Flow

Diagrams and
Instrumentation
TYPE OF FLOW DIAGRAMS

Flow diagrams describe in a schematic drawing format

the flow of fluids and gases through a unit or an entire
plant. By using symbols to represent various pieces of
equipment, the flow diagram provides the piping designer
with an overall view of the operation of a facility.
The flow diagram used in this chapter is representative
of the types used by many companies in the piping industry. While actual symbols may vary slightly from one
company to the next, the look and feel of flow diagrams is the same throughout the piping industry.
Students must become familiar with the piping, equipment, instrumentation symbols and abbreviations used on
flow diagrams, in order to be able to read and interpret
them.
One of the most difficult concepts for students to comprehend is the absence of scale in the preparation of flow
diagrams. The flow diagram should be laid out in a very
simplistic and logical order and be read from left to right.
It guides the drafter and designer in the same manner a
road map guides a traveler.

Process engineers are responsible for developing flow

diagrams. In many large engineering firms, an entire
department is dedicated to the development of flow diagrams. Today almost all flow diagrams are laid out with
CAD, using third-party piping packages such as ProFlow or individually developed company packages.
Process Flow Diagram
The process flow diagram is the first flow diagram
developed by the flow diagram department. It includes
the following:
1. major equipment
2. main piping
3. direction of flow
4. operating pressure and temperature
5. major instrumentation
The process flow diagram will denote the following:

USES OF FLOW DIAGRAMS

Conditions to be used for the design of various

pieces of equipment (fractionation columns, pumps,
heaters, etc.) required for facility operation.
Operating and design conditions under which a particular unit or piece of equipment will normally
operate. Design conditions establish the limits that
equipment used in the facility can withstand. Design
pressure is calculated to be at least 10% above the
maximum operating pressure or 25# greater (whichever is largest). The design temperature will be at
least the maximum operating temperature, but
should be at least 25 degrees above the normal operating temperature.
Composition of the commodities used in the process
sequence as they enter and leave the unit.

The flow diagram is used by the piping group to

develop and lay out the plot plan. When developing the
plot plan, the arrangement of the equipment in the facility
reflects, in part, the logical sequence of flow depicted on
the flow diagram. However, many other factors such as
code requirements, client standards and preferences,
worker safety, and cost also influence the positioning of
equipment.
Once the plot plan is finalized, the piping designer
routes the pipe between two vessels as indicated by the
flow diagram using piping specifications and accepted
design practices. The flow diagram is usually yellowed
out as each line is completed and incorporated into the
design.

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Figure 7-1 shows a sample process flow diagram.

Mechanical Flow Diagram
From the process flow diagram, the mechanical group
develops the mechanical flow diagram. The mechanical flow
diagram provides much more detailed data than the process
flow diagram. Many companies refer to the mechanical flow
diagram as the P & ID (process and instrument diagram).
Often referred to as the bible of the design process, this
drawing provides the pipe drafter with the design criteria for
the unit. Mechanical flow diagrams include the following:
1. pipe line numbers and direction of flow
2. pipe specifications and line sizes
3. all equipment
4. all valves
5. all instrumentation with controlling devices
The mechanical flow diagram defines the exact
sequence in which all equipment, valves, instrumentation,

connections, etc., are to be made on each pipe throughout

the facility.
Figure 7-2 shows a sample of the mechanical flow
diagram.
The Utility Flow Diagram
The utility flow diagram shows the piping, valves, and
instrumentation for the basic plant utilities. Utilities are
services that are essential to the proper function of the
plant. These utilities correspond to some of the same utilities used in a typical house, such as water, gas, and sewer
drains.
Some of the common plant utilities are:
steam

condensate

fuel oil

utility air

instrument air

cooling water

drainage systems

flare system

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The flow diagram is a dynamic document. It may be revised

and updated during the project to reflect the clients changes or
modifications imposed by governmental regulations.
Figure 7-3 shows a sample utility flow diagram.

FLOW DIAGRAM INSTRUMENTS

Instruments function by sensing changes in the variables they monitor. The four basic instrument groups are:
Flow
(F)
Level
(L)
Pressure
(P)
Temperature
(T)
The types of instruments used to sense, control and
monitor these variables are:
Controller
(C)
Indicator
(I)
Gauge
(G)
Alarm
(A)
Recorder
(R)
By learning these nine terms, students will be able to
understand most of the instrument symbols found on a
mechanical flow diagram.

Figure 7-4 illustrates a combination of the symbols and

abbreviations used to represent an instruments function
on flow diagrams. The first letter in the symbol indicates
the instrument group, and the second and/or third letters
indicate the instrument type.
To indicate a change or to control the flow, level, pressure, or temperature, an instrument must first sense a
change in the variable. Once a change has been detected,
the instrument then transmits this information via
mechanical, electronic, or pneumatic means to a control
panel where it can be observed and recorded. At the same
time, the instrument may activate other devices to affect
and change process conditions in the facility. Some
instruments are read in the plant at the instruments actual
location. Others are displayed on a control panel located
in an operators control room.
Instrument Types
Gauges. Gauges are instruments that measure the liquid level inside a vessel or the temperature and/or pressure in the piping system. Level, temperature, or pressure
gauges are locally mounted to enable plant operators to
obtain a visual reading.

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Flow Diagrams and Instrumentation

Controllers. Devices used to maintain a specified liquid level, temperature, pressure, or flow inside a vessel or
piping system. They activate the control valve that regulates the level, temperature, pressure, and flow in and out
of the vessel.
Alarms. Signals via lights or horns that indicate the
liquid level, temperature, or pressure inside a vessel is too
high or too low or that there is no flow or reverse flow.
Indicators. Devices used to indicate the liquid level,
temperature, pressure or flow rate inside a piping system.
Recorders. Devices used to record the liquid level,
temperature, pressure, and flow rate inside a vessel or
piping system throughout a certain shift or period of time.
These same instruments may be found in combination
such as Level Recording Controller. Here the instrument
not only records the liquid level but also sends a signal to
a control valve to control the liquid level inside the vessel.

PIPING SYMBOLS
Figure 7-5 shows some flow diagram piping symbols.
Notice all valves, no matter the pipe size and pound rating, are drawn the same size. Generally, nozzles and
reducers are not shown on the mechanical flow diagram.
The flow diagram in Figure 7-2 shows reducers in order
to aid the students in visualizing and understanding the
flow diagram and its relationship to the actual piping
arrangement drawing. Symbols used on flow diagrams
represent the actual piece of equipment. Typically these

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symbols have some resemblance to the actual pieces of

equipment in the field.

FLOW PLAN ARRANGEMENT

The flow plan should be arranged in a logical order of
flow. The main flow through the unit should be obvious
by even a brief examination of the flow plan. Use the
following checklist as an aid when developing a flow
diagram.

Avoid crossing lines where possible.

Space equipment on the sketch to avoid overcrowding.
Use notes with symbols where necessary for clarity.
Use arrows to show flow direction.
Show equipment numbers when it is necessary to
identify equipment.
Show control systems on the sketch. The control
scheme is frequently the most important part of a
flow plan sketch.
Show important valves, orifice flanges, and control
valves.
Show flow directions through exchangers with
arrows.
Do not run lines diagonally across the drawing.
Label feed lines entering the unit from the field
where the line enters the unit. Label product lines
leaving the unit by name.
Do not draw lines any closer together than necessary.

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CHAPTER 7 REVIEW QUIZ

1. List five items shown on the process flow diagram.
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2. List five items shown on the mechanical flow diagram.
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
3. List the four basic instrument groups.
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
4. List the five instrument functions.
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
5. What type of instrument is used to maintain a certain liquid level?
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
6. Identify the following instrument abbreviations:
a. LG _______________________________________________________________________________________
b. FA _______________________________________________________________________________________
c. TI _______________________________________________________________________________________
d. PC _______________________________________________________________________________________
e. TRC ______________________________________________________________________________________
f. LC _______________________________________________________________________________________
g. PSV ______________________________________________________________________________________
h. HCV _____________________________________________________________________________________
i. LAH______________________________________________________________________________________
j. LAL ______________________________________________________________________________________
7. Identify the following flow diagram abbreviations:
a. DF _______________________________________________________________________________________
b. SC _______________________________________________________________________________________
c. CSO ______________________________________________________________________________________
d. LC _______________________________________________________________________________________
e. NO ______________________________________________________________________________________

Flow Diagrams and Instrumentation

EXERCISE INFORMATION
Use the instructions accompanying Figure 7-6 to create
the flow diagram symbols with AutoCAD as shown. Use
the BASE command to place the base point as indicated.
BLOCK each object using the exact symbol name provided. OOPS the symbol to redisplay. SAVE the drawing
as FLOSYMBL.

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Exercises 1, 2, and 3.
Recreate the flow diagrams as shown. Using the
symbols in Figure 7-6 where applicable. Symbols representing other pieces of equipment can be developed on an
as-needed basis. Although equipment is not drawn to
scale, it should be proportional to the other symbols used
in the drawing.

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CHAPTER 7 DRAWING EXERCISES

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