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How do you use process flow diagrams for FEED to support decision making and problem solving?

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Process flow diagrams (PFDs) are essential tools for front end engineering design (FEED) of industrial plants and processes. They show the main equipment, piping, and streams of a process system, as well as the operating conditions and specifications. PFDs help you to visualize, communicate, and optimize your process design, as well as to support decision making and problem solving throughout the FEED phase. In this article, you will learn how to use PFDs for FEED effectively and efficiently.

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1 Benefits of PFDs for FEED

Process Flow Diagrams (PFDs) offer several advantages for Front End Engineering Design (FEED). These diagrams provide a clear and concise overview of the process system, enabling the identification and evaluation of design options, requirements, and constraints. PFDs also facilitate collaboration between different engineering disciplines, stakeholders, and contractors involved in the FEED project. Additionally, they enable the estimation and optimization of process performance, efficiency, and safety by showing key parameters like flow rates, pressures, temperatures, compositions, and heat and mass balances. Furthermore, PFDs support the development and validation of process simulation models for testing and refining design assumptions. Finally, they form the basis for the preparation of detailed engineering design documents such as P&IDs, equipment lists, and datasheets.

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James Breaux, PE

Senior Project Director
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PFDs also form the basis for Project Control. The majority of the WBS (Work Breakdown Structure) and CBS (Cost Breakdown Structure) are depicted in the PFDs, which, when augmented by infrastructure, geographical, and environmental factors, can significantly improve the quality of the estimate, understanding of the schedule, and specificity of the PEP (Project Execution Plan).

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Marc Young, PE

Licensed Consulting Engineer
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Typically, through Preliminary Engineering and into FEED the PFDs are the governing documents. Once they are agreed upon they should be frozen and only changed through a rigorous Management of Change Review process. They are the starting point and thus the foundation of the Piping and Instrumentation Diagrams (P&IDs), Equipment datasheets and should be used for the preliminary Process Safety analysis such as Hazard Identification and a Preliminary HAZOP.

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2 Steps to create PFDs for FEED

Creating effective and accurate PFDs for FEED requires several steps. First, you must define the process scope and objectives, based on the client's specifications, industry standards, and regulatory requirements. Then, collect and review the relevant data and information to develop and compare preliminary process alternatives. Afterwards, select the optimal process alternative based on technical, economic, environmental, and social criteria. After that, build and run the process simulation model to calculate and verify the process parameters and balances. Additionally, draw and label the PFDs with a software tool such as AutoCAD or Visio to show the equipment, piping, streams of the process system, operating conditions, and specifications. Finally, review and revise the PFDs with feedback from engineering team members, clients, or third-party reviewers. Sensitivity analysis, risk assessment, or value engineering can also be used to optimize and improve the process design.

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Marc Young, PE

Licensed Consulting Engineer
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Development of PFDs should have begun in the initial stages of Preliminary Engineering progressing from an initial block diagram that was built from Unit Operations needed to satisfy the objectives of the project as outlined by the client and their expressed needs. Based on the block diagram a heat and material balance can be built often using a process simulator for each scenario that the process is expected to have to be able to serve.

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3 Best practices for PFDs for FEED

To ensure the quality and consistency of your PFDs for FEED, you can implement a range of best practices. This includes using consistent and clear naming and numbering systems for equipment, piping, and streams. Additionally, you should include all relevant information and data on the PFDs, such as flow rates, pressures, temperatures, compositions, heat duties, power requirements, and control loops. Furthermore, it is important to avoid cluttering and overlapping the PFDs by using appropriate scales, layouts, and orientations. Moreover, you should follow industry standards and guidelines for PFDs such as ISO 10628 or ANSI/ISA-5.1. Finally, it is important to document and update the PFDs regularly by using version control, revision history, and approval stamps as well as checklists, quality assurance, and quality control procedures to verify and validate the PFDs.

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4 Examples of PFDs for FEED

To demonstrate how PFDs are used for FEED, here are some examples of PFDs for different types of industrial plants and processes. For instance, a natural gas processing plant may have a PFD which outlines the main process units, such as gas dehydration, acid gas removal, natural gas liquids recovery, and sulfur recovery. It also includes the flow rates, pressures, temperatures, compositions, and heat duties of the process streams. Similarly, a biodiesel production plant has a PFD which displays the main process units, such as transesterification, glycerol separation, methanol recovery, and biodiesel purification. This PFD also reveals the flow rates, pressures, temperatures, compositions, and power requirements of the process streams. Lastly, a water treatment plant has a PFD that illustrates the main process units like coagulation, flocculation, sedimentation, filtration, disinfection, and distribution. This PFD also indicates the flow rates, pressures, temperatures, compositions, and control loops of the process streams.

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Marc Young, PE

Licensed Consulting Engineer
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A heat and material balance can be built often using a process simulator for each scenario that is expected. Some scenarios may be considered mutually exclusive (like Early Life and Late Life) and may require different PFDs and identifications of changes that may be needed during the life of the project if the client wants to understand the full lifecycle and costs for the project. Multiple PFDs based on several heat and material balances may need to be developed so that operating ranges of equipment needed to satisfy operational needs like turndown during initial, midlife and later life, before the equipment specification and datasheets are developed. If one design not then deferred costs to handle a later design in lieu of single design.

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5 Challenges of PFDs for FEED

PFDs can present challenges for FEED, such as the need for a lot of data and information which may not be readily available. Additionally, trade-offs and compromises may affect the process design and performance, requiring a balance between technical, economic, environmental, and social aspects. Furthermore, PFDs are subject to changes and revisions which may alter the project scope, schedule, and budget. Therefore, it is important to update PFDs according to new data, feedback from the engineering team, client, and third-party reviewers, or changes in the design criteria or scenarios.

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Marc Young, PE

Licensed Consulting Engineer
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Once the PFDs are developed, material selection is critical and the PFDs are key start for diagrams which identify based on the fluid properties (Temperature, Pressure and Composition) the key type of materials needed for piping and equipment. This will also identify insulation for energy conservation and personnel protection. This information will be key to development of the P&IDs. Key control loops and isolation points will be identified on the PFD used in conjunction with the various heat and material balances to help instrument engineers determine the requirements for the Instrument Loops needed for the P&IDs and to identify key specification breaks and potential relief requirements. Key to consider is a degrees of freedom analysis.

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How do you use process flow diagrams for FEED to support decision making and problem solving?

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1 Benefits of PFDs for FEED

2 Steps to create PFDs for FEED

3 Best practices for PFDs for FEED

4 Examples of PFDs for FEED

5 Challenges of PFDs for FEED

Front End Engineering Design (FEED)

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