SETTING UP A PLANT

PILOT PLANT
BLOCK DIAGRAM
IN

OUT

MATERIAL BALANCE
120
80

200

PFD PROCESS FLOW DIAGRAM

P&ID PIPING AND INSTRUMENT DIAGRAM

INFORMATIONS
COMMUNICATED BY FLOW
SHEETS TO
TOP MANAGEMENT
RESEARCH & DEVELOPMENT GROUP
ENGINEERING DEPARTMENT
CONTRACTORS MODIFICATION OR
REVAMP
OPERATING PERSONNELS TRAINING

TYPES OF FLOWSHEETS
[A]

QUALITATIVE

(a)

BLOCK FLOW SHEET

RECTANGULAR BOXES ENCLOSINIG PHYSICAL &
CHEMICAL OPERATIONS ALONG WITH
DESCRIPTION OF STREAMS ENTERING AND
LEAVING THE BOX.

(b)

SIMPLIFIED EQUIPMENT FLOW SHEET

INTER RELATION SHIP OF MAJOR PROCESS

EQUIPMENTS SHOWN BY LINE CONNECTION.

FLOW OF MATERIALS

UNIT OPERATION

SPECIAL INFORMATION ON OPERATING

CONDITIONS.

TYPES OF FLOWSHEETS
[B]

QUANTITATIVE

(a)

MATTERIAL BALANCE FLOW SHEETS

CONTAINS ALL STREAMS COMPOUNDS AND MASS
PLACED AT STREAMS (LINES) INTER CONNECTING
EQUIPMENTS.

(b)

ENERGY BALANCE FLOW SHEETS

CONTAINS HEAT BALANCE RESULTS
INCORPORATED IN TO EQUIPMENT FLOW SHEET.

COMBINED - DETAIL
[A]

DETAILED EQUIPMENT FLOW SHEET

INCORPORATES PROCESS PIPING, VALVES, DRAINS
BYPASS, VENTS ETC., USED FOR CONSTRUCTIONS.

(B)

INSTRUMENTATION FLOW SHEET

INCORPORATES INSTRUMENTS AND CONTROLS
DETAIL FOR ALL PROCESS AND UTILITIES.

COMBINED - DETAIL
(C)

PIPING & INSTRUMENTATION DIAGRMS (P&ID)

INCORPORATES ALL INSTRUMENTATIONS,
MEASURING SENSING ELEMENTS, CONTROL
VALVES, INTERLOCKS, SHUTDOWN SYSTEM,S
PIPING SPECIFICATION, RATING, SIZE, SAFETY
SYSTEMS IN DETAILED EQUIPMENT FLOW SHEETS

(D)

AUXILARY FLOW SHEET

COVERS AUXILIARY PROCESS REQUIREMENTS
SUCH AS STEAM, WATER, FUEL, AIR, EFFLUENT
AND OTHER UTILITIES.

BLOCK DIAGRAM
IT TRANSLATES PROCESS DESCRIPTION IN
TO WORKING PATTERN.
PHYSICAL AND CHEMICAL OPERATIONS OF
THE PROCESS ARE PRESENTED BY
RECTANGULAR BLOCKS.
ALL STREAM ENTERING AND LEAVING THE
BOX WILL HAVE DESCRIPTION.
USED FOR PRESENTATION AND TRAINING.

MATERIAL BALANCE SHEETS

8

RECYCLE (HYDROGEN)

PURGE

Makeup
Hydrogen
3
2

REACTOR

Py.Gasoline

HEATER

1
5

COOLER
Stream No : 1
State
Liq/Gas
Flow
Kg/Hr M3/Hr.
Component
Temp. oC
Press Kg/Cm2g.

SEPARATOR
6

For
Separtaion

ENERGY BALANCE DIAGRAM

RECYCLE (HYDROGEN)
PURGE

REACTOR
Py.Gasoline

HEATER

Q1
HEAT SUPPLIED Q1 = 2.0 mmkcal/Hr.
HEAT REMOVED Q2 = 0.8 mmkcal/Hr.
Stream No : 1
Temp. oC
Press Kg/Cm2g.
Heat Content
Kcal/Kg

COOLER
Q2

SEPARATOR
For
Separtaion

PROCESS FLOW DIAGRAM

(PFD)
ONCE THE MATERIAL AND ENERGY BALANCE ARE
ESTIMATED IT IS NECESSRAY TO TRANSLATE THESE
INFORMATIONS IN TERMS OF MAJOR INDIVIDUAL
EQUIPMENT. PFD WILL SHOW THE ACTUAL
REPRESENTATION OF THESE EQUIPMENTS.
THROUGH THE SYMBOLS OF EQUIPMENTS FOR
PRESENTATION ARE NOT STANDARDISE THE SYMBOL
WILL HAVE RESEMBLANCE WITH ACTUAL EQUIPMENT.

PFD WILL INCLUDES

ALL PROCESS EQUIPMENTS IN SEQUENTIAL
ORDER.
ALL MAIN PROCESS LINES CONNECTING THE
EQUIPMENTS.
FLOW RATES (VOLUME OR, MASS OR MOLES)
TEMPERATURE, PRESSURE AND PHYSICAL
PROPERTIES OF EACH STREAM. DETAIL
COMPONENT ANALYSIS OF EACH STREAM.
IT INCLUDES VALVE ONLY THOSE ARE ESSENTIAL
FROM OPERATION POINT OF VIEW. (e.g. CONTROL
VALVE)

PFD DOES NOT COVER

UTILITIES LIINES OR DETAIL
INSTRUMENTATION UNLESS ESSENTIAL.
IT WILL NOT SHOW VALVES OTHER
THAN THOSE WHICH ARE ABSOLUTELY
NECESSARY FOR OPERATION.

PFD USED FOR THE PURPOSE OF

COST ESTIMATION.
ECONOMIC EVALUATION OMB
YIELDS CALCULATION
SELECTION, DESIGN AND SPECIFICATION OF
EQUIPMENTS (SIZING).
ESTIMATION OF UTILITIES REQUIREMENT.
OFFSITE REQUIREMENT.
CONTROL & INSTRUMENTATION
MAINTENANCE ESTIMATION.
QUICK UNDERSTANDING OF PROCESS
TRAINING PREPARATION OF OPERATING
MANUAL.

PIPING & INSTRUMENTS DIAGRAM

(P&ID)
IT COVERS

ALL PROCESS LINES INCLUDING ESSENTIAL

UTILITY LINES.

LINES ARE USUALLY SPECIFIED WITH CODE.

ALL EQUIPMENTS AND VALVES SHOULD

APPEAR IN THE SHEET.

ALL INSTRUMENTS AND CONTROL DEVICES.

INTERLOACKS AND SHUTDOWN SYSTEM.

SAFETY VALVES AND SET PRESSURE.

PIPING & INSTRUMENTS DIAGRAM

(P&ID)
IT DOES NOT COVER

ELABORATE PIPIGN DETAILS

FLANGE, FITTINGS, DRAINS & VENTS.
(THESE ARE AVAILABLE IIN ISOMETRIC)

ELABORATE INSTRUMENTS DETAILS

(TYPE, CAPACITY, SIZE ETC.)

IT GIVES INFORMATIONS

TO PIPING DESIGNER A VERIETY OF INFORMATION

PIPE SCHEDULE

FLANGE RATING

TYPE AND SIZE OF VALVES

LINE SIZE AND SERVICE

IT GIVES INSTRUMENT LOCATION.

IT IS A BASIC REFERENCE FOR INSTRUMENT

SPECIFICATION AND PANEL BAOARD PLANNING.

IT IS A BASIC REFERENCE TO MAKE FLOW GRAPHICS ON

DCS.

IT ASSISTS TO PREPARE OPEATING MANUAL.

PREPARE SOP (STANDARD OPERATING PRACTICE).

SHUTDOWN LOGICS

EMERGENCY HANDLING PROCEDURE

(CONTROL VALVE FAILURE POSITION)

APPLICATION (USES)
PROJECTS
PRELIMINARY FLOW DIAGRAM FOR
PRECONSTRUCTION COST ESTIMATES
TO DECIDE PROJECT FEASIBILITY &
VIABILITY.
DETAIL FLOW DIAGRAMS FOR DETAIL
& ACCURATE COST ESTIAMTES.

WHAT IS LEAD SHEET ?

IT CONTAINS THE LEGEND BY WHICH THE OTHER
ENGINEERING FLOW DIAGRAMS ARE CONSTRUCTED
OR UNDERSTOOD.
GENERALLY IT CONTAINS.
LINE IDENTIFICATION SYSTEM.
SYMBOLS FOR VALVES & THEIR ACTUATORS.
PIPING FITTING.
ALL ABBRIVATION USED FOR P&ID.
SYMBOLS FOR EQUIPMENTS, ISOLATION VALVES,
CONTROL VALVES, SOLENOID VALVES,
INSTRUMENTS, RELIEF VALVES, ETC.

Specification for making P & ID

A- LINE IDENTIFICATION , LINE LEGEND

B- PIPING SYMBOLS

C- INSTRUMENT SYMBOLS

D- EQUIPMENT SYMBOLS

LINE LEGEND
HYDROCARBON SERVICE

P PROCESS LINE

SV- SAFETY VALVE DISCHARGE

FL- FLARE

CLBD- COLD LIQUID BLOW DOWN

HLBD- HOT LIQUID BLOW DOWN

FX- FLUX OIL

PC- POLYMER CEMENT

PS- POLYMER SLURRY

WO- WASH OIL

CHEMICALS

AO- ANTI OXIDANT

AS- SULPHURIC ACID

LINE LEGEND(CONTN)

CC- CAUSTIC SOLUTION

DMS- DIMETHYL SULPHIDE

HD- HYDRAZINE

CI- CORROSION INHIBITOR

LO- LUBRICATION OIL

ME- METHANOL

PA- POLYMER ADDITIVE

PH- PHOSPHATE

EFFLUENTS

OWS- OILY WATER SEWER

CS- CAUSTIC SEWER

SS- STORM WATER SEWER

LINE LEGEND(UTILITIES-STEAM)
HS- SUPER HIGH PRESSURE STEAM (120 KG/CM2)
SH- HIGH PRESSURE STEAM (40 KG/CM2)
SHM- HIGH-MEDIUM PRESS. STEAM
SM- MEDIUM PRESS. STEAM (14 KG/CM2)
SLM- LOW MEDIUM PRESS. STEAM ( 5 KG/CM2)
SL- LOW PRESS. STEAM ( 3.5 KG/CM2)
SE- EXHAUST STEAM (3.5 KG/CM2 SUPER HEATED)
ST- TRACING STEAM

CONDENSATE & BFW

BD- BLOW DOWN
CH- HIGH PRESS. CONDENSATE
CM- MEDIUM PRESS.CONDENSATE
CL- LOW PRESS. CONDENSATE
DM- DE-MINERALIZED WATER

LINE LEGEND(UTILITIES)

BF- BOILER FEED WATER

TF- TLE FEED WATER

WATER

CWS- COOLING WATER SUPPLY

CWR- COOLING WATER RETURN

DW- DRINKING WATER

FW- FIRE WATER

PW- PROCESS WATER

RW- RAW WATER

SW- SERVICE WATER

AIR

AP- PLANT AIR

AI- INSTRUMENT AIR

LINE LEGEND(UTILITIES)

IG- INERT GAS (NITROGEN)

PG- PURGE GAS

FUEL

FO- FUEL OIL(LSHS ,RFO ,HSHS )

FG- FUEL GAS

LDO- LIGHT DESEAL OIL

REFRIGERATION

F22- FREON 22

PR- PROPYLENE REFRIGERANT

ER- ETHYLENE REFRIGERANT

AR- AMMONIA REFRIGERANT

Q- CALCIUM NITRATE BRINE

PIPING SYMBOLS

CLASS DESIGNATION CODE = LETTER,NUMBER,LETTER

E .g. B4K

FIRST LETTER INDICATES PRESS.RATING

A = 150 Lb

E = 900 Lb

J = 250 Lb

B = 300 Lb

F = 1500 Lb

S = Special

C = 400 Lb

G = 2500 Lb

T = Atmospheric

D = 600 Lb

H = 125 Lb

V = Vaccum

THE MIDDEL NUMBER INDICATES DIFFERENCE IN THE

SPECIFICATION IN THE SAME RATING & MATERIAL

LAST LETTER INDICATES TYPE OF MATERIAL

A = CARBON STEEL

B = CARBON MOLY

PIPING SYMBOLS

D = 1 CHROME , MOLY

E = 2 CHROME 1 MOLY

G = 5 CROME , MOLY

H = 3 NICKEL

N = CAST IRON

P = CONCRETE

S = ASBESTOSE CEMENT

T = ALUMINIUM

U = COPPER

V = BRASS

K = SS 304L , 304 OR 304 H

L = SS 316 L ,316 OR 316 H

W = MONAL

X = GALVANIZED STEEL

Y = LINED STEEL

Flange Basic
Rating Material
Class Lbs

A1A

150

C. S

Press. &
Temp. limits
0 C & Kg/cm2

Service

10 & 260

Process , non
corrosive liq.vapour &
gas ,fuel oil and
gas,chemical
injection & caustic

A2A

125

C. S

12 & 75

A3A

150

10 & 260

A4A

125

C. S
C. S
Galvanised

10 & Amb.

A5A

150

C. S Low temp.

10 & -45

A6A
A1D

150
150

C. S
1 1/2 Cr.1/2 Mo

10 & 260
4 & 450

A1K

150

3 1/2 Nical

20 & -100

B1A
B2A
B3A

300
300
300

C. S
C. S
C. S

30 & 300
20 & 370
18 & 190

Cooling water,fire
water and utility water
LP
condensate,Instrume
nt air,Utility air,Inert
gas
Drinking water
Non corrosive
process liq. & vapour
LP steam
,Dil.steam,exhaust
steam,
Tranfer line
Non corrosive low
temp. process liq.
Non corrosive
process liq. & vapour
,Fuel gas
MP steam ( IBR )
MP Condensate

Flange Basic
Rating Material
Class Lbs
B4A
B5A

300
300

B1D

300

B1K

300

B2K
D2K

300
600

D3A
D1D

600
600

F1A
F2A

1500
1500

Press. &
Temp. limits
0 C & Kg/cm2

Service

Non corrosive
C. S Low temp.
50 & -45
process liq. & vapour
C. S
40 & 260
Hydrogen
Non corrosive
1 1/4 Cr. 1/2 Mo
8.6 & 600
process liq. & vapour
Compressor seal and
SS Cr. Ni.
23 & 65
lube oil
Non corrosive low
temp.process liq. &
SS
43 & -150.
vapour
C. S
46.5 & 410
MP steam & BF (IBR)
Non corrosive low
temp.process liq. &
CS Low temp.
101 & -45
vapour
1 1/4 Cr. 1/2 Mo
32.3 & 404
Hydrogen
Steam & Blow down
C. S.
140 & 350
(IBR)
C. S.
160 & 350 OR 200 & 160 BFW (IBR)