Process

Instrumentation
ERT 213

Process Flow Diagram (PFD)

Miss Hanna Ilyani Zulhaimi
 Outline
—  Process diagram/Flowsheeting
—  Block Flow Diagram
—  Process Flow Diagram
—  Introduction to Microsoft Visio
 Learning outcome:
By the end of this lecture, students will be able to:

Ø  Understand and interpret block flow diagram

Ø  Analyze and demonstrate process flow diagram
based on symbology

Ø  To employ process flow diagram to Microsoft Visio

Software
 LEARNING FLOW
Valves In
Industry

Process & Instrumentation

Diagram (P&ID)
Pump,
Compressor,
Fan & Blower

ISA
Symbology

Process Flow
Diagram (PFD)
Roughly speaking, communication is paramount ~ As an
Engineer, transfer the most amount of information with
the least amount of effort on the part of the reader
 Introduction to Flowsheeting
Flowsheets are the pictorial representation of the process

GOAL:
Transmit the most
amount of information
with the least amount
of effort on the part of
the reader
Type of Flowsheeting/Diagram
—  Block Diagram
—  Material Flow Sheet
—  Energy Flow Sheet
—  Process Flow Diagram
—  Information Flow Diagram
—  Piping and Instrumentation Diagram
 What is Block Flow Diagram?
q  It  is  the  simplest  flowsheet.  

q  Par,cularly  useful  in  ini,al  studies  

q  Useful  to  show  interrela,on  of  streams  

q  Process  engineer  begins  process  design  with  a  block  diagram  in  which  only  the  feed  and  product  
streams  are  iden7fied.  

q   The  processes  described  in  the  BFD  are  then  broken  down  into      basic  func,onal  elements  such  as  
reac7on  and  separa7on  sec7ons.  

q   Also  iden,fy  the  recycle  streams  and  addi7onal  unit  opera7ons  to  achieve  the  desired  opera,ng  
condi,ons.  
 BLOCK FLOW DIAGRAM (BFD)
Example  1:  
Mixed  Gas  
Toluene,  C7H8   2610  kg/hr  
10,000  kg/hr  

Reactor   Gas  Separator   Benzene,  C6H6  

C6H6  
8,210  kg/hr  
CH4  
Hydrogen  H2  
820  kg/hr   C7H8  
Mixed  Liquid  

75%  Conversion  of    

Toluene  

Reac,on  :  C7H8  +  H2                                    C6H6  +  CH4  

Figure  1:  Block  Flow  Diagram  for  the  Produc7on  of  Benzene  
 Exersice 1
Ammonia-air mixture is feed to the bottom
stream of an absorber with flow rate of 10L/
min. Water then feed to the upper stream of
the same absorber with desired flow rate of
5L/min. There are two outputs from the
absorber where upper stream is insoluble NH3
and bottom stream is NH3-Water mixture. This
NH3-water mixture then feed up to a batch
distillation column. The column produces
ammonia gas as a top product which this
product then will be condensate with a
condenser to produce liquid ammonia. Develop
Block Flow Diagram (BFD) for this process.
 Process Flow Diagram (PFD)
—  Conveys the major processing steps represented by the
equipment
Ø  useful for conveying the heat and material balances
Ø  Useful for conveying major pieces of equipment
Ø  Useful for conveying processing conditions
Ø  Useful for conveying utilities

—  There are no hard and fast rule but Howat Standards include:
—  Essentially every major pieces of equipment
—  Every flow stream
—  Every temperature
—  Every pressure
—  Utility flows
—  Process unit tagging and numbering
 Major Pieces of Equipment
R-­‐100   P-­‐100   T-­‐100   E-­‐100   P-­‐101   R-­‐101  
Reactor   Pump   Dis7lla7on  Column   Condenser   Pump   Reactor  

Hot  water  out  

Ethylene  
E-­‐100   Ethylene  
V-­‐104   liq.  
Cold  water  in  
V-­‐106  
CV-­‐100   T-­‐100  
CV-­‐101  
Ethanol   V-­‐105  

V-­‐100   V-­‐101   V-­‐102   Hydrogen  

H2SO4   V-­‐103   V-­‐107  
R-­‐100   Ni   Ethane  
R-­‐101  
P-­‐100  
H2O   P-­‐101  
 Utility Streams
R-­‐100   P-­‐100   T-­‐100   E-­‐100   P-­‐101   R-­‐101  
Reactor   Pump   Dis7lla7on  Column   Condenser   Pump   Reactor  

Hot  water  out  

Ethylene  
E-­‐100   Ethylene  
V-­‐104   liq.  
Cold  water  in  
V-­‐106  
CV-­‐100   T-­‐100  
CV-­‐101  
Ethanol   V-­‐105  

V-­‐100   V-­‐101   V-­‐102   Hydrogen  

H2SO4   V-­‐103   V-­‐107  
R-­‐100   Ni   Ethane  
R-­‐101  
P-­‐100  
H2O   P-­‐101  
 Process Flow Streams
Stream  Numbering  and  Drawing  

   
-­‐  Number  streams  from  le]  to  right  as  much  as  possible.    

-­‐  Horizontal  lines  are  dominant.    

Yes   No   No  
 Process Flow Streams
—  Stream Information (Operating conditions such as P, T, F)

Ø  Since  diagrams  are  small  not  much  stream  informa,on    

 can  be  included.    
 
Ø  Include  important  data  –  around  reactors  and  towers,  etc.    
q   Flags  are  used    
q   Full  stream  data  

Ø  Details  informa,on  for  each  stream  in  PFD  is  represented  
in  the  table  below  the  drawing.  
 Process Flow Streams
Stream  Informa7on  -­‐  Flag    

600   Temperature  
300  

3   8   24   Pressure  
9  
6   7   Mass  Flowrate  
10.3  
1   10  
108   Molar  Flowrate  
600  
24  

2   5   12   Gas  Flowrate  

4   11   Liquid  
Flowrate  
24  
13  
 Stream  Informa7on  -­‐  Flag    
R-­‐100   P-­‐100   T-­‐100   E-­‐100   P-­‐101   R-­‐101  
Reactor   Pump   Dis7lla7on  Column   Condenser   Pump   Reactor  

Hot  water  
out  

Ethylene   E-­‐100   Ethylene  liq.  

6  
V-­‐104  

Cold  
T-­‐100  
water  in   CV-­‐101   V-­‐106  
25   CV-­‐100  
28   V-­‐105  
Ethanol   5   20  
1   V-­‐101   V-­‐102   38  
H2SO4   4   Hydrogen  
V-­‐100  
V-­‐103   V-­‐107   Ni   9  
R-­‐100  
R-­‐101   Ethane  
3   8  
2   35   10  
35   31.0   7  
H2O  
P-­‐101  
32.2  
P-­‐100  
 Stream  Data  Table  
R-­‐100   P-­‐100   T-­‐100   E-­‐100   P-­‐101   R-­‐101  
Reactor   Pump   Dis7lla7on  Column   Condenser   Pump   Reactor  

Hot  water  
out  

Ethylene   E-­‐100   Ethylene  liq.  

6  
V-­‐104  

Cold  
water  in   V-­‐106  
25   CV-­‐100  
T-­‐100  
CV-­‐101  
28   V-­‐105  
Ethanol   5   20  
H2SO4   1   V-­‐101   V-­‐102  
4   38   Hydrogen  
V-­‐100  
V-­‐103   V-­‐107   Ni  
9  
R-­‐100  
Ethane  
3   8  
R-­‐101  
2   35   10  
35   31.0   7   H2O  
32.2   P-­‐101  

P-­‐100  

Stream Number 1 2 3 4 5 6 7 8 9 10
Temperature (oC) 25.0 35.0 35.0 35.0 35.0 60.3 41 38 54 45.1
Pressure (psi) 28 32.2 31.0 31.0 30.2 45.1 31.3 24.0 39 2.6
Vapor fraction
Mass flow (tonne/hr) 10.3 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6
Mole flow (kmol/hr) 108 114.2 301.0 1204. 758.8 1204. 42.6 1100. 142.2 244.0
0 4 8
 Process Unit Tagging & Numbering
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  
Additional description of equipment given on top of PFD  
Information
 
 Process Unit Tagging &
Numbering
R-­‐100   P-­‐100   T-­‐100   E-­‐100   P-­‐101   R-­‐101  
Reactor   Pump   Dis7lla7on  Column   Condenser   Pump   Reactor  

Hot  water  out  

Ethylene  
E-­‐100   Ethylene  
V-­‐104   liq.  
Cold  water  in  
V-­‐106  
CV-­‐100   T-­‐100  
CV-­‐101  
Ethanol   V-­‐105  

V-­‐100   V-­‐101   V-­‐102   Hydrogen  

H2SO4   V-­‐103   V-­‐107  
R-­‐100   Ni   Ethane  
R-­‐101  
P-­‐100  
H2O   P-­‐101  
 PROCESS FLOW DIAGRAM (PFD)
A/B  LeYer  
Example  

Hot  water  
out   Hot  water  
out  
Ethylene  
Ethylene  

Ethylene  liq.  
Cold  
water  in   Cold   Ethylene  liq.  
Ethanol   water  in  
Ethanol  
H2SO4   Hydrogen   Ethane   H2SO4   Hydrogen   Ethane  
Ni  
Ni  
H2O   H2O  

P-­‐100  A/B   P-­‐100  A  

P-­‐100  B  

In  Real  Plant  
In  PFD  
Thank you J