PIPING & INSTRUMENTATION DIAGRAM (P&ID)

PROCESS CONTROL FOR DESIGN

PROJECT

Profesor Madya Ts Dr Noor Asma Fazli

bin Abdul Samad

Faculty of Chemical & Process Engineering Technology

Universiti Malaysia Pahang Al-Sultan Abdullah

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 Course Instructor
CEV663

◼ Noor Asma Fazli Bin Abdul Samad

◼ Academic Qualifications:

◼ Postdoctoral (Properties Prediction), DTU

◼ [Link] (Process Modelling and Control), DTU

◼ M. Eng. (Process Control), UTM

P & ID

◼ [Link]. (Chemical Engineering)

◼ Contact:

◼ Email: asmafazli@[Link]

◼ Room: A3-05

◼ Phone No: 013-2881807 Office No: 09-5492919

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 Module Overview
CEV663

◼ Process Flow Diagram

➢ Process Description, Operating Conditions, Variables Involved

◼ Elements of Control System

➢ Variables Classification, Controller Strategies
P & ID

◼ Piping & Instrumentation Diagrams

➢ Identification Format and Symbols

◼ Case Studies:
➢ Examples of PFD, Control Configuration, P&ID

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 Course Outcomes
CEV663

◼ To identify controller objective from Process Flow Diagram

◼ To identify CV, MV and DV as well as basic control strategy for

equipment involved in PFD
P & ID

◼ To construct configuration control based on standard format and

symbols

◼ To develop complete P&ID for plant design case study

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 CEV663

Process Flow Diagram (PFD)

P & ID

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 CEV663
Process Flow Diagram (PFD)

◼ Process Flow Diagram (PFD) is a graphical representation that

shows the flow of chemical processes and the equipment involved

◼ Contents:
• Major equipment such as reactors, pumps, compressors,
and heat exchangers.
P & ID

• Process flow lines indicating the movement of materials

(liquids, gases, solids).

• Direction of flow, usually with arrows.

• Material balances showing flow rates and compositions

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 P & ID CEV663

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 CEV663
P & ID Process Description

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 CEV663
Material Balances
Can be obtained from manual calculation or simulation using Aspen,
SuperPro softwares
P & ID

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Objective of Process Control

The primary objective of process control is

to maintain the process at the desired
operating conditions, safely, efficiently,
P & ID

while satisfying environmental, and

product quality requirements.

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 CEV663
Identifying Controller Objectives
Extract information from PFD and Material/Energy Balances
P & ID

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 CEV663
P & ID Example 1: Heater

Question: Identify control objectives for this heater?

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P & ID Example 2: Reactor

Question: Identify control objectives for this reactor?

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 CEV663

Elements of Control System

P & ID

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 CEV663
Elements of Control System

➢ Sensor – Thermocouples,
flow meters, Gas
chromatography
➢ Controller – Receives
information from
P & ID

measuring devices and

decides what action to be
taken
➢ Final control element –
Implement the decision
taken by the controller

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 CEV663 Design Aspects of a Process Control System

First: Develop a good understanding of the

process

◼ Define control objectives:

~> “what operational objective do we want to
P & ID

achieve?”
❑ disturbance rejection (most common)

❑ set-point tracking

❑ process stability

❑ optimisation

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 Second: What variables should we measure and
CEV663

adjust?

◼ Measurement selection
~> which output variable(s) should we measure ?
❑ temperature, pressures, concentrations, flows ?
~> are sensors available ? .. and at what cost ?
P & ID

◼ Manipulated variable selection

~> which input variable(s) do we manipulate?

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 CEV663
Third: What control configuration should we
recommend?
◼ Control configuration selection
❑ Feed back control (most common by far)

❑ Feed forward control

❑ Inferential control

❑ Ratio control

❑ Cascade control
P & ID

◼ Controller design
❑ Result is the control law

❑ Control law is the equation that converts

measured values into adjustments of manipulated
variables

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 CEV663
Control Terminology

◼ Controlled variables - these are the variables which

quantify the performance or quality of the final product,
which are also called output variables.
◼ Manipulated variables - these input variables are adjusted
dynamically to keep the controlled variables at their set-
points.
P & ID

◼ Disturbance variables - these are also called "load"

variables and represent input variables that can cause the
controlled variables to deviate from their respective set
points.

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 CEV663
P & ID Control Variable Selection

Guideline 1.
• All variables that are not self-regulating must be
controlled.

Guideline 2.
• Choose output variables that must be kept within
equipment and operating constraints (e.g.,
temperatures, pressures, and compositions).
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 CEV663 Manipulated Variable Selection

Guideline 1.
• Select inputs that have large effects on controlled
variables.
Guideline 2.
• Choose inputs that rapidly affect the controlled
P & ID

variables.
Guideline 3.
• The manipulated variables should affect the controlled
variables directly rather than indirectly.
Guideline 4.
• Avoid recycling of disturbances.
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 CEV663 Valve Selection for ATO ATC

Guideline 1. Fail-Safe Position

• Use ATO if it's safer to stop flow (e.g., toxic chemicals,
flammable gases).
• Use ATC if it's safer to maintain flow (e.g., cooling
water to prevent overheating)
P & ID

Guideline 2. Process Safety Consideration

• Reactor overpressure? → Valve should open to relieve
pressure → ATC
• Dangerous reactant leak? → Valve should shut to stop
flow → ATO
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 CEV663
P & ID Example 3: Boiler Drum

Question: Based on controller objectives, classify variables based

on CV, MV and DV
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 CEV663
P & ID Example 3: Feedback Control for Boiler Drum

Feedback Control Strategy

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 CEV663 Example 3: Feedforward Control for Boiler
Drum
P & ID

Feedforward Control Strategy

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 CEV663
P & ID Example 4: Reactor

Question: Based on controller objectives, classify variables based

on CV, MV and DV

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 CEV663

Piping and Instrumentation Diagram

(P&ID)
P & ID

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 CEV663
Piping & Instrumentation Diagram (P & ID)
• Detailed engineering drawing that shows the interconnection of
process equipment, piping, and instrumentation used in a process

• The drawing of P & ID follows the standard developed and approved by a

collaboration between the American National Standards Institute (ANSI)
and the Instrumentation, Systems and Automation (ISA) Society.

• The P & ID can be drawn in Microsoft Visio or Auto Cad

P & ID

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 CEV663
P & ID Piping & Instrumentation Diagram (P & ID)

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 CEV663
The Identification Format

▪ Each loop on P&ID used ISA symbols to show

the particular devices that perform certain
functions.
▪ The first letter of tag number is correspond to
the measured process variables.
P & ID

▪ The succeeding letters in the tag number

describe the function of the elements in the
loop such as T for transmit, I for indicate, R
for record, and or C for control.

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 CEV663
P & ID Instrumentation Identification Letters

Table A.1. Fraser (2001). Process Measurement and Control Page 1-31
 Typical Tag Number
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▪ TIC-103 Temperature Indicate Control (loop

number) 103
▪ Where
• TXX-103 identifies the loop by first letter
and number and IC in place of XX identifies
P & ID

the functions by succeeding letter.

• Hyphens are optional

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 CEV663
P & ID Instrument Line Symbols

Table A.1. Fraser (2001). Process Measurement and Control

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 General Instruments Or Functions
CEV663

▪ The ballons, rectangles, hexagons, and

diamonds are used to denote the
instrumentation.
▪ A line through a symbol means it is accessible
to an operator, such as being in a panel in the
control room.
P & ID

▪ No lines means that the instrument is located

in the field and is not accessible to the
operator.
▪ A dashed line means that the device is
inaccessible by virtue of being located within
other equipment, such as behind the panel of
a control room.
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P & ID General Instruments Or Functions

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Example: Mixer
P & ID

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P & ID Example: Mixer

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P & ID Example: Reactive Distillation

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P & ID Example 4: Reactor

Question: Based on CV, MV and DV, draw configuration control for

reactor

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 CEV663

Example of Piping & Instrumentation Diagram

(P & ID)
P & ID

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 CEV663 Summary
◼ Process control involves good understanding
of the process before design and
implementation of the controller.
◼ Need to know:

1. Control objectives (CV)

P & ID

2. Disturbances affecting the process

3. Measurements to make and where

4. Adjustment to make (MV)

5. Appropriate control configuration (i.e.

feedback, feedforward etc)
▪ Identification format for P&ID
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