43 (Lecture - Instrumentation For P&ID's - Cookbook)

INSTRUMENTATION
FOR
P&IDs
But first....
Design pressures...
Its best to group equipment and give
it all the same maximum op. pressure
What groups would you create?

What would the max op. pressure be?
Ground rules for additional

equipment
Send non-useful gases (Gas_purge 200 kg/hr,

Lights 51 kg/hr) for combustion in the syngas
htr (its a fired heater)
Send Fusil_oil (19 kg/hr) to waste treatment

plant or to the syngas htr (need tank & pump)
- implications?

equipment
Storage Tanks
Provide an off spec tank for the Product sized for 12
hours of hold-up at normal rates
In addition, provide at least 2 tanks for the Product
Provide an 8 hour storage tank for the Recovr_water
Storage Tanks can have L/D = 1 (or less)
Show product storage tanks sending material to

existing truck and railcar loading
Show Recovr_water storage tank sending water to
waste treatment plant - recycle issues?

equipment
Pumps
Put a pump on the acetone column bottoms
product so we can run it at as low a pressure as
possible (at simulation stated pressures) to ensure
we remove all lights etc.
dont put a pump on degasser bottoms (lets
increase the pressure accordingly)
what are the trade-offs?
Provide a pump on the off spec storage tank to
recirc material back to the Acetone column feed.
This will help us during start-up or upsets

equipment
?
hrs
?
hrs
12
hrs
8 hrs
Now Back to our regularly

scheduled show...
Instrumentation Cookbook
Why Are We Doing This
Instrumentation
ESTIMATOR - To Size The Pumps We

Need To Include Inline
Instrumentation
Provide A Basic Understanding Of
Controls Nomenclature and Their
Application
FE
PI
Objective:
Instrumentation
To Produce A Viable Control Scheme in a

way that uses and improves our
understanding of the simulation and gives
us essential information to size the pumps
To have some examples of controls that
could be applied to our process
To understand why these control schemes

were selected so that you can form your own
judgement
A Simple Feedback
Control
Loop Control Loop
Set Point Often not shown
Measured
Variable (temp,
pressure, flow...)
FE
FIT
Controller
FIC
Manipulated
Variable
FV
Controllers
Initiating or
First
Measured Variable
Letter
Analysis
A
Burner, Combustion
B
Users Choice
C
Users Choice
D
Voltage
E
Flow Rate
F
Flow Quantity
FQ
Flow Ratio
FF
Users Choice
G
Hand
H
Current (Electrical)
I
Power
J
Time
K
Level
L
Users Choice
M
Recording Indicating blind

ARC
AIC
AC
BRC
BIC
BC
Readout Devices
Switches and Alarm Devices
Self
Actuated
Control
Valves
Recording Indicating High
Low
Comb
AR
AI
ASH
ASL
ASHL
BR
BI
BSH
BSL
BSHL
Transmitters
Recording Indicating Blind

ART
AIT
AT
BRT
BIT
BT
Instrumentation Naming
ERC
FRC
FQRC
FFRC
EIC
FIC
FQIC
FFIC
IRC
JRC
KRC
LRC
HIC
IIC
JIC
KIC
LIC
EC
FC
FCV FICV
FFC
ER
FR
FQR
FFR
EI
FI
FQI
FFI
ESH
FSH
FQSH
FFSH
ESL
FSL
FQSL
FFSL
HR
IR
JR
KR
LR
HI
II
JI
KI
LI
ISH
JSH
KSH
LSH
ISL
JSL
KSL
LSL
ESHL
FSHL
ERT
FRT
Instrument Society Of America (ISA)
Initiating or
First
Measured Variable
Letter
Analysis
A
Burner, Combustion
B
Users Choice
C
Users Choice
D
Voltage
E
Flow Rate
F
Flow Quantity
FQ
Flow Ratio
FF
Users Choice
G
Hand
H
Current (Electrical)
I
Power
J
Time
K
HC
KC
LC
KCV
LCV
Solenoids,
Relays,
Computing Primary
Devices
Element
AY
AE
BY
BE
EY
FY
FQY
HY
IY
JY
KY
EE
FE
FQE
FE
Well Of
Test Point Probe
AP
AW
BW
FP
Viewing
Device,
Glass
HS
ISHL
JSHL
KSHL
LSHL
Safety
Device
BG
FG
IE
JE
KE
ISA Typical Letter Combinations.xls
HRT
IRT
JRT
KRT
LRT
Final
Element
AV
BV
EZ
FV
FQV
FFV
HV
IZ
JV
KV
EIT
FIT
FQIT
ET
FT
FQT
HIT
IIT
JIT
KIT
LIT
HT
IT
JT
KT
LT
Equipment
Symbology
P&IDs
- Symbology
Instrumentation Symbology
See the document P&ID Symbols and

Photos.DOC
P&IDs - Symbology
LIC
Located in DCS
(process control
computer)
Software Signal
LT
Physically
located
in field
Physical wire
hardwired
The Control Valve
Actuator driven by
Compressed
Air
Valve
Elec Signal
To valve
(4-20 mA
DC signal)
Level
Typical
Controls
Flow
Pressure
Temperature
Composition
Level Control
Purpose
Prevent the tank from overfilling /
running dry
LT
LIC
LV
Level Control
Purpose
Hold a liquid Seal
LT
LIC
No Gas!
LV
Level Control
Purpose
Prevent pump from running dry and
thus being destroyed
LT
LIC
LV
Note: - valve always on disch to prevent flashing on pump suction
- pump may also require a minimum flow bypass
Control Systems
Aside - Speed
Measured Variable can be slow to

measure (I.e. the composition using an
analyser) or fast (pressure)
The Manipulated Variable can be slow
too (I.e. adjusting the hot water tap in
your shower)
The level in a tank can take hours to
change (slow)
Control Systems
Aside - Speed
Slow Things
Say > few seconds
Reducing Pressure
by Opening a valve
on a large gas filled
tank
Measure
Composition
(analysers)
Change Level In
Large Tank
Fast Things
Less than a
second
Measure Pressure
Measure Flow (Diff
Press)
Measure Temp (?)
But. Its all RELATIVE !!
Flow Control
Purpose: Ensure steady material flow rate
Smooth feed to columns

Set Production rate
Fast to Measure
Flow Changes usually require a control valve to
change its position which can take seconds.
Vapour systems have a capacitance that
need to be overcome before the flow changes
are experienced everywhere in the system
Flow Control
FT
FIC
FT
FE
FIC
FE
FV
SIC
Variable Speed Drive
Mount FE upstream in vapour systems to minimize pressure/density

effects
- Ratio Flow
Control
FIC
SP
FT
FE
FRIC
FT
FV
FIC
SP
SP
Set one flow

rate
Other flow is
proportionall
y controlled
to first flow
FE
FV
Ensure correct
mixture /
recipes
Pressure Control
Similar to Level (control of material

inventory)
Very fast for incompressible fluids
Hard to say for compressible fluids,
depends on system volume but
probably slow
Pressure Control
Control Upstream | Control Downstream

PIC
PIC
PT
PT
PV
Need to control vessel pressure
PV
Need to downstream (header or

process) pressure
Pressure Control
Condensable Gas
PIC
PV
PT
Need to control vessel pressure
Fast or slow?
Pressure Control
Liquid Pressure Control
PIC
PT
PV
Control pump discharge pressure - not very useful
Pressure Control
Liquid Pressure Control
PIC
FIC
PT
PV
Control pump discharge pressure - ensure
constant feed pressure to FV
FT
FE
FV
Temperature Control
Normally control the flow of one fluid

to change the temperature of another
In Reality its an LMTD change that
affects the exchanger duty
Q = U A Tln
Temperature Control
C/w
Liquid / Liquid - control on cooling media
Temperature Control
C/w
Liquid / Liquid - control on process
Temperature Control
Steam Pressure Control
Increase Stm
Pressure
Temperature Control
Condensate Level Control
Reduce flooded
Area
Example - Driving
to Montreal
Cascade
Control
Youre driving / steering the car

Someone else is telling you which
roads to drive on and when to turn
Cascade Control
One Control Loop Determines Setpoint
of a Second Loop
FT
High Speed
FE
M
I
Low Speed
Flow
SIC
SP
Variable Speed Drive
FIC
SP
-Using the
flow through
the pump to
control the
rotational
speed of the
pump
Cascade
Control
FIC
PIC
FT
FE
FV
PT
Common Around
Distillation Columns Where
There Are Slow Loops
Many Controllers
Interact but some
Controller
Interaction
configurations Interfere with each other

I.e.
the control of reflux flow interacts
with the column bottom level control
but two flow controllers on the same
pipe will interfere with each other
(they duel for control of the flow)
Duelling Control
?
Controller
Interaction
LT
LIC
FIC
FT
FE
LV
Duelling Control
?
Controller
Interaction
LIC
LT
FIC
FT
LV
FE
Duelling Control
?
Controller
Interaction
SP= 75 psig
PIC
100 psig
Compressed
Air
SP= 35 psig
PIC
PT
PV
PT
PV
User 1
User 2
User 3
User 1
User 2
User 3
P&ID Cookbook
-By Equipment
P&ID Cookbook
- Pumps
PI
PRV
PI
HS
I
HS
Pump - Min Flow Bypass

RO
PI
LT
PI
LIC
LV
HS
I
HS
Reflux Tanks
Set@
Vent to Safe Locn
PI
From Condenser
From Pump
HLL = 4-6
NLL = 3-6
LLL = 2-0
LLLL = 2-0
TI
LSLL
LIT
LAHL
LIC
TO
LV
LALL
Pump
S/D
To Pump
Compressors - Centrifugal
For our purposes treat controls as a black box

But... Provide an input control signal (cascade)
Remember cooling water reqd (lube system...)
CWS
Control
From ?
CWR
SIC
By Vendor
By Owner
Columns
Composition control
Pressure control
Put a control
scheme to
ensure
Feed rate is
constant or is
slowly
changing
Level control
Level control
Composition
control
Treat the
top and bottom
independently
of each other
Columns Bottoms
Put level control on bottoms outflow

when
outflow rate > 10 x boil up rate

Put level control on Steam control
boilup rate > 10 x outflow rate

otherwise either scheme okay
FIC
FT
HHLL
LIT
5 bar
Stm
HLL
NLL
LLL
LLLL
TE
LAHL
LIC
TIC
Low
P Cond
TE
Columns Overhead
TIC
PT
PIC
CWS
FV
CWR
Set@
FIC
PV
PI
RO
FT
HLL = 4-6
NLL = 3-6
LLL = 2-0
LLLL = 2-0
TI
LSLL
LIT
LAHL
LIC
PI
PI
LALL
Pump
S/D
LV
HS
I
HS
Column Control
If a flow rate dominates use it to control

the level
Column Overhead Control - Scheme 1

when the draw rate is 10 x > reflux rate
Manipulate Distillate draw rate to control

Reflux level
Manipulate reflux rate to control Column
Composition
Column Control
Column Overhead Control - Scheme 2

when the reflux rate is 10 x > draw
rate
Manipulate Distillate draw rate to

Manipulate Column Composition
Manipulate reflux rate to control control
Reflux Drum level
Tanks
- Storage
PRV
Temperature
Control
May Be
Required
-does material
freeze / boil?
LAHH
LSHH
LY
LSHH
TI
LI
LSLL
LAHL
LIT
LV
Workshop
Draw the level control that should go on a

storage tank
Provide a different control scheme for the
reactor / condenser / flasher P&ID
Hand this in at the end of class...
draw it
explain how your scheme works and responds to
upsets
explain the pros/cons of your scheme
using a BFD, including the syngas process,

show how pressure control can be done
END
Tanks - Process Surge
PSV
Consider
Pressure
Control
LT
LIC
LV
Heat Exchangers Condenser

Vent to Safe Locn
TV
TIC
TV on condenser outlet
to prevent c/w flashing
inside condenser during
turndown
CWS
TAHL
TE

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INSTRUMENTATION

What groups would you create?

Ground rules for additional

Send non-useful gases (Gas_purge 200 kg/hr,

Send Fusil_oil (19 kg/hr) to waste treatment

Ground rules for additional

Show product storage tanks sending material to

Ground rules for additional

Ground rules for additional

Now Back to our regularly

ESTIMATOR - To Size The Pumps We

To Produce A Viable Control Scheme in a

To understand why these control schemes

Set Point Often not shown

Recording Indicating blind

Recording Indicating Blind

Instrument Society Of America (ISA)

ISA Typical Letter Combinations.xls

See the document P&ID Symbols and

Measured Variable can be slow to

But. Its all RELATIVE !!

Purpose: Ensure steady material flow rate

Smooth feed to columns

Mount FE upstream in vapour systems to minimize pressure/density

Set one flow

Similar to Level (control of material

Control Upstream | Control Downstream

Need to control vessel pressure

Need to downstream (header or

Liquid Pressure Control

Liquid Pressure Control

Normally control the flow of one fluid

Liquid / Liquid - control on cooling media

Liquid / Liquid - control on process

Steam Pressure Control

Condensate Level Control

Youre driving / steering the car

Variable Speed Drive

configurations Interfere with each other

Pump - Min Flow Bypass

Vent to Safe Locn

For our purposes treat controls as a black box

Put level control on bottoms outflow

outflow rate > 10 x boil up rate

boilup rate > 10 x outflow rate

If a flow rate dominates use it to control

Column Overhead Control - Scheme 1

Manipulate Distillate draw rate to control

Column Overhead Control - Scheme 2

Manipulate Distillate draw rate to

Draw the level control that should go on a

Hand this in at the end of class...

using a BFD, including the syngas process,

Heat Exchangers Condenser

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