Chapter 1

Diagrams for Understanding

Chemical Processes

Department of Chemical Engineering
West Virginia University
Copyright - R. Turton and J. Shaeiwitz, 2012 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.

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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
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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
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The Block Flow Process Diagram
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The Block Flow Plant Diagram
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The Process Flow Diagram
PFD shows all process engineering
information
Diagram developed in junior year design
projects (especially the 2
nd
semester)
Often PFD is drawn on large paper textbook
breaks down information into 1 diagram and
2 tables

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The Process Flow Diagram (contd)
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
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The Process Flow Diagram (contd)
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The Process Flow Diagram (contd)
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Table 1.2 : Conventions Used for Identifying Process Equipment


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

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 (contd)
Thus, T-905 is the 5
th
tower in unit nine hundred P-
301 A/B is the 1
st
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

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Stream Numbering and Drawing
Number streams from left to right as much as
possible
Horizontal lines are dominant


yes no no
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Stream Numbering and Drawing (contd)
Add arrows for
Change in direction
Inlet of equipment
Utility streams should use convention given in
Table 1.3, lps, cw, fg, etc.
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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
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Stream Information - Flags
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The Process Flow Diagram (contd)
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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 (m
3
/h)

Significant Physical Properties

Density

Viscosity

Other

Thermodynamic Data

Heat Capacity

Stream Enthalpy

K-values

Stream Name

Table 1.4: Information in a Flow Summary
The Process Flow Diagram (contd)
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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



A Portion of Table 1.5
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
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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
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Equipment Information
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Vessel V-101 V-102
Temperature (C) 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)
A Section of Table 1.7: Equipment Summary
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
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The Piping and Instrument Diagram(P&ID)
P&ID Construction Bible
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
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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
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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

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Other Common Diagrams
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Section of Plot Plan Section of Elevation Diagram
Other Common Diagrams (contd)
Piping Isometrics show piping in 3-
dimensions
Vessel Sketches show key dimensions of
equipment and locations of inlet and outlet
nozzles etc.
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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
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OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS
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OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS
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OPERATOR AND 3-D IMMERSIVE TRAINING SIMULATORS