How to Read a

P&ID
For
Risk
Analysis
P&ID is a Piping and
Instrumentation
Diagram
To identify risk from a set of
P&ID you must have clear
understanding of three
things
#1
Understand the
process
#2
Understand the
failures
#3
Understand the
consequence
Lines are used for showing
piping, equipment and
instrumentation
connections
so people can
communicate the
process sequence and
the relationship of
different equipment
Equipment and
instrumentation are
connected by lines
Here are some common
connections
Pipe
Common Failure Modes:
- Collapse
- Burst/Rupture
- Erosion
- Corrosion
Electrical Signal
Common Failure Modes:
- Open connection
- Electrical shorting
- Electromagnetic interference
Pneumatic Signal
Common Failure Modes:
- Leakage of internal fluid
- High components friction
level
- Loss of pressure
Data Signal
Common Failure Modes:
- Radio interference
- Signal filtering
- Packets Loss
- Loss of signal
Flexible Pipe
Common Failure Modes:
- Compressive failure
- Tensile failure
- Over bending
- Rupture
Symbols are used to
simplify drawings
From this
To this
>>>
>>>
>>>
Some equipment are
used to add or reduce
energy in the material
Blower
Common Failure Modes:
- Fail to operate on demand
- Loss of pressure
Furnace
Common Failure Modes:
- Flame out
Pump
Common Failure Modes:
- Fail to operate on demand
- Loss of pressure
- Over pressure
Compressor
Common Failure Modes:
- Fail to start
- Damage due to liquid
- Over pressure
- Excessive vibration
Heat exchanger
Common Failure Modes:
- Leakage
- Corrosion
- Plugged
Plate Heat Exchanger
Common Failure Modes:
- Leakage
- Corrosion
- Plugged
Aerial Fan
Common Failure Modes:
- Loss of air circulation
Some equipment are
used for material storage
Floating Storage Tank
Common Failure Modes:
- Overflow
- Leakage
Sphere Tank
Common Failure Modes:
- Overpressure
Pressurized Vessel
Common Failure Modes:
- Overpressure
Some equipment are
used to separate material
Horizontal Separator
Common Failure Modes:
- Overpressure
Vertical Separator
Common Failure Modes:
- Overpressure
Fluid Contacting
Column
Common Failure Modes:
- Overpressure
- Corrosion
- Plugged
Tray Column
Common Failure Modes:
- Overpressure
- Contamination
Valves are used to
control the flow of
material
Manual Valve
Common Failure Modes:
- External leakage
- Internal leakage
- Inadvertent position
Control Valve
Common Failure Modes:
- Fail to close on demand
- Fail to open on demand
- Spurious operation
- Leakage
Solenoid Valve
S
Common Failure Modes:
- Structural failure
- Seat Leakage
- Seal Leakage
- Loss of actuator
Motor-operated Valve
M
Common Failure Modes:
- Motor failure
- Fail to stroke
Butterfly Valve
Common Failure Modes:
- Fail to close on demand
- Fail to open on demand
- Spurious operation
Globe Valve
Common Failure Modes:
- Fail to close on demand
- Fail to open on demand
- Spurious operation
- Leakage
Needle Valve
Common Failure Modes:
- Fail to close on demand
- Fail to open on demand
- Spurious operation
- Leakage
Ball Valve
Common Failure Modes:
- Fail to close on demand
- Fail to open on demand
- Spurious operation
- Leakage
Check valve
Common Failure Modes:
- Leakage
- Stuck at open position
Some equipment are
used to relief pressure
in the process
Relief Valve
Common Failure Modes:
- Fail to open
Curved Gas Vent
Common Failure Modes:
- Plugged
Rupture Disk
Common Failure Modes:
- Corrosion
Control system are used
to manage the behaviour
of the process
Programmable Logic
Control
Common Failure Modes:
- Software error
- Execution error
Shared display, shared
Control
Common Failure Modes:
- Software error
- Execution error
Sensors are used to
measure the physical
properties of the process
and convert it into a signal
Flow Transmitter
FT
Common Failure Modes:
- Spurious measurement
- Loss of measurement
Pressure Transmitter
PT
Common Failure Modes:
- Spurious measurement
- Loss of measurement
Level Transmitter
LT
Common Failure Modes:
- Spurious measurement
- Loss of measurement
Now lets identify the risk
of this process
LT
253
HLL=2550mm
NLL=1650mm
LLL=250mm
LC
LY
LV
Steam
Condensate
Toatmosphereatsafe
location
PSV
D101
D101ReboilerCondensatePot
253 253
253
111
DrawingRef.
DrawingRef.
LG
253
2
2
3
3
3/4
3/4
6
6
6
6
Size
SET@700kPag
6
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
LT
253
HLL=2550mm
NLL=1650mm
LLL=250mm
LC
LY
LV
Steam
Condensate
Toatmosphereatsafe
location
PSV
D101
D101ReboilerCondensatePot
253 253
253
111
DrawingRef.
DrawingRef.
LG
253
2
2
3
3
3/4
3/4
6
6
6
6
Size
SET@700kPag
6
S
t
a
r
t
Step 2: Identify possible
failures
The control loop can
malfunction causing the
valve LV253 to fail in the
closed position
LT
253
HLL=2550mm
NLL=1650mm
LLL=250mm
LC
LY
LV
Steam
Condensate
Toatmosphereatsafe
location
PSV
D101
D101ReboilerCondensatePot
253 253
253
111
DrawingRef.
DrawingRef.
PG
253
2
2
3
3
3/4
3/4
6
6
6
6
Size
SET@700kPag
6
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
Now you have identified
the cause of the
overpressure hazard, can
you identify the
safeguard?
The pressure relief with
a set point of 700 kPa will
open and reduce but not
eliminate the risk of
rupture
LT
253
HLL=2550mm
NLL=1650mm
LLL=250mm
LC
LY
LV
Steam
Condensate
Toatmosphereatsafe
location
PSV
D101
D101ReboilerCondensatePot
253 253
253
111
DrawingRef.
DrawingRef.
LG
253
2
2
3
3
3/4
3/4
6
6
6
6
Size
SET@700kPag
6
By understanding the
P&ID you can clearly
assess risk in your
operation and make good
decisions
Any Questions?
Risk. Inspired.
For more lessons go to
www.icarus-orm.com