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研究生：	石祳祥 Reynaldo, Raymond
論文名稱：	在連續製程中兩種不同類型安全連鎖的設計與保養 Design and Maintenance of Two Distinct Types of Safety Interlocks in Continuous Processes
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：	2017
畢業學年度：	105
語文別：	英文
論文頁數：	98
外文關鍵詞：	Corrective maintenance, Preventive maintenance, Interlock, Warm-standby, Cold-standby, Spare, Genetic algorithm, Non-uniform Interval Inspection Time, Weibull Distribution
相關次數：	點閱：106 下載：1
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An interlock is a feature that makes the states of two mechanisms or functions mutually dependent, and the safety interlocks are needed in almost every continuous chemical plant for mitigating the detrimental effects of hazardous incidents. On the various processing units in a plant, the interlocking systems may be installed to achieve two completely opposite goals, i.e., emergency shutdown (type I) and operation sustaining (type II). Thus, the corresponding configurational features and maintenance policies are determined in this study with two separate optimization codes to minimize the expected total life-cycle expenditures for their respective operational objectives. Specifically, the well-established genetic algorithm (GA) has been adopted to produce two distinct MATLAB codes. Non-uniform inspection intervals are adopted for maintenance of the actuators and warm standbys, while the ages of these components are assumed to follow Weibull distributions.
For the single-layer type-I interlocks that are used for emergency shutdown, the encoded data in each binary string should be: (1) the number of measurement channels and the corresponding alarm logic, (2) the numbers of online and spare sensors in each channel and the corresponding voting gate, (3) the number of shutdown channels and the corresponding tripping configuration, (4) the numbers of online and standby actuators in each channel and the corresponding activation mechanism, and (5) the inspection schedule of each shutdown channel.
In order to sustain continuous operation of the critical processes, each type-II interlock is equipped with an online unit, a switch, and one or more warm standby unit. The online unit is usually monitored with a set of known sensors (measurement channels). From the optimum solution, one can obtain the following specifications: (1) the numbers of online and spare sensors in each measurement channel, (2) the inspection schedule of the switch and the number of spares, (3) the inspection schedule of warm standby and the number of its cold standbys.
Finally, two examples, one for each type, are provided in this thesis to demonstrate the feasibility of the proposed approach.

TABLE OF CONTENTS

ABSTRACT	I
ACKNOWLEDGEMENT	II
TABLE OF CONTENTS	III
LIST OF FIGURES	V
LIST OF TABLES	VI
LIST OF ABBREVIATION	VII
SYMBOL DESCRIPTION	VIII
Chapter 1 INTRODUCTION	1
1.	Background	1
2.	Literature Review	1
3.	Research objectives	3
4.	Thesis Framework	3
Chapter 2 BASIC INTERLOCK STRUCTURES	4
1.	General Structure of a Protected System	4
2.	Type-I Interlocks	4
3.	Type-II Interlocks	7
Chapter 3 MAINTENANCE POLICIES OF CRITICAL COMPONENTS	10
1.	Weibull Distribution	10
2.	Corrective Maintenance Policies for Detection Subsystems	11
3.	Preventive Maintenance Policies for Nullifying Subsystems	18
3.1.	Inspection schedule	18
3.2.	Preventive maintenance policies with repairs	18
3.3.	Preventive maintenance policies without repairs	25
Chapter 4 EVALUATION PROCEDURE OF LIFE-CYCLE EXPENDITURE	27
1.	Type-I Interlocks	27
1.1.	Enumeration of Possible Scenarios	27
1.2.	Model Constraints	27
1.2.1.	Alarm Subsystem	27
1.2.2.	Shutdown Subsystem	29
1.3.	Total Expected Life-Cycle Expenditure	30
1.3.1.	Total Expected Life-Cycle Loss	30
1.3.2	Total Expected Life-Cycle Cost of Alarm Subsystem	31
1.3.3	Total Expected Life-Cycle Cost of Shutdown Subsystem	32
1.4.	Example I	32
2.	Type-II Interlocks	36
2.1.	Model Constraints	36
2.2.	Scenario Enumeration	39
2.3.	Total Expected Life-Cycle Expenditure	45
2.3.1.	Total Expected Life-Cycle Loss	45
2.3.2.	Total Expected Life-Cycle Costs	45
2.3.2.1.	Monitoring System	45
2.3.2.2.	Switch	46
2.3.2.3.	Warm Standby	46
2.4.	Example II	47
3.	Budget Limits	51
Chapter 5 GENETIC ALGORITHM	52
1.	Genetic Algorithm	52
2.	Inspection Schedules	52
3.	Type-I Interlocks	55
3.1.	Encoding Scheme	55
3.2.	Chromosome Generation	57
3.3.	Fitness Measure	57
3.4.	Evolution procedure	58
3.5.	Convergence Criteria	59
4.	Type-II Interlocks	60
4.1.	Encoding Scheme	60
4.2.	Fitness Measure	60
4.3.	Convergence Criteria	60
Chapter 6 CASE STUDIES	62
1.	Type-I Interlocks (Refrigeration Case)	62
2.	Type-II Interlocks (Fan System in a Plant)	66
Chapter 7 CONCLUSIONS AND FUTURE WORKS	74
1.	Conclusions	74
2.	Future Works	74
REFERENCES	76
APPENDIX I LEIBNIZ INTEGRAL RULE	78
APPENDIX II BINARY GENETIC ALGORITHM	79
APPENDIX III CORRECTIVE MAINTENANCE CODE	82
APPENDIX IV PREVENTIVE MAINTENANCE CODE	88


                                    

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