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研究生： 陳星志
Chan, Sing-Zhi
論文名稱： 化工廠中多事件連鎖與多層次備援機制之最適化
Optimization of Multi-event Interlocks and Multi-layer Standby Mechanisms in Chemical Plants
指導教授： 張珏庭
Chang, Chuei-Tin
學位類別： 碩士
Master
系所名稱： 工學院 - 化學工程學系
Department of Chemical Engineering
論文出版年： 2020
畢業學年度： 108
語文別： 英文
論文頁數： 152
外文關鍵詞： Interlock, Expected loss, Standby, Reliability, Genetic algorithm
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    • The design and maintenance of interlock and standby systems are critical issues to be addressed for safety and reliability of modern chemical processes. Although the processing units in modern chemical plants are often equipped with various safety interlocks, almost every conventional design was created by conjecturing the proper protective mechanism against a single abnormal event. In reality, multiple independent abnormal events may take place in various processes. Thus, there is a definite need to develop a systematic approach for designing the multi-event interlocks. On the other hand, every critical unit in a continuous process must always function normally, and the multi-layer standby mechanisms are usually installed to sustain uninterrupted operation. Furthermore, there is also another class of continuous processes operated under varying loads and, thus, the multi-layer standby mechanisms are needed to ensure that the fluctuating demand is always satisfied. The ultimate objective of the present study is to construct the mathematical programming models to address the optimization issues in implementing the aforementioned multi-event interlocks and multi-layer standbys. Extensive case studies are presented in this thesis to demonstrate the feasibility and effectiveness of the proposed methods.

    ABSTRACT i CONTENTS ii LIST OF TABLES vi LIST OF FIGURES vii CHAPTER 1 INTRODUCTION 1 1.1 Background 1 1.2 Literature Review 2 1.2.1 Safety interlocks 2 1.2.2 Standby mechanisms in long-term processes under a constant load 5 1.2.3 Standby mechanisms in short-term processes under varying loads 8 1.3 Research Objectives 9 1.3.1 Multi-event safety interlocks 9 1.3.2 Standby mechanisms in long-term processes under a constant load 9 1.3.3 Standby mechanisms in short-term processes under varying loads 9 1.4 Thesis Structure 10 CHAPTER 2 OPTIMAL DESIGNS OF MULTI-EVENT INTERLOCKS 11 2.1 Illustrative Example 11 2.2 Superstructure 14 2.3 Mathematical Programming Model 18 2.4 Case Studies 24 2.5 Concluding Remarks 33 2.6 Nomenclature 34 CHAPTER 3 OPTIMAL DESIGNS OF MULTI-LAYER STANDBY MECHANISMS IN LONG-TERM PROCESSES UNDER A CONSTANT LOAD 36 3.1 Multi-layer Standby Mechanisms in Long-term Processes under a Constant Load 36 3.2 Superstructure in Single Protection Layer 38 3.3 Generalized Event Tree 41 3.4 Model Formulation for Characterizing a Single Protection Layer 44 3.4.1 Online units 44 3.4.2 Monitoring subsystem 44 3.4.3 Switch 46 3.4.4 Warm standby 47 3.5 Mathematical Description of Fault Propagation Scenarios 47 3.6 Objective Function 49 3.6.1 Total expected lifecycle loss 50 3.6.2 Expected lifecycle cost of monitoring subsystem 50 3.6.3 Expected lifecycle cost of switches 51 3.6.4 Expected lifecycle cost of standby subsystem 52 3.7 Case Studies 53 3.8 Concluding Remarks 65 3.9 Nomenclature 65 CHAPTER 4 OPTIMAL DESIGNS OF MULTI-LAYER STANDBY MECHANISMS IN SHORT-TERM PROCESSES UNDER VARYING LOADS 69 4.1 Multi-layer Standby Mechanisms in Short-term Processes under Varying Loads 69 4.2 Superstructure in Single Protection Layer 72 4.3 Generalized Event Tree 76 4.4 Model Formulation for Characterizing a Single Protection Layer 81 4.4.1 Online units 81 4.4.2 Monitoring subsystems 82 4.4.3 Switch 83 4.4.4 Warm standby 84 4.5 Total Expected Lifecycle Loss 84 4.6 Objective Function 88 4.6.1 Expected lifecycle cost of monitoring subsystems 89 4.6.2 Expected lifecycle cost of switches 89 4.6.3 Expected lifecycle cost of standby subsystem 90 4.7 Case Studies 90 4.8 Concluding Remarks 101 4.9 Nomenclature 102 CHAPTER 5 CONCLUSIONS AND FUTURE WORKS 106 5.1 Conclusions 106 5.2 Future Works 107 APPENDICES 109 (A) Determination of Financial Loss Caused by Every Possible Scenario in Multi-event Interlocks 109 (B) Corrective Maintenance Policy of the Monitoring Subsystem in Processes under a Constant Load 112 (C) Preventive Maintenance Policy of Switches 115 (D) Preventive Maintenance Policy of Warm Standby in A Single Layer 116 (E) Mathematical Representation of a 3-layer Standby Mechanism for Long-term Processes under a Constant Load 119 (F) Derivations of Distribution Functions in Processes under Varying Loads 124 (G) Corrective Maintenance Policy of α- and β- Monitoring Subsystems in Processes under Varying Loads 126 (H) Mathematical Representation of a 4-layer Standby Mechanism for Short-term Processes under Varying Loads 129 REFERENCES 146 AUTOBIOGRAPHY 152 List of Publications 152

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