Flow Diagrams Overview

The most effective way of Communicating

Information about a process is through the use
of Flow Diagrams
Flow Diagrams

1. The Key Document or Road Map in Process DesignA Process Flow Diagram (PFD) is the
key document or road map used in process design.

2. It’s a Diagrammatic Model of the ProcessIt describes the process steps in a proper
sequence using symbols to represent the various components—equipment, lines, and
control instrumentation—that make up the unit.

Importance
• Shows the arrangement of the equipment selected to carry out the process.
• Shows the streams' concentrations, flow rates, and compositions.
• Shows the operating conditions.
• During plant start-up and subsequent operation, the flow sheet forms a basis for
comparison of operating performance with design.
• It is also used by operating personnel for the preparation of operating manuals and
operator training.
Three Main Levels of Diagrams

1.Block Flow Diagram (BFD)

2.Process Flow Diagram (PFD)
3.Piping and Instrumentation Diagram (P&ID) –
often referred to as Mechanical Flow Diagram
Information to Be Included

Essential Information
1.Stream Composition:
1. (i) The flow-rate of each individual component, kg/h
(preferred), or
2. (ii) The stream composition as a weight fraction.
2.Total stream flow-rate, kg/h.
3.Stream temperature, degrees Celsius (preferred).
4.Nominal operating pressure (the required operating
pressure).
Optional Information
1.Molar percentages composition.
2.Physical property data, mean values for the stream, such as:
1. (i) Density, kg/m³
2. (ii) Viscosity, mN s/m²
3.Stream name, a brief, one or two-word description of the nature of the
stream, for example "ACETONE COLUMN BOTTOMS".
4.Stream enthalpy, kJ/h.

•Note: The stream physical properties are best estimated by the process
engineer responsible for the flow-sheet. If they are then shown on the
flow-sheet, they are available for use by the specialist design groups
responsible for the subsequent detailed design. It is best that each group
use the same estimates, rather than each decide its own values.
Block Flow Diagram

•Shows overall processing picture of a chemical complex.

•Useful as an orientation tool.
•Used to sketch out and screen potential process alternatives.
•BFD forms the starting point for developing PFD.
•BFD is helpful in conceptualizing new processes.
•Gives a general view of a large complex plant.
Conventions & Formats of BFD

•Operations shown by blocks.

•Major flow lines shown with arrows.
•Flow goes from left to right whenever possible.
•Light streams toward top with heavy stream toward bottom.
•Critical information unique to process supplied.
•If lines cross, then horizontal line is continuous.
•Simplified material balance provided.
Process Flow Diagram (PFD)

A PFD is a simplified flow diagram of a single process unit, a utility unit, a complete process
module.

Purpose: To provide a preliminary understanding of the process system indicating only the
main items of equipment, the main pipelines, and the essential instruments, switches, and
control valves.
A PFD also indicates operating variables, such as mass flow, temperatures, and pressures,
which are tabulated at various points in the system.

Information Contained in a PFD

• Process conditions and physical data of the main process streams.
• Main process equipment with design data.
• Main process lines.
• Mass (material) balance.
• Heat balance (if applicable).

Note: If the PFD doesn’t contain any data about the flow rates, it is called a qualitative
flowsheet, while if the flow rates are involved, the PFD is called a combined flowsheet in
which qualitative information and quantitative data are combined on the basis of one
flowsheet.
Typical Commercial PFD
Content
1.All the major pieces of equipment in the process will be represented on the
diagram along with a description of the equipment. Each piece of equipment will
have assigned a unique equipment number and a descriptive name.

2.All process flow streams will be shown and identified by a number. A description
of the process conditions and chemical composition of each stream will be
included. These data will be either displayed directly on the PFD or included in an
accompanying flow summary table.

3.All utility streams supplied to major equipment that provides a process function
will be shown.

4.Basic control loops, illustrating the control strategy used to operate the process
during normal operations, will be shown.
Basic Information Categories in a PFD
1.Process topology.
2.Stream information.
3.Equipment information.
Conventions Used for
Identifying Process Equipment
Example: P-101A/B

•P-101A/B identifies the equipment as a pump.

•P-101A/B indicates that the pump is located in area 100 of the plant.
•P-101A/B indicates that this specific pump is number 01 in unit 100.
•P-101A/B indicates that a backup pump is installed. Thus, there are two
identical pumps, P-101A and P-101B. One pump will be operating while
the other is idle.
Stream numbering & Drawing
Stream Information

•Each of the process streams is identified by a number in a diamond box located on

the stream. The direction of the stream is identified by one or more arrowheads.
•The process stream numbers are used to identify streams on the PFD.

•Utility Streams: Utilities are needed services that are available at the plant. Chemical
plants are provided with a range of central utilities that include electricity, compressed
air, cooling water, refrigerated water, steam, condensate return, inert gas for
blanketing, chemical sewer, wastewater treatment, and flares.

• A list of the common services is given, which also provides a guide for the
identification of process streams.
• Each utility is identified by the initials provided.

•Electricity used to power motors and generators is an additional utility that is not
identified directly on the PFD but is treated separately.
•Most of the utilities shown are related to equipment that adds or removes heat
within the process in order to control temperatures. This is common for most chemical
processes.
Conventions for Identifying
Process and Utility Streams
Information Provided in a Flow
Summary
Flow Summary Table for the
Benzene Process Shown
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).
 Equipment Descriptions for PFD
and P&IDs
Equipment Summary for
Toluene Hydro-dealkylation PFD
PFD and P&ID
•The process flow-sheet (PFD) shows the arrangement of the major pieces of
equipment and their interconnection. It is a description of the nature of the process.
•The Piping and Instrument diagram (P&ID) shows the engineering details of the
equipment, instruments, piping, valves, and fittings; and their arrangement. It is also
called the Engineering Flow-sheet or Engineering Line Diagram.

•P&ID: A Key Document:

• Acts as a directory to all field instrumentation and control that will be
installed on a process and thus is a key document to the control engineer.
• Plays an important role in the design, installation, and day-to-day
maintenance of the control system.
• A key piece of information in terms of understanding what is currently being
used in the plant for process control and safety.
P&ID: Representation
•Schematics where process units
and instruments are represented
using special symbols.
P & ID

A P&ID diagram shows the arrangement of the process

equipment, piping, pumps, instruments, valves and other
fittings. It should include:

• All process equipment identified by an equipment

number.
• All pipes identified by a line size, material code and line
number.
• All valves with an identified size and number.
• Fittings.
• All pumps identified by a suitable code number.
• All control loops and instruments.
Exclusions from P&ID

•Operating Conditions T, P
•Stream Flows
•Equipment Locations
•Pipe Routing
•a. Pipe Lengths
•b. Pipe Fittings
•Supports, Structures, and Foundations
Conventions in Constructing Piping
and Instrumentation Diagrams
Flowsheet Symbols
•To reduce detailed written descriptions on flowsheets, it is usual practice to develop or
adopt a set of symbols and codes which suit the purpose.
•Many symbols are pictorial, which is helpful in representing process as well as control and
mechanical operations.

Line Symbols and Designation

1.Those representing outlines and details of equipment, instruments, etc., and
2.Those representing pipe carrying process or utility liquids, solids, or vapors and electrical
or instrument connections.

•The Usual Complete Line Designation Contains:

• Line size (nominal)
• Material code
• Sequence number
• Materials of construction
•Examples: 2"-CL6-CS40, 3"-CL6a-CS40
P&ID: It Should Show

•All process equipment are identified by

an equipment number.
•The equipment are usually drawn in
proportion. The location of nozzles are
shown.
•All pipes are identified by a line number.
The pipe size and material of construction
should be shown. The material may be
included as part of the line identification
number.
P&ID: It Should Show

All valves, control valves, and block

valves are shown with identification
number. The type and size should also be
shown. The type may be shown by the
symbol used for the valve or included in
the code used for the valve number
P&ID: It Should Show

P&ID: Utility Lines

•For simple processes, the utility lines (service lines) can be shown
on the P&ID.
•Utility connections are identified by a numbered box in the P&ID.
The number within the box identifies the specific utility.
•The key identifying the utility connections is shown in a table on
the P&ID.
•For complex processes, separate diagrams should be used to
show the utility lines. Then, the service connections to each unit
should be shown on the P&ID.
•The same equipment identification numbers should be used on
both diagrams.
Codes and Standards: PFD and
P&ID

•IS: 3232-1999: Graphical Symbols for Process Flow Diagrams, P&ID

(Reaffirmed 2005)
•IS: 9446: Graphical Symbols for Pipelines and Instrumentation Diagrams
US Standards
•ANSI Y32.2.3: Graphical Symbols for Pipe Fittings, Valves, and Piping
•ANSI Y32.2.11: Graphical Symbols for Process Flow Diagrams
•ISA 5.5: Graphical Symbols for Process Displays
Codes and Standards: PFD and
P&ID

British Standards
•BS: 16461 to 4: Symbolic Representation for Process Measurement,
Control Functions, and Instrumentation
German Standards
•DIN 19227 P1 to P3: Graphical Symbols and Identifying Letters for
Process Measurement and Control Functions
P&ID: Line Code

P&ID: Line Code

Example 1
•2"AARX-304 S/S-1"F:
• 2" diameter, Type 304 S/S pipe in Acetic acid Reactor
discharge service, insulated with 1" of Fiberglass insulation.
Example 2
•2"AARX-304 S/S:
• The fluid has cooled enough to eliminate the insulation.
P&ID Example: V-104
•Look at V-104 on P&ID:
• V-104 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.
• The final control element in nearly all chemical process
control loops is a valve.
P&ID: A Simple Mixing Tank
Alarm and Safety Trips

•Audible and visual alarms are used to alert operators of serious, and potentially
hazardous, deviations in process conditions.
•Some key instruments are fitted with a trip system to take action automatically to
avoid hazardous situations, such as shutting down pumps, closing valves, operating
emergency systems.
• Example: On high temperature, the high-temperature alarm operates a
solenoid valve to release the air on the pneumatic activator, and thus close
the valve.
False Alarm

•Alarms that actuate because of faulty sensors or because the alarm limit
is set too close to normal operating conditions frequently provide false
alarms.
•It is difficult to tell when these unreliable alarms are warning of a real
deviation that requires action.
•If a display is crowded with many such nuisance alarms, operators may
fail to notice a real alarm that requires action.
•Advice: Never ignore safety alarms.
•If your plant has alarms that do not require a response, evaluate the
need for the alarms.
Based on the P&ID Diagram
•Mech and Civil Engrs will design and install pieces of equipment.
•Instrument Engrs will specify, install, and check control systems.
•Piping Engrs will develop plant layout and elevation drawings.
•Project Engrs will develop plant and construction schedules.
4) Utility Flowsheet (Process Engineering Utility Flow Diagram - PEUFD)
•Used to summarize and detail the interrelationship of utilities such as air, water (various
types), steam (various types), heat transfer mediums, process vents and purges, safety
relief blow-down, etc., to the basic process.
•The amount of detail is often too great to combine on other sheets, so separate sheets
are prepared.

The PEUFD is a Document Containing Information On

•Main distribution or arrangement of each individual utility system, except electrical
systems.

PEUFD Function
•A typical process uses utilities such as water, air, and electric power. Water may be used
either in the process, or for cooling and/or production of steam. Air may also be used in
the process or for instrument applications. Electric power, of course, is typically used at
various points in the process and throughout the site.
•The PEUFD shall state characteristics and consumption figures of the particular utility
concerned: cooling water, fire water, drinking water, steam, plant air, instrument air, fuel
oil/gas, inert gas, and similar utilities.
5) Process Safeguarding Flow Diagram (PSFD)
•The PSFD is a document highlighting information on:
• Types and levels of protection offered by the devices installed
and their interrelation to demonstrate the plant’s safety.

•The P&ID contains all information required for a PSFD; however, the
PSFD highlights protection in case of extreme conditions and measures
to be taken to safeguard personnel and the environment.

•Note: In general, these schemes will only be made for complex

installations like offshore process platforms. For simple applications, the
information shown on the P&ID is usually sufficient to highlight safety
devices and aspects.
Exercise