Use Operator Training Simulators

for FCC Units

Authors:
S. Dasgupta, G. Mijares, E. Yap & E. Gbordzoe

Publication / Presented:
Fuel Technology and Management

Date:
July/August 1998

Notes:
The M.W. Kellogg Co., Houston, TX
The fluid catalytic cracking (FCC) of heavier hydrocarbons
into lighter, more valuable products, such as olefins and
gasoline, remains a significant factor in the overall profit-
ability of a refinery. The trend in the hydrocarbon process-
ing industry (HPI) has been increased use of advanced
computer applications, such as advanced control and online
optimization, to improve profitability, efficiency and safety.
Units are also operated with lean staffs to reduce the overall
operating costs.
The need for highly skilled plant operators is therefore
now paramount to ensure smooth and trouble-free plant
operations. The need for increased (and certifiable) training
is the basis for OSHA Guidelines 1910. As a licensor of FCC
technology, our company offers the FCC operator training
simulator (OTS), for the training of operators and engineers
responsible for running these units.
OTS Description
A typical OTS consists of two parts. One part consists of the
simulation computer(s) on which the dynamic simulation of
the process is executed. This dynamic model is ideally of such
quality that responses to simulated disturbances are indistin-
guishable from responses to real disturbances in the plant.
Connected to the simulation computer is a terminal
that is dedicated as an instructor’s console. The instruc-
tor controls the training session by initiating equipment
malfunctions, introducing process disturbances, pausing and
running the simulator, etc.
The second part of an OTS comprises the distributed
control system (DCS) consoles, where the trainees are
seated.
The complete OTS tool therefore provides a simulated,
though realistic, plant control room-like environment for the
training of operators and engineers. The trainee’s interaction
and reaction is similar to that in an actual plant since he or
she cannot distinguish between the simulated and the real
process. An obvious advantage with such a system is that of
realistic but risk-free training since the consequences of the
trainee’s mistakes will not be catastrophic.
Importance of OTS
Rapid advances in computer technology have heightened
awareness and acceptance of an OTS as part of an effective
training program. The major driving factors for an OTS are:
• Improved profitability;
• Enhanced plant operations;
• Extended equipment life;
• Favorable insurance considerations;
• Satisfaction of regulatory mandates (e.g., OSHA
1910);
• Risk-free training.
The installation of computer applications like advanced
process control and optimization in the HPI is beginning to
change the role and required skill set of a plant operator. This
is especially true in the FCCU, where small changes in oper-
ating conditions can greatly impact the plant’s profitability.
A second trend, which aims to improve efficiency by
increasing processing capacity with fewer employees, is also
increasing the burden on engineers and operators “to be
flexible and knowledgeable in a lot of areas in order to effi-
ciently and safely operate the plant.” The combination of the
above two trends will shifty the operator’s role into that of a
more highly skilled decision-making professional.
An OTS is an important central tool in an effective
training program because it allows operators and process
engineers to acquire and maintain their operational skills
and enhance their process understanding. This is especially
valuable in an FCCU, where the interactions between the
manipulated and controlled variables are highly nonlinear
and the plant is being run against multiple constraints. A
solid understanding of the underlying fundamental physical
and chemical forces that drives the catalyst circulation, coke
formation, heat balance and product yields can be readily
achieved by the use of an OTS
Because the conditions and options are simulations
only, training with an OTS is totally risk-free. The trainee
is free to learn by trying different alternatives. This would
not be possible in the real plant because of the danger and
economic impact that might result from the disturbance.
In addition to imparting process understanding, the use of
an actual DCS for the training also ensures that the trainees
become familiar with the regulatory control equipment. A
standardized training program will not only allow the objec-
tive grading of a trainee’s performance for certification but
also minimizes the operating variations between plant shifts.
Major Features
The M.W. Kellogg FCC OTS was developed with a com-
mercial dynamic simulation software with extensive and
versatile training capability, including:
• User-configurable exercises;
• Instructor-initiated malfunctions and disturbances;
• Dynamic process trends;
• Saving and loading snapshots of process conditions;
For more information, visit www.kbr.com
 • Trainee performance monitoring and evaluation;
• Simulation pause/run modes;
• Simulation running mode control (real time or faster/
slower than real time);
• User-friendly GUI instructor console;
• Extensive equipment of library of (pumps, compres-
sors, PID controllers, etc.).
• These are the major features found in an OTS that are
helpful in building an effective training program.
FCC Model
A pivotal criterion of an effective FCC OTS is the dynamic
simulation of the FCCU itself. It is essential that the major
transient behavior of the model closely reflect that of an
actual FCCU. A fully integrated FCCU reactor and regen-
erator model with heat and material balance is necessary
to describe the highly nonlinear interactions between the
regenerator and reactor. The major features of an FCCU that
our OTS model include:
• Regenerator
• Coke and CO combustion kinetics;
• Dilute-phase afterburn;
• Catalyst entrainment into the dilute phase;
• Dilute-phase temperature profile;
• Dense-bed and dilute-phase densities;
• Flue gas composition;
• Cyclone efficiencies;
• Catalyst addition and withdrawal;
• Reactor
• Proprietary-product and coke yields;
• Catalyst deactivation;
• Riser pressure profile;
• Stripper efficiency;
• Feed preheat exchanger.
The previous list provides a brief description of Kel-
logg’s proprietary OTS model of the FCCU. In addition to
modeling the FCC itself, the OTS covers other auxiliary
equipment, such as the combustion air blower, wet gas com-
pressor, riser outlet temperature controllers, feed preheat
controller, stripper level controller, etc.; these were modeled
using standard library blocks in the simulation software.
All key controllers necessary to operate the FCCU in the
plant are available in the OTS. The trainee can manipulate
these controllers to gain greater confidence and understand-
ing of the complex interactions between the variables. For
example, the trainee can see the effect of changing the riser
outlet temperature on gasoline yields, coke make, regenera-
tor temperature, flue gas composition, etc.
Included in the OTS are FCC-specific training exercises
that are important to as basic understanding of the working
and operations of a FCCU:
• Startup and shutdown;
• Changes in combustion air flow (e.g., loss of air
blower);
• High pressure in reactor (e.g., loss of wet gas com-
pressor);
• Low pressure in regenerator (e.g., flue gas valve fails
open);
• Loss of feed;
• Loss of stripping or dispersion steam;
• Changes in feed temperature;
• Changes in feed.
Most of the exercises are preconfigured and saved in
scenario files, ready to be initiated by the instructor during a
training session. Among the many important lessons learned
include:
• Appreciation of the driving forces for catalyst circula-
tion;
• Importance of maintaining adequate pressure drop
across plug valves;
• Importance of coke formation in maintaining the heat
balance;
• Effect of regenerator temperature on catalyst circula-
tion;
• Control of afterburn in the regenerator;
• Correct response to changes in operating conditions,
such as a change in gasoil feed characteristics.
Training Emphasis
The FCCU is a highly complex process because of the nonlinear
interactions of the systems variables (riser outlet temperature,
regenerator temperature, coke formation, product yields, etc.).
As greater demands and expectations are placed on operators,
it is essential that there be a corresponding increase in emphasis
on advanced operator training, which is readily met by the use
of an OTS. When used as part of an effective training program,
it will yield many tangible and intangible benefits.
The OTS is a first-principles model capable of rigorous
heat, material and pressure balances. Experience has shown
that a high-fidelity OTS can be enlisted to perform other
functions, such as troubleshooting, developing new operat-
ing and control strategies, making the simulator a useful tool
not only for training but also for the process and control
engineer.
For more information, visit www.kbr.com