01/11/2020

INSTRUMENTASI DAN
KESELAMATAN PROSES
PERANCANGAN PABRIK KIMIA
Dr. Endah Retno Dyartanti

Daftar Isi

a. P & I Diagram (Sinnott, Ch 5.1 dan 5.2)

b. Kontrol dan Instrumentasi (Sinnott, Ch 5.7, 5.8)
c. Keselamatan proses (Sinnott, Ch 5.9; Turton, Ch
24.6)

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DIAGRAM ALIR

Macam-macam Diagram Alir

1. Diagram alir sederhana
2. Diagram alir Blok :
Proses dalam pengolahan digambarkan sebagai
kotak, umumnya kumpulan beberapa alat satu
kotak
a. Kualitatif : dengan kondisi operasi
b. Kuantitatif : macam dan jumlah massa aliran 3

3. Process Engineering Flow Diagram

• Diagram alir yang memuat segala sesuatu mengenai
prosesnya, kondisi operasi, aliran massa, beban panas
alat-alat instrumentasi dan kontrol. PEFD dapat berdiri
sendiri dan menerangkan dirinya sendiri. Alat-alat
umumnya digambarkan menurut bentuknya. Beberapa
alat digambarkan dengan kode-kode, mis, HE, pompa,
kompressor dll.

4. Simplified Flow Diagram

• PEFD yang disederhanakan, untuk prarancangan tingkat
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pendahuluan

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5. Engineering Flow Diagram

• Digunakan untuk keperluan konstruksi , pada detail
desain oleh Project Engineer. Flow diagram ini
merupakan sumber informasi dan dipakai oleh semua
bagian dalam kelompok desainer. Semua informasi
tercantum di flow diagram.
6. Plant Lay out
• Gambar datar keletakan alat
7. Plant Elevation
• Gambar keletakan tinggi alat 5

8. Process Flow Diagram

• Digunakan oleh process engineer dalam pekerjaan dan
mempelajari proses. Kondisi operasi dan kecepatan aliran
dicantumkan dengan aliran proses utama digaris tebal.
Arus-arus yang penting diberi keterangan suhu tekanan
dan kecepatan aliran. Data-data perancangan yang
penting ditulis (beban panas HE, informasi vessel dll). Alat-
alat standar digambar simbolnya (pompa, HE). Valves,
arus utilitas dan arus lain yang kurang penting tidak perlu
digambar. Hanya instrument kontrol yang penting yang
perlu digambar. 6

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9. Piping and Instrument Diagram

• Diagram Pemipaan dan instrumentasi (P&ID)
menunjukkan peralatan proses, pemipaan, pompa-
pompa, instrumentasi, valves dan fitting. Gambar ini
harus mencantumkan hal berikut :
1. Semua alat yang digunakan
2. Line number
3. Semua valve
4. Fitting pipa
5. Pompa
6. Loop kontrol dan instrumentasi 7

FLOW DIAGRAM

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Outline

• Flow Diagrams
– Block Flow Diagrams (BFD)
– Process Flow Diagrams (PFD)
– Piping and Instrument Diagrams (P&ID)

• Other common diagrams

• 3-D plant layout diagrams

3 Levels of Diagram
• Block Flow Diagram (BFD)

• Process Flow Diagram (PFD)

• Piping and Instrumentation Diagram (P&ID) – often

referred to as Mechanical Flow Diagram

Complexity Conceptual
increases understanding
increases
As chemical engineers, we are most familiar
with BFD and PFD.
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The Block Flow Diagram (BFD)

• BFD shows overall processing picture of a

chemical complex
– Flow of raw materials and products may be
included on a BFD
– BFD is a superficial view of facility – Ch E
information is missing

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Block Flow Diagrams (BFD)

• Emphasis not on details regarding blocks; focus

on flow of streams through process.
• Conventions:
– Operations shown by blocks
– Major flow lines shown with arrows giving flow
direction
– Flow goes from left to right whenever possible
– Light streams toward top, heavy streams toward
bottom
– Critical information unique to the process
supplied (i.e., reaction stoichiometry, conversion)
– Avoid crossing lines; horizontal continuous,
vertical broken.
– Simplified material balance (overall)
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Definitions of BFD
• Block Flow Process Diagram
–Figure 1.1
–Similar to sketches in material and energy balances

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The Block Flow Process Diagram

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The Block Flow Plant Diagram

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The Process Flow Diagram (PFD)

• PFD shows all process engineering

information
• Typical conventions (vary by company):
– All major equipment represented, uniquely numbered
– All process flow streams shown and uniquely
numbered, with description of thermodynamic
conditions and composition (often in an
accompanying table)
– All utility streams supplied to major process
equipment shown
– Basic control loops, illustrating control strategy
during normal operation 16

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The Process Flow Diagram (cont’d)

– The topology of the process – showing the

connectivity of all the streams and the equipment
• Example for toluene HDA – Figures 1.3 and 1.5
• Tables 1.2 and 1.4 – list information that should
be on the PFD but cannot fit
• Use appropriate conventions – consistency is
important in communication of process information
• ex. Table 1.2

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Process Flow Diagram (cont’d)

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Process Flow Diagram (cont’d)

Figure C.1 Process Flow Diagram for the Production of Allyl

Chloride (Reaction Section) 19

Equipment Numbering

• XX-YZZ A/B/>
– XX represents a 1- or 2-letter designation for
the equipment (P = pump)
– Y is the 1 or 2 digit unit number (1-99)
– ZZ designates equipment number of unit (1-
99)
– A/B/> represents presence of spare
equipment

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Equipment Numbering (cont’d)

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Equipment Numbering (cont’d)

• T-905 is the 5th tower in unit nine hundred

• P-301 A/B is the 1st Pump in unit three hundred

plus a spare

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Equipment Numbering (cont’d)

• Use unambiguous letters for new equipment

– Ex. Turbine use Tb or J not T (used for tower)
– Replace old vessel V-302 with a new one of different
design - use V-319 (e.g.) not V-302 – since it may be
confused with original V-302

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Stream Numbering & Drawing

• Number streams left to right when possible

• Horizontal lines are dominant

ye n n
s o o
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Stream Numbering & Drawing (cont’d)

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Stream Numbering & Drawing (cont’d)

• Add arrows for

– change in direction
– inlet of equipment

• Utility streams
– use convention in Table 1.3
– lps, cw, fg, etc.

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Stream Information

• Since diagrams are small, not much stream

information can be included
• Include important data – around reactors and towers,
etc.
– Flags are used – see toluene HDA diagram
– Full stream data, as indicated in Table 1.4, are
included in a separate flow summary table – see
Table 1.5

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Stream Numbering & Drawing (cont’d)

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Stream Information - Flags

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Stream Drawing

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Stream Drawing

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The Process Flow Diagram (cont’d)

Table 1.4: Information in a
Flow Summary

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Basic Control Loops

• Often the basic control loops (those involving
maintaining material balance and reactor controls) are
included on the PFD; instrumentation and other control
loops are not shown

• The final control element in nearly all chemical

process control loops is a valve.

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Basic Control Loops

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Basic Instrumentation Symbols

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INSTRUMENTASI
DAN PENGENDALIAN

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Pengertian

• Instrumentasi adalah alat yang dipakai di suatu proses

kontrol untuk mengatur jalannya proses agar diperoleh hasil
sesuai dengan yang diharapkan.
• Tujuan pengendalian tersebut adalah agar kondisi proses di
pabrik mencapai tingkat kesalahan (error) yang paling
minimum sehingga produk dapat dihasilkan secara optimal
(Perry, 1999)

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• Fungsi instrumentasi adalah sebagai pengontrol,

penunjuk (indicator), pencatat (recorder), dan pemberi
tanda bahaya (alarm).

• Instrumentasi bekerja dengan tenaga mekanik atau

tenaga listrik dan pengontrolannya dapat dilakukan secara
manual atau otomatis.

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Berdasar Proses kerjanya

• Manual (indikator): alat pengamatan yang dipasang pada

alat proses dimana kondisinya tidak memerlukan ketelitian.
Peralatan proses hanya dipasang penunjuk/pencatat

indicator/recorder
• Otomatis: controller dipasang pada proses yang memerlukan
ketelitian kondisinya. Perubahan kondisi proses sedikit saja
akan mempengaruhi produk baik kualitas maupun kuantitas

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Tujuan

• Menjaga keamanan dan keselamatan kerja

• Memenuhi spesifikasi produk yang diinginkan
• Menjaga peralatan proses dapat berfungsi sesuai yang
diinginkan dalam desain
• Menjaga agar operasi pabrik tetap ekonomis.
• Memenuhi persyaratan keselamatan dan efisiensi kerja
serta lingkungan
• Mempermudah pengoperasian alat

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Bagian Instrumentasi
 Indikator
Untuk mengetahui secara langsung kondisi operasi suatu
titik tertentu dari suatu peralatan. Misal : level indicator
 Controller
Untuk mengendalikan suatu kondisi operasi dalam aliran
proses pada harga yang telah ditentukan. Misal : Flow
controller mengendalikan laju alir fluida didalam pipa,
Temperature controller mengendalikan suhu pada proses
 Recorder
Untuk menunjukkan dan mencatat secara kontinu kondisi
operasi pada harga yang telah ditentukan.
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 Sensor (Transducer)
Berfungsi untuk kontak langsung dengan objek yang diukur
untuk mengubah besaran fisik menjadi sinyal (besaran)
listrik
 Sensor Error Detector
Berfungsi mengukur kesalahan yang terjadi Antara keluaran
actual dengan yang diinginkan
 Penggerak daya (ajuator)
Mengendalikan aliran energy ke sistem yang dikendalikan,
sebagai elemen pengendali akhir. Elemen ini harus mampu
menggerakkan beban ke suatu harga yang diinginkan.

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Faktor-faktor yang diperlukan dalam pemilihan

instrumentasi adalah :

 Jenis instrumentasi
 Range yang diperlukan untuk pengukuran
 Ketelitian yang diperlukan
 Bahan konstruksi serta pengaruh pemasangan pada kondisi
proses
 Mudah dalam pengoperasian
 Mudah perawatan dan perbaikan : reability dan
maintainability
 Faktor ekonomi

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Berdasarkan instrumen sendiri ada beberapa

faktor pemilihannya
 Kegunaan instrumen yang sesuai dengan kondisi
proses yang akan diamati dan dikendalikan
 Kriteria instrumen:
o Reability: sedikit gangguan, kerusakan dan
berumur panjang/awet
o Maintainability: Perawatan dan pemeliharaan dapat
dilakukan dengan mudah dan cepat, serta berbiaya
tidak mahal

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Macam Instrumentasi

 Secara umum Indikator atau alat control di

gunakan untuk mengetahui atau mengontrol:
Suhu, Tekanan, Laju alir maupun ketinggian Fluida
 Indikator hanya sebagai pengukur, tanpa elemen
pengontrol/ control valve tidak ada hanya sensing
elemen dan penunjuk kondisi proses

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Alat kontrol

 Sensing elemen: bagian alat untuk merasakan kondisi proses

yang berlangsung
 Controller : bagian alat untuk mengembalikan kondisi proses
yang keluar dari setting awal kepada kondisi setting yang semula
 Control valve: bagian alat berupa valve yang dapat
membesarkan/mengecilkan aliran fluida sehingga
mengembalikan kondisi proses kedalam keadaan yang
diharapkan

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Control

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3 Elemen alat control: Sensor, Controller dan Control Valve

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Basic Instrumentation Symbols

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Basic Instrumentation Symbols

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Equipment Information

• Equipment are identified by number and a label

(name) positioned above the equipment on the
PFD

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Equipment Information

• Basic data such as size and key data are

included in a separate table (Equipment
Summary Table) Table 1.7 (and Table 1.6) in
TBWS

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Equipment Information

A Section of Table 1.7: Equipment Summary

Vessel V-101 V-102
Temperature (ºC) 55 38
Pressure (bar) 2.0 24
Orientation Horizontal Vertical
MOC CS CS
Size
Height/Length (m) 5.9 3.5
Diameter (m) 1.9 1.1
Internals s.p. (splash plate)

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PFD Summary

• PFD, Equipment Summary Table, and Flow

Summary Table represent a complete PFD
• This information is sufficient to permit a one to
complete a preliminary estimation of capital
investment and cost of manufacture.

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Piping & Instrument Diagram

• Piping & Instrument Diagram (P&ID) –
Construction Bible

• Contains: plant construction information (piping,

process, instrumentation)

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Piping & Instrument Diagram

• P&ID info explained in Tables 1.8 and 1.9

• Instrumentation conventions shown in

Fig. 1.10

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Piping & Instrumentation Diagram (P&ID)

• support documents of the PFD used for

planning for plant construction and
maintaining the plant thereafter
• Each PFD requires many P&IDs to
provide the necessary data
• Used as a checklist at the final walk-through
prior to start up to assure each detail has
been attended to

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Piping & Instrumentation Diagram (P&ID)

• Use by/to
– MEs and CEs to build/install equipment
– Instrument engineers to specify/install/check
control systems
– Piping engineers to develop plant layout and
elevation drawings
– Project engineers to develop plant and
construction schedules

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The P&ID (cont’d)

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Look at V-102 on P&ID

• V-102 contains an LE (Level Element)
• LE senses liquid level in separator and adjusts
flow rate leaving, by opening or closing a
valve, depending on liquid level
• Together, the LE and valve represent a
• feedback control loop

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Valve Symbols

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More Valve Symbols

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More Valve Symbols

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Other Common Diagrams

• Plot Plans – plan or map drawn looking down

on plant (drawn to scale with all major
equipment identified)
• Foundation drawings

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Other Common Diagrams

• Elevation Diagrams – show view from side

and give information about equipments
distance from ground
• Electrical drawings

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Plot Plan

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Plot Plan

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Elevation Diagram

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Elevation Drawing

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Foundation Drawing

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Electrical Drawing

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Other Common Diagrams (cont’d)

• Piping Isometrics – show piping in 3-
dimensions

• Vessel Sketches – show key dimensions of

equipment and locations of inlet and outlet
nozzles etc.

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Scale Models and Virtual Plants

• 25 yr ago physical models used for review

• Now virtual or electronic models are

generated using software (3D plant diagrams)

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Scale Models and Virtual Plants

• Purpose of Models – catch errors such as

– Piping clashes

– Misaligned piping

– Equipment not easily accessed

– Sample points not easily reached by operators

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3-D Plant Dia

Diagrams
rams

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