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PROCESS DESIGN ENGINEERING COURSE

LESSON 07 (PART 01)
HOW TO DEVELOP PFD & P&ID ?

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DEVELOPMENT OF PROCESS DESIGN AND ENGINEERING DRAWINGS

Introduction
The general perception of process design is to perform simulations, sizing and
design calculations for various equipment and unit operations; but another
important highlight in a process engineer’s career is the development of
engineering drawings which brings the design in to reality.
During this lessons we deals with the development of process design and
engineering drawings which are helpful for the design, engineering and
construction of a plant/facility.
The process design engineering drawings are prepared in the following sequence.

Facility Process
Description

Block Flow
Diagram

Process Flow
Diagram

Piping And
Instrumentation
Diagram

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BLOCK FLOW DIAGRAM

Block Flow Diagram (BFD) is a schematic representation of the major process of a
facility.
In a block flow diagram, unit operations are represented, using blocks or rectangles.
The blocks are connected by straight lines which represent the process flow
streams that flow between the units. The process flow streams may be a mixture
of liquids, gases and solids flowing in pipes or duct, or solids being carried on a
conveyor belt.
In order to prepare clear, easy to understand and unambiguous block flow
diagrams a number of rules should be followed:
 Unit operations such as mixers, separators, reactors, distillation columns,
pump etc., are usually denoted by a simple blocks or rectangles.
 Process flow streams flowing into and out of the blocks are represented by
neatly drawn straight lines. These lines should either be horizontal or
vertical.
 The direction of the each process flow stream must be clearly indicated by
arrows.
 Flow streams should be numbers sequentially in a logical order.
 Unit operations (i.e., blocks) should be labeled.
 Where possible the diagram should be arranged so that the process material
flows from left to right, with upstream units on the left and downstream
units on the right.
This figure depict a very small and simplified BFD:

Overhead Storage Tank

T-102

Under Ground Water TanK Water Transfer Pump

T-101 P- 201

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BLOCK FLOW DIAGRAM EXAMPLE:

This diagram explains the operating principle of the whole installation in just a
few boxes.
The schematic diagram of the N’Kossa site in the Congo is given below.

Task: Develop BFD for the process on the basis of given facility description.
Production Of Ethane From Ethanol
Ethanol is feed in to continuous reactor in the presence of H2SO4 catalyst to
produce ethylene. Then distillation process will be applied to separate ethylene and
H2O mixture. Top product from the column is then condense by condenser to get
liquid ethylene. Which introduced in another reactor for Hydrogenation in
presence of Nickel catalyst to produce ethane as a final product.

CH3CH2OH  CH2=CH2 + H2O (In Presence Of H2SO4 Catalyst)

CH2=CH2 + H2  CH3CH3 (In Presence Of Ni Catalyst)

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Solution:

PROCESS FLOW DIAGRAM

Process Flow Diagram (PFD) is a schematic diagram showing the main equipment
and controls (Pressure, temperature, flow, level, etc.) of the process in the facility,
using symbols. The diagram also shows stream numbers of important / main fluid
streams flowing into, through and out of the facility.

A summary of the process operating parameter like composition, mass flow rates,
energy flow rates, operating pressure, operating temperature and physical
properties of the numbered process streams are presented in a tabular form on the
PFD or on a separate sheet known as Heat & Material Balance Sheet ( H&MB).

Objective:
PFD: To give an overview of the process taking place in the facility / plant.
H&MB: To provide a summary of the process simulation data for the design of the
facility / plant.

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Input required for preparation

PFD H&MB
Process description of the facility Stream numbers from PFDs
Block flow diagram of the facility Stream data from simulation

Uses:
PFD:
 To correlate the stream numbers with those used in simulations and / or
Heat & Mass Balance.
 Prepare Piping and Instrumentations Diagrams
H&MB:
 Perform equipment sizing calculations
 Perform line sizing calculations
 Perform instrument sizing calculations
 Generate process specification / datasheets for the equipment and
instruments
 Generate line schedule

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PROCESS FLOW DIAGRAM EXAMPLE:

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PIPING AND INSTRUMENTATION DIAGRAM (P&ID)

The process flow diagram (PFD) is the primary source of information for the
development of piping and instrumentation diagram (P&ID). The P&ID is a
schematic diagram which shows the interconnection of the process equipment and
the instrumentation used to control the process. The P&ID should define piping,
equipment and instrumentation well enough for cost estimation and subsequent
design, engineering, construction, pre-commissioning, operation, maintenance and
modification of the process.
During the design and engineering phase of a project, the P&ID provides the basis
for the development of system control schemes, allowing for further safety and
operational investigation, such as the hazard and operability study (HAZOP).
P&IDs are also referred as Engineering Flow Diagrams (EFDs).
A P&ID as a minimum should include:
 Mechanical equipment with names and numbers
 Instrumentation and designations
 Process piping, sizes and identification
 All valves and their identifications
 Vent, drains, piping specialty fittings, sampling lines, reducers, expanders,
etc.
 Permanent start-up and flush lines
 Flow directions
 Interconnections references
 Control input and output, interlocks
 Interface for pipe class changes
 Vendor and contactor interfaces
 Identification of components and subsystems delivered by others
In short, P&ID is just a pictorial representation of
 Key piping and instrument details
 Control and shutdown schemes
 Safety and regulatory requirements
 Basic start-up and operational information

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INPUT REQUIRED FOR P&ID PREPARATION

 Process design basis

 Process flow diagram
 Equipment list
 Process description
 Operation philosophy
 Control philosophy
 Shutdown philosophy
 Isolation philosophy
 Symbols and legends
 Numbering system
 Pipe class specification
 Vendor package details
 Sizing calculations ( Line, Equipment, Instrument )
 Equipment datasheets / general arrangement drawing
 Instrument data sheets
 Cause and effect chart
NOTE: P&IDs are used throughout the life of the facility and are constantly updated
for any modification / changes that happen from time to time.
In the process industry, a standard set of symbols are used to prepare drawing for
various processes. Refer section ISA–5.5 or PIP (Process Industry Practices) for the
typical symbols / legends.

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SYMBOLS & LEGENDS

General Abbreviations

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EQUIPMENT SYMBOLS (Centrifugal Pumps)

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EQUIPMENT SYMBOLS (Positive Displacement Pumps)

EQUIPMENT SYMBOLS (Storage Vessel & Tanks)

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EQUIPMENT SYMBOLS (Compressors)

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EQUIPMENT SYMBOLS (Heat Exchangers)

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EQUIPMENT SYMBOLS (Heat Exchangers)

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EQUIPMENT SYMBOLS (Heat Exchangers)

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EQUIPMENT SYMBOLS (Heat Exchangers)

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EQUIPMENT SYMBOLS (Columns)

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LINE LEGEND

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Line Numbering Philosophy

Line

Line Service Codes

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PIPING FITTINGS

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PIPING SPECIALTY ITEMS

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VALVES

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INSTRUMENT SYMBOLS

Instrument Designation

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