Lecture 2

Process Diagram
Instrumentation
Process Diagram
Process Diagram
 Categories
– Process Flow Diagram (PFD)
 Also called System Flow Diagram (SFD) or Flowsheet
 Describes Primary flow path through operating unit
 Provides quick snapshot of operating units
– Process and Instrumentation Diagram (P&ID)
 Also called Piping and Instrument Diagram
 Is a graphical representation of
• Equipment
• Piping
• Instrumentation
Process Diagram Standards
 International/Regional/National Standards
– International Organization for Standardization or Organisation
Internationale de Normalisation widely known as (ISO)
– Deutsches Institut für Normung e.V. or German Institute for
Standardization (DIN)
 Government Regulation
– US Occupational Safety and Health Administration (OSHA)
 Organization/Association
– American Society of Mechanical Engineers (ASME)
– Instrumentation, Systems, and Automation Society (ISA),
originally known as Instrument Society of America
– Tubular Exchanger Manufacturers Association, Inc. (TEMA)
– Process Industry Practices (PIP) by Construction Industry
Institute (CII) at The University of Texas at Austin
Process Diagram Standards
 Industry Codes and Standards
– American National Standards Institute (ANSI)
– Standards Australia (SA) or formerly Standard
Association of Australia (SAA)
 Proprietary Standards
– Standard Process Design Criteria (Fluor)
– Design Engineering Practices (Shell)
– Snamprogetti (Italy)
– Mitsubishi Heavy Industries (Japan)
Process Flow Diagram (PFD)
 PFD includes:
– Process stream names – Major bypass and
– Process piping recirculation lines
– Major equipment – System ratings and
symbols, names and operational data such as
identification numbers minimum, normal and
maximum flow,
– Control valves and temperature and pressure,
valves that affect etc., often with reference
operation of the system to a mass balance
– Interconnection with – Composition of fluids
other systems
Process Flow Diagram (PFD)
 PFD excludes:
– Pipe class and/or line numbers
– Process control instrumentation
– Secondary or Minor flows
– Minor bypass lines
– Isolation and shutoff valves
– Maintenance vents and drains
– Relief and safety valves
– Flanges
– Code class information
– Seismic class information
Process Flow Diagram
Standards
 ISO 10628: 1997 Flow Diagrams For
Process Plants – General Rules
 ANSI Y32.11: Graphical Symbols For
Process Flow Diagrams (withdrawn 2003)
 SAA AS 1109: Graphical Symbols For
Process Flow Diagrams For The Food
Industry
 DIN
Process Flow Diagram (PFD)
Block Flow Diagram (BFD)
 a.k.a. as Schematic
Flow Diagram
 PFD of multiple units
as schematic
illustration of major
processes
Block Flow Diagram (BFD)
Guidelines
 Unit operations are usually denoted by a simple block or
rectangle and labeled
 Groups of unit operations may be noted by a single block or
rectangle
 Process flow streams flowing into and out of the blocks are
represented by neatly drawn horizontal or vertical lines
 Direction of flow of each of the process flow streams must be
clearly indicated by arrows
 Flow streams should be numbered sequentially in a logical order
 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
Block Flow Diagram (BFD)
Process and Instrumentation
Diagram (P & ID)
 Pictorial representation of
– Key piping and instrument details
– Control and shutdown schemes
– Safety and regulatory requirements
– Basic start up and operational information
 Purpose
– To have a common language for instrument
technicians, process engineers and suppliers
– To properly document plant designs for installation
in graphical form
– To help in maintenance, failure analysis and
troubleshooting
Process and Instrumentation
Diagram (P & ID)
 Identify
– Process Lines from Instrument
Lines
– Location of the instrument
– Function of the instrument
 Provide other relevant
information
Elements of P&ID
 Flow Diagram
 Equipment Location

 Elevation Plan

 Electrical Layout

 Loop Diagram

 Title Block and Legends

 Foundation Drawings
P&ID Types
 Process and Utility
 Utility Distribution

 Interconnecting Lines

 Auxiliary

 Special Controls
Process and Instrumentation
Diagram (P & ID)
 P&ID includes:
– Instrumentation and – Control inputs and outputs,
designations interlocks
– Mechanical equipment with – Interfaces for class changes
names and numbers – Seismic category
– All valves and their – Quality level
identifications – Annunciation inputs
– Process piping, sizes and
identification – Computer control system
input
– Miscellanea – vents, drains,
special fittings, sampling – Vendor and contractor
lines, reducers, increasers and interfaces
swaggers – Identification of components
– Permanent start–up and flush and subsystems delivered by
lines others
– Flow directions – Intended physical sequence of
the equipment
– Interconnections references
Process and Instrumentation
Diagram (P & ID)
 P&ID excludes:
– Instrument root valves
– Control relays
– Manual switches
– Equipment rating or capacity
– Primary instrument tubing and valves
– Pressure temperature and flow data
– Elbow, tees and similar standard fittings
– Extensive explanatory notes
ISA Standard for P&ID
 ISA 5.1 – Instrumentation Symbols and
Identification
 ISA 5.2 – Binary Logic Diagrams for Process
Operations
 ISA 5.3 – Graphic Symbols for Distributed
Control / Shared Display Instrumentation,
Logic and Computer Systems
 ISA 84.01 – Application of Safety
Instrumented Systems for the Process
Industries
ISA Standard
[ Sec 5.1 – 1984 (Rev 1994) ]

Common Connecting Lines*

Process or Instrument Line

Undefined Signal

Pneumatic Signal

Electric Signal
OR
Hydraulic Signal

Capillary Tube

Electromagnetic or Sonic
Signal (Guided)
ISA Standard
[ Sec 5.1 – 1984 (Rev 1994) ]

Common Connecting Lines*

Electromagnetic or Sonic
Signal (Not Guided)
Internal System Link
(Software or Data Link)
Mechanical Link

*Following abbreviation used to denote type of supply

IA – Instrument Air GS – Gas Supply HS – Hydraulic Supply
AS – Air Supply NS – Nitrogen Supply SS – Steam Supply
PA – Plant Air ES – Electric Supply WS – Water Supply
ISA Standard
[ Sec 5.1 – 1984 (Rev 1994) ]

 Graphical Elements  Location Categories*

– Discrete instruments – Primary location
[Circular Element] [Single Horizontal Line
Across Graphical Element]
– Shared control/display
[Circle circumscribed by a – Auxiliary location
square] [Double Horizontal Line
Across Graphical Element]
– Computer function
[Hexagon] – Field mounted
[No Horizontal Line Across
– Programmable logic Graphical Element]
controller (PLC)
[Triangle inside a square] *Inaccessible Devices
(Mounted Behind Panel Board)
[Dashed Horizontal Line]
ISA Standard
[ Sec 5.1 – 1984 (Rev 1994) ]

 General Instrument or Function Symbols

– Symbol size may vary according to the user's needs and
type of document
– Abbreviations of the
user's choice may be
used when necessary
to specify location
– Inaccessible (behind
the panel) devices
may be depicted
using the same
symbol but with a
dashed horizontal bar
ISA Standard
[ Sec 5.1 – 1984 (Rev 1994) ]

 Letter and Number Combinations

– Appear inside each graphical element
– Numbers are user assigned schemes vary
 Some companies use of sequential numbering
 Some tie the instrument number to the process line
number
 Others adopt unique and sometimes unusual
numbering systems
ISA Standard
[ Sec 5.1 – 1984 (Rev 1994) ]

 Instrument Identification (1) Measured Process

or Tag Number Variable
– 1st letter defines the (2) Output Function
measured or initiating
variables (3) Function Modifier
– Succeeding letters
defining 2 3
1
 Readout
 Passive function
Output function
PRC


 Modifier
101
– Number refers to loop
number where instrument Balloon (or Bubble)
belongs
ISA Standard
[ Sec 5.1 – 1984 (Rev 1994) ]

(1)
(2) (3)

(4,5)

(6)
(2)

(2)

(7)
F
(8,9,10)
(11)

Measured or
(8)

(13)
(2,12)
(14) (8,9,10)
(8,9)
(2)
ISA Standard
[ Sec 5.1 – 1984 (Rev 1994) ]

(2)

(18)
(16)
(15)

(19)
(6)
(17) F
(5) (6)

(20)

(21)
Measured
(6,17,22)
Example
Letter Code First Letter SecondLetter
A
B
Analysis
Burner
Alarm
PRC
C Conductivity Control
D Density 101
E Voltage Primary Element
F Flow
G Gage Glass(sight tube)
H High
I
J
Current
Power
Indicator  PRC means
K
L
Time
Level
Control Station
Light – Pressure
M Moisture
O Orifice – Recording
P Pressure Point
Q Quantity – Controller
R Radioactivity Record
S
T
Speed
Temperature
Switch
Transmit
 101 means that
U
V
Multivariable
Viscosity
Multifunction
Valve
instrument belongs
W
Y
Weight Well
Relay
to Loop # 101
Z Position Drive
 P&ID Symbols
[ Sec 5.1 – 1984 (Rev 1994) ]

Pipe Insulated Pipe Jacketed Cooled or Flexible Pipe

Pipe Heated Pipe

Valve Manual Control Valve Ball Valve Globe Valve

Valve

Needle Butterfly Diaphragm Pressure Steam Trap

Valve Valve Valve Reducing
Valve

Covered Curved Gas Funnel Filter Dust Trap

Gas Vent Vent
P&ID Symbols
[ Sec 5.1 – 1984 (Rev 1994) ]

Fan Axial Fan Radial Fan Pump Vacuum

Pump or
Compressor

Bag Gas Bottle Viewing Back Draft Dryer

Glass Damper

Furnace Heater Cooler Cooling Pressurized

Tower Horizontal
Vessel
 P&ID Symbols
[ Sec 5.1 – 1984 (Rev 1994) ]

Pressurized Tray Packed or Fluid Autoclave or

Vertical Vessel Column Contacting Jacketed Mixing
Column Vessel

Half Pipe Mixer Heat Exchanger Heat Exchanger Fixed Straight

or Reactor w/ no crossflow w/ crossflow Tube Heat
Exchanger

Double Pipe U–Tube Spiral Heat Plate and Frame

Heat Heat Exchanger Heat Exchanger
P&ID Symbols
P&ID Symbols
P&ID Symbols
P&ID Symbols
Example of P&ID
Example of a P&ID
A Heat Exchanger Control System
Steam in

TY
343

Reactant in TT TC
343 343
Reactant out
FI
344
FT FRC
342 342

Steam FR
342
out
Example of P&ID
Constructing An Instrument
Flow Sheet
 Identify the process
 Define the control objective/s
 Create a process flow diagram
 Identify the equipment and process lines
 Determine the instrument and connecting lines
 Use of standard symbology like ISA codes to
identify instrument and functions
References
1. Hughes, Thomas A. Measurement and Control Basics, 3rd ed. Research
Triangle Park, NC: The Instrumentation, Systems, and Automation Society, 2002.

2. Madsen, D. A. et al. Engineering Drawing and Design. 4th ed. New York:
Delmar Cengage Learning , 2006.

3. Perry, R. H. and D. W. Green (ed.) Perry’s Chemical Engineers’ Handbook. 7th

ed. New York: The McGraw-Hill Companies, Inc., 1997.

4. PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria.

Austin, Texas: Process Industry Practices, Construction Industry Institute,
TheUniversity of Texas at Austin, Apr 2008.

5. Seborg, Dale E. et al. Process Dyanmics and Control. 2nd ed. New York: John
Wiley & Sons, Inc, 2004.

6. Thomas, C. Process Technology Equipment and Systems. 2nd ed. New York:
Delmar Cengage Learning , 2007.
Internet Sources
1. BFD – Block Flow Diagram. http://www.engineeringtoolbox.com/bfd-
block-flow-diagram-d_467.html

2. Harrold, Dave. How To Read P&ID. http://lamspeople.epfl.ch/kirrmann/

Slides/HowToReadP&ID.htm, Aug 1, 2000.

3. P&ID Piping and Instrumentation Diagram.

http://www.engineeringtoolbox.com/p&id-piping-instrumenation-
diagram-d_466.html

4. PFD – Process Flow Diagram.

http://www.engineeringtoolbox.com/pfd-process-flow-diagram-
d_465.html

5. http://www.wikipedia.org