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Delivering Values to Customers
HOW TO READ A P&IDFOR
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
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