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Chem Chapter.ppt
1. 1
CHAPTER 1
Chemical Process Diagrams
THE MOST EFFECTIVE WAY OF
COMMUNICATING INFORMATION
ABOUT A PROCESS IS THROUGH
THE USE OF FLOW DIAGRAMS
2. 2
The Generic Block Flow Process Diagram
There are features common to all chemical processes.
Figure below provides a generic Block Flow Process
Diagram that shows a chemical process broken down into
six basic areas or blocks.
3. 3
The Generic Block Flow Process Diagram
Each of these blocks may contain several unit
operations. For example, A separation section might
contain (four distillation columns, two flash units, and a
liquid-liquid decanter)
Reactor Feed preparation and Separator Feed
Preparation sections mainly involve changing the
conditions (temperature and pressure) of the process
streams to the conditions required by the reactor or
separator.
4. 4
CHAPTER 1
Chemical Process Diagrams
Design is an evolutionary process:
Input/output is a crude block flow diagram in which only feed and
product streams are identified.
Generic Diagram Break the process into its basic elements such as
reaction and separation , and recycle sections.
BFD include the material balance calculations.
PFD complete mass and energy balance and preliminary equipment
specs.
P&ID includes the mechanical and instrumentation details.
Input/output diagram Generic diagram BFD PFD P&ID.
5. 5
Chemical Process Diagrams
3 Main Levels of Diagrams
Block Flow Diagram (BFD)
Process Flow Diagram (PFD)
Piping and Instrumentation Diagram
(P&ID) – often referred to as Mechanical
Flow Diagram
7. 7
The Block Flow Diagram (BFD)
Shows overall processing picture of a
chemical complex
Useful as an orientation tool
Used to sketch out and screen potential
process alternatives.
8. 8
Definitions of BFD
Block Flow Process Diagram (BFPD)
BFPD forms the starting point for developing
PFD
BFPD is helpful in conceptualizing new
processes
See Fig 1.1
Block Flow Plant Diagram
Gives a general view of a large complex plant
See Fig 1.2
11. 11
Block Flow Diagrams
Conventions and Formats for 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
12. 12
The Process Flow Diagrams (PFD)
A PFD contains the bulk of the Chem Eng data
necessary for the design of a chemical process.
Basic information provided by a PFD:
Process Topology
Stream Information
Equipment Information
13. 13
The Process Flow Diagrams (PFD)
A typical commercial PFD will contain the
following information:
All major pieces of equipments in the process will be
represented along with a descriptive name and
number.
All process flow streams will be shown and identified
with a number. A description of the process conditions
and chemical composition of each stream will be
included.
All utility streams supplied to major equipment that
provides a process function will be shown.
Basic control loops will be shown.
14. 14
The Process Flow Diagram (cont’d)
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 lists 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
17. 17
The Process Flow Diagram (cont’d)
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
18. 18
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
20. 20
Equipment Numbering (cont’d)
Thus, T-905 is the 5th tower in unit nine hundred P-301
A/B is the 1st Pump in unit three hundred plus a spare XX-
YZZ A/B/…
Use unambiguous letters for new equipment
Example: 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 the presence of spare equipment
24. 24
Stream Numbering and Drawing (cont’d)
Add arrows for
Change in direction
Inlet of equipment
Utility streams should use convention given in Table
1.3 (lps, cw, fg, etc)
25. 25
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
28. 28
Stream Information
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 (m3/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
30. 30
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
31. 31
Equipment Information
Vessel V-101 V-102
Temperature (ºC) 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
33. 33
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 5) and
cost of manufacture (Chapter 6) to be made
34. 34
The Piping and Instrument Diagram (P&ID)
P&ID – Construction Manual
Contains: plant construction information (piping,
process, instrumentation, and other diagrams)
P&ID construction convection is explained in Table1.9
Conventions for instrumentation are shown in Table
1.10.
39. 39
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
The final control element in nearly all chemical
process control loops is a valve
40. 40
P&ID
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.
41. 41
Additional Diagrams
UTILITY FLOWSHEET
VESSEL SKETCHES
WIRING DIAGRAMS
SITE PLANS
PLOT PLANS
ELEVATION DIAGRAMS
DO NOT POSSESS ADDITIONAL PROCESS
INORMATION
42. 42
Additional 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
44. 44
Additional Diagrams (cont’d)
Piping Isometrics – show piping in 3-dimensions
Vessel Sketches – show key dimensions of
equipment and locations of inlet and outlet
nozzles etc.
45. 45
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
47. 47
Problem 1.9
Figure below is a portion of a PI&D. Find at least six
errors in it. All errors are actually shown on the drawing.
48. 48
Solution:
Errors include:
1. LI on pump discharge should be PI.
2. Direction of arrowheads should be reversed.
3. TCV on control valve should be labeled FCV.
4. LAH on control loop should be FAH (Since no level
signal is shown)
5. Add isolation valve to the left of the control valve.
6. Add a bleed valve between control valve and isolation
valve.
7. Suction piping should be larger than discharge piping,
switch 4” with 8”.
8. Label insulation.
9. Pumps should be labeled P-102 A and P-102B.