HOW TO READ A P&ID

FOR
RISK ANALYSIS

Delivering Values to Customers

P&ID IS A PIPING AND

INSTRUMENTATION
DIAGRAM

Delivering Values to Customers

TO IDENTIFY RISK FROM A

SET OF P&ID YOU MUST
HAVE CLEAR
UNDERSTANDING OF
THREE THINGS

Delivering Values to Customers

#1 - UNDERSTAND THE
PROCESS
#2 - UNDERSTAND THE
FAILURES
#3 UNDERSTAND THE
CONSEQUENCE
Delivering Values to Customers

LINES ARE USED FOR

SHOWING PIPING,
EQUIPMENT AND
INSTRUMENT
CONNECTIONS

Delivering Values to Customers

..SO PEOPLE CAN

COMMUNICATE THE
PROCESS SEQUENCE AND
THE RELATIONSHIP OF
DIFFERENT EQUIPMENT

Delivering Values to Customers

EQUIPMENT &
INSTRUMENTATION ARE
CONNECTED BY LINES
HERE ARE SOME COMMON
CONNECTIONS..

Delivering Values to Customers

PIPE
COMMON FAILURE MODES

COLLAPSE

BURST/RAPTURE

CORROSION

EROSSION

Delivering Values to Customers

ELECTRICAL SIGNAL
COMMON FAILURE MODES

OPEN CONNECTION

ELECTRICAL SHORTING

ELECTROMAGNETIC INTERFERENCE

Delivering Values to Customers

PNEUMATIC SIGNAL
COMMON FAILURE MODES

LOSS OF PRESSURE

LEAKAGE

HIGH COMPONENTS FRICTIONLEVEL

Delivering Values to Customers

DATA SIGNAL
COMMON FAILURE MODES

RADIO INTYERFERENCE

LOSS OF SIGNAL

PACKETS LOSS

SIGNAL FILTERING

Delivering Values to Customers

FLEXIBLE PIPE
COMMON FAILURE MODES

COMPRESSIVE FAILURE

TENSILE FAILURE

OVERBENDING

RAPTURE

Delivering Values to Customers

SOME EQUIPMENTS ARE

USED TO ADD OR REDUCE
ENERGY IN THE MATERIAL

Delivering Values to Customers

BLOWER

COMMON FAILURE MODES

FAIL TO OPERATE ON DEMAND

LOSS OF PRESSURE

Delivering Values to Customers

FURNACE

COMMON FAILURE MODES

FLAME OUT

Delivering Values to Customers

PUMP

COMMON FAILURE MODES

FAIL TO OPERATE ON DEMAND

LOSS OF PRESSURE

OVER PRESSURE

Delivering Values to Customers

COMPRESSOR

COMMON FAILURE MODES

FAIL TO START

DAMAGE DUE TO LIQUID

OVER PRESSURE

EXCESSIVE VIBRATION

Delivering Values to Customers

HEAT EXCHANGER

COMMON FAILURE MODES

LEAKAGE

CORROSION

PLUGGED

Delivering Values to Customers

PLATE HEAT EXCHANGER

COMMON FAILURE MODES

LEAKAGE

CORROSION

PLUGGED

Delivering Values to Customers

AERIAL FAN

COMMON FAILURE MODES

LOSS OF AIR CIRCULATION

Delivering Values to Customers

SOME EQUIPMENTS ARE

USED FOR MATERIAL
STORAGE

Delivering Values to Customers

FLOATING STORAGE TANK

COMMON FAILURE MODES

OVERFLOW

LEAKAGE

Delivering Values to Customers

SPHERE TANK

COMMON FAILURE MODES

OVER PRESSURE

Delivering Values to Customers

PRESSURIZED VESSEL

COMMON FAILURE MODES

OVER PRESSURE

Delivering Values to Customers

SOME EQUIPMENTS ARE

USED TO SEPARATE
MATERIAL

Delivering Values to Customers

HORIZONTAL SEPERATOR

COMMON FAILURE MODES

OVER PRESSURE

Delivering Values to Customers

VERTICAL SEPERATOR

COMMON FAILURE MODES

OVER PRESSURE

Delivering Values to Customers

COLUMN

COMMON FAILURE MODES

OVERPRESSURE

CORROSION

PLUGGED

Delivering Values to Customers

TRAY COLUMN

COMMON FAILURE MODES

OVERPRESSURE

CONTAMINATION

Delivering Values to Customers

VALVES ARE USED TO

CONTROL THE FLOW OF
MATERIAL

Delivering Values to Customers

MANUAL VALVE

COMMON FAILURE MODES

EXTERNAL LEAKAGE

INTERNAL LEAKAGE

INADVERTENT POSITION

Delivering Values to Customers

CONTROL VALVE

COMMON FAILURE MODES

FAILTO CLOSE ON DEMAN

FAIL TO OPEN ON DEMAN

SUPRIOUS OPERATION

LEAKAGE

Delivering Values to Customers

SOLENOID VALVE

COMMON FAILURE MODES

STRUCTURAL FAILURE

SEAT LAEAKGE

SEAL LEAKAGE

LOSS OF ACTUATOR

Delivering Values to Customers

MOTOR OPERATED VALVE

COMMON FAILURE MODES

MOTOR FAILURE

FAIL TO STROKE

Delivering Values to Customers

BUTTERFLY VALVE

COMMON FAILURE MODES

FAIL TO CLOSE ON DEMAND

FAIL TO OPEN ON DEMAND

SPRIOUS OPERATION

Delivering Values to Customers

GLOBE VALVE

COMMON FAILURE MODES

FAIL TO CLOSE ON DEMAND

FAIL TO OPEN ON DEMAND

SPRIOUS OPERATION

LEAKAGE

Delivering Values to Customers

GLOBE VALVE

COMMON FAILURE MODES

FAIL TO CLOSE ON DEMAND

FAIL TO OPEN ON DEMAND

SPRIOUS OPERATION

LEAKAGE

Delivering Values to Customers

NEEDLE VALVE

COMMON FAILURE MODES

FAIL TO CLOSE ON DEMAND

FAIL TO OPEN ON DEMAND

SPRIOUS OPERATION

LEAKAGE

Delivering Values to Customers

BALL VALVE

COMMON FAILURE MODES

FAIL TO CLOSE ON DEMAND

FAIL TO OPEN ON DEMAND

SPRIOUS OPERATION

LEAKAGE

Delivering Values to Customers

CHECK VALVE

COMMON FAILURE MODES

LEAKAGE

STUCK AT OPEN POSITION

Delivering Values to Customers

SOME EQUIPMENTS
ARE USED TO RELIEF
PRESSURE IN THE
PROCESS

Delivering Values to Customers

RELIEF VALVE

COMMON FAILURE MODES

FAIL TO OPEN

Delivering Values to Customers

CURVED GAS VENT

COMMON FAILURE MODES

PLUGGED

Delivering Values to Customers

RAPTURE DISC

COMMON FAILURE MODES

CORROSION

Delivering Values to Customers

CONTROL SYSTEM ARE

USED TO MANAGE THE
BEHAVIOUR OF THE
PROCESS

Delivering Values to Customers

PLC

COMMON FAILURE MODES

SOFTWARE ERROR

EXECUTION ERROR

Delivering Values to Customers

SHARED DISPLAY &

CONTROL

COMMON FAILURE MODES

SOFTWARE ERROR

EXECUTION ERROR

Delivering Values to Customers

SENSORS ARE USED TO

MEASURE THE PHSICAL
PROPERTIES OF THE
PROCESS AND CONVERT IT
INTO A SIGNAL

Delivering Values to Customers

FT/PT/LT

COMMON FAILURE MODES

LOSS OF MEASUREMENT

SPURIOUS MEASUREMENT

Delivering Values to Customers

NOW LETS IDENTIFY THE

RISK OF THIS PROCESS..

Delivering Values to Customers

Delivering Values to Customers

STEP 1: UNDERSTAND THE PROCESS

1.

THERE IS A LOW PRESSURE STEAM FLOWING INTO THE

VESSEL

2.

THE STEAM COOLS AND FORMS CONDENSATE IN THE

CONDESATE POT

3.

THE LEVEL OF THE CONDESATE LIQUID IS CONTROLED

BY LEVEL CONTROL LOOP

4.

CONDESATE DRAINED OUT THE BOTTOM OF VESSEL

STEP 2: IDENTIFY POSSIBLE FAILURES

1.

THE CONTROL LOOP CAN MALFUNCTION CAUSING

THE VALVE TO FAIL IN THE CLOSED POSITION

Delivering Values to Customers

STEP 3: ASSESS THE CONSEQUENCES

1.

THE LEVEL CONTROL FAILS IN THE CLOSED POSITION

CAN MALFUNCTION BLOCKING THE DRAIN LINE

2.

HAZARD IS HIGH LEVEL AND HIGH PRESSURE IN THE

TANK

3.

POTENTIAL CONSEQUENCES OF LOSS OF

CONTAINMENT AND EQUIPMENT DAMAGE WITH $$$$
LOSSES.

Delivering Values to Customers

NOW YOU HAVE IDENTIFIED THE CAUSE OF THE

OVERPRESSUREHAZARD, CAN YOU IDETIFY THE SAFE

THE PRESSURE RELIEF WITH A SET POINT OF 700 KPA

WILL OPEN AND REDUCE BUT NOT ELIMINATE THE RISK
OF RAPTURE

BY UNDERSTANDING THE P&ID YOU CAN CLEARLY ASSESS

RISK IN YOUR OPERATION AND NAKE GOOD DCISIONS

Delivering Values to Customers

Questions

Delivering Values to Customers