How to Read a P&ID For Risk Analysis

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P&ID is a Piping and Instrumentation Diagram

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To identify risk from a set of P&ID you must have clear understanding of three things

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#1 Understand the process

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#2 Understand the failures

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#3 Understand the consequence

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Lines are used for showing piping, equipment and instrumentation connections

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so people can communicate the process sequence and the relationship of different equipment

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Equipment and instrumentation are connected by lines Here are some common connections
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Pipe

Common Failure Modes: Collapse Burst/Rupture Erosion Corrosion 8/31/12

Electrical Signal

Common Failure Modes: Open connection Electrical shorting Electromagnetic interference 8/31/12

Pneumatic Signal

Common Failure Modes: Leakage of internal fluid High components friction level Loss of pressure 8/31/12

Data Signal

Common Failure Modes: Radio interference Signal filtering Packets Loss Loss of signal 8/31/12

Flexible Pipe

Common Failure Modes: Compressive failure Tensile failure Over bending Rupture 8/31/12

Symbols are used to simplify drawings

> > > > > 8/31/12 From this To this

Some equipment are used to add or reduce energy in the material

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Blower

Common Failure Modes: Fail to operate on demand Loss of pressure

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Furnace

Common Failure Modes: Flame out

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Pump

Common Failure Modes: Fail to operate on demand Loss of pressure Over pressure 8/31/12

Compressor

Common Failure Modes: Fail to start Damage due to liquid Over pressure Excessive vibration 8/31/12

Heat exchanger

Common Failure Modes: Leakage Corrosion Plugged 8/31/12

Plate Heat Exchanger

Common Failure Modes: Leakage Corrosion Plugged 8/31/12

Aerial Fan

Common Failure Modes: Loss of air circulation

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Some equipment are used for material storage

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Floating Storage Tank

Common Failure Modes: Overflow Leakage

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Sphere Tank

Common Failure Modes: Overpressure

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Pressurized Vessel

Common Failure Modes: Overpressure

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Some equipment are used to separate material

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Horizontal Separator

Common Failure Modes: Overpressure

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Vertical Separator

Common Failure Modes: Overpressure

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Fluid Contacting Column

Common Failure Modes: Overpressure Corrosion Plugged 8/31/12

Tray Column

Common Failure Modes: Overpressure Contamination

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Valves are used to control the flow of material

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Manual Valve

Common Failure Modes: External leakage Internal leakage Inadvertent position 8/31/12

Control Valve

Common Failure Modes: Fail to close on demand Fail to open on demand Spurious operation Leakage 8/31/12

Solenoid Valve
S

Common Failure Modes: Structural failure Seat Leakage Seal Leakage Loss of actuator 8/31/12

Motor-operated Valve
M

Common Failure Modes: Motor failure Fail to stroke

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Butterfly Valve

Common Failure Modes: Fail to close on demand Fail to open on demand Spurious operation 8/31/12

Globe Valve

Common Failure Modes: Fail to close on demand Fail to open on demand Spurious operation Leakage 8/31/12

Needle Valve

Common Failure Modes: Fail to close on demand Fail to open on demand Spurious operation Leakage 8/31/12

Ball Valve

Common Failure Modes: Fail to close on demand Fail to open on demand Spurious operation Leakage 8/31/12

Check valve

Common Failure Modes: Leakage Stuck at open position

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Some equipment are used to relief pressure in the process

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Relief Valve

Common Failure Modes: Fail to open

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Curved Gas Vent

Common Failure Modes: Plugged

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Rupture Disk

Common Failure Modes: Corrosion

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Control system are used to manage the behaviour of the process

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Programmable Logic Control

Common Failure Modes: Software error Execution error

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Shared display, shared Control

Common Failure Modes: Software error Execution error

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Sensors are used to measure the physical properties of the process and convert it into a signal

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Flow Transmitter

FT

Common Failure Modes: Spurious measurement Loss of measurement

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Pressure Transmitter

PT

Common Failure Modes: Spurious measurement Loss of measurement

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Level Transmitter

L T
Common Failure Modes: Spurious measurement Loss of measurement

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Now lets identify the risk of this process

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D-101 Re-boiler Condensate Pot

PS 11 V 1
Size SET @ 700kPag

Stea m

To atmosphere at safe location

Drawing Ref.

D-101
2 3

3/4

LT 25 3

LG 25 3
2

HLL=2550 mm NLL=1650 mm LLL=250 mm

3

LC 25 3
6

3/4

LY 25 3
6 6

LV 25 3

Condensat e Drawing Ref.

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Step 1: Understand the process

There is low pressure steam flowing into the vessel The steam cools and forms condensate in the

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D-101 Re-boiler Condensate Pot S t a Stea r m Drawing Ref. t

3/4 2 3

PS 11 V 1

Size SET @ 700kPag

To atmosphere at safe location

D-101
LT 25 3

LG 25 3
2

HLL=2550 mm NLL=1650 mm LLL=250 mm

3

LC 25 3
6

3/4

LY 25 3
6 6

LV 25 3

Condensat e Drawing Ref.

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Step 2: Identify possible failures The control loop can malfunction causing the valve LV253 to fail in the closed position
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D-101 Re-boiler Condensate Pot

PS 11 V 1
Size SET @ 700kPag

Steam
Drawing Ref.

To atmosphere at safe location

D-101
2 3

3/4

LT 25 3

PG 25 3
2

HLL=2550 mm NLL=1650 mm LLL=250 mm

3

LC 25 3
6

3/4

LY 25 3
6 6

LV 25 3

Condensat e Drawing Ref.

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Step 3: Assess the consequence The level control valve fails in the closed position blocking the drain line

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Now you have identified the cause of the overpressure hazard, can you identify the safeguard?
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The pressure relief with a set point of 700 kPa will open and reduce but not eliminate the risk of rupture
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D-101 Re-boiler Condensate Pot

PS 11 V 1
Size SET @ 700kPag

Stea m

To atmosphere at safe location

Drawing Ref.

D-101
2 3

3/4

LT 25 3

LG 25 3
2

HLL=2550 mm NLL=1650 mm LLL=250 mm

3

LC 25 3
6

3/4

LY 25 3
6 6

LV 25 3

Condensat e Drawing Ref.

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By understanding the P&ID you can clearly assess risk in your operation and make good decisions

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Any Questions?

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Risk. Inspired.
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