OSE571 Ocean Plant Design

Process Operation and Control Philosophy

Daejun CHANG (djchang@kaist.edu)

Division of Ocean System Engineering

Korea Advanced Institute of

Science and Technology

Design Procedure and Key deliverables

Concept Consolidation
Production Availability

Design Basis (Philosophy)

System Description
Process Flow Diagram

Equipment Specification

Process Simulation

Equipment Design

Process Operation and

Control Philosophy
P&ID
Layout
Safety Studies

Risk Assessment
HAZOP
Caution: Not universally applicable
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Ocean Systems Engineering

Hazards and Safety Systems

Emergency Response
(Escape Route, TR, Evacuation Means,
Rescue Equipment, Emergency Power)
Accident Mitigating Protection
(Active/Passive Fire Protection, Fire/Blast Walls)

Accident:
Fire/Explosion

Accident Controlling Protection

(F&G Detection, ESD, Depressurization, Alarm)

Potential Accident:
Gas Leak

Preventive Protection
(Structural & Machinery Integrity, Relief, PSV)
Basic Process Control
(P, T, F, Surge, Back Pressure)
Inherent Safety Design
(Layout, Inventory, Leak, Ignition)

Layered Structure of Safety Systems against Fire and Explosion

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Ocean Systems Engineering

Workflow for Process Control

System Description (W4)
Process Operation and Control Philosophy (W9)
P&ID (W11)
Functional Design Specification (W11)
Logic Diagram
Field Implementation
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Ocean Systems Engineering

What is in the process operation and control philosophy

The key document for operation and control
Operation Philosophy
Big picture of operation
Operation modes defined
Operation philosophy for each mode
Safety instrumentations
Control Philosophy
Detailed feature
Unit-by-unit description
Control loops defined

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Ocean Systems Engineering

Operation Philosophy

Big picture of operation

Working principles
Degree of automation
Number of operators required
Control system architecture

Operation modes defined

Operation philosophy for each mode
Safety instrumentations

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Ocean Systems Engineering

Operation Philosophy
Big picture of operation
Operation modes defined
Steady
- Operational cases: loading, offloading, etc.
- Capacity: Max, Normal, Min (turndown)
Dynamic
- Start-up
- Shutdown
- Emergency shutdown
Operation philosophy for each mode
Safety instrumentations

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Ocean Systems Engineering

Operation Philosophy

Big picture of operation

Operation modes defined
Operation philosophy for each mode
Governing philosophy only
Details deferred to Control Philosophy

Safety instrumentations

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Ocean Systems Engineering

Operation Philosophy

Big picture of operation

Operation modes defined
Operation philosophy for each mode
Safety instrumentations
What if an unwanted emergency occurs?
Causes and counter measures

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Ocean Systems Engineering

Control Philosophy
Detailed feature
Subsystems (units), equipment, components
Control targets and variables
Set points
Control and operation procedure

Unit-by-unit description
Control loops defined

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Ocean Systems Engineering

Control Philosophy
Detailed feature
Unit-by-unit description
Follow the main stream
Describe the situation and circumstance where control is required
Describe how to manipulate the components

Control loops defined

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Ocean Systems Engineering

Control Philosophy
Detailed feature
Unit-by-unit description
Control loops defined
Controlled variables with set point
Manipulated variables
Disturbances
Working mechanism

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Ocean Systems Engineering

Some Questions
Why about control of other subsystems like power generation?
Utility: well proven, repeated design Well established control
Process: specific to the facility
New design Need to establish the control algorithm
Who will take care about the followings tasks including P&ID and
logic diagram?
P&ID process engineers
Logic diagram electrical engineers
Functional design specification (W11) to bridge them
Can we make it without knowledge of control theory?
Advanced controls very rare in real process industry (Why?)
Fundamental understanding of the process control enough

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Ocean Systems Engineering