Networking

CAPE Alliance
Implementation Research

(Project 2311)

Computer Aided Process Engineering Tools, Techniques and Environments

(proposed)

http://CAPE-Alliance.ucl.org.uk

Tools for Concurrent Front-End Engineering

Long-Term Objectives & Problems with Today's Capabilities
"Front End" engineering (i.e. design of the process, together with its control, safety, environmental, and other systems) is always on the critical path and there is always severe pressure to reduce timescales and to deliver earlier and better information to "downstream" plant engineering disciplines (such as vessels, machines, instruments, and electrical). The current approach to front end development and design is largely sequential - specific issues are addressed one at a time and, as new ideas and concepts are developed and as problems are exposed, revisions are made and the sequence repeated. This approach results in revision loops which build up in both process and plant design and consequent problems with costs, schedules, quality and audit trails. The current generation of design tools both reflects and reinforces this approach. (See Fig. i)
Select Process Configuration
Consultation with Plant Design (vessels, instruments, electrical, piping, etc)

Normal Operating Conditions

Technical & Cost Optimisation

Revisions

Release/Revision

Equipment Design & Selection

Capital & Operating Costs

Batch Operations

Continuous Operations

Dynamics & Control

Safety & Relief

Environment & Waste Management

Operability, Resilience & Reliability

Flexible & Campaign Operations

Utilities

Control & Instruments, Operability, Reliability, etc Abnormal Operating Regimes

Release/Revision

Safety & Relief

Environmental Studies

Fig. ii
Process Package to Plant Design Revisions from Plant Design

Utilities

Fig. i It is vital that tools and techniques are developed which enable the earlier generation of better, more balanced designs, which are "complete" in the sense that all key issues have been addressed, even if only approximately, and so there are no "hidden surprises".

To make such improvements requires the introduction of increased concurrency, both within front end engineering and between front end engineering and the disciplines of plant engineering, so that a more parallel or "broadside" and truly multidisciplinary approach can be adopted from the earliest stages, exposing and addressing issues which would otherwise cause later recycling of the design. (See Fig. ii) Issues to be addressed in the longer term will include, for example, the following: Appropriate development of new business processes to exploit the opportunity, for example, support for multi-disciplinary teams, innovation & rapid prototyping, alliances & remote working. More thorough integration of the design of both continuous & batch processes and their measurement, control, safety & environmental protection systems at an early stage. Our objective will be inherently better processes, to improve the basic performance and behaviour characteristics of our processes by eliminating problems, not covering them up or trying to control them by expensive additional equipment. Early-stage development of operating and safety procedures, interlocks, etc

(Note that a number of other critical issues, such as information management, decision-support and simulation of continuous and batch processes are addressed elsewhere in the Alliance's proposals.) The benefits of making substantial improvements in this area include the following: a dramatic reduction in the time taken to develop new processes and to respond to market opportunities safer, cleaner, more flexible, more efficient & more sustainable processes Reduced timescales & rapid prototyping: timely incorporation of new technologies. "Design Warehouse": capture and sharing of knowledge and design information, rationale, decisions, etc. Ensure that desired operating characteristics are built-in, not afterthoughts

Such concurrent engineering techniques have been introduced in other sectors and great claims are made for the benefits of doing so (see, for example, CALS initiative of US DoD). (More detailed information may be found on the Alliance website.)

Near-Term Objectives & Priorities

The above objectives represent a major programme and will inevitably take a number of years to complete. It has been remarked that "the longest journey begins with the first step" and so a number of sub-topics have been identified, as listed below, which are of particularly high priority and which therefore constitute an appropriate "first step" - ie. Phase 1 of the programme. Note that these topics and their relative priorities are still evolving and so this lists will be subject to change & refinement during the process of proposal preparation & consortia formation. We will endeavour to keep those with a "registered interest" informed and up-to-date (and, of course, you are very welcome to contribute to this evolution). The focus in this area will be on introducing closer concurrency/integration of the development & design of the process with that of its utilities, measurement, control, safety & environmental protection networks. The initial focus will be on the "nonprocess" aspects, to deliver the new tools & techniques that process engineers require: follow-up projects will focus on integrating these tools with the "traditional process engineering" tools in the supporting environment. There is significant overlap with Conceptual Process Development and particularly close coordination between these two areas will be maintained. Benchmarking of existing approaches on a variety of different industrial examples, to refine R&D objectives, identify BAT (Best Available Technology) and develop Good Practice Guidelines Appropriate interactions with other areas (especially Teamworking Environment, Process Models & Conceptual Development projects) to ensure CoFEE requirements are addressed and to assess deliverables and CoFEE-customisation requirements Measurement, Control & Automation: optimisation of sensor & controller networks/systems (incl. soft sensors): move away from "multiple-SISO" towards true MIMO control improved methods for the effective development of operating & safety procedures, interlocks, etc Tools to facilitate front-end engineering of batch processes (joint with CPD): catalogue engineering & detailed performance rating "plant simulation"

routes & recipes batch-specific control & automation S'88 & SP'95, etc scheduling/peak loadings Tools to assist with Safety, Health & Environmental & Sustainability studies (joint with CPD): earlier estimation of inventories (incl. pipework) HazId, HazOp & HazAn studies QRA, incl. rare catastrophes SHE metrics & visualisation analysis of transients, emergencies, abnormal operating regimes, fault propagation, etc: improved design of relief & waste management systems fault trees, FMEA, FCCA, etc, for routine use by process engineers