Process Control Design

Typically in new builds and large modifications, there is no dedicated owner of the overall process operability. Instead, the process control design is done in individual packages and process systems with limited coordination on overall operability.

Often, there is a organizational segregation into operations and project, where the project organization may have limited practical operational experience and therefore also missing a library of proven control solutions.

This leads to the following issues:

  • Equivalent functional requirements are realized differently in different systems, rather than by a common best practice solution.

  • Design is utilizing control solutions proven not to work in practice rather than robust proven control solutions

Right in the first place


To secure a sufficiently high focus on process operability from design, it is suggested that the process control design is separated from the process design and that an overall Process Control Responsibility is established.

ABB Process Performance can then, based on input from process design on operating envelopes and planned operations, deliver a process control based on our library of control solutions proven in operation. The control solutions will then support operators in efficiently carrying out the planned operations within the operating envelope.

Benefits: 

  • Significant time savings during engineering, as well as for re-engineering of issues discovered in commissioning and start-up.

  • An easier to operate plant with consistent control solutions

References

Customer confidential - integration of large modification 

Smooth and flawless integration of modifications 

During Phase 1 it is estimated that the benefit was in the range of 120 MSM3 reduced deferment of produced gas + zero cost of re-engineering and waiting time onsite amounting to about 500kUSD - due to zero process control related trips during the integration

During the integration of the new pipeline reception facilities (Phase 2) - it is estimated that the benefit was in the range of 300 MSM3 reduced deferment of produced gas + zero cost of re-engineering and waiting time onsite amounting to about 250kUSD due to zero process control related trips during the integration

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