Process Control

Introduction to Operability

Riezqa Andika
 What is Operability?

LAH

Basic Flowsheet
LAL
L
2 Design with Operability
LC
LC
1 1

FC
1 FC
1

TC
2 TC
1

F
4
fuel
T
10 T
11
T
12

T
13
 What is Operability?

▪ Is design complete when we have a solution for the base

case material and energy balances?
 What is Operability?

▪ Is design complete when we have a solution for the base

case material and energy balances?

NO
It could be unsafe, unreliable, be unable to satisfy
production quantity or quality changes – and many more
deficiencies!
 What is Operability?

▪ Ensuring that the plant has the capacity and flexibility to

achieve a range of operating conditions safely, reliably,
profitably and with good dynamic performance and
product quality.

▪ Process Operability ≈ Robust Design

Some engineers prefer the term “Robust Design”. The two terms have the same general
meaning.
 Operability

▪ We need to regulate the flow, but how complex should

the equipment be?

▪ Rank designs for simplicity, cost, reliability, flexibility and

other factors that you select.
F
A
F

B
C
F

D
 Operability

Design A
▪ Strengths: It can measure and influence the flow,
simplicity, and low cost.
▪ Weaknesses: It must shutdown process to repair or
replace faulty (e.g., leaking) control valve, cannot ensure
tight shutoff.
 Process Design Procedure

Often performed for But, we need to operate plant over a range

one operating point of conditions, including many operating
points and transitions between them.
 Key Operability Issues

▪ Operating window
▪ Flexibility and controllability
▪ Reliability
▪ Safety & equipment protection
▪ Operation during transitions
▪ Dynamic Performance
▪ Efficiency
▪ Monitoring & diagnosis
 Operating Window
Solvent

Shape of operating window?

T

Reactant

Coolant

Principles: Size equipment!

▪ Depends of variability
infeasible
▪ Depends on flexibility
▪ Not rectangular!
infeasible feasible
 Flexibility and Controllability

Q = U A (T) Which to influence?

PC

T too high
CW
NC

LC

Not recommended!
 Flexibility and Controllability

Q = U A (T) Which to influence?

Fully open

CW
PC

NC

LC

Recommended!
 Reliability
LAH
L LAL To flare
2 What aspects contribute to reliability?
LC
1

FC
1

TC
2 TC
1

F
4
fuel
T
10 T
11
T
12

T
13

* Copyright by CCPS/American Institute of Chemical Engineers

 Reliability
LAH
L LAL To flare
2

LC
1
By-pass valves
Diversity FC
1

TC
2 TC
1

F
4
fuel
T
10 T
11
T
12

T
13
Parallel pumps Hot spot

* Copyright by CCPS/American Institute of Chemical Engineers

Safety and Equipment Protection
EMERGENCY/COMMUNITY RESPONSE

CONTAINMENT

RELIEF
• Concentrate on
Safety Instrumented System the first four
ALARMS layers
BPCS • Stay close to
the process
 Safety and Equipment Protection
L
LAH
LAL To flare Safety Relief
2

Alarm
LC
1 SIS for low flow rate

FC
1

TC
2 TC
1

F
4
fuel
T
10 T
11
T
Temperature
12
control
T
13

Fail closed valve

* Copyright by CCPS/American Institute of Chemical Engineers

 Safety and Equipment Protection
HAZOP (hazard and operability study) method provides a structured manner for
safety analysis (using qualitative analysis)
Note the specific location
Unit: ________Fired heater____________________

Node:___air pipe after compressor and valve_ Parameter: __Pressure____________________

Guide Word Deviation Cause Consequence Action

Low pressure in the Stoppage of power Uncombusted fuel in SIS based on the
lower fuel pipe node to motor or turbine the fire box – danger rotation of motor
turning the of explosion shaft *
compressor
Uncombusted fuel –
Principles wasted fuel

Break of coupling “ SIS based on

FC
between motor and rotation of
compressor compressor shaft*
Failure of “
feed
compressor, e.g., (plus danger from
Engineering practice TC
breakage of blades
Closure of air valve
flying metal)
“ Fail open valve
due to failure
Any of the above “ SIS that measures
product
the flow of air after
the pipe and
air activates the
fuel
shutdown if the flow
if too low
Closure of air valve “ Air flow controller
due to poor decision with ratio to fuel
by operator flow
 Operation During Transition

Special equipment and procedures (controls) are

required during transition.

Steady-state processes
▪ Start-up and shutdown
▪ Regeneration
▪ Short runs with frequent switches
▪ Load following (highly variable demand)

Unsteady-state processes
• Batch
 Operation During Transition
LAH
L LAL To flare
2
Disposition of effluent during
LC start-up
1 (recycle, flare, storage, etc.)

FC
1

TC
2 TC
1

F
4
fuel
T
10 T
11
T
12

Heating required during

13 Extra sensor with large range
start-up
* Copyright by CCPS/American Institute of Chemical Engineers
 Assignment

Read “The Truth Is Out There” by Cahyo Hardo

Priyoasmoro!