Control, Automation, Optimisation and Safety
Florin Omota
Amsterdam Office, Netherlands
Future design from an industrial perspective
Process Control 2023
June 6-9, 2023, Strobskie Pleso, Slovakia
Process Control
Optimisation
` Simple proportional integrative
derivative (PID) control loops
` Define objectives and priorities
0%-100%
H
81FT
412
LY
011C
L
81
KAT
15A
` Define objectives
81FC
400
Deaerator
V-101
81FC
412B
DIFF. B
81
KAT
15B
V8173
Future
Deaerator
V-102
81FC
401
LY
011A
0%-100%
TY
011
LICA
011B
H
H
TI
010
LI
011B
TICA
012
CWS
TI
025
E-101
H
E-7107
PCC LIGHT
FIC
020
CWS
TI
026
E-102
CWR
TICA
024
H
E-7108
PCC HEAVY
Deaerator
FIC
030
LI
011D
TI
110
DIFF. A.[OP] = FT412.[PV] - FT401.[PV]
DIFF. B.[OP] = FT412.[PV] - FT400.[PV]
RAT15A.[OP] = FT412.[PV] ° RatioA
RAT15B.[OP] = FT412.[PV] ° RatioB
RatioA = Flow to First Bed/Total Flow
RatioB = Flow to Second Bed/Total Flow
LSEL = Low Selector Switch
RENEWABLE FEED TO R8101
CWR
TICA
022
LI
011C
R8101
81FT
412C
H
NCC HOT
TI
021
E-103
CWR
TICA
114
NNF
H
T-102
NNF
E-104
CWS
NNF
CWR
A-101
Polisher
PCC Tank
E-7110
Deaeration
Cleaned
PCC Tank
Demin Water
T-101
50%-100%
LY
011F
0%-100%
50%-100%
FIC
09
LY
011E
P-103 A/B
0%-100%
HA20230293-001
P-101 A/B/C
123TI
098
123TI
100
123TI
102
123TI
104
123TI
106
123TI
108
123TI
110
123TI
112
NOTE 5
NOTE 2
123-S7
123TI
114
SET AT:..BARG
SIZE:..”X..”
LP STEAM
COND.
NOTE 4 250
R1
50
R6
GV
(CWR)
(CWS)
NOTE 4 250
R2 R7o
LL
HH
NL 850
123LT
092
ET
ET
123LC
093
50
H
Rundown
Tank Mode
Selection
Secondary
Tank Mode
Selection
Pump A/B
Selection
HS
01
HS
02
HS
03
HS
04
UZ-ZZ0
TANK A OVERFILL
PROTECTION
(HH)
(HH)
` Complex interlocks
LZA
01A
HH
LL
KS-XX0
PRODUCT RUNDOWN ROUTE SWITCHING
TANK A
TANK B
Rundown
Rundown and Mixing
Rundown and Transfer
Idle
Mixing
Export
Transfer
Tank A
UZ-ZZ1
AA-BB
TAPB
TBPA
123-V2
123US
923
R8b
123FT
095
R4
NOTE 5 50
123FIC
095
ET
FC
123FV
095
123F XV
095
123UZV
091
123UXV
091
123UZ
922
FC
TSO
30
(IA)
Safety
123UZ
921
KS-02A
Safety Requirements Specification for the Safety
Instrumented System
ENGINEERING
KS-02B
KS-02C
KS-03B
KS-03C
FICA-01A
Phase 0
Project Initiation
To OSBL
KS-04A
` Complex interlocks
Allocation of Safety Functions to Safety Instrumented Systems or
Other Means of Risk Reduction
CONSTRUCTION
Tank B
UZ-VV1
` Cause and effect diagram
Risk Analysis and Protection Layer Design
Phase 1
Scope Definition
and Concept
Development
Phase 2
Preliminary Engineering
Construction Planning
Phase 3
Detailed Engineering and
Site Initiation
Phase 4
Construction, Final Design,
and Engineering Support for Construction
Phase 5
Checkout and
Startup Support
Phase 6
Project Closeout
Management of
Functional
Safety and
Functional
Safety
Assessment
Safety Lifecycle
Structure and
Planning
Design and Development of Other
Means of Risk Reduction
Design and Development of Safety
Instrumented System
` Safety Integrity System (SIS)
sequence flow charts
Analysis
Installation, Commissioning, and Validation
Verification
Realization
Pump A
Pump B
(HH)
(LL)
START/STOP
M
6900
FIC
012
Modification
6300GZ-013C
6300GZ-013B
6300GZ-013A
6300GZ-012C
START/STOP
6300GZ-012B
M
KS-04B
(HH)
UZ-YY0
PUMP A/B
PROTECTION
(LL)
6300GZ-012A
E
01A
Operation
Operation and Maintenance
Continuous functions
` Instrument self-diagnostics
` SIL verification
Decommissioning
Sequential activities
` Hazard and operability/layers of
protection analysis/safety integrity
level (SIL) studies
` Safety requirements specifications
(documentation)
6900
FIC
012
FICA
01A
` Relying on new process
intensification alternatives
H
123IC
095 L
Start Effective
Construction
LL
` Complex control based on simple
PID controllers
LL
HH
` Variable speed driver system (VSDS)
to minimise energy consumption
` Advanced process control
H
LZA
01B
KS-01B
KS-03A
Rundown
Tank A/B
Selection
` Focused on energy efficiency
NL 950
ET
123LIC
092 L
ET
ET
R3
100
123LZ
091
ET
R7b 50
R8a
123UZ
920
123LZ
096
123LT
095
123LG
094
UZ-ZZ0
TANK A OVERFILL
PROTECTION
` Logic diagrams
123UZ
20
R1
Construction Move-in
KS-01A
123UZ
930
21
123-PGH-069N-250-HF A2H-IH
50
` Define level of automation
` BPCS sequence flow charts
500
123-W-10-50-16C-ET
Automation
Form
Product
Column
123-AD-2-200-16S
123-AD-2-200-16S
RECLAIMER
EFFLUENT
123UXV
092-2
123PI
092
H
Example. How to split the flow of polished water return
at three heat exchangers receiving condensate
123UXV
092-1
123GB
512
123UZV
092
50
SOLVENT
RECLAIMING
SYSTEM
123GS O
512 C
123-PGH-236N-50-HF A2H
DCC BLOWDOWN
FLUE GAS
LO
123R0
096
LO
NOTE 5
123SS
091
123UZ
301
123-PGH-69C-100-64C
SET AT:..BARG
SIZE:..”X..”
123SS
092-B FO
123TT
118
123TI
118
(HPF)
INERLOCK
SET AT:..BARG
SIZE:..”X..”
123-PGH-068N-250-HF A2H
123TI
116
CAUSTIC
32
123SS
092-A
123TI
117
123TI
114
(HPF)
HFA2H
123-EF-002N-..-HAA2H
123TI
114
123TT
114
HFA2H
DMW
HFA2H
Example. Control two flows based on five flow
measurements
123-PGH-067N-250-HF A2H
CO2 PRODUCT
ACTIVATED CARBON
32
HFA2H
TREATED GAS
Future
E-7109
NNF
TI
Demin Water
NCC Tank
CWS
TI
029
FIC
110
Project Phases
P8104
COMBUSTION WATER
Assessment recommended
Future
` Autonomous operation
` Less or no operator alarms
` Balance investment versus
operation costs
NNF
TICA
011A
FIC
010
V-103
81FT
401
` AI based control
` Robotisation
` Dynamic simulation
Notes:
1. Overfilling protection
2. Overheating protection (SP=80˚C)
3. Pump minimum flow protection
H-SEL
TI
020
` Advanced process control
` Redundant instrumentation
Moo4
LSEL
V-104
` Redundant instrumentation
(availability)
Future
0%-100%
Note 2
81FT
412A
` Simple basic process control system
(BPCS) interlocks
0%-100%
LICA
011A
81FT
412B
` Replace pneumatic actuation
by electrical
LI
011A
Note 1
Deaerator
` Keep simple PID control, but
develop complex control
LY
011D
LSEL
81FT
400
` Functional specifications
LY
011B
0%-100%
` Complex control
` Implementation details
` Model based process control
100%-0%
50%-100% 0%-50%
81FC
412A
DIFF. A
Example. Automate import, recycle, transfer and export
of two storage tanks with two pumps
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Contact
Example. Safety life cycle
` Redundant instrumentation
(reliability)
` Sharing instrumentation BPCS/SIS
` More automatic actions in BPCS
` High performance instrumentation
https://www.fluor.com
florin.omota@fluor.com
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