Lecture 2

Process Diagram
Instrumentation

Process Diagram

Process Diagram

Categories
Process Flow Diagram (PFD)

Also called System Flow Diagram (SFD) or Flowsheet

Describes Primary flow path through operating unit
Provides quick snapshot of operating units

Process and Instrumentation Diagram (P&ID)

Also called Piping and Instrument Diagram

Is a graphical representation of

Equipment
Piping
Instrumentation

Process Diagram Standards

International/Regional/National Standards

International Organization for Standardization or Organisation

Internationale de Normalisation widely known as (ISO)
Deutsches Institut fr Normung e.V. or German Institute for
Standardization (DIN)

Government Regulation

US Occupational Safety and Health Administration (OSHA )

Organization/Association

American Society of Mechanical Engineers (ASME)

Instrumentation, Systems, and Automation Society (ISA),
originally known as Instrument Society of America
Tubular Exchanger Manufacturers Association, Inc. (TEMA)
Process Industry Practices (PIP) by Construction Industry
Institute (CII) at The University of Texas at Austin

Process Diagram Standards

Industry Codes and Standards

American National Standards Institute (ANSI)
Standards Australia (SA) or formerly Standard
Association of Australia (SAA)

Proprietary Standards

Standard Process Design Criteria (Fluor)

Design Engineering Practices (Shell)
Snamprogetti (Italy)
Mitsubishi Heavy Industries (Japan)

Process Flow Diagram (PFD)

PFD includes:
Process stream names
Process piping
Major equipment
symbols, names and
identification numbers
Control valves and
valves that affect
operation of the system
Interconnection with
other systems

Major bypass and

recirculation lines
System ratings and
operational data such
as minimum, normal
and maximum flow,
temperature and
pressure, etc., often
with reference to a
mass balance
Composition of fluids

Process Flow Diagram (PFD)

PFD excludes:

Pipe class and/or line numbers

Process control instrumentation
Secondary or Minor flows
Minor bypass lines
Isolation and shutoff valves
Maintenance vents and drains
Relief and safety valves
Flanges
Code class information
Seismic class information

Process Flow Diagram

Standards
ISO 10628: 1997 Flow Diagrams For
Process Plants General Rules
ANSI Y32.11: Graphical Symbols For
Process Flow Diagrams (withdrawn 2003)
SAA AS 1109: Graphical Symbols For
Process Flow Diagrams For The Food
Industry
DIN

Process Flow Diagram (PFD)

Block Flow Diagram (BFD)

a.k.a. as Schematic
Flow Diagram
PFD of multiple units
as schematic
illustration of major
processes

Block Flow Diagram (BFD)

Guidelines

Unit operations are usually denoted by a simple block or

rectangle and labeled
Groups of unit operations may be noted by a single block or
rectangle
Process flow streams flowing into and out of the blocks are
represented by neatly drawn horizontal or vertical lines
Direction of flow of each of the process flow streams must be
clearly indicated by arrows
Flow streams should be numbered sequentially in a logical
order
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

Block Flow Diagram (BFD)

Process and Instrumentation

Diagram (P & ID)

Pictorial representation of

Key piping and instrument details

Control and shutdown schemes
Safety and regulatory requirements
Basic start up and operational information

Purpose
To have a common language for instrument
technicians, process engineers and suppliers
To properly document plant designs for installation
in graphical form
To help in maintenance, failure analysis and
troubleshooting

Process and Instrumentation

Diagram (P & ID)

Identify
Process Lines from Instrument
Lines
Location of the instrument
Function of the instrument

Provide other relevant

information

Elements of P&ID
Flow Diagram
Equipment Location
Elevation Plan
Electrical Layout
Loop Diagram
Title Block and Legends
Foundation Drawings

P&ID Types
Process and Utility
Utility Distribution
Interconnecting Lines
Auxiliary
Special Controls

Process and Instrumentation

Diagram (P & ID)

P&ID includes:

Instrumentation and
designations
Mechanical equipment with
names and numbers
All valves and their
identifications
Process piping, sizes and
identification
Miscellanea vents, drains,
special fittings, sampling
lines, reducers, increasers and
swaggers
Permanent startup and flush
lines
Flow directions
Interconnections references

Control inputs and outputs,

interlocks
Interfaces for class changes
Seismic category
Quality level
Annunciation inputs
Computer control system
input
Vendor and contractor
interfaces
Identification of components
and subsystems delivered by
others
Intended physical sequence
of the equipment

Process and Instrumentation

Diagram (P & ID)

P&ID excludes:

Instrument root valves

Control relays
Manual switches
Equipment rating or capacity
Primary instrument tubing and valves
Pressure temperature and flow data
Elbow, tees and similar standard fittings
Extensive explanatory notes

ISA Standard for P&ID

ISA 5.1 Instrumentation Symbols and
Identification
ISA 5.2 Binary Logic Diagrams for
Process Operations
ISA 5.3 Graphic Symbols for Distributed
Control / Shared Display Instrumentation,
Logic and Computer Systems
ISA 84.01 Application of Safety
Instrumented Systems for the Process
Industries

ISA Standard
[ Sec 5.1 1984 (Rev 1994) ]

Common Connecting Lines*

Process or Instrument Line
Undefined Signal
Pneumatic Signal
Electric Signal
Hydraulic Signal
Capillary Tube
Electromagnetic or Sonic
Signal (Guided)

OR

ISA Standard
[ Sec 5.1 1984 (Rev 1994) ]

Common Connecting Lines*

Electromagnetic or Sonic
Signal (Not Guided)
Internal System Link
(Software or Data Link)
Mechanical Link
*Following abbreviation used to denote type of supply
IA Instrument Air
AS Air Supply
PA Plant Air

GS Gas Supply
NS Nitrogen Supply
ES Electric Supply

HS Hydraulic Supply
SS Steam Supply
WS Water Supply

ISA Standard
[ Sec 5.1 1984 (Rev 1994) ]

Graphical Elements
Discrete instruments
[Circular Element]

Shared control/display
[Circle circumscribed by a
square]

Computer function
[Hexagon]

Programmable logic
controller (PLC)
[Triangle inside a square]

Location Categories*
Primary location
[Single Horizontal Line
Across Graphical Element]

Auxiliary location
[Double Horizontal Line
Across Graphical Element]

Field mounted
[No Horizontal Line Across
Graphical Element]
*Inaccessible Devices
(Mounted Behind Panel Board)
[Dashed Horizontal Line]

ISA Standard
[ Sec 5.1 1984 (Rev 1994) ]

General Instrument or Function Symbols

Symbol size may vary according to the user's needs and
type of document
Abbreviations of the
user's choice may be
used when necessary
to specify location
Inaccessible (behind
the panel) devices
may be depicted
using the same
symbol but with a
dashed horizontal bar

ISA Standard
[ Sec 5.1 1984 (Rev 1994) ]

Letter and Number Combinations

Appear inside each graphical element
Numbers are user assigned schemes vary
Some companies use of sequential numbering
Some tie the instrument number to the process line
number
Others adopt unique and sometimes unusual
numbering systems

ISA Standard
[ Sec 5.1 1984 (Rev 1994) ]

Instrument Identification
or Tag Number
1st letter defines the
measured or initiating
variables
Succeeding letters
defining

Readout
Passive function
Output function
Modifier

(1)

(2)
(3)

Measured Process
Variable
Output Function
Function Modifier
2

PRC

101
Number refers to loop
number where instrument Balloon (or Bubble)
belongs

ISA Standard
[ Sec 5.1 1984 (Rev 1994) ]

(1)
(2)

(3)

(4,5)
(6)
(2)

(2)
(7)
(8,9,10)
(11)
(8)
(13)

(2,12)
(14)
(2)

(8,9,10)
(8,9)

ISA Standard
[ Sec 5.1 1984 (Rev 1994) ]

(2)
(15)
(6)
(17)

(16)
(18)
(5)

(19)
(6)

(20)
(6,17,22)
(21)

Example
Letter Code
A
B
C
D
E
F
G
H
I
J
K
L
M
O
P
Q
R
S
T
U
V
W
Y
Z

First Letter
Analysis
Burner
Conductivity
Density
Voltage
Flow
Gage
Current
Power
Time
Level
Moisture
Pressure
Quantity
Radioactivity
Speed
Temperature
Multivariable
Viscosity
Weight
Position

Second Letter
Alarm

PRC
101

Control
Primary Element
Glass(sight tube)
High
Indicator

Control Station
Light

Orifice
Point
Record
Switch
Transmit
Multifunction
Valve
Well
Relay
Drive

PRC means

Pressure
Recording
Controller

101 means that

instrument belongs
to Loop # 101

P&ID Symbols
[ Sec 5.1 1984 (Rev 1994) ]

Pipe

Insulated Pipe

Jacketed
Pipe

Cooled or
Heated Pipe

Flexible Pipe

Valve

Manual
Valve

Control Valve

Ball Valve

Globe Valve

Needle
Valve

Butterfly
Valve

Diaphragm
Valve

Pressure
Reducing
Valve

Steam Trap

Covered
Gas Vent

Curved Gas
Vent

Funnel

Filter

Dust Trap

P&ID Symbols
[ Sec 5.1 1984 (Rev 1994) ]

Radial Fan

Pump

Gas Bottle

Viewing
Glass

Back Draft
Damper

Heater

Cooler

Cooling
Tower

Fan

Axial Fan

Bag

Furnace

Vacuum Pump
or
Compressor

Dryer

Pressurized
Horizontal
Vessel

P&ID Symbols
[ Sec 5.1 1984 (Rev 1994) ]

Pressurized
Vertical Vessel

Tray
Column

Packed or Fluid
Contacting
Column

Half Pipe Mixer Heat Exchanger Heat Exchanger

or Reactor
w/ no crossflow
w/ crossflow

Double Pipe
Heat

UTube
Heat

Spiral Heat
Exchanger

Autoclave or
Jacketed Mixing
Vessel

Fixed Straight
Tube Heat
Exchanger

Plate and Frame

Heat Exchanger

P&ID Symbols

P&ID Symbols

P&ID Symbols

P&ID Symbols

Example of P&ID

Example of a P&ID
A Heat Exchanger Control System
Steam in
TY
343

Reactant in

TT
343

TC
343

FI
344
FRC
342

FT
342

Steam out

FR
342

Reactant out

Example of P&ID

Constructing An Instrument
Flow Sheet

Identify the process

Define the control objective/s
Create a process flow diagram
Identify the equipment and process lines
Determine the instrument and connecting lines
Use of standard symbology like ISA codes to
identify instrument and functions

References
1.

Hughes, Thomas A. Measurement and Control Basics, 3rd ed. Research Triangle
Park, NC: The Instrumentation, Systems, and Automation Society, 2002.

2.

Madsen, D. A. et al. Engineering Drawing and Design. 4th ed. New York: Delmar
Cengage Learning , 2006.

3.

Perry, R. H. and D. W. Green (ed.) Perrys Chemical Engineers Handbook. 7th

ed. New York: The McGraw-Hill Companies, Inc., 1997.

4.

PIP PIC001 Piping and Instrumentation Diagram Documentation Criteria .

Austin, Texas: Process Industry Practices, Construction Industry Institute,
TheUniversity of Texas at Austin, Apr 2008.

5.

Seborg, Dale E. et al. Process Dyanmics and Control. 2nd ed. New York: John
Wiley & Sons, Inc, 2004.

6.

Thomas, C. Process Technology Equipment and Systems. 2nd ed. New York:
Delmar Cengage Learning , 2007.

Internet Sources
1.

BFD Block Flow Diagram. http://www.engineeringtoolbox.com/bfdblock-flow-diagram-d_467.html

2.

Harrold, Dave. How To Read P&ID. http://lamspeople.epfl.ch/kirrmann/

Slides/HowToReadP&ID.htm, Aug 1, 2000.

3.

P&ID Piping and Instrumentation Diagram.

http://www.engineeringtoolbox.com/p&id-piping-instrumenationdiagram-d_466.html

4.

PFD Process Flow Diagram.

http://www.engineeringtoolbox.com/pfd-process-flow-diagramd_465.html

5.

http://www.wikipedia.org