols and legends Numbering system Pipe class specification Vendor package details Sizing calculations ( Line, Equipment, Instrument ) Equipment datasheets / general arrangement drawing Instrument data sheets Cause and effect chart NOTE: P&IDs are used throughout the life of the facility and are constantly updated for any modification / changes that happen from time to time. In the process industry, a standard set of symbols are used to prepare drawing for various processes. Refer section ISA–5.5 or PIP (Process Industry Practices) for the typical symbols / legends. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. SYMBOLS & LEGENDS General Abbreviations Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. EQUIPMENT SYMBOLS (Centrifugal Pumps) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. EQUIPMENT SYMBOLS (Positive Displacement Pumps) EQUIPMENT SYMBOLS (Storage Vessel & Tanks) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. EQUIPMENT SYMBOLS (Compressors) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. EQUIPMENT SYMBOLS (Heat Exchangers) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. EQUIPMENT SYMBOLS (Heat Exchangers) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. EQUIPMENT SYMBOLS (Heat Exchangers) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. EQUIPMENT SYMBOLS (Heat Exchangers) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. EQUIPMENT SYMBOLS (Columns) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. LINE LEGEND Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Line Numbering Philosophy Line Line Service Codes Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. PIPING FITTINGS Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. PIPING SPECIALTY ITEMS Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. VALVES Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. INSTRUMENT SYMBOLS Instrument Designation Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. If you want to learn new skills online. Join or expert LED training courses. Registration Process Kindly follow the mentioned below steps to proceed further. 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