KOP dan Operating
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Transcript of KOP dan Operating
7/27/2019 KOP dan Operating
http://slidepdf.com/reader/full/kop-dan-operating 1/6
Contoh KOP
KOP's
(for 2007)
Description
(of KOP)
Set point
(value or profile)
Operating
Window(absolute limits or
deviation (%)
from target)
Effect 1
out of window
Effect 2
out of window
Corrective
action(standard)
SOP nr Monitoring
/ recording(manual or
SCADA)
Criteria for reporting in
MMBeing out of window (but
within operator correction
zone); when to send
indicator to morning
meeting (% of time, # of
correction)
Operator
correction zonelimit
(absolute value
or % of set point)
Effect 1
out of operator
correction
zone
Specific
actionwhen out of
operator
correction
zone
TT30504
TT30404
Reactor Column
Head Temp
Determined
by production
order
100 < T >105
Set point ± 5% in °C
when under vacuum
> 105 C Loss of
Glycol
< 100 C Slow
Reaction
> 105 C
Corrections
Reactor Cooling
Reduce N2 flow rate
Check Reflux Filters
SOP 94,
95
SOP 94,
95
SCADA
Hourly Check
Sheet
30 mins out of window > 115 C Loss of Glycol
Q2 / Q3
Full Cooling
MM
R30401
R30501
Reactor
Viscosity
Determined
by production
order
Target Specification
on Production order
Off-Specification
Product
Monetary
Loss
Corrections SOP 57 SCADA
Hourly Check
Sheet
Out of Specification Off Specification Q3 / Q4
batches
Check Trends
Inform QA
Dept.
MM
PT30401
PT30501
Reactor Vacuum
Profile
Determined
by production
order
Set point ± 5% in
mbar
BTT o ff-spec Qualit y
Problems
Check Vac Pumps
Check Vac Cooler
H91301
SOP 129 SCADA
Hourly Check
Sheet
30 mins out of window Under SCADA
control >
1 Hour without
vacuum
Q3 batches Inform
Maintenance
MM
TT90101
FT90101
Thermal Oil
Temperature /
Thermal Oil Flow
260 °C Set point ± 5% in °C BTT off-spec Pump
damage
Check Primary Oil
Pump
Check Hygrotherm
SOP 10 SCADA
Hourly Check
Sheet
1 hr out of window T < 200 T > 285 Q3 batches
Loss of
services eg
Steam
Inform
Maintenance
MM
R30401
R30501
Reactor Nitrogen
Flow
Determined
by production
order
Set point ± 5% in l/min Quality Problems
Poor Colour
Variations in
cook time
BTT off-spec Steam N2 line SOP 35 SCADA
Hourly Check
Sheet
Report always for PBC
1 hr out of window
> 10% set point Q2 / Q3
batches
Inform
Maintenance
MM
FT90301
TT90301
TT90301
Cooling Water
Flow
Cooling water
Temp.
200 m3/hr
aaaaaaaaa
25 °C
> 150 < 250 m3/hr
aaaaaaaaaaaaaaaa
>>30 °C
Extended drop
times and Quality
Problems
BTT off-spec Check Cooling Pump
Check Fan operation
SOP 130 SCADA
Hourly Check
Sheet
1 hr out of window < 150 m3/hr
>30 °C
Plant Downtime
Q2/Q3
Inform
Maintenance
MM
PT90401 St eam Pressure 95 PSI ± 10 PSI from Set
point
Failure of
Reactor drop
valves
A5/A6 liquid
unavailable-
Plant
Downtime
Check Steam
Generator
SOP 11 SCADA
Hourly Check
Sheet
30 mins out of window < 60 PSI Plant Downtime Inform
Maintenance
MM
FT90251
FT90250
Incinerator
Aqueous and
Organic flow
rates
Aq 3.0 lts/m
Org 0.23
lts/min
Aq 2.0 - 4.0 lts/min
Org 0.2 - 0.25 lts/min
Build up of
process waste
leading to Plant
Downtime
Expensive off-
site disposal
Inc flow rate
Check Burners
Check Filters
SOP 108 SCADA
Shift manager
Daily Checklist
1 hr out of window <2.0 lts/min Aqu.
<0.2 lts/min Org.
Process waste
build up
Inform
Maintenance
MM
(PRIORITY 1)
EP Batch Time
Target (BTT)
Reactor
Batch time
spec. sheet
Mid Target Set point ±
30 mins
Inconsistent
Product
Planning
Issues
Report via AU tool SCADA
AU
Weekly
Performance
Spreadsheet
Report via AU tool Check Trends
Inform QA
Dept.
KOP SPEC Standard correc t ion mode (proac t ive) Prob lem zone
Key Operating Parameters List - Ellesmere Port Ver.2.0
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Contoh KOPNo.
Tag
Number Description Unit
Normal
Set-
point
Lower
limit
value
Consequense if
below lower limit
Action if the
lower limit is
reached
Upper
limit
value
Consequense if
upper limit is
exceeded
Action if the
upper limit is
reached
Remarks Display
a b c d e f g h i j k l l
Sheet-2, Heat Transfer Salt System
1 AIC-3001 O2 in flue gas from F 3001 % volume 3.5 2
C : Pembakaran
tidak sempurna, COyang terbentuk
bertambah
tambah flowudara pembakar
via FIC 3014
10C: Effisiensipembakaran turun
kurangi flow
udarapembakar via
FIC 3014
Yes
2 FI-3014 Air to air fan K 3001 Nm3/hr 23000 NA
C: Pembakaran
tidak sempurna, CO
yang terbentuk
bertambah
tambah flow
udara pembakar
via FIC 3014,
kontrol dengan
AIC-3001
25000C: Effisiensi
pembakaran turun
kurangi flow
udara
pembakar via
FIC 3014,
kontrol dengan
AIC-3001
No
3 FI-3012 Natural gas flow to furnace Nm3/hr 1800 NA NA NA 1900 C: Pemakaian fuelboros
Atur
pembakaran
dengan
menyesuaikan
beban sertamonitor O2 di
flue gas dengan
kontrol AIC-
3001
Yes
4 PI-3016Pressure Nitrogen in salt
vesselmBarG 25 5
C: VSV 3013
membuka dan udara
luar akan
masuk.Terjadi
oksidasi salt
sehingga temperatur
pelelehan salt naik
Tambah flow
nitrogen ke salt
vessel via FI-
3022
60
C: PSV 3012 akan
popping dan jika
tidak maka PSE
3011 akan pecah
kurangi flow
nitrogen ke salt
vessel via FI-
3022
Kondisi BV
sample 50 %
open
No
5 TIC-3022Salt outlet F 3001 to reactor
R-3101o C 435 420
C: Temperature
reaktor yang
diharapkan tidak
tercapai
naikkan setting
TIC-3022,kurangi flow
urea feed ke
reaktor jika tidak
bisa diatasi
maka plant
harus stop
445
C: Furnace akan
trip oleh TSH 3020
atau salt furnace
akan over heating
Turunkan
temperatur via
setting TIC-
3022
No
6 LI-3002 Level Salt vessel V 3002 % 25 15
C: Pompa salt akan
trip bila level sampai
ke LSL-3002
make-up larutan
salt30
C: Kalau ada case
drain, maka level
akan menyentuh
LAH
NA No
7 PI-3009 Fuel gas supply BarG 19 15
C: tekanan fuel di
furnace berkurang
dan bisamengakibatkan
furnace trip
naikkan tekanan
fuel via setting
PIC-3009, kalautidak bisa maka
harus turun rate
40 NA NA
supply fuel ke
furnace diatur
oleh PCV-3008&PCV300
9
No
Sheet-3, NH3 Supply
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Action
UCL
LCL
Pro-active
Re-active
In control
Action
Definitions:
• Set point: green line
• Operating window, green range: in
control
• Action window, orange range:
operator action required, pro-active
• Action window, red range: process not
in optimal condition, direct operator
action required, report and support.
• Operating window is always narrower
than the Safe Operating Window.
Set point
Measure performance:
Operating Window, Action window
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KOP dan Operating Window
LCL
(K)OPPressure control
Safe Upper Limit, (design limit of process or system)
Rupture
Rupture
Operating limit, (limits from SHE-point of view where action needs to
be taken. Either by operator due to alarms, procedure or instruction,
or by SIS, whatever comes first ).
M O C
M O C
Safe Lower Limit, (design limit of process or system)
UCL
LCL
Operating limit, (limits from SHE-point of view where action needs to
be taken. Either by operator due to alarms, procedure or instruction,
or by SIS, whatever comes first ).
UCL
PAR