OSE571 Ocean Plant Design
Process Operation and Control Philosophy
Daejun CHANG (djchang@[Link])
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
