Bioprocess Diagrams Including PFD and P&ID THE MOST EFFECTIVE WAY OF THE MOST EFFECTIVE WAY OF COMMUNICATING INFORMATION COMMUNICATING INFORMATION ABOUT A PROCESS IS THROUGH ABOUT A PROCESS IS THROUGH THE USE OF THE USE OF FLOW DIAGRAMS FLOW DIAGRAMS
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Bioprocess Diagrams Including PFD and P&ID THE MOST EFFECTIVE WAY OF COMMUNICATING INFORMATION ABOUT A PROCESS IS THROUGH THE USE OF FLOW DIAGRAMS.
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Bioprocess Diagrams Including PFD and
P&ID
THE MOST EFFECTIVE WAY OF THE MOST EFFECTIVE WAY OF COMMUNICATING INFORMATION COMMUNICATING INFORMATION
ABOUT A PROCESS IS THROUGH ABOUT A PROCESS IS THROUGH THE USE OF THE USE OF FLOW DIAGRAMSFLOW DIAGRAMS
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.
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.
Flow DiagramDesign 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.
Piping and Instrumentation Diagram (P&ID) – often referred to as Mechanical Flow Diagram
Comparison
BFDBFD
PFDPFD
P&IDP&ID
Level of ComplexityIncreases
Level of Conceptual
UnderstandingIncreases
The Block Flow Diagram (BFD)
Shows overall processing picture of a Shows overall processing picture of a chemical complex chemical complex
Useful as an orientation tool Useful as an orientation tool
Used to sketch out and screen Used to sketch out and screen potential process alternatives.potential process alternatives.
Definitions of BFD • Block Flow Process Diagram (BFPD)Block Flow Process Diagram (BFPD)
– BFPD forms the starting point for developing BFPD forms the starting point for developing PFD PFD
– BFPD is helpful in conceptualizing new BFPD is helpful in conceptualizing new processesprocesses
• Block Flow Plant Diagram Block Flow Plant Diagram – Gives a general view of a large complex Gives a general view of a large complex
plantplant
The Block Flow Process Diagram
The Block Flow Plant Diagram
Block Flow DiagramsConventions and Formats 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
The Process Flow Diagrams (PFD)
• A PFD contains the bulk of the Chem A PFD contains the bulk of the Chem Eng data necessary for the design of Eng data necessary for the design of a chemical process.a chemical process.
• Basic information provided by a PFD:Basic information provided by a PFD:– Process TopologyProcess Topology– Stream InformationStream Information– Equipment InformationEquipment Information
The Process Flow Diagrams (PFD)
• A typical commercial PFD will contain the A typical commercial PFD will contain the following information:following information:– All major pieces of equipments in the process All major pieces of equipments in the process
will be represented along with a descriptive will be represented along with a descriptive name and number.name and number.
– All process flow streams will be shown and All process flow streams will be shown and identified with a number. A description of the identified with a number. A description of the process conditions and chemical composition of process conditions and chemical composition of each stream will be included.each stream will be included.
– All utility streams supplied to major equipment All utility streams supplied to major equipment that provides a process function will be shown.that provides a process function will be shown.
– Basic control loops will be shown.Basic control loops will be shown.
The Process Flow Diagram (cont’d)
• The topology of the process – showing the The topology of the process – showing the connectivity of all the streams and the connectivity of all the streams and the
equipmentequipment
– Example for toluene HDA Example for toluene HDA
– Tables 1.2 lists information that should be Tables 1.2 lists information that should be on the PFD but cannot fiton the PFD but cannot fit
-Use appropriate conventions – consistency is -Use appropriate conventions – consistency is important in communication of process important in communication of process information . e.g Table 1.2information . e.g Table 1.2
The Process Flow Diagram (cont’d)
Symbols for Drawing PFD
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
Equipment Numbering
• XX-YZZ A/B/…XX-YZZ A/B/… – XX represents a 1- or 2-letter XX represents a 1- or 2-letter
designation for the equipment (P = designation for the equipment (P = pump) pump)
– Y is the 1 or 2 digit unit number (1-99) Y is the 1 or 2 digit unit number (1-99) – ZZ designates the equipment number ZZ designates the equipment number
for the unit (1-99) for the unit (1-99) – A/B/… represents the presence of A/B/… represents the presence of
spare equipmentspare equipment
The Process Flow Diagram (cont’d)
Equipment Numbering (cont’d)
• Thus, T-905 is the 5th tower in unit nine Thus, T-905 is the 5th tower in unit nine hundred, P-301 A/B is the 1st Pump in hundred, P-301 A/B is the 1st Pump in unit three hundred plus a spareunit three hundred plus a spare XX-YZZ XX-YZZ A/B/…A/B/…
• Use unambiguous letters for new Use unambiguous letters for new equipment equipment – Example: Turbine use Tb or J not T (for tower) Example: Turbine use Tb or J not T (for tower) – Replace old vessel V-302 with a new one of Replace old vessel V-302 with a new one of
different design - use V-319 (say) not V-302 – different design - use V-319 (say) not V-302 – since it may be confused with original V-302since it may be confused with original V-302 the presence of spare equipmentthe presence of spare equipment
Stream Numbering and Drawing
• Number streams from left to right as much as possible
• Horizontal lines are dominant
Stream Numbering and Drawing
(cont’d)
• Add arrows for Add arrows for
– Change in direction Change in direction
– Inlet of equipment Inlet of equipment
• Utility streams should use convention Utility streams should use convention given in Table 1.3 (lps, cw, fg, etc)given in Table 1.3 (lps, cw, fg, etc)
Stream Information • Since diagrams are small not much stream Since diagrams are small not much stream
information can be included information can be included
• Include important data – around reactors and Include important data – around reactors and towers, etc. towers, etc.
– Flags are used – see toluene HDA diagram Flags are used – see toluene HDA diagram
– Full stream data, as indicated in Table 1.4, are Full stream data, as indicated in Table 1.4, are included in a separate flow summary table – see included in a separate flow summary table – see Table 1.5Table 1.5
DO NOT POSSESS ADDITIONAL PROCESS DO NOT POSSESS ADDITIONAL PROCESS INORMATIONINORMATION
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
Additional Diagrams
Section of Plot Plan Section of Elevation Diagram
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.
Scale Models and Virtual Plants
• 25 years ago physical models were used 25 years ago physical models were used for review for review
• Now virtual or electronic models are Now virtual or electronic models are generated using software (3-d plant generated using software (3-d plant diagrams) diagrams)
• Purpose of Models – catch errors such as Purpose of Models – catch errors such as – Piping clashes Piping clashes – Misaligned piping Misaligned piping – Equipment not easily accessed Equipment not easily accessed – Sample points not easily reached by Sample points not easily reached by