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PRACTICAL GUIDE TO
DEVELOPING PROCESS
FLOW DIAGRAMS AND
PRELIMINARY ENGINEERING
LINE DIAGRAMS PROCESS
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
CONTENTS
1 INTRODUCTION
2 DESCRIPTION OF METHODOLOGY
3 WORKBOOK
5 REFERENCES
TABLES
1 DESIGN OBJECTIVES
2 OUTPUT FROM EACH STAGE
3 STEP BY STEP APPROACH
4 FUNCTION
5 OPERATION
6 FAILURES
7 STAGE 3 PROMPTS (DATA SHEET)
8 PRELIMINARY MASS BALANCE
9 PRELIMINARY EQUIPMENT LIST
10 POTENTIAL PROBLEMS
11 STAGE 2: DEVELOPMENT OF OPERATING STATES AND
TRANSMISSIONS
12 POTENTIAL PROBLEMS
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
1 DESIGN PROCESS
2 DESIGN PHILOSOPHY.
3 SUMMARY OF METHODOLOGY
4 POSSIBLE OUTCOMES FROM A KEYWORD PROMPT
5 OPERATING STATES
6 OPERATING STATES/TRANSITIONS
7 EXAMPLE: OVERALL BLOCK DIAGRAM
8 EXAMPLE: “PRIMITIVE PFD”
9 EXAMPLE: STAGE 1 “WORKING DIAGRAM”.
10 EXAMPLE: MAIN OPERATING STATES AND TRANSITIONS
11 EXAMPLE: DETAILED PFD (END OF STAGE 1)
12 EXAMPLE: STAGE 2 “WORKING DIAGRAM”
13 EXAMPLE: STAGE 3 “REV 0” ELD
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Figure 1 shows a schematic of the design process from the initial "idea"
through to a completed set of ELDs. There is a well-established
methodology for the development of an initial "idea" through to preliminary
process design ("Professor Douglas" Methodology, Ref.1). In contrast
there appears to be no published approach to guide the development of
the output from preliminary process design into PFDs and subsequently
into ELDs. During this latter development successive layers of detail are
added, the design team increases in size and it becomes more expensive
and it takes more time to do any rework associated with design changes.
In addition, the increase in detail makes it difficult to maintain a "global
view" of the whole process as a single PFD is replaced by a set of detailed
PFDs and ELDs. There is thus a need for a methodology to drive the
development of PFDs and ELDs. This process SHE Guide represents a
considered and documented approach for this step.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Every design project will be different and it is important that the design
process takes a fresh view to meeting objectives and implementing
solutions. It should however be recognized that successful projects will
make use of existing knowledge and understanding and will integrate into
the local culture. There is no point in re-inventing wheels but the skill will
be in applying the right set of wheels.
This stage takes the preliminary process design information and uses a
structured approach to identify all the issues relevant to PFD
development. This allows development of an overall PFD, together with a
process description and operating strategy.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
This stage uses the overall PFD as a basis for notional ELDs, and uses a
structured approach to add the next layer of detail with the emphasis on
what is required, rather than how requirements are to be implemented in
specific hardware.
This stage turns intent into hardware proposals, which are displayed on
"Revision 0" ELDs. These ELDs can then be refined further in an ongoing
process of ELD development and review.
(a) Function: here the focus is on those design objectives that are key
to the normal operation of the plant.
(b) Operation: here the focus is on the various operating states and
transitions (e.g. start-up, shutdown) that the plant must be designed
to handle.
A risk assessment can then be made, and where necessary safeguard actions
proposed and implemented.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
For each guideword the outcomes are recorded and any actions are identified
and noted. There is no need for elaborate records; notes on the notional PFD or
the notional ELD, together with a simple table of Guideword/Comments/Actions
should be sufficient for subsequent reference and to demonstrate that a
systematic method was used.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
A key part of "Operation" in Stage 1 is the definition of the operating states that
the plant must be able to operate at and the transitions between these operating
states that should be possible. Figure 5 shows an example of possible operating
states for a plant together with transitions between them. Some transitions, such
as between regeneration and ready to start-up, will be carried out in a controlled
way; others, such as between normal operation and shutdown, may be initiated
by automatic detection of a fault by the plant shutdown system.
For each operating state it is possible to define the status of each process
stream, service or item of equipment and thus define the actions required during
any given transition (Figure 6). This provides a basis for the systematic
development of operating instructions.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
2.3.2 Interactions
There are a number of global design issues, such as control, measurement and
analysis, that span the whole plant. Furthermore some of these issues, such as
isolation and relief, interact with each other. It is difficult to handle these issues
once the level of detail is such that the design is presented on more than one
PFD or ELD. It is also recognized that much of the detailed development,
particularly on large projects, may be carried out by different teams at different
times. It is therefore proposed to retain and use a single overall PFD in addition
to the more detailed sectional PFDs that might be developed. This overall PFD
should show the main plant items (MPIs) and lines, together with "global" details
such as relief, isolation, control and instrumentation relevant to control of the
whole plant (inventory control in particular). This PFD should suppress as much
"local" detail as possible, such as local instrumentation and control (except
control valves that might isolate vessels from relief devices), and local kick back
lines. This global PFD should be updated as the project progresses.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
This clause describes how to develop a concept into a line diagram with
its associated supporting design information. The description is based
around a whole plant design and the development of a set of line
diagrams but is equally applicable to a single diagram, e.g. in a
modification to an existing plant. The methodology considers the
development in a series of defined stages and uses a set of guidewords to
define the purpose of the design and find acceptable solutions.
Figure 3 shows the stages in the proposed method. This guide starts with
a preliminary proposal and ends with a set of Rev "0" ELDs and
supporting data sheets. Further details of the output and the typical
support information, required at each stage, are given in Table 2.
The approach to be adopted is described in outline in Table 3. It will be
noted that at each stage, the proposed design is critically examined with
respect to function, operation and failure, using a set of guidewords.
These guidewords are described in Tables 4 to 6. A specific set, loosely
based on the information needed for datasheets, is also available for
stage 3 (Table 7).
For a new plant, the overall PFD and section ELDs develop together. For
a modification to an existing plant, these drawings and supporting design
data should already be available. It is however critical to review the overall
PFD and ELDs to ensure that all new potential interactions are fully
considered.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
4.2 Stage 1
The overall objective of this stage is to convert the primitive PFD to a more
detailed PFD using the guidewords under each of the three headings of
function, operation and failure. A copy of the primitive PFD can be used as
a working diagram (e.g. Figure 9) to record decision and comments.
(a) Function
One of the key activities at this stage is to make explicit the main
operating states and the transitions between them. Figure 10 has
been developed for this example. This in turn allows the main
instrumentation and control requirements to be defined and added
to the working diagram. Measurement of pH and organics, together
with observation of the interface are flagged as areas that will need
additional consideration. The need for process water for
commissioning and for washout before maintenance is noted.
(c) Failures
At this stage, the potential problems and their possible solutions are
listed in Table 10:
A detailed PFD (Figure 11) can be produced from the working diagram. This diagram
becomes the starting point for the Stage 2 work.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
4.3 Stage 2
(a) Function
The operating states and transitions that were defined in Stage 1 are
developed in more detail; this can be done most effectively in a tabular
format like Table 11. This table can be used to write outline operating
instructions: by way of example the outline instructions for the transitions
"add caustic" and "add acid effluent" are as follows:
Table 11, together with these outline operating instructions should enable
detailed consideration of the remaining guidewords and allow
development of the working diagram Figure 12.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Additions to the working diagram (Figure 12) are made as required. This
diagram becomes the starting point for the Stage 3 work.
4.4 Stage 3
5 REFERENCES
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries