Fundamental Industrial Communication Skills PDF

Unit A-10 • Fundamental Industrial Communication Skills Objective 5 Discuss updating procedures for piping and instrumentation diagrams. Piping and instrumentation diagrams (P&IDs) are important communication tools for operators, tradespeople, plant administration, and engineers. P&IDs have severa...

Unit A-10 • Fundamental Industrial Communication Skills Objective 5 Discuss updating procedures for piping and instrumentation diagrams. Piping and instrumentation diagrams (P&IDs) are important communication tools for operators, tradespeople, plant administration, and engineers. P&IDs have several uses, some of which are listed below: • Troubleshoot process abnormalities • Communicate process information to designers, consultants, technicians, and vendors that work off-site • Determine equipment lockout requirements • Operator training • Worker safety P&IDs are first developed early in the plant design stage. Revisions are made after initial review by process engineers and safety auditors, and then again during construction. Once construction and commissioning is complete, final versions (referred to as “As-Built” drawings) are developed. These become the first Piping and Instrumentation Drawings authorized for use in the plant. Within a few years, though, P&IDs become obsolete, and they must be updated. This is because over the life of a plant: a) Process equipment is modified when components fail, wear out, or become obsolete. b) Plants grow in capacity, resulting in new processes and new equipment being tied-in to existing process lines. c) Processes are optimized by adding, moving, or removing equipment, and making piping system modifications to suit the changes in material flow. Even small equipment changes make original as-built drawings obsolete. For example, when hand valves are substituted for different makes, models, materials of construction, or valve type, the P&IDs no longer correctly reflect the installation. Similarly, P&IDs become obsolete when a resistance temperature sensor is substituted for a thermocouple, when a drain or vent line is added to a process line, or when a different type of steam traps is substituted for an existing trap. Because they are important communication tools, P&IDs must be kept current. 3-22 4th Class Edition 3 • Part A Plant Communications • Chapter 3 Procedure For Updating P&IDs Procedures must be in place for updating plant diagrams, and they must be followed. These procedures vary from plant to plant. However, update procedures have many common elements. One key element is the creation of an official, authorized master P&ID set. This set is the most current and most accurate revision. It is “owned” by an individual authorized to make revisions. Plants typically have three master sets: 1. The electronic master, in native design format (a CAD drawing) and kept in a secure location. This file set is only accessible to the owner and the owner’s designate. This set can be modified only with the owner’s approval. 2. The print master, in secure pdf format and kept in a shared network location. This set is accessible to individuals for printing and personal use. These files cannot be edited. 3. The hard copy, which is a printed set kept by the owner. This is a printout of the electronic master set, which may or may not include markups (changes not yet incorporated in the electronic master). Employees can check their printed copies against the hard copy to see if there are any process changes. It is important for all three of these sets to be made current, and to be updated, simultaneously. The process for revising P&IDs is typically as follows: 1. Plant personnel (especially operators) trace equipment lines in specified plant areas. They then compare them to the actual piping and instrumentation with the print master, and document any changes with red ink on the print master. This is referred to as “red-lining.” Some of the changes operators look for are: a) Replaced fittings, such as valves or steam traps b) Altered pipe tie-in locations c) Added or deleted piping, vents, drains, or tie-in points d) Added or deleted instruments e) Change in instrument type f ) Relocation of equipment 2. After the P&IDs are “red-lined,” they are submitted to the owner of the master sets. Here, the redlined drawings are compared to the hard copy set. 3. Previously unrecorded changes are brought to the attention of the persons responsible for the process area under review. If the changes are acceptable, they are made to the hard copy. The hard copy is then used to update the electronic master set. 4. When the electronic master set is revised, it is marked with a revision number. The latest revision becomes the official authorized set of drawings. When the electronic master is revised, the print master and hard copy are also revised. SOPs that refer to plant diagrams must be updated when plant diagrams are updated. 4th Class Edition 3 • Part A 3-23 Unit A-10 • Fundamental Industrial Communication Skills Chapter Summary Communication arises from a need to exchange information. In a power plant, much of the information exchanged is critical for the safe and efficient operation of the plant Therefore, information must be communicated accurately and with no room for misinterpretation. Both written and verbal forms of communication are interactive information exchanges, involving both transmission and reception of ideas. Those who are transmitting the information must state their ideas clearly and precisely, to reduce the chance of misinterpretation. Those who are receiving the information must read carefully, or listen actively, to reduce misinterpretation. Active listening includes repeating back to the transmitter, and asking questions to seek clarity. Verbal communication is necessary when communication must be instantaneous. To eliminate miscommunication when communicating verbally, phonetic alphanumeric pronunciation systems have been developed. As well, a special vocabulary, and certain etiquette rules, are applied when using two-way radios. Written forms of communication include e-mails, log books, log sheets, maintenance requests, SOPs, and P&IDs. Log books and log sheets directly fulfill legal obligations. All other written documents, including maintenance requests, work orders, e-mails, SOPs, and P&IDs may be summoned as evidence in a court of law. Therefore, written communication must be accurate, thorough, and carefully completed. For the same reason, SOPs, and P&IDs must be carefully controlled, and diligently kept up-to date. All instances of communication must be professional. Communicators must always be focused, concise, accurate, and polite. 3-24 4th Class Edition 3 • Part A