Soo ssntsncemon ovoiee S86 mts MASTER @ Process Diagrams OBJECTIVES ‘After studying this chapter, the student will be abl to: w process diagram symbols. be the use of process diagrams and the information they contain 1 process flow diagram. + Draw a process and instrument drawing + Describe the various process equipment relationships. 251MASTER @ Key Terms Electrical drawings—symbols and diagrams that depict an electrical process. Elevation drawings—a graphical representation that shows the location of process equipment in relation to existing structures and ground level Equipment location drawings—show the exact floor plan for location of equipment in relation to the plan's physical boundaries, Flow diagram—a simpitied sketch that uses symbols to identiy instruments and vessels and to describe the primary flow path through a unit Foundation drawings—concrete, wire mesh, and stee! specications that identify width, depth, ‘and thickness of footings, support beams, and foundation. Legends—a document used to define symbols, abbreviation, prefixes, and specialized equipment. Process and Instrument drawing (P&ID}—a complex diagram that uses process symbols to describe a process unit also called piping and instrumentation drawing ‘Types of Process Diagrams Process diagrams can be broken down into two major categories: process flow diagrams (PFDs) and process and instrument drawings (P&IDs), ‘sometimes called piping and instrumentation drawings. A flow diagram is a simple ilustration that uses process symbols to describe the primary flow path through a unit. A process flow diagram provides a quick snapshot of ‘he operating unit. Flow diagrams include all primary equipment and flows. ‘A technician can use this document to trace the primary flow of chemicals through the unit. Secondary or minor flows are not included. Complex con: ‘tol loops and instrumentation are not included, The flow diagram is used {or visitor information and new employee training [A process and instrument drawing is mote complex. The P&ID inchides a ‘graphic representation ofthe equipment, piping, and instrumentation. Mod: ‘em process control can be clearly inserted into the drawing to provide a process technician with a complete picture of electronic and instrument ‘systems, Process operators can look a their process and see how the en. sineering department has automated the unit. Pressure, temperature, flow, {and level control loops are all included on the unit PAID, Basic Instrument Symbols Process technicians use P&lDs to identiy all of the equipment, instru ments, and piping found in their units. New technicians use these drawings 22MASTER @ Basic Instrument Symbols VALVES Figure 12a Process and Instrument SymbolsMASTER @ Chapter 12 ¢ Process Diagrams veconotar Prwere Contr ‘ayer Taner ®OOOOOOO @ © & © © © @) , | PPBGOOOOO convoiioop tonicity (ot Figure 12.18 Process and Instrument Symbols (continued) during their inal training period. Knowing and recognizing these symbols is important for a new technician. The chemical processing industry has as- signed a symbol for each type of valve, pump, compressor, steam turbine, heat exchanger, cooling tower, basic instrumentation, reactor, distillation column, furnace, and boiler (Figure 12.1). There are symbols to represent major and minor process lines and pneumatic, hydraulic, or electic lines, and there is a wide varity of electrical symbols. Flow Diagrams New technicians are required to study a simple flow diagram of their as- signed operating system. Process flow diagrams typically include the major ‘equipment and piping path the process takes through the unit. As operators learn more about symbols and diagrams, they graduate to the much more ‘complex PIDs, 254MASTER @ Flow Diagrams (om. a Fumace L ttt | E Rapa Figure 12.2 Process Flow Diagram (PFD) ‘Some symbols are common among plants; others differ from plant to plant. ‘Some standardization of process symbols and diagrams is taking place. ‘The symbols used in this chapter reflect a wide variety of petrochemical and refinery operations. Figure 12.2 is a PFD that shows the basic relationships and flow paths found in a process unt. tis easier to understand a simple flow diagram iit is broken down into sections: feed, preneating, the process, and the final products. This simple left-to-right approach allows a technician to identity, ‘here the process starts and where it will eventually end, The feed section includes the feed tanks, mixers. piping, and valves. n the second step. the process flow is gradually heated for processing, This section includes heat ‘exchangers and furnaces. In the third section, the process is included. Typ- ical examples found in the process section could include distillation columns or reactors. The process area is a complex collection of equipment that works together to produce products that willbe sent tothe final section, assMASTER @ Chapter 12 ¢ Process Diagrams 256 Process and Instrument Drawings ‘A PAID is a complex representation of the various units found in a plant (Figure 12.3). lis used by people in a varity of crafts. The primary users fof the document after plant startup are process technicians and instrument ‘and electrical, mechanical, saely, and engineering personnel In order to read a PAID, the technician needs an understanding of the ‘equipment, instrumentation, and technology. The next stop in using a P&ID. is to memorize your plants process symbol Ist. This information can be found on the process legend. Process and instrument drawings have a va riety of elements, including low diagrams, equipment locations, elevation plans, electrical layouts, oop diagrams, tile blocks and legends, and foun- dation drawings. The entre P&ID provides a three-dimensional look atthe various operating units in a plant. Process Legend ‘The process legend (Figure 12.4) provides the information needed to intr: pret and read the P&ID. Process legends are found at the front of the P&I. ‘The legend includes information about piping, instrument and equipment Figure 12.3 Process and Instrument Diagram (P&ID}MASTER @ Process and Instrument Drawings VALVE SYMBOLS EQUIPMENT CONT. LINE SYMBOLS. Z (cone ot] yranaTFbaing [Duanawomar ‘ok eat ane ‘Sossas ABBREVIATIONS Figure 124 Process Legend astMASTER @ ~ y Bibeame a eg ewse cyte Figure 12.5 Foundation symbols, abbreviations, unit name, drawing number, revision number, approvals, and company profixes. Because symbol and diagram standard ization is not complete, many companies use their own symbols in unit ) Taam ower [ae ponerse was Teeny oe none AL Circuit Breaker « protective device | {| AR Satimeraps carentton troupe an [|S] Smee L ¥ Figure 12.7 Electrical Drawing 260Soo ssonssncemo orosee S86 mea MASTER @ ‘Process and Instrument Drewings or off. a tripping problem occurs, the technician should cal for an electri= cian. Fuses are devices designed to protect equipment from rant. A thin stip of metal will melt if design specifications are exceeded During operational rounds, technicians check the ammeters inside the MCC for current flow to their electrical systems. Voltmeters, electrical devices used to monitor voltage in an electrical system, are also checked during routine rounds. Equipment Location Drawing Equipment location drawings (plot plans) show the exact location of {equipment in relation to the plants physical boundaries (Figure 12.8). One ofthe most aifficult concepts to explain to a new process technician is the scope and size of modem chemical processing, Most chemical plants and refineries closely resemble small cites; they have well-defined blocks and areas connected by a highway of piping and equipment. Equipment loca- tion drawings provide information about the neighborhood, Loop Diagrams ‘A loop diagram traces all instrument connections between the field instru- ment and the control oom panel. This includes instrument airlines, wiring connections at field junction boxes, and control room panels and front connections. Electrical One-Line Diagrams Like the piping in process systems, the wiring in a unit follows a path. Electri= cal diagrams show a flow path for dstbuting power throughout the unit and Figure 12.8, Equipment Location 261MASTER @ Chapter 12 ¢ Process Diagrams to all electrical equipment. These diagrams show the siffeent voltage levels. in the unit, electrical equipment such as transformers, circuit breakers, fu land motors and horsepower required. It also includes start/stop switches, ‘emergency circuits, and motor control centers. Process technicians can use these diagrams to trace a system from the power source tothe load, Review of Basic and Specialized Symbols Piping and Valves Each plant will have a standardized fle for their piping symbols. Process technicians should carefully review the piping symbols for major and minor flows; electric, pneumatic, capillary, and hydraulic elements; and future ‘equipment (Figure 12.9). The major flow path through a unit illustrates the Figure 12.9 Piping Symbols Tagl _ Remevaie Spot vay Seamer as ri coon A “7 id wy B OH Deaupeaster 1Bi_ soar vabe tr! Eoin () mateo ture Equipment ecromaante, Sone Mow ponte pel Near Moo hoses —t— comectnatine A tia A Non connecting ine PdMASTER @ Review of Basic and Specialized Symbols critical areas a new technician should concentrate on. A variety of other symbols are included on the piping. These include valves (Figure 12.10) strainers, filters, flanges, spool pieces, insulation, piping size, pressure rat- ing, material codes, and steam trap. Pumps and Tanks Pumps and tanks come in a variety of designs and shapes. Common pump and tank symbols are shown on Figure 12.11 Compressors, Steam Turbines, and Motors Because compressors and pumps share a common set of operating prin- ciples and are classified as dynamic or positive displacement, the sym bols for compressors may closely resemble those for pumps (compare 2a = hiv ee haat e SEkEes & ry “= =) = oO Figure 12.10 Valves 268MASTER @ | G semnome TP A ve] eset Oem Reciprocating Pama oS m CC [S| Figure 12.11 Pumps and Tanks Figures 12.11 and 12.12). Inmost cases, the compressor symbol is slightly larger than the pump symbol In the mutistage, centrifugal compressors, the narrowing ofthe symbol from left to right denotes compression of the gas before its released. This is in ‘sharp contrast othe steam turbine symbol, which ilustrates the opposite ef fect as the steam expands while passing over the rotor. Modern P&IDs show the motor symbol connected to the driven equipment. This equipment may be a pump, compressor, mixer, or generator. Figure 12.12 illustrates the standardized symbols for compressors, steam turbines, and motors. Heat Exchangers and Cooling Towers Heat exchangers and cooling towers are two types of industial equipment that share a unique relationship, A heat exchanger is a device used to 264MASTER @ Review of Basic and Specialized Symbols aoa |} fo Oat Compressor ‘Tatbine Onven cay compressor = or one 4 I] ie to Figure 12.12 Compressors, Steam Turbines, and Motors transfer heat energy between two process flows. The cooling tower por forms a similar function, but cooling towers and heat exchangers use dif= ferent scientific principles to operate. Heat exchangers transfer heat energy through conductive and convective heat transfer, whereas cooling towers transfer heat onergy tothe outside air through the principle of evaporation Figures 12.13 and 12.14 ilustrate the standard symbols used for heat exchangers and cooling towers. ‘The symbol for a heat exchanger clearly illustrates the flows through the device. It is important for a process technician to be able to recog- rize the shell init and outlet and the tube inlet and outlet fiow paths. A heat exchanger with an arrow drawn through the body illustrates ‘whether the tubeside flow is being used to heat or cool the shellside {luid, The downward direction indicates heating: the upward direction il lustrates cooling 265MASTER @ Chapter 12 ¢ Process Diagrams Figure 12.13, Heat Exchangers tS Figure 12.14 Cooling Towers dah 26stick rane oes wow MASTER @ Review of Basic and Specialized Symbols ‘The symbol for a cooling tower is designed to resemble the actual device in the process unit, Cooled product flows out ofthe bottom of the tower and to the processing units. Hot water returns to a point located above the fil “The symbol will ot show all ofthe various components of the cooling tower system, but it will provide a techniclan with a good foundation in cooling ‘tower operation and enough information to clealy see the process, Furnaces and Boiler ‘The standard symbols file for furnaces and bollers is shown in Fig- Ure 12.15. Ifa proprietary process includes several types of equipment not 'ypically found on a standard symbol fie, the designer will draw the device as i visually appears in the unit. Distillation Columns Distillation columns come in two basic designs, plate and packed (Fig- ture 12.16). Flow arrangements vary from process to process. The sym- bols allow the technician to identify primary and secondary tlow paths. Distilation is a process designed to Separate the various components in a mixture by their bolling points. (See Chapter 15.) A distilation column is. the central component of a much larger system. This system typicaly in- cludes all of the equipment symbols found in this chapter. Plate distillation columns include sieve trays, valve trays, and bubble-cap trays. Packed columns are filled with packing material, rings, saddles, sulzer, and rosette. Reactors Reactors (Figure 12.17) are stationary vessels and can be classified as batch, semibatch, of continuous, A reactor is designed to allow chemi- cals to mix together under specific conditions to make chemical bonds, break chemical bonds, or make and break chemical bonds to form new products. Figure 12.15 Furnace and BoilerChapter 12 ¢ Process Diagrams Figure 12.16 Distillation Symbols 268 MASTER @ Cenene ay [er FED wb Sources of Information for Process Technicians Information used by process technicians comes from a variety of sources, ‘Some of these soutces are: ‘Operating training manuals ‘+ Process descriptions Process control manuals Equipment summaries ‘Safety, health, and environment regulations Operating procedures ‘Startup and shutdown proceduresa Vaecractng roses iy) a Fad one a o aun TL Lit Emergency procedures Process diagrams ‘Technical data books Detailed equipment vendor information Summary Process flow diagrams (PFDs) and process and instrument drawings (PAIDs) are used to outine or explain the complex flows, equipment, in strumentation, electronics, elevations, and foundations that exist in a process unit. A PED is a simple flow diagram that describes the primary ‘ow path through a unit. A P&ID is a complex representation ofthe various Units found in a plant, Standardized symbols and diagrams have been developed for most pieces of industrial equipment, process flows, and instrumentation, MASTER @ Summary Figure 12.17 Reactor Symbols 269MASTER @ Chapter 12 ¢ Process Diagrams (Review Questions a0 Describe a process flow diagram and a process and instrument drawing. Draw the symbols for a gate, globe, and automatic valve, Draw the symbols for a centrifugal pump and posiive displacement pump. Draw the symbols or a blower and a reciprocating compressor. Draw the symbols for a steam turbine and centrifugal compressor, Draw the symbols for a heat exchanger and a cooling tower. Draw the symbols for a packed distillation column and plate distilation column Draw the symbols for a furnace and a boiler Draw a simple process flow diagram using the symbols from questions 2-8, What information is obtained from a loop diagram? ‘What information is available on electrical one-line diagrams? ‘What information is contained on a plot plan drawing?