Contoh KOP KOP's (for2007) Description (of KOP) Set point (value orprofile) Operating Window (absolute limits ordeviation (%) from target) Effect 1 out of window Effect 2 out ofwindow Corrective action (standard) SOP nr Mon ito rin g / recording (manual orSCADA) Criteria for reporting in MM Being out of window (but within operator correction zone); when to send indicator to morning meeting (% of time, # ofcorrection) Operatorcorrection zone limit (absolute value or % of set point) Effect 1 out ofoperatorcorrection zone Specific action when out ofoperatorcorrection zone TT30504 TT30404 Reactor Column Head Temp Determined by production order100 < T >105 Set point ± 5% in °C when under vacuum > 105 C Loss ofGlycol < 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 ReactorViscosity Determined by production orderTarget Specification on Production orderOff-Specification Product Monetary Loss Correcti ons SOP 57 SCADA Hourly Check Sheet Out of Specification Off S pecification Q3 / Q4 batches Check Trends Inform QA Dept. MM PT30401 PT30501 Reactor Vacuum Profile Determined by production orderSet point ± 5% in mbarBTT of f-spec Quality Problems Check Vac Pumps Check Vac CoolerH91301 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 ofservices eg Steam Inform Maintenance MM R30401 R30501 Reactor Nitrogen Flow Determined by production orderSet point ± 5% in l/min Quality Problems Poor ColourVariations 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 WaterFlow Cooling waterTemp. 200 m3/hraaaaaaaaa 25 °C > 150 < 250 m3/hraaaaaaaaaaaaaaaa >>30 °C Extended drop times and Quality Problems BTT o ff-spec Check C ooling 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 Ste am Pressure 95 PSI ± 1 0 PSI f rom Set point Failure ofReactor drop valves A5/A6 liquid unavailable- Plant Downtime Check Steam GeneratorSOP 11 SCADA Hourly Check Sheet 30 mins out of window < 60 PSI Plant DowntimeI nform Maintenance MM FT90251 FT90250 IncineratorAqueous 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 ofprocess waste leading to Plant Downtime Expensive off- site disposal Inc flow rate Check Burners Check Filters SOP 108 S CA DA Shift managerDaily 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) ReactorBatch 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. K OP SPEC Standard correct i on mode (proactive) Pr oblem zone Key Operating Parameters List - Ellesmere Port Ver.2.0
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