Site Acceptance Test

For DCU Section

Bharat Oman Refineries Limited,

Bina

REVAMP OF ADVANCE PROCESS CONTROL

Document No. : S176-BORL-APC-DCU-SAT-01

Date: 31st December 2020

 Revision History

Revision Date Prepared Checked Approved

0 19/11/2020 SDK SM SM
1 30/11/2020 SDK SM SM
2 31/12/2020 SDK SM SM
Table of Contents

1. Introduction ............................................................................................................................. 5

2. SAT & BASE CASE TIMELINE........................................................................................... 5

3. DCU Advance Process Control Status.................................................................................... 6

3.1 HTRMF Controller ......................................................................................................... 6

3.2 GASREC Controller ....................................................................................................... 8

3.3 Optimization Performance ............................................................................................. 9

3.4 RQE Performance ......................................................................................................... 11

4. Benefits ................................................................................................................................. 14

4.1 Product Yield: ........................................................................................................... 14

4.2 LCGO Maximization: .............................................................................................. 14

4.3 CV – Standard deviation: ........................................................................................ 17

4.4 RQE – Standard deviation: ..................................................................................... 20

 ACKNOWLEDGEMENT

We would like to sincerely thank Digitalization team, Technical Services, Operations and
Instrumentation team of BORL, Bina for their assistance and cooperation during the APC revamp
project. Their dedication and commitment have enabled us to complete the project despite several
difficulties.
Special thanks to the BORL DCU operation team and Technical Services group. Their close
cooperation and operational knowledge sharing helped us tremendously in improving our controller
design. The project management and commitment by Digitalization team to meet schedule-targets,
thoughtful insights and encouragement provided by them during the course of this project has helped
in successful and timely completion of this project. The benefit achieved, as calculated because of
APC, is Rs 217.225 Lakhs/year. Majorly the benefit is quantified in LCGO where significant
reduction is observed in LCGO- HCGO overlap. Besides this there are many other improvements
observed which are explained in the report.
 1. Introduction
As part of APC Remodeling in DCU unit, there are two Main Controllers namely HTRMF
and GASREC Controller.

Main No. of No. of Execution

Sl. No Sub Controller No. of DV's
Controller MV's CV's Period
Heater 9 11 2 60 Sec
1 HTRMF
Main Fractionator 6 11 7 60 Sec
2 GASREC Debut 5 6 3 60 Sec

Site Acceptance Test was carried out from 03rd Nov 2020 20:00 hrs to 07th Nov 2020 21:00 hrs. The
purpose of Site Acceptance Test was to evaluate the performance of the controller and to capture the
improvements being made in plant operations as a result of it with respect to base case.

From the SAT conducted for HCU APC the Controller Performance has been given below:

Sl. No Main Controller Sub Controller Uptime (%)

Heater 100
1 HTRMF
Main Fractionator 97.851
2 GASREC Debut 96.944

2. SAT & BASE CASE TIMELINE

SAT Record: DCU Section

START TIME END TIME

03/11/2020 20:00 hrs 07/11/2020 21:00 hrs

Base Case Record: DCU Section

START TIME END TIME

18/12/2019 10:00 hrs 22/12/2019 10:00 hrs

Plant Design Load – 220T/hr

Feed Flow (T/h) Plant Load (%)
S. No Section
Base case SAT Base case SAT
1 DCU 230.85 197.563 104.93 89.8
 3. DCU Advance Process Control Status

3.1 HTRMF Controller

Online status of Heater Controller (Including the plant disturbances)

MV Uptime:

S. NO Tag Description MV Uptime Remarks

1 14FC2005.SV HTR1 PASS1 FLOW 100
2 14FC2006.SV HTR1 PASS2 FLOW 100
3 14FC2007.SV HTR2 PASS1 FLOW 100
4 14FC2008.SV HTR2 PASS2 FLOW 100
5 14TC2113.SV HTR1 PASS1 COT 100
6 14TC2114.SV HTR1 PASS2 COT 100
7 14TC2115.SV HTR2 PASS1 COT 100
8 14TC2116.SV HTR2 PASS2 COT 100
9 14FIC1351.SV HP STEAM FLOW 100

CV Uptime:

S. NO Tag Description CV Uptime Remarks

1 14H1FD1 HTR1 PASS1 FD 100
2 14H1FD2 HTR1 PASS2 FD 100
3 14H1MST1 HTR1 PASS1 MAX SKIN TEMP 100
4 14H1MST2 HTR1 PASS2 MAX SKIN TEMP 100
5 14H2FD1 HTR2 PASS1 FD 100
6 14H2FD2 HTR2 PASS2 FD 100
7 14H2MST1 HTR2 PASS1 MAX SKIN TEMP 100
8 14H2MST2 HTR2 PASS2 MAX SKIN TEMP 100
9 TOTAL_SEC_FEED TOTAL SEC FEED 100
10 14TI1205.PV P102 OUT FLOW 100
11 14TI1801.PV HTR CHARGE TEMP 100
Online status of Main Fractionator Controller (Including the plant disturbances)

MV Uptime:

MV
S. NO Tag Description Uptime Remarks
During drum switchover, it was taken out
1 14TIC1402.SV FRAC O/H TEMP 99.71 of APC for 10 mins on 05/11/2020.
2 14TIC1409.MV LCGO DRAW OPENING 100
3 14FC1401.SV HCGO PUMP AROUND 100
4 14FC1701.SV HCGO WASH FLOW1 100
5 14FC1702.SV HCGO WASH FLOW2 100
Respective RQE:CV "CCR" was taken out
FRAC STRIPPING of APC during Drum switchover, related
6 14FC1602.SV STEAM 90.63 single MV came out of APC

CV Uptime:

S. NO Tag Description CV Uptime Remarks

During drum switchover, corresponding
MV "14TIC1402.SV" was taken out of APC
1 14PCT1402 FRAC TOP PCT 99.7079 for 10 mins on 05/11/2020.
2 14TIC1507 HCGO DRAW TEMP 100
FRAC BTM RECYCLE
3 RECYCLE_RATIO RATIO 100
Due to process constraints, this CV was
REF/SEC FEED not taken online from 03/11/2020 20:00
4 RATIO REF/SEC FEED RATIO 80.9851 hrs to 04/11/2020 14:26 hrs.
5 14TI1409.PV LCGO DRAW TEMP 100
6 NAPHTHA_D95% NAPTHA_D95% 90.854
7 LCGO_D5% LCGO_D5% 90.8883
8 LCGO_D95% LCGO_D95% 90.8883
9 HCGO_D5% HCGO_D5% 90.6306 During drum switchover, RQE's were
taken out of APC as they are not an
10 HCGO_D95% HCGO_D95% 90.8883 important parameter to monitor during
11 CCR CCR IN HCGO 93.2426 that time.
 3.2 GASREC Controller

Online status of GASREC Controller (Including the plant disturbances)

MV Uptime:

S. NO Tag Description MV Uptime Remarks

MV Went "Inactive" because
LEAN LCGO FLOW TO respective "RQE:CV-FG_C3" taken out
1 14FC3603.SV SPNG ABS 86.9021 of APC during Drum Switchover
MV Went "Inactive" because
respective "RQE:CV-FG_C3" taken out
2 14FC3902.SV STAB NAP FLOW 88.2595 of APC during Drum Switchover
DEBUT REBOLING
3 14FIC3703.SV STEAM 100
MV Went "Inactive" because
respective "RQE:CV-FG_C3" taken out
4 14PC3601.SV SPNG ABS PRESSURE 90.6478 of APC during Drum Switchover
MV went "Inactive" for 3 mins on
06/11/2020 as respective CV taken
5 14TIC3701.SV DEBUT TOP TEMP 99.9313 out of APC

CV Uptime:

S. NO Tag Description CV Uptime Remarks

Taken out of APC for 3 mins on
1 14DT3801.PV LPG DENSITY 99.9141 06/11/2020 13:34 hrs
Taken out of APC for 3 mins on
2 14PCT3701 DEBUT TOP PCT 99.9313 06/11/2020 13:34 hrs
3 14PCT3702 DEBUT BTM PCT 100
4 14TI3505.PV DEBUT BTM TEMP 100
During drum switchover, RQE's
5 FG_C3 C3/C4 IN FUEL GAS 90.7852
were taken out of APC as they are
not an important parameter to
6 NAPHTHA_RVP NAPHTHA_RVP 91.0258 monitor during that time.
 3.3 Optimization Performance

Irrespective of MVs/CVs, optimization mode in APC will operate towards its low limit in case of
“Minimization” and operate towards its high limit in case of Maximization function subjected to Low
and High limits being set.

HEATER Controller:
Avg_
S. No. Tag - Description Avg_Lo Limit Avg_Hi Limit Remarks
Value

14TC2113.SV - HTR1
1 PASS1 COT 490 502.37 502.4

14TC2114.SV - HTR1
2 PASS2 COT 490 499.33 499.3

14TC2115.SV - HTR2
3 PASS1 COT 490 500.50 500.5

14TC2116.SV - HTR2
4 PASS2 COT 490 499.32 499.3

5 TOTAL_SEC_FEED 155 257.07 257.1 Operated towards high limit

subjected to "Maximization"
14TI1801.PV - HTR function based on MV limit set
6 CHARGE TEMP 273.09 285.81 290.1 points

14H1FD1 - HTR1 PASS1

7 FD 0 0.0046 1

14H1FD2 - HTR1 PASS2

8 FD 0 -0.0075 1

14H2FD1 - HTR2 PASS1

9 FD 0 0.013 2 Operated towards low limit
subjected to "Minimization"
14H2FD2 - HTR2 PASS2 function based on MV limit set
10 FD 0 -0.0105 2 points
Main Fractionator Controller:

Avg_ Avg_Hi
S. No. Tag - Description Avg_Lo Limit Remarks
Value Limit
Operated towards low limit subjected to
"Minimization" function based on related
CV limit set points. Due to very high noise
in 14FIC1204.PV, Recycle ratio(CV) value
keeps changing and hence wash flow
14FC1701.SV - HCGO (MV)kept changing. As a result, it was not
1 WASH FLOW1 18.15 20.12 20.79 operated closer to low limit value.
Operated towards low limit subjected to
"Minimization" function based on related
CV limit set points. Due to very high noise
in 14FIC1204.PV, Recycle ratio(CV) value
keeps changing and hence wash flow
14FC1702.SV - HCGO (MV)kept changing. As a result, it was not
2 WASH FLOW2 18.15 19.88 20.79 operated closer to low limit value.

14FC1602.SV - FRAC
3 STRIPPING STEAM 357.34 409.25 500.00

Operated towards low limit subjected to

"Minimization" function based on related
4 NAPHTHA_D95% 149.41 151.33 160.00 CV limit set points.
Operated towards low limit subjected to
"Minimization" function based on MV limit
5 LCGO_D5% 190.52 195.50 208.20 set points
GASREC Controller:

Avg_Lo Avg_Hi
S. No. Tag - Description Avg_Value Remarks
Limit Limit
Operated towards high limit
subjected to "Maximization"
function based on MV limit set
points. MV was operated in
limit constraint 10% of the
14PCT3701 - DEBUT TOP times and Limit intervention
1 PCT 49.19 54.64 60.2 was around 44 times.
Operated towards low limit
subjected to "Minimization"
function based on MV limit set
points. MV was operated in
limit constraint 16% of the
times and Limit intervention
2 NAPHTHA_RVP 43.3 46.58 51.6 was around 38 times.

3.4 RQE Performance

LCGO_D5%

RQE Prediction
S. No Time stamp Lab Value Accuracy Remarks
Value

1 04-11-2020 16:00 178.6 180.79 98.7738

2 05-11-2020 17:32 194 192.22 99.08247
3 06-11-2020 20:00 199.7 190.9 95.59339
4 07-11-2020 15:30 188.9 200.62 93.79566
5 08-11-2020 12:30 187.5 185.15 98.74667
Avg Accuracy 97.1984

LCGO_D95%

RQE Prediction
S. No Time stamp Lab Value Accuracy Remarks
Value

1 04-11-2020 16:00 344.3 348.12 98.8905

2 05-11-2020 17:30 346.5 355.11 97.51515
Please note that LAB sample on
3 07-11-2020 15:30 348.1 352.64 98.69578 06thNov 2020 was not entered due to
more variation.
4 08-11-2020 12:30 342.6 349.65 97.94221
Avg Accuracy 98.26091
 HCGO_D5%
RQE
S.
Time stamp Lab Value Prediction Accuracy Remarks
No
Value
1 04-11-2020 16:00 319.8 325.597 98.1873
2 05-11-2020 17:30 315 323.279 97.37175
3 06-11-2020 20:00 321.2 321.813 99.80915
4 07-11-2020 15:30 324.4 322.59 99.44205
5 08-11-2020 12:30 315.4 318.676 98.96132
Avg Accuracy 98.75431

HCGO_D95%
RQE
Lab
S. No Time stamp Prediction Accuracy Remarks
Value
Value
1 04-11-2020 16:00 510 519.431 98.15078
2 05-11-2020 17:32 514 519.993 98.83405
3 06-11-2020 20:00 508 514.53 98.71457
4 07-11-2020 15:30 516 508.06 98.46124
5 08-11-2020 12:30 511.6 510.98 99.87881
Avg Accuracy 98.80789

Naphtha_D95%
RQE Prediction
S. No Time stamp Lab Value Accuracy Remarks
Value
1 04-11-2020 16:00 134.4 153.87 85.51339
2 05-11-2020 17:32 144 144.78 99.45833
Lab sample variation is more for same
3 06-11-2020 20:00 132.9 145.477 90.53649
column profile
Lab sample variation is more for same
4 07-11-2020 15:30 132.8 136.897 96.91491
column profile
Lab sample variation is more for same
5 08-11-2020 12:30 143.8 137.25 95.44506
column profile
Avg Accuracy 93.57364
 Naphtha_RVP
RQE Prediction
S. No Time stamp Lab Value Accuracy Remarks
Value
1 04-11-2020 16:00 46 45.18 98.21739
Lab sample variation is more for same
2 05-11-2020 17:32 41 44.88 90.53659
column profile
3 06-11-2020 20:00 48 48.37 99.22917
Lab sample variation is more for same
4 07-11-2020 15:30 40 47.81 80.475
column profile
Lab sample variation is more for same
5 08-11-2020 12:30 44 37.52 85.27273
column profile
Avg Accuracy 90.74617

CCR
RQE
Lab
S. No Time stamp Prediction Accuracy Remarks
Value
Value
1 04-11-2020 16:00 0.95 1.058 88.63158
2 05-11-2020 17:30 1.02 1.069 95.19608
3 06-11-2020 20:00 0.97 1.049 91.85567
4 07-11-2020 15:30 1 0.973 97.3
5 08-11-2020 12:30 0.97 0.995 97.42268
Avg Accuracy 94.0812

FG_C3+
RQE Prediction
S. No Time stamp Lab Value Accuracy Remarks
Value
1 04-11-2020 06:01 2.46 3.48 58.53659 Lab result variation is high
2 05-11-2020 06:02 0.69 0.647 93.76812 Lab result variation is high
Lab result variation is high. Please note
3 08-11-2020 06:30 1.33 1.237 93.00752 that 2 samples (06th & 07th Nov) were
not entered due to this

Note: The RQE is developed based on limited inputs available. Also, it is observed that variations in
considered inputs (from column) do not reflect much in its lab results. In such condition, accuracy of
this RQE may not be very good.
 4. Benefits
4.1 Product Yield:

Average value
S. NO Description Base case SAT
1 LCGO Yield 27.2791 29.5248
2 HCGO Yield 20.6722 22.5151
3 LPG Yield 3.3271 3.5781
4 Naphtha Yield 9.9145 9.6337
5 Coke Yield 38.807 34.748
6 14FIC1204.PV - DCU Primary Feed 230.849 197.563

Note: Average feed (VR) qualities in Base case and SAT case are as follows:
Base case- VR_D5% & CCR: 524 deg C & 24.9 respectively
SAT case- VR_D5% & CCR: 506 deg C & 23.3 respectively

Due to considerable difference in feed qualities in the two cases, improvement is decided to be
considered based on LCGO- HCGO overlap. The overlap is considerably reduced and that ultimately
helped in improving LCGO yield.

4.2 LCGO Maximization:

S. No Description Value Units

C1 SD in LCGO_D95% during APC OFF 7.247 Deg C
C2 Avg. LCGO flow (14FI3605.PV + 14FI3607.PV) 58.376 Ton/Hr
C3 SD in LCGO_D95% during APC ON 2.094 Deg C
Increase of LCGO_D95% with APC
C4 ∆𝑋 3*(C1-C3) 6.6989 Deg C
Slope of LCGO ASTM curve
C5 =Average(LCGOD95%-LCGOD90%)/5 1.445 Deg C/Vol %
C6 APC Online Factor 0.95
The above increase in LCGO D95% point amount to an
C7 increase in the LCGO D95 vol% by, =C4/C5 4.635917 Vol%
C8 Increase in LCGO mass flow, =C2*C7/100 2.706263 MT/hr
C9 Price of LCGO 25518 Rs/MT
C10 Price of HCGO 23171 Rs/MT
C11 Differential Price, =C10-C11 2347 Rs/MT
C12 On-stream Working hours, =300*24 7200 Hr/year
Benefit from LCGO maximization,
C13 =C6*C8*C12*(C11/100000)*0.5 217.225 Lakh Rs/Year
Notes:
1. C13: Due to varying feed conditions during base case and SAT period, it is decided to consider
50% of the calculated benefit that can be attributed from APC. Hence in consultation with BORL
team, *0.5 multiplication factor is used here.
2. Note: Differential price is used for benefit calculation. This indicates that reduction in HCGO is
increment in LCGO.
3. C5: Slope of LCGO ASTM at heavy end for audit samples = Avg((D95%−𝐷90%)/ 5); Refer to
below table-1.
4. C13: Benefit calculated as Benefit = Increase in mass flow rate × On stream working hours ×
differential price in Lakhs Metric ton × APC online factor × 0.5. Final amount is divided by 100000
for conversion from “Rs.” To “Lakh Rs.”
Table-1
LCGO_D95
95 % Recovery
Sampling Date Sampling Time Density @15°C 90 % Recovery (v/v) Temp (v/v) Temp
04/11/2020 16:00:00 851.3 331.3 344.3
05/11/2020 17:30:00 864.9 342 346.5
07/11/2020 15:30:00 863.9 343.4 348.1
08/11/2020 12:30:00 855.9 335.9 342.6
Average value 859 338.15 345.375
Slope, Avg(D95%-
D90%)/5 1.445

Please find table-2 & table-3 for details on Overlap difference between LCGO_D95% &
HCGO_D5% during base case & SAT.
Table-2
Base case
S. No Time stamp
HCGO_D5%_Lab Value LCGO_D95%_Lab Value Overlap

1 18-12-2019 07:30 354.2 315.8 38.4

2 19-12-2019 18:00 369.5 316.6 52.9
3 20-12-2019 20:00 373.1 316.4 56.7
4 21-12-2019 20:30 369 311.4 57.6
Average_Overlap 51.4

Table-3
SAT
S. No Time stamp HCGO_D5%_Lab LCGO_D95%_Lab Overlap
Value Value Difference
1 04-11-2020 16:00 319.8 344.3 24.5
2 05-11-2020 17:30 315 346.5 31.5
4 07-11-2020 15:30 324.4 348.1 23.7
5 08-11-2020 12:30 315.4 342.6 27.2
Average_Overlap 26.725
Notes:

Stripping Steam:
As per observations and BORL feedback, stripping steam is found having very little impact. Hence,
many times this is stopped also. Hence, this stream is not being considered to visualize any
improvement.

HP Steam Consumption in Pre- heat section:

Plant loads during Base period and SAT period were about 105 % and 90 % respectively. HP steam
consumption depends up on many parameters. During SAT period APC is observed to have used this
well to optimize the pre- heat temp. The average Low and high limit range in APC for the steam was
5000 & 8310 Kg/hr respectively. Thus, steam was consumed purposely in this range. Hence, it is not
being compared with base case period where average consumption was at the rate of around 15148.27
Kg/ hr and average steam consumption was around 7929.39 kg/hr.
 4.3 CV – Standard deviation:

Kindly make a note that, APC tuning was made parallel during SAT period. Hence standard deviation
values during SAT period is more. Apart from that, Limit interventions were also more.

Heater Section:

Standard
Deviation Average value
S.
N Descriptio Base Base SAT_Avg_L SAT_Avg_H
O Tag n case SAT case SAT L L
HTR1 0.064 0.024
1 14H1FD1 PASS1 FD 9 3 0.003 0.0046 0 1
HTR1 0.029 0.012
2 14H1FD2 PASS2 FD 6 3 -0.0055 -0.0076 0 1
HTR1
PASS1
MAX SKIN 1.567 2.165 621.498 635.142
3 14H1MST1 TEMP 8 6 6 3 0 650
HTR1
PASS2
MAX SKIN 1.772 2.380 629.934
4 14H1MST2 TEMP 1 1 661.611 4 0 650
HTR2 0.029 0.025
5 14H2FD1 PASS1 FD 3 5 0.0013 0.0135 0 2
HTR2 0.030 0.011
6 14H2FD2 PASS2 FD 1 1 0.0012 -0.0105 0 2
HTR2
PASS1
MAX SKIN 2.414 2.527 623.608
7 14H2MST1 TEMP 8 8 622.035 8 0 650
HTR2
PASS2
MAX SKIN 1.602 1.597 621.543
8 14H2MST2 TEMP 7 7 633.461 2 0 650
TOTAL_SEC_FEE TOTAL 1.516 257.064 257.072289
9 D SEC FEED 1.319 1 288.648 8 155 5
P102 OUT 215.368 199.389518 229.389518
10 14TI1205.PV FLOW 2.975 4.538 230.359 3 9 9
HTR
CHARGE 285.804 273.089805 290.104564
11 14TI1801.PV TEMP 2.814 4.408 291.774 9 3 7

a) Standard deviation in Heater Max skin temperatures were more in SAT because Limit
interventions in respective MV’s were around 35 times.
b) Standard deviation in 14TI1801.PV & 14TI1205.PV were more in SAT because Limit
interventions in respective MV: 14FIC1351.SV – HP steam flow was around 18 times.
Main Fractionator Section:

Standard
Deviation Average value
S. Base Base
NO Tag Description case SAT case SAT SAT_Avg_LL SAT_Avg_HL

1 14PCT1402 FRAC TOP PCT 1.29 1.57 103.16 105.17 94.80 112.10
HCGO DRAW
2 14TIC1507 TEMP 2.98 4.03 348.59 338.75 334.82 339.28
FRAC BTM
3 RECYCLE_RATIO RECYCLE RATIO 1.71 2.46 8.81 13.30 10.00 15.55
REF/SEC FEED REF/SEC FEED
4 RATIO RATIO 0.03 0.07 0.46 0.63 0.50 0.75
LCGO DRAW
5 14TI1409.PV TEMP 4.19 4.85 202.03 207.32 198.00 207.57

6 NAPHTHA_D95% NAPTHA_D95% 2.41 5.19 136.25 151.33 149.41 160.00

7 LCGO_D5% LCGO_D5% 13.21 7.03 185.45 195.50 190.52 208.20

8 LCGO_D95% LCGO_D95% 7.25 2.09 366.45 355.19 360.00 370.00

9 HCGO_D5% HCGO_D5% 2.13 3.56 315.05 324.76 322.00 325.78

10 HCGO_D95% HCGO_D95% 0.75 2.83 523.60 517.53 505.00 550.00

11 CCR CCR IN HCGO 0.06 0.02 1.19 1.05 0.60 1.00

a) LCGO_D95% - Average Operating value is lesser than Average Low limit set value
during SAT, due to constraints in increasing High limit setpoint of 14TI1409.PV. High
limit of 14TI1409.PV cannot be increased beyond 208 deg C due to process constraints.
LCGO Draw temperature – 14TI1409.PV average value is 207.32 deg C which is
average High limit value. Either Low limit of LCGO_D95% should have been decreased
or high limit of 14TI1409.PV should have been increased further. Please note that,
LCGO_D95% RQE average accuracy is 98%. Apart from that, respective MV –
14TIC1409.MV : LCGO Draw opening valve was operated at 100% opening around
37.5% of the times.

b) Recycle ratio: Transmitter 14FI1204.PV has higher noise and confirmed the same with
operations team as well. Due to this higher noise, HCGO wash flow was manipulated
more frequently to keep respective “CV - Recycle ratio.PV” within limits. Hence CCR
average value is slightly higher than average high limit value as it is second priority CV
comparing to Recycle ratio which is first priority CV. Standard deviation in Recycle ratio
is more due to transmitter noise issue.
 c) Standard deviation in 14TIC1507.PV – HCGO Draw Temperature is more during SAT
because limit intervention was there around 40 times.

GASREC Section:

Standard Deviation Average value

S. Base
NO Tag Description Base case SAT case SAT SAT_Avg_LL SAT_Avg_HL
1 14DT3801.PV LPG DENSITY 0.0031 0.0056 0.523 0.52 0.51 0.52
DEBUT TOP
2 14PCT3701 PCT 1.85 2.57 53.61 54.64 49.19 60.19
DEBUT BTM
3 14PCT3702 PCT 5.27 10.49 139.65 149.87 144.22 158.96
DEBUT BTM
4 14TI3505.PV TEMP 2.65 3.07 175.89 180.36 178.61 182.07
C3/C4 IN FUEL
5 FG_C3 GAS ** 0.732 ** 2.19 0.62 1.88
6 NAPHTHA_RVP NAPHTHA_RVP 3.77 2.99 48.25 46.58 43.30 51.58

** -- Please note that FG-C3+ sample frequency is very less during Base case period. Hence std.
deviation and average values are not calculated for the same.

a) FG-C3+ average value is higher than average high limit because respective MV’s
14FC3603.SV - Lean absorber flow, 14FC3902.SV – Stabilized naphtha flow &
14PC3601.SV – Sponge absorber pressure were operated at limit constraints around 18%,
22% and 32% of the times. Hence CV was only 32% compliant with respect to its limits.
b) Standard deviation in 14PCT3701 & 14PCT3702 is more in SAT because limit intervention
was around 18 & 16 times in respective CV limits. Also, limit intervention was around 44 &
38 times in corresponding MV’s.
 4.4 RQE – Standard deviation:

Sl. Standard Deviation Average Value

Tag
No Base case SAT Base case SAT
1 LCGO_D5% 13.21 7.031 185.45 189.74
2 LCGO_D95% 7.247 2.094 366.45 345.38
3 HCGO_D5% 2.128 3.563 315.05 319.16
4 HCGO_D95% 0.748 2.833 523.6 511.92
5 Naphtha_D95% 2.41 5.192 136.25 137.58
6 Naphtha_RVP 3.767 2.993 48.25 43.8
7 CCR 0.061 0.0248 1.188 0.982
8 FG_C3+ ** 0.7318 ** 1.4933

** -- Please note that FG-C3+ sample frequency is very less during Base case period. Hence std.
deviation and average values are not calculated for the same.

a) Even though Standard deviation in HCGO_D5% & HCGO_D95% were more in SAT
period, RQE accuracy is around 98.8%. Standard deviation is more because corresponding
Tray temperature – 14TIC1507.PV standard deviation is more.
b) LAB sample variation in SAT is more in Naphtha_D95%. Hence standard deviation is more.