PROCESS FLOW DIAGRAM

Reporters: Daigan, Lope Demetri, Gaas, Nimrod Bu, Pacional, Carl

• What is a process flow diagram?
• History
• Purpose and benefits
• Process Flow Diagram Symbols and Elements
• How to research and plan the process flow
• Tips for process flow diagrams
 PROCESS FLOW DIAGRAM
A Process Flow Diagram (PFD) is a type of flowchart that illustrates the
relationships between major components at an industrial plant. It's most
often used in chemical engineering and process engineering, though its
concepts are sometimes applied to other processes as well. It’s used to
document a process, improve a process or model a new one. Depending on its
use and content, it may also be called a Process Flow Chart, Flowsheet, Block
Flow Chart Diagram, Schematic Flow Diagram, Macro Flowchart, Top-down
Flowchart, Piping and Instrument Diagram, System Flow Diagram or System
Diagram. They use a series of symbols and notations to depict a process. The
symbols vary in different places, and the diagrams may range from simple,
hand-drawn scrawls or sticky notes to professional-looking diagrams with
expandable detail, produced with software.
 HISTORY
This type of diagram has its roots in the 1920s.
In 1921, industrial engineer and efficiency expert
Frank Gilbreth, Sr. introduced the “flow process
chart” to the American Society of Mechanical
Engineers (ASME). Over the next several decades,
the concept spread throughout industrial
engineering, manufacturing and even business, in
the form of Business Process Diagrams, and
information processing, in the form of Data Flow
Diagrams and other chart types.
PURPOSE AND BENEFITS
A process flow diagram has multiple purposes:
• To document a process for better understanding, quality control and training of
employees.
• To standardize a process for optimal efficiency and repeatability.
• To study a process for efficiency and improvement. It helps to show unnecessary
steps, bottlenecks and other inefficiencies.
• To model a better process or create a brand-new process.
• To communicate and collaborate with diagrams that speak to various roles in the
organization or outside of it.
PROCESS FLOW DIAGRAM SYMBOLS AND ELEMENTS

The most common PFD symbols in use today come from

agencies such the International Organization for
Standardization (ISO 10628 – Flow Diagrams for Process Plants,
General Rules), the German Institute for Standardization
(DIN) and the American National Standards Institute (ANSI.)
However, many companies use their own symbols, which are
often similar but vary as they become more detailed.
A typical PFD for a single unit process will include these elements:
• Major equipment. Examples include compressors, mixers, vessels, pumps, boilers
and coolers, transformers, etc.
• Process piping: Moves the product, usually fluids, between equipment pieces.
• Process flow direction
• Control valves and process-critical valves
• Major bypass and recirculation systems
• Operational data: Such as pressure, temperature, density, mass flow rate and
mass-energy balance. Values often will include minimum, normal and maximum.
• Composition of fluids
• Process stream names
• Connections with other systems
What to exclude in a PFD:
• Pipe classes and pipe line numbers
• Process control instruments
• Minor bypass values
• Isolation and shutoff valves
• Maintenance vents and drains
• Relief valves and safety valves
• Code class information
Other Types of PFDs
When the diagram needs to show multiple unit processes at a
plant, it becomes more of an overview, containing less detail. These
are also called Block Flow Diagrams and Schematic Flow Diagrams.
Each block can depict a single piece of equipment or a stage in a
process. A rectangle is usually used to show a piece of equipment and
labels illustrate function. The process flow is usually shown from left
to right, and arrows show flow direction.
On the other hand, a Piping and Instrument Diagram (P&ID) is
more technical, describing mechanical details for piping designers,
electrical engineers, instrument engineers and other technical
experts who need this detail more than they need process details.
P&IDs take the conceptual aspects of a PFD and add detail about the
equipment, process sequence, process and utility piping, bypass lines,
instruments, valves, vents, drains and other items.
 HOW TO RESEARCH AND PLAN THE
PROCESS FLOW
• Define the scope of your process to be studied and what you hope to gain.
• Decide on what level of detail is needed for your purposes. For a sophisticated process, different
versions of the diagram may be drawn to communicate with people in different roles.
• For an advanced process such as at an industrial plant, the research may be done through a project
team, quality control group or a consultant. For a smaller, more basic process, you might do this
yourself, perhaps even starting with sticky notes.
• Study the equipment, activities and relationships through observation and interviews. If you’re
modeling a brand-new process, study whatever data is available, including standards for whatever is
being produced in the process.
• Draw a draft diagram and confirm it with people involved in the process. Make any necessary
changes, additions or deletions in collaboration with them.
• Now the diagram(s) can be used for its intended purpose of documentation, quality assurance,
improvement or whatever other goal there might be.
 TIPS FOR PROCESS FLOW DIAGRAMS
• These diagrams can have a lot of value for even a basic process. If you’re new to PFDs, try it out,
gathering sufficient detail for your purpose. Don’t worry about the chart itself at first. Just capture the
information on sticky notes or sheets of paper.
• Move on to diagram software once you have your information. With intuitive software like Lucidchart,
it’s not hard to create professional-looking diagrams to clearly communicate a process flow to your
colleagues. The software also may help you to highlight missing data in your diagram.
• Be consistent with your symbols to avoid confusion. Remember who your intended audience is, and do
whatever makes the most sense to give them what they need for the intended purpose. If you’re using
diagram software, it will include a set of symbols to use.
• On a sophisticated PFD, you may need to use standard symbols such as ISO 10628 to clearly
communicate and collaborate with diverse audiences such as other companies or agencies.
• Include a symbol key on your diagram for clarity.