How to read a P&ID for Risk Analysis
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Transcript of How to read a P&ID for Risk Analysis
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How to Read a P&ID ForRiskAnalysis
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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
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Electrical Signal
Common Failure Modes:- Open connection- Electrical shorting- Electromagnetic interference
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Pneumatic Signal
Common Failure Modes:- Leakage of internal fluid- High components friction level- Loss of pressure
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Data Signal
Common Failure Modes:- Radio interference - Signal filtering- Packets Loss- Loss of signal
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Flexible Pipe
Common Failure Modes:- Compressive failure- Tensile failure- Over bending - Rupture
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Symbols are used to simplify drawings
From this To this
>>>>>>
>>>
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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
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Compressor
Common Failure Modes:- Fail to start- Damage due to liquid- Over pressure- Excessive vibration
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Heat exchanger
Common Failure Modes:- Leakage- Corrosion- Plugged
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Plate Heat Exchanger
Common Failure Modes:- Leakage- Corrosion- Plugged
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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
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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
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Control Valve
Common Failure Modes:- Fail to close on demand- Fail to open on demand- Spurious operation- Leakage
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Solenoid Valve
S
Common Failure Modes:- Structural failure- Seat Leakage- Seal Leakage- Loss of actuator
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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
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Globe Valve
Common Failure Modes:- Fail to close on demand- Fail to open on demand- Spurious operation- Leakage
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Needle Valve
Common Failure Modes:- Fail to close on demand- Fail to open on demand- Spurious operation- Leakage
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Ball Valve
Common Failure Modes:- Fail to close on demand- Fail to open on demand- Spurious operation- Leakage
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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
LT
Common Failure Modes:- Spurious measurement- Loss of measurement
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Now lets identify the risk of this process…
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LT253
HLL=2550 mmNLL=1650 mm
LLL=250 mm LC
LY LV
Steam
Condensate
To atmosphere at safe location
PSV
D-101
D-101 Re-boiler Condensate Pot
253253
253
111
Drawing Ref.
Drawing Ref.
LG253
2”
2”
3”
3”
3/4”
3/4”
6” 6”
6”
6”
Size ½SET @ 700kPag
6”
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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 condensate pot
• The level of the condensate liquid is controlled by a level control loop
• Condensate is drained out the bottom of the vessel
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LT253
HLL=2550 mmNLL=1650 mm
LLL=250 mm LC
LY LV
Steam
Condensate
To atmosphere at safe location
PSV
D-101
D-101 Re-boiler Condensate Pot
253253
253
111
Drawing Ref.
Drawing Ref.
LG253
2”
2”
3”
3”
3/4”
3/4”
6” 6”
6”
6”
Size ½SET @ 700kPag
6”
Star
t
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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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LT253
HLL=2550 mmNLL=1650 mm
LLL=250 mm LC
LY LV
Steam
Condensate
To atmosphere at safe location
PSV
D-101
D-101 Re-boiler Condensate Pot
253253
253
111
Drawing Ref.
Drawing Ref.
PG253
2”
2”
3”
3”
3/4”
3/4”
6” 6”
6”
6”
Size ½SET @ 700kPag
6”
![Page 60: How to read a P&ID for Risk Analysis](https://reader034.fdocuments.in/reader034/viewer/2022050801/5453d83faf7959a4058b7a81/html5/thumbnails/60.jpg)
Step 3: Assess the consequence
• The level control valve fails in the closed position blocking the drain line
• Hazard is high level and high pressure in the tank
• Potential consequence of loss of containment and equipment damage with $$$$ losses
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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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LT253
HLL=2550 mmNLL=1650 mm
LLL=250 mm LC
LY LV
Steam
Condensate
To atmosphere at safe location
PSV
D-101
D-101 Re-boiler Condensate Pot
253253
253
111
Drawing Ref.
Drawing Ref.
LG253
2”
2”
3”
3”
3/4”
3/4”
6” 6”
6”
6”
Size ½SET @ 700kPag
6”
![Page 64: How to read a P&ID for Risk Analysis](https://reader034.fdocuments.in/reader034/viewer/2022050801/5453d83faf7959a4058b7a81/html5/thumbnails/64.jpg)
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.
For more lessons go to www.icarus-orm.com