1 / 63

ERT 213/4 Process instrumentation

ERT 213/4 Process instrumentation. MISS. RAHIMAH BINTI OTHMAN (Email: rahimah@unimap.edu.my). COURSE OUTCOMES. LEARNING FLOW. Valves In Industry. Process & Instrumentation Diagram (P&ID). Pump, Compressor, Fan & Blower. ISA Symbology. Process Flow Diagram (PFD). OUTLINES.

tiva
Download Presentation

ERT 213/4 Process instrumentation

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. ERT 213/4 • Process instrumentation MISS. RAHIMAH BINTI OTHMAN (Email: rahimah@unimap.edu.my)

  2. COURSE OUTCOMES

  3. LEARNING FLOW Valves In Industry Process & Instrumentation Diagram (P&ID) Pump, Compressor, Fan & Blower ISA Symbology Process Flow Diagram (PFD)

  4. OUTLINES • TYPES of piping and instrumentation symbols. • How to CHOOSEthe suitable symbols in Process Flow Diagram? • How to DEVELOP thepiping systems and the specification of the process instrumentation, equipment, piping, valves, fittings. • The ARRANGEMENT in PFD for the bioprocess plant design.

  5. 1. Block Flow Diagram (BFD) 2. Process Flow Diagram (PFD) PROCESS DIAGRAMS 4. Piping and Instrumentation Diagram (P&ID) 3. Process equipments symbol and numbering

  6. BLOCK FLOW DIAGRAM (BFD) • Is the simplest flowsheet. • Process engineer begins the process design with a block diagram in • which only the feed and product streams are identified. • Input-output diagrams are not very detailed and are most useful in • early stages of process development. • Flow of raw materials and products may be included on a BFD. • The processes described in the BFD, are then broken down into • basic functional elements such as reaction and separation sections. • Also identify the recycle streams and additional unit operations to • achieve the desired operating conditions.

  7. BLOCK FLOW DIAGRAM (BFD) Example 1: Mixed Gas 2610 kg/hr Toluene, C7H8 10,000 kg/hr Reactor Gas Separator Benzene, C6H6 8,210 kg/hr C6H6 CH4 C7H8 Hydrogen H2 820 kg/hr Mixed Liquid 75% Conversion of Toluene Reaction : C7H8 + H2 C6H6 + CH4 Figure 1: Block Flow Diagram for the Production of Benzene

  8. H2SO4 CH3CH2OH CH2=CH2 + H2O CH3CH3 CH2=CH2 + H2 Ni Hot water out Ethylene liq. CH2CH2 (l) Ethylene, CH2CH2 (g) Ethanol, C2H5OH Cold water in Ethane, CH3CH3 CH2CH2 H2O Hydrogen, H2 H2SO4 Distillation column Ni H2O Example 2: Production of Ethane from Ethanol Ethanol is feed to continuous reactor with presence of Acid Sulphuriccatalyzer to produce ethylene.Distillation process then will be applied to separate ethylene-H2O mixture. Ethylene as a top product is then condensate with condenser to perform liquid ethylene.Hydrogenation of ethylene applies in another reactor with presence of Nickel catalyzer to produce ethane as a final product. Develop BFD for these processes. Answer: Reactor 1 Reactor 2

  9. Exercise 1: Ammonia-air mixture is feed to the bottom stream of an absorber with flow rate of 10L/min. Water then feed to the upper stream of the same absorber with desired flow rate of 5L/min. There are two outputs from the absorber where upper stream is insoluble NH3and bottom stream is NH3-Water mixture. This NH3-water mixture then feed up to a batch distillation column. The column produces ammonia gas as a top product which this product then will be condensate with a condenser to produce liquid ammonia. Develop Block Flow Diagram (BFD) for this process.

  10. Exercise 1 (ANSWER): Ammonia-air mixture is feed to the bottom stream of an absorber with flow rate of 10L/min. Water then feed to the upper stream of the same absorber with desired flow rate of 5L/min. There are two outputs from the absorber where upper stream is insoluble NH3and bottom stream is NH3-Water mixture. This NH3-water mixture then feed up to a batch distillation column. The column produces ammonia gas as a top product which this product then will be condensate with a condenser to produce liquid ammonia. Develop Block Flow Diagram (BFD) for this process. Hot water out Insoluble ammonia Ammonia liquid Condenser Water 5 L/min Ammonia gas Absorber Batch Distillation Cold water in Ammonia-water mixture Ammonia-air mixture 10 L/min

  11. Block Flow Diagram (BFD) Process Flow Diagram (PFD) PROCESS DIAGRAMS Process equipments symbol and numbering Piping and Instrumentation Diagram (P&ID)

  12. PROCESS FLOW DIAGRAM (PFD) A Process Flow Diagram generally includes following information; Flow rate of each stream in case of continuous process or quality of each reactant in case of a batch process. Composition streams. Operating conditions of each stream such as pressure , temperature, concentration, etc. Heat added or removed in a particular equipment. Flows of utilities such as stream, cooling water, brine, hot oil, chilled water, thermal fluid, etc. Major equipment symbols, names and identification. Any specific information which is useful in understanding the process. For example, symbolic presentation of a hazard, safety precautions, sequence of flow, etc.

  13. 1. Major Pieces Of Equipment 2. Utility Streams PFD 4. Basic Control Loops 3. Process Flow Streams

  14. PROCESS FLOW DIAGRAM (PFD)

  15. 1. Major Pieces Of Equipment 2. Utility Streams PFD 4. Basic Control Loops 3. Process Flow Streams

  16. PROCESS FLOW DIAGRAM (PFD) PFD will contains the following information:- 1. All major pieces of equipment (descriptive name, unique equipment no.), pumps and valves. 2. All the utility streamssupplied to major equipments such as steam lines, compressed air lines, electricity, etc.

  17. H2O S PROCESS FLOW DIAGRAM (PFD) Process Unit Symbols Symbol Description Heat exchanger Water cooler Steam heater Cooling coil

  18. PROCESS FLOW DIAGRAM (PFD) Process Unit Symbols Symbol Description Heater coil Centrifugal pump Turbine type compressor Pressure gauge

  19. PROCESS FLOW DIAGRAM (PFD) Process Unit Symbols Symbol Name Description A separator unit used commonly to liquid mixture into gas phase. Stripper A separator unit used commonly to extract mixture gas into liquid phase. Absorber

  20. or PROCESS FLOW DIAGRAM (PFD) Process Unit Symbols Symbol Name Description A separator unit used commonly to crack liquid contains miscellaneous component fractions. Distillation column A process unit that used to mix several components of liquid. Liquid mixer

  21. PROCESS FLOW DIAGRAM (PFD) Process Unit Symbology Name Description Symbol A process unit where chemical process reaction occurs Reaction chamber A unit to store liquid or gas. Horizontal tank or cylinder

  22. PROCESS FLOW DIAGRAM (PFD) Process Unit Symbology Symbol Name Description A unit for heating. Boiler Centrifuge A separator unit that to physically separated liquid mixture. (exp: oil-liquid)

  23. PROCESS FLOW DIAGRAM (PFD) Valve Symbology Symbol Name Gate Valve Globe Valve Ball Valve Check Valve Butterfly Valve

  24. PROCESS FLOW DIAGRAM (PFD) Valve Symbology Symbol Name Relief Valve Needle Valve 3-Way Valve Angle Valve Butterfly Valve

  25. H2SO4 CH3CH2OH CH2=CH2 + H2O CH2=CH2 + H2 CH3CH3 Ni R-100 Reactor P-100 Pump T-100 Distillation Column E-100 Condenser P-101 Pump R-101 Reactor Hot water out Ethylene Ethylene liq. E-100 V-104 Cold water in V-106 T-100 CV-100 CV-101 Ethanol V-105 Hydrogen V-101 V-102 V-100 H2SO4 V-107 V-103 Ni R-101 R-100 Ethane P-100 H2O P-101 Example 4 Production of Ethane from Ethanol Ethanol is feed to continuous reactor with presence of Acid Sulphuric catalyzer to produce ethylene. Distillation process then will be applied to separate ethylene-H2O mixture. Ethylene as a top product is then condensate with condenser to perform liquid ethylene. Hydrogenation of ethylene applies in another reactor with presence of Nickel catalyzer to produce ethane as a final product. Develop PFD for these processes.

  26. Example 2: (from previous example) H2SO4 CH3CH2OH CH2=CH2 + H2O CH3CH3 CH2=CH2 + H2 Ni Hot water out Ethylene liq. CH2CH2 (l) Ethylene, CH2CH2 (g) Ethanol, C2H5OH Cold water in Ethane, CH3CH3 CH2CH2 H2O Hydrogen, H2 H2SO4 Distillation column Ni H2O Production of Ethane from Ethanol Ethanol is feed to continuous reactor with presence of Acid Sulphuriccatalyzer to produce ethylene.Distillation process then will be applied to separate ethylene-H2O mixture. Ethylene as a top product is then condensate with condenser to perform liquid ethylene.Hydrogenation of ethylene applies in another reactor with presence of Nickel catalyzer to produce ethane as a final product. Develop BFD for these processes. Answer: Reactor 1 Reactor 2

  27. Exercise 2 Ammonia-air mixture is feed to the bottom stream of an absorber with flow rate of 10L/min. Water then feed to the upper stream of the same absorber with desired flow rate of 5L/min. There are two outputs from the absorber where upper stream is insoluble NH3 and bottom stream is NH3-Water mixture. This NH3-water mixture then feed up to a batch distillation column. The column produces ammonia gas as a top product which this product then will be condensate with a condenser to produce liquid ammonia. Develop Process Flow Diagram (PFD) for this process.

  28. Exercise 1 (ANSWER): Ammonia-air mixture is feed to the bottom stream of an absorber with flow rate of 10L/min. Water then feed to the upper stream of the same absorber with desired flow rate of 5L/min. There are two outputs from the absorber where upper stream is insoluble NH3and bottom stream is NH3-Water mixture. This NH3-water mixture then feed up to a batch distillation column. The column produces ammonia gas as a top product which this product then will be condensate with a condenser to produce liquid ammonia. Develop Block Flow Diagram (BFD) for this process. Hot water out Insoluble ammonia Ammonia liquid Condenser Water 5 L/min Ammonia gas Absorber Batch Distillation Cold water in Ammonia-water mixture Ammonia-air mixture 10 L/min

  29. Example 5 Ammonia-air mixture is feed to the bottom stream of an absorber with flow rate of 10L/min. Water then feed to the upper stream of the same absorber with desired flow rate of 5L/min. There are two outputs from the absorber where upper stream is insoluble NH3 and bottom stream is NH3-Water mixture. This NH3-water mixture then feed up to a batch distillation column. The column produces ammonia gas as a top product which this product then will be condensate with a condenser to produce liquid ammonia. Develop Process Flow Diagram (PFD) for this process. T-100 Absorber Column T-101 Batch Distillation Column E-100 Condenser Insoluble ammonia gas Hot water out Ammonia gas Ammonia liquid Water 5 L/min Cold water in Ammonia-air mixture 10 L/min Ammonia-water mixture

  30. 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 thenumber 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 PROCESS FLOW DIAGRAM (PFD) Process Unit Tagging and Numbering

  31. Hot water out Ethylene Ethylene liq. Cold water in Hydrogen Ethane Ni P-100 A/B H2O H2O PROCESS FLOW DIAGRAM (PFD) A/B Letter Example Hot water out Ethylene Cold water in Ethylene liq. Ethanol Ethanol H2SO4 H2SO4 Ethane Hydrogen Ni P-100 A P-100 B In Real Plant In PFD

  32. 1. Major Pieces Of Equipment 2. Utility Streams PFD 4. Basic Control Loops 3. Process Flow Streams

  33. PROCESS FLOW DIAGRAM (PFD) PFD will contains the following information:- All process flow streams: identification by a number, process condition, chemical composition.

  34. PROCESS FLOW DIAGRAM (PFD) Stream Numbering and Drawing - Number streams from left to right as much as possible. - Horizontal lines are dominant. Yes No No

  35. R-100 Reactor P-100 Pump T-100 Distillation Column E-100 Condenser P-101 Pump R-101 Reactor Hot water out Ethylene liq. Ethylene E-100 6 V-104 Cold water in V-106 CV-101 CV-100 V-105 5 Ethanol 1 V-101 V-102 H2SO4 4 Hydrogen 9 V-100 Ni V-103 V-107 R-100 Ethane 3 8 10 2 H2O T-100 7 P-101 P-100 R-101 Example 4- cont’

  36. PROCESS FLOW DIAGRAM (PFD) Stream Information • Since diagrams are small not much stream information • can be included. -Include important data – around reactors and towers, etc. • Flags are used • Full stream data

  37. PROCESS FLOW DIAGRAM (PFD) Stream Information - Flag Temperature 600 300 3 Pressure 8 24 9 6 7 Mass Flowrate 10.3 1 10 Molar Flowrate 108 600 24 2 5 12 Gas Flowrate 11 Liquid Flowrate 4 13 24

  38. R-100 Reactor P-100 Pump T-100 Distillation Column E-100 Condenser P-101 Pump R-101 Reactor Hot water out Ethylene liq. Ethylene E-100 6 V-104 Cold water in 25 35 35 V-106 CV-101 31.0 28 32.2 CV-100 V-105 Ethanol 5 20 1 38 V-101 V-102 4 H2SO4 Hydrogen 9 V-100 Ni V-103 V-107 R-100 Ethane 3 8 10 2 H2O T-100 7 P-101 P-100 R-101 Example 4- cont’

  39. PROCESS FLOW DIAGRAM (PFD) Stream Information - Full stream data:

  40. R-100 Reactor P-100 Pump T-100 Distillation Column E-100 Condenser P-101 Pump R-101 Reactor Hot water out Ethylene liq. Ethylene E-100 6 V-104 Cold water in V-106 CV-100 CV-101 V-105 25 35 35 5 Ethanol 20 1 V-101 V-102 31.0 32.2 28 H2SO4 4 Hydrogen 38 V-100 9 Ni V-103 V-107 R-100 Ethane 3 8 10 2 H2O 7 P-101 P-100 T-100 R-101 Example 4- cont’

  41. 1. Major Pieces Of Equipment 2. Utility Streams PFD 4. Basic Control Loops 3. Process Flow Streams

  42. PROCESS FLOW DIAGRAM (PFD) PFD will contains the following information:- - Basic control loops: showing the control strategy used to operate the process under normal operations.

  43. Example 4- cont’ R-100 Reactor P-100 Pump T-100 Distillation Column E-100 Condenser P-101 Pump R-101 Reactor Hot water out Ethylene liq. Ethylene E-100 6 V-104 Cold water in LIC V-106 CV-101 CV-100 V-105 25 35 35 5 Ethanol 20 1 V-102 V-101 31.0 32.2 28 H2SO4 4 Hydrogen 38 9 V-100 Ni V-103 V-107 R-100 Ethane 3 8 10 2 H2O 7 LIC P-101 P-100 T-100 R-101

  44. PIPING AND INSTRUMENTATION DIAGRAM (P&ID) Instrumentation Symbology Instruments that are field mounted. -Instruments that are mounted on process plant (i.e sensor that mounted on pipeline or process equipments. Field mounted on pipeline

  45. PIPING AND INSTRUMENTATION DIAGRAM (P&ID) Instrumentation Symbology Instruments that are board mounted -Instruments that are mounted on control board.

  46. PIPING AND INSTRUMENTATION DIAGRAM (P&ID) Instrumentation Symbology Instruments that are board mounted (invisible). -Instruments that are mounted behind a control panel board.

  47. PIPING AND INSTRUMENTATION DIAGRAM (P&ID) Instrumentation Symbology Instruments that are functioned in Distributed Control System (DCS) - A distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring.

  48. PIPING AND INSTRUMENTATION DIAGRAM (P&ID) Instrumentation Symbology

  49. IDENTIFICATION LETTERS & TAG NUMBERS • The initial letter indicates the measured variable. • The second letter indicates a modifier, readout, or device function. • The third letter usually indicates either a device function or a modifier. • Numbers on P&ID symbols represent instrument tag numbers. • Often these numbers are associated with a particular control loop (e.g., flow transmitter 123).

More Related