Introduction to Manufacturing and Processing Technology in Food - PDF

Introduction to Manufacturing and Processing Technology in Food FOOD ENGINEERING DESIGN AND ECONOMICS GENERAL CONSIDERATIONS IN PLANT DESIGN  Some GENERAL CONSIDERATIONS IN A PLANT DESIGN 1. Plant location 2. Plant layout 3. Plant operation and control 4. Utilities 5. Struc...

Introduction to Manufacturing and Processing Technology in Food FOOD ENGINEERING DESIGN AND ECONOMICS GENERAL CONSIDERATIONS IN PLANT DESIGN  Some GENERAL CONSIDERATIONS IN A PLANT DESIGN 1. Plant location 2. Plant layout 3. Plant operation and control 4. Utilities 5. Structural design 6. Storage 7. Waste disposal Operations in Manufacturing Plants PROCESS FLOW DIAGRAMS PIPING & INSTRUMENTATION DIAGRAMS Process Flow / Block Flow diagrams  A process flow or block flow diagram is the original diagram used during the concept design of the plant. It is a simple diagram showing inputs and outputs and “black boxes” as the process step  For example a process: A C Final Mixer Filling Product B 5 Water  6 After the original process concept has been approved using a Process Flow Diagram (PFD). The next stage of design can begin. During this stage of design a Piping & Instrumentation Diagram (P&ID) is drawn. The P&ID uses symbols to explain the process. Introduction It does not show the physical location of - P&ID equipment but simply process order and equipment type. The different types of equipment used in the process are identified by a unique symbol. This makes the P&ID easy to follow and understand.  7 The P&ID’s are detailed drawings of the plant equipment and the links between equipment, systems and utilities A number of different process steps Introduction are normally needed to make a Food product. This means that different - P&ID types of equipment may be used to make the final product. The different types of equipment and reactors can be located in different parts of the manufacturing plant.  8 Introduction - P&ID A major responsibility for the A Piping & Instrumentation Diagram technician is to make the product (P&ID), is frequently used to show and correctly. explain the steps and equipment needed manufacturing process. P&ID’s provide an accurate and quick method of understanding all the steps This means monitoring and controlling the needed to make a final product. processing steps needed to make the product. The technician therefore needs to know the individual steps involved in making a product and the correct equipment to use for each step.   A very important aspect of the P&ID is the Title Block.  The Title Block gives information such as:  The name of the company that has drawn the P&ID, normally the people who have designed the plant  The name of the client for whom the P&ID has been drawn Title Block  The title of the drawing  A specific drawing reference number  Project reference number 9  10 It also gives details as to the Revision number of the drawing. Every time the drawing is updated it is given a new revision number that is dated, signed by the draughtsman, and signed by the engineer. At the same time, the drawing status is Title Block entered. “As Built” means the P&ID reflects the final built plant. All of the above make sure that the P&ID is used for the right purpose and all changes are authorised. Symbols  We will have a look at the P&ID symbols that are used on the ITT drawings  The following slides will give a background as to the various types of equipment that you might come across in making products and the types of symbols used for this equipment.  All equipment on a P&ID is given what is called a tag number. That is a number that is unique to that bit of equipment. It makes it quickly identifiable. The number is usually specific to the area in the plant. 11 Reactors  A reactor can be represented as a Pressure Vessel in a P&ID with the identification name and tag added to the block to identify the equipment.  Reactors can also have a surrounding external jacket which can have both heating and cooling capabilities.  Stirring mechanisms are also commonly found in reactor vessels.  All these components can be represented by P&ID symbols. 12 Reactor P&ID Symbols 13  14 Measuring ALL PROCESSES NEED THIS IS DONE USING THERE ARE A Gauges CAREFUL GAUGES LOCATED NUMBER OF MONITORING OF AT CRITICAL DIFFERENT TYPES OF PARAMETERS SUCH LOCATIONS GAUGES WHICH ARE AS TEMPERATURE, THROUGHOUT THE REPRESENTED PRESSURE AND FLOW MANUFACTURING DIFFERENTLY ON RATES. PROCESS AND P&ID’S. TRANSFER EQUIPMENT. A GAUGE IS REPRESENTED BY A CIRCLE WITH A SOLID LINE CONNECTING IT TO THE PIPE-WORK OR EQUIPMENT.  15 There is a simple lettering system used to indicate what a gauge is measuring. A temperature gauge has the letter T in the circle, flow rate has an F, pressure has a P and level control has an L. Types of Some types of gauges do not have automatic result readouts and must be checked Measuring manually. These gauges are classified as indicating only and have the letter I after the Gauges gauge type. Other gauges may be recording the results automatically by printing them on a printout or sending them to a control system. These are indicated by the letter T in the gauge symbol, after the letter identifying the parameters being measured. The “T” means the parameter is being transmitted. Measuring Gauge Symbols 16  17 Control Gauges GAUGES CAN ALSO THESE TYPES OF ON A P&ID CONTROL HELP TO CONTROL A GAUGES ARE VALVES ARE PROCESS. FOR EXAMPLE CLASSIFIED AS CONNECTED TO THE THE READINGS ON A “CONTROL GAUGES” EQUIPMENT THAT THEY GAUGE CAN BE USED BECAUSE THE ARE CONTROLLING BY TO DECIDE WHETHER A INFORMATION DOTTED OR CROSS- VALVE SHOULD BE OBTAINED BY THEM IS HATCHED LINES. OPENED OR CLOSED USED TO CONTROL DURING A PROCESS. SPECIFIC TASKS DURING GAUGE READINGS CAN THE PROCESS. ALSO BE USED TO TURN ON PUMPS OR OTHER TYPES OF EQUIPMENT. Temperature Control Gauge 18   Pipe-work is used to transfer materials both into and out of equipment and to different locations in the plant.  The P&ID symbols for the different types of pipe-work are important to recognize  For example Product pipe-work is generally shown as a straight line, whereas Clean In Place (CIP) solution is shown as a dot/dash line (·-·) Pipe-Work  The direction of the liquid flow in the pipe- work is indicated by an arrow on the lines and a flagged arrow at the edge of the pages.  A typical reactor could have two pipes, one for the incoming starting material and the second could be used to transport the product after the process has been completed. 19  Pipe-Work  Sometimes pipes will need to be joined together to make a longer connection before a material transfer can occur. Pipes are joined together using a flanged joint.  Pipe-work that is not in use, may be blocked off at the end, to stop any liquid flowing or leaking.  In a process plant it is common for pipes to cross over each other with no physical connection between them. Similarly on a P&ID lines often cross over each other. This can be shown by putting a break in the line meaning the lines that cross each other are not in physical contact. 20 Pipe Crossover 21 Valves 22  Valves play a crucial role in controlling processes. Manual and automatic valves are the two main types found in a plant. Incorrect operation of these valves could not only cause serious damage to the product and equipment but could also create an unsafe working environment.  Manual valves require the operator’s direct intervention.  Automatic valves require no manual intervention.  There are many different types of manual and automatic types each with a different P&ID symbol Manual Valve 23  24 Valves  Manual valves are used throughout the plant to stop flow or change the direction of flow. The transfer of material into different processing equipment such as a tank /vessel /reactor can also be controlled by valves.  Automatic valves can also be controlled by the process conditions. This could involve only allowing material to transfer at a certain temperature or pressure. The valve is controlled by the sensor gauges and is programmed to open and shut at certain values. Automatic Valve 25  26 Pumps & Heat Exchangers Sometimes during a process, material may have to be Materials in a During a process heated or cooled. There are a number reactor may also be materials are of different pump For example the heated or cooled transferred to types used within ingredients in a vessel / by pumping fluids different vessels and reactor may be the plant. Each has and steam through process equipment required to reach a a different P&ID the jacket through pipe-work certain temperature symbol. before the process will surrounding a using pumps. start. A heat exchanger reactor. is normally used for heating or cooling operations in a plant. Heating a Reactor 27  28 Process Control Where a delay or slow response Alarms are used to alert could lead to a hazardous operators to serious and situation the control instrument potentially hazardous deviations will most likely be fitted with a trip in process conditions. Key system to take action instruments are fitted with automatically to avert the audible and visible alarms on hazard. This could mean shutting control panels. down pumps and closing valves.  29 Temperature Control Reactor temperatures will normally be controlled by regulating the flow of the If a high temperature is heating or cooling fluid that recorded the temperature flows through the reactor sensor could activate a valve jacket. There will be a and circulate coolant liquid to temperature sensor in the decrease the temperature in reactor measuring the the process temperature which will regulate the flow of the heating or cooling liquid.  30 Summary Layout of a P&ID Process Measuring and Pipe-work and How to read and equipment control gauge valve symbols interpret basic symbols symbols Piping & Instrumentation Diagrams