KOP dan Operating

7/27/2019 KOP dan Operating

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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

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>>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



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





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



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



Singkatan:

KOP = Key Operating Parameter

UCL = Upper Control Limit

LCL = Lower Control LimitSUL = Safe Upper Limit

SLL = Safe Lower Limit

SIS = Safety Integrity SystemPAR = Proven Acceptable Ranges

Documents

KOP dan Operating