Guideline Technology

Title: Review of Piping and Unique Identifier: 240-56030537

Instrumentation Diagrams
Guideline
Alternative Reference Number: 474-171

Area of Applicability: Engineering

Documentation Type: Guideline

Revision: 1

Total Pages: 12

Next Review Date: October 2013

Disclosure Classification: CONTROLLED

DISCLOSURE

Compiled by Approved by Authorised by

………………………………….. ………………………………….. …………………………………..

S. Govender K. Govender Z.T Mathe

Corporate Specialist Gas, CoE Manager Gas Plant Senior Manager Power Plant
Solar CSP and Wind Plant (Acting)

Date: …………………………… Date: …………………………… Date: ……………………………

Supported by TDAC

…………………………………..

D. Odendaal
TDAC Chairperson

Date: ……………………………
 Review of Piping and Instrumentation Diagrams Guideline Unique Identifier: 240-56030537
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CONTENTS
Page
1. INTRODUCTION ...................................................................................................................................................... 3
2. SUPPORTING CLAUSES ........................................................................................................................................ 3
2.1 SCOPE .............................................................................................................................................................. 3
2.1.1 Purpose ..................................................................................................................................................... 3
2.1.2 Applicability................................................................................................................................................ 3
2.2 NORMATIVE/INFORMATIVE REFERENCES .................................................................................................. 3
2.2.1 Normative .................................................................................................................................................. 3
2.2.2 Informative ................................................................................................................................................. 4
2.3 DEFINITIONS .................................................................................................................................................... 4
2.3.1 Classification ............................................................................................................................................. 4
2.4 ABBREVIATIONS .............................................................................................................................................. 4
2.5 ROLES AND RESPONSIBILITIES .................................................................................................................... 4
2.6 PROCESS FOR MONITORING ........................................................................................................................ 4
2.7 RELATED/SUPPORTING DOCUMENTS ......................................................................................................... 5
3. DOCUMENT CONTENT........................................................................................................................................... 5
3.1 CLASSIFICATION OF P&ID REVIEWS DURING DIFFERENT PLCM PHASES ............................................ 5
3.2 CONDUCTING A P&ID REVIEW ...................................................................................................................... 6
3.2.1 Step 1: Classify the P&ID review (Functional and Detailed P&ID Review) ............................................... 6
3.2.2 Step 2: Material required for Proper P&ID Review (Functional and Detailed P&ID Review) .................... 6
3.2.3 Step 3: Understand the System (Functional and Detailed P&ID Review) ................................................ 6
3.2.4 Step 4: Does the P&ID reflect Safe Operation and Outage Contingencies (Detailed P&ID Review) ....... 7
3.2.5 Step 5: Essential Information Checklist (Detailed P&ID Review) .............................................................. 7
3.2.6 Step 6: Key Questions (Detailed P&ID Review) ........................................................................................ 7
4. AUTHORISATION .................................................................................................................................................... 8
5. REVISIONS .............................................................................................................................................................. 8
6. DEVELOPMENT TEAM ........................................................................................................................................... 8
7. ACKNOWLEDGEMENTS ........................................................................................................................................ 8
APPENDIX A ................................................................................................................................................................ 9

FIGURES
Figure 1: Classification of P&ID reviews and associated activities .............................................................................. 5

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1. INTRODUCTION
The review of piping and instrument diagrams (P&ID’s) forms an integral part of engineering activities in
the Definition phase (DRA) and Execution phase (ERA) of the design in the Project Life Cycle Model
(PLCM) [1]. In the context of Eskom, the P&ID’s issued during the DRA and ERA of the PLCM are
subjected to different depths of review. According to the Design Review Procedure [2], the review of
P&ID’s falls under the day-to-day review classification. For the DRA phase typically a functional review is
required to ensure that the intended function of the process is achieved. However for the ERA phase a
detailed review of the P&ID’s needs to be undertaken.
In summary reviewing a P&ID in itself is quite difficult if you do not understand the main objective of the
process or unit operation described in the diagram, and which engineering level it belongs in (basic or
detailed engineering) in the Design Review Procedure [2]. The current procedure is intended to provide a
general guideline to reviewing P&ID’s (basic or detailed engineering) and could be used to supplement
the existing knowledge of experienced reviewers.

2. SUPPORTING CLAUSES

2.1 SCOPE

2.1.1 Purpose

The purpose of this guideline is to define the principles and essential steps which must be taken to
ensure a structured and uniform approach when reviewing P&ID’s within the framework of the
Engineering Design Review [2] procedure.
The purpose of P&ID review is firstly to ensure that the P&ID description will perform the intended
operation as described in the concomitant operation philosophy document. Secondly compliance with
ESKOM standards and legislation (viz. OSH act) is verified. In principle the P&ID review provides an
opportunity (especially at the basic design phase) to correct the baseline before the detailed design
basis is established. As indicated, the RAM, HAZID/HAZOP, FMECA are complementary studies that
influence the P&ID review before the design is ultimately frozen.

2.1.2 Applicability

This guideline is applicable to staff, as well as all contractors and seconded personnel, performing
engineering work in the DRA and ERA phases of the PLCM.

2.2 NORMATIVE/INFORMATIVE REFERENCES

Parties using this document shall apply the most recent edition of the documents listed in the following
paragraphs.

2.2.1 Normative

[1] Eskom Group Capital Division Enterprises Programme Management Office EPMO: Capital
Projects Lifecycle Model Ver. 9.0 16 February 2011
[2] Design Review Procedure 474-1325
[3] Reliability Engineering Manual 474-37

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[4] Hazard and Operability (HAZOP) Study Guideline 200-4397-PGZ 45-24 Rev 0A
[5] Failure Mode Effects (and Criticality) Analysis (FME(C)A) Guideline 200-4393-PGZ 45-25 Rev 0A
[6] Eskom Standards-Appendix A
[7] ESKOM Drawing Symbology

2.2.2 Informative

None

2.3 DEFINITIONS

2.3.1 Classification

Controlled Disclosure: Controlled Disclosure to External Parties (either enforced by law, or

discretionary).

2.4 ABBREVIATIONS

Abbreviation Description
DRA Definition Release Agreement
ERA Execution Release Agreement
HAZID Hazard Identification
FMEA Failure Modes Effects Analysis
FMECA Failure Modes Effects and Criticality Analysis
HAZOP Hazard and Operability
HMB Heat Mass Balance
MSD Material Selection Diagram
P&ID Piping and Instrumentation Diagram
PFD Process Flow Diagram
PLCM Project Life Cycle Model
RAM Reliability, Availability and Maintainability

2.5 ROLES AND RESPONSIBILITIES

None

2.6 PROCESS FOR MONITORING

None

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2.7 RELATED/SUPPORTING DOCUMENTS

None

3. DOCUMENT CONTENT

3.1 CLASSIFICATION OF P&ID REVIEWS DURING DIFFERENT PLCM PHASES

P&ID reviews may be classified depending on the phase in which the review is carried out in the PLCM.
Figure 1 shows the classification with the complementary studies.

Figure 1: Classification of P&ID reviews and associated activities

P&ID Review

Sets the Baseline for

Detailed Design Design Freeze
DRA-Basic Design ERA-Detailed Design
Functional P&ID Review Detailed P&ID Review

RAM RAM

HAZID HAZOP

FMECA

The P&ID”s issued during the basic design phase are conceptual and are not for construction. Given that
the P&ID is not issued for construction a detailed review of it would not be beneficial. For this reason, a
functional P&ID review is warranted where the aim of the review is to verify that the P&ID description
agrees with the function and safety requirements of the entire system/process. With the Design Review
Procedure borne in mind, Figure 1 indicates that during the basic design phase a functional review of
P&ID’s is adequate. In the DRA phase, the Reliability, Availability and Maintainability (RAM) [3] and
Hazard Identification (HAZID) [4] reviews naturally follow the functional P&ID review. All issues raised in
the RAM and HAZID needs to be incorporated into the P&ID description. The revised P&ID’s, conceptual
RAM assessment and the findings of the HAZID will form part of the documentation for the end of phase
review for the basic design. Acceptance of the basic design will then set the baseline to develop the
detailed design.
The P&ID’s issued during the detailed phase are issued by the contractor, so a detailed P&ID review is
warranted. In the detailed design phase (ERA), the RAM and Hazard and Operability Study (HAZOP) [4]
can follow the detailed P&ID review of the contractor’s detailed designs. In addition to the RAM study,
the Failure Modes Effects and Analysis (FMEA) or Failure Modes Effects and Criticality Analysis
(FMECA) [5] follow the RAM study. The HAZOP, RAM, FMECA or FMEA serve as important
gatekeepers to ensure a safe and operable plant that complies with legislation, Engineering Standards
[6] and Drawing Symbols [7] (where applicable) prescribed by ESKOM. All of the P&ID’s that make up
the contractors detailed design package will then in principle be subjected to a design freeze in

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readiness for construction. Any changes downstream of this freeze will result in a compensation event,
the quantum of which is dependent on the degree of rework.

3.2 CONDUCTING A P&ID REVIEW

There are key steps that need to be performed in a P&ID review, and these are detailed with
descriptions below. The classification level is indicated in parenthesis at each step.

3.2.1 Step 1: Classify the P&ID review (Functional and Detailed P&ID Review)

Using Figure 1, determine whether the P&ID review is at the basic design or detailed design level. For
example at the basic design stage the P&ID may not show some obvious equipment like drains etc. It
would not be beneficial for the reviewer making suggestions/comments on details when the aim of the
review is to verify the function of the entire process against the operation philosophy of the
system/process. In many instances, the availability of an operating philosophy at the basic design level
is limited, in this case the P&ID’s should be reviewed in order to verify the system functionality in
accordance with the process flow diagrams (PFD’s) and the heat and mass balance (HMB’s).

3.2.2 Step 2: Material required for Proper P&ID Review (Functional and Detailed P&ID Review)

In order to make a meaningful review of a P&ID (irrespective of the classification), additional information
coming from previous engineering levels is required. These include (as a minimum) but are not limited
to:
The Basic Engineering Design Basis (BED) document,
The Process description,
The Heat and Mass Balances (HMB’s),
The Material Selection Diagrams (MSD’s),
The key to materials used in piping,
The level of redundancy typically assumed for instrument systems,
The Operation Philosophy Document.

3.2.3 Step 3: Understand the System (Functional and Detailed P&ID Review)

Regardless of the classification of the P&ID review (according to Figure 1), prepare a simple start-up,
shut-down and emergency procedure summary for the system and check if all the piping, valve types
and instrumentation are on the P&ID to cater for these normal or abnormal operations. Keeping in mind
equipment maintenance requirements like spares, draining to closed and open drain systems, and the
fact that instruments and exchangers may require purging from time to time. Lastly, look for what is not
provided but for this you might need to prepare an inventory of what is required at different stages of
operation in the field as well as control room apart from Emergency shutdown procedures. You might
also want ask questions like, what happens if a trip occurs, or what happens if instrument air fails or
over-pressure occurs and so on. One could argue that this would normally fall into a HAZID/HAZOP but
often there are some simple things to pick e.g. A missing pressure relief valves (PRV's), or non-return
valves (NRV’s) located (not located) where they should not (should be) located etc.

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3.2.4 Step 4: Does the P&ID reflect Safe Operation and Outage Contingencies (Detailed P&ID
Review)

According to the OSH act, the employer must identify any hazards on the plant and the mitigating actions
required to reduce or eliminate the identified hazards. Furthermore, the employer must do everything
possible to provide a safe working environment. This needs to be in the reviewer/designer’s mind from
the very outset. As an example, consider alternatives when the isolation you want is not present. What
options are possible? For example, is there an interlock/isolation valve further upstream/downstream or
would you be forced to a plant outage? You need to take a look at each situation regarding "what
happens if this fails" and incorporate a design that can remedy the "what if it fails" question. It appears
that almost every heavy industrial facility upgrade is installing "double redundancy" for safety purposes.
Bear in mind however that redundancy is equated to increased cost. These suggestions will need to be
traded off in the RAM and FMECA and Hazop studies.

3.2.5 Step 5: Essential Information Checklist (Detailed P&ID Review)

The following equipment requires the following essential information:

Equipment Number, Power rating, Temperature, Pressure, Flowrate
Temperature sensors and transmitters, pressure sensors and transmitters, flow meters and
transmitters, tanks, vessels, vents, drains, purges, all safety features, heat exchangers,
pumps, meters, Filters, valves-major block check valves, control, safety relief, valve actuator
type, heaters, pipe with sizes (line number and line specification), flow directions, control set point
(pressures, flow, temperatures), signal type (electrical or pneumatic and routing), interconnects,
process permissions and interlocks

3.2.6 Step 6: Key Questions (Detailed P&ID Review)

The final step in the P&ID review really comes with experience. However the steps indicated below are
designed to assist a first time reviewer and to make a better experienced reviewer. In general, one
should question the P&ID and typically a good P&ID should answer adequately. The typical questions
include (but should not be limited to):
a. Tagging: Is it consistent with the legends?
b. Symbology: Is it consistent with the supplied sheets/line types?
c. What is the process or unit operation designed for?
d. Against the backdrop of the process conditions, can the intended function/operation be performed
with the selected equipment?
e. Can the mechanical design of the pipeline contain the fluids at the design flow rate, pressure,
temperature and corrosion due to contained fluid? Do the tags associated with the lines contain this
information with symbols defined in the consultants/contractors attached symbology?
f. Can the process be safely controlled with the selected instruments (or control systems)?
g. Can the Operator/DCS monitor what is happening in the process units or do you need more field
mounted sensors with feedback via DCS to Control room?
h. How do valves fail: Fail Open or Fail Close?
i. Do you require heat tracing on the line?
j. What if there is a process excursion e.g. High temperature, high pressure or high flow
k. These deviations must be considered and recorded in the HAZOP study.

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l. Contingencies for maintenance/emergency shutdowns?

m. Relief Devices-Pressure Relief Valve (PRV): Is the set/relief point indicated?
n. What happen months or years of operation? Will there be fouling or deposits? Will a purging system
be required?
o. Review storage tank capacities and determine if these are sufficient for the system to operate in a
practicable manner
p. Review flaring systems for safety and the incorporation of many vent/flare lines into a main header
q. Review pump selection and suitability for the application
r. Based on the category of fluids being processed, designate the plant according to relevant
area classification zones. SANS 10108 Hazardous area classifications.

4. AUTHORISATION
This document has been seen and accepted by:
Name Designation
Saneshan Govender Corporate Specialist Gas Turbines, GTD
Chiraag Gokaldas Process Engineer, EON Consulting
Eugene Pininski Chief Engineer-Reliability Engineering GTD
Titus Mathe Senior Manager Power Plant, GTD
This Document has been approved by TDAC ROD 13 February 2013

5. REVISIONS
Date Rev. Compiler Remarks
November 2012 0 Draft Document for review created from 474-171
May 2013 1 Final Document for Publishing

6. DEVELOPMENT TEAM
The following people were involved in the development of this document:
Titus Mathe
Chiraag Gokaldas
Eugene Pininski

7. ACKNOWLEDGEMENTS
Titus Mathe
Chiraag Gokaldas
Eugene Pininski

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APPENDIX A
ESKOM STANDARDS REQUIRED FOR P&ID REVIEWS
Code Description
0.00/1290 Cable tag numbering
0.00/1285 Cable terminations for PVC cables
0.00/10355 shts 1-4 Power & Control wiring termination standard
0.52/1037 - 0 MV and LV switchgear front panels pad lockable lever lock
0.52/1038 - 0 MV and LV switchgear rear panels fastener
0.52/1174 - 0 63 Amp and 125 Amp maintenance sockets outlets
arrangements
0.54/430 - 0 Outdoor Isolators Padlock
0.54/03695 – 1985 sht 1 MV, LV and DC switchgear labels and name plate details
arrangement diagram
0.54/03695 – 1985 sht 2 General labels and name plate details arrangement diagram
0.54/5609 Switchgear cable lugs standard dimensions
0.00/1310 Standard Power and Control Cable code
0.00/2713 Instrument cable code
0.54/393 – 22 Part 1 Earthing Standards (Common Section)
0.54/393 Part 2 Earthing Standards (General Section)
0.54/393 Part 3 Earthing Standards (General Section)
FM Global’s Property Loss FM Global’s – “Fire Protection for Gas Turbine Installations”
Prevention Data Sheet 7-79
ESKAMAAD1 Storage and handling of Flammable and Combustible Liquids
ESKASAA04 Electronic Protection and Fault Monitoring Equipment
ESKASAAU7 Quality requirements for the procurement of assets, goods and
services.

ESKSCSAAD0 Specification For continuous analogue indicating instruments for

electrical quantities.
GGG 0450 Guideline to Acceptance of Contractors Drawings
GGS 0182 Process flow diagrams and piping instrumentation diagrams
GGS 0317 Specification for storage Tanks
GGS 0183 Fire Barrier Seals for Electrical Cable Installation for Power
Stations
GGS 0445 Drawing numbering system
GGP 0448 Procedure for On-site Inspection and pressure testing of
pipelines constructed with steel pipes for duties up to 25 bar and

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100 0C
GGS 0853 List of Approved Relays
GGP 0349 Procedure for On-site Commissioning of Low Pressure Systems
GGSS 0423 Specification for low pressure valves
GGS 0690 Specification for medium pressure pipelines
GGS 0456 Specification for switch gear and associated equipment for
voltages up to and including AC 1090 V and DC 1200 V

GGS 0462 Quality requirements for engineering and construction work

GGS 0802 Specification, power station electrical motors procurement
GGS 1030 Storage of power station electrical motors
GGS 1080 Transport of power station electrical motors
IEC 60071 Insulation Co-ordination
IEC 60034 – 1 Rotating electrical machines Part 1 – Rating and performance
IEC 60034 – 5 Rotating electrical machines Part 5 – Classification of degrees of
protection provided by enclosures of rotating electrical machines
IEC 60044 – 1 Instrument Transformers Part 1 – Current transformers
IEC 60044 – 2 Instrument Transformers Part 2 – Inductive voltage transformers
IEC 60051 Direct acting analogue electrical measuring instruments and their
accessories
IEC 60060 - 1 High voltage test techniques Part 1 – General definitions and test
requirements
IEC 60269 Low voltage fuses
IEC 60529 Degrees of protection provided by enclosures (IP code)
IEC 60898 Electrical accessories – Circuit breakers for over current
protection for household and similar installations

IEC 60947 Low voltage switchgear and control gear – Part 2 – (circuit
breakers)
ISO 898 - 1 Mechanical properties of fasteners made of carbon steel and
alloy steel: Part 1 – Bolts, screws and studs
NRS002 Graphic symbols for electric diagrams
GGR 0992 Eskom Plant Safety Regulations
GGS 0386 rev 4 Requirements for control and power cables for power stations
NFPA 85 Boiler and Combustion System Hazards Code
NRS 042 Guide for the Protection of Electronic Equipment against
Damaging Transients
OPS 0002 Eskom Documentation Standard

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OHSA no 85 of 1993 Electrical Installation Regulation under Occupational Health and

Safety
SABS 62 Steel pipes and pipe fittings up to 150 mm nominal bore suitable
for Screwing to SABS 1109 pipe threads
SABS 135 ISO metric black bolts, screws and nuts (hexagon and square)
SABS 0162 The structural use of steel
SABS 719 Electric welded low carbon steel pipes for aqueous fluids
(ordinary Duties)
SABS 763 Hot-dip (galvanized) zinc coatings
SABS 974-1 Rubber joint rings (non-cellular) for use in water, sewer and
drainage systems
SABS 1109 ISO pipe threads for pipes and fittings where pressure – tight
joints are made on the threads.
SABS 1123 Steel pipe flanges
SABS 1411 Cable construction
SANS 152 Low voltage air break switches, air break disconnectors, air
break switch disconnectors and fuse combination units
SANS 156 Moulded case circuit breakers
SANS 1019 Standard voltages, currents and insulation levels for electricity
supply
SANS 1091 National colours for paint
SANS 1274 Coating applied by the powder-coating process
SANS 1507 Electrical cables with extruded solid dielectric insulation for fixed
insulations (300/500V TO 1900/3300V)
SANS 1574 Electric cables – Flexible Cords
SANS 9000 to 9004 Quality Management systems and standards
SANS 10108 The classification of hazardous locations and selection of electric
apparatus for use in such locations
SANS 10140-3 Identification Colour Markings
SANS 10142 Code of Practice for the wiring of premises.
SANS 10198 - 13 Part 13 – The handling and selection of electrical power cables of
rating not exceeding 33kV
SABS 0199 – 1985 The design and installation of an earth electrode
SANS 60439 Low voltage switchgear and control gear assemblies
SANS 61136 - 1 Semiconductor power converters – Adjustable speed electric
drive systems – General requirements Part 1 – Rating
specifications particular for DC motor drives
IEC 60071 Insulation Co-ordination

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IEC 60034 Rotating Electrical Machines

IEC 60044 Instrument Transformers
IEC 60076 Power Transformers
IEC 60079 Electrical apparatus for explosive gas atmospheres
IEC 60502 Power cables with extruded insulation and their accessories for
rated voltages
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60694 Common Specifications for High-Voltage
Switchgear and Control gear Standards
IEC 60896-11 Stationary lead-acid batteries – Vented Type
IEC 60947 LV Switchgear and Control gear
IEC 61439 LV Switchgear and Control gear Assemblies
IEC 61649 Enclosed Low-Voltage Switchgear and Control gear Assemblies
– Guide for Testing under Conditions of Arcing due to Internal
Fault
IEC 62271 High Voltage Switchgear and Control gear
Eskom standard Specification for LV Switchgear and Control gear Assemblies and
Associated Equipment for Voltages up to and Including 1000V
GGSS 0456 Rev. 4
AC and 1500V DC

Eskom standard AC Metal Enclosed (Metal-Clad) Switchgear and Control gear for
Voltages Above 1kV up to and Including 52kV.
GGSS 1201 Rev. 0
PGZ 45-24 Rev 0A Hazard and Operability (Hazop) Study Guideline
PGZ 45-25 Rev 0A Failure Modes Effects and Criticality (FMECA) Study Guideline
474-37 Rev 0 Reliability Engineering Manual

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