Operator Training System for Hydrocracking unit: Real world questions and Answers.

Aleksandr Muravyev and Martin Berutti. MYNAH Technologies, Chesterfield, MO

Abstract

The paper presents a case study on development and implementation of the operator training system for a green-field
Hydrocracker unit at a large North American refinery. The users wanted a realistic simulation for operator training and
automation design validation. However, the project schedule was compressed and the refinery staff had no experience
with developing or maintaining simulators. The challenge of the project team was to find an appropriate balance between
a simple simulation model and sophisticated unit operations modeling that mirrored the real process. The solution for this
challenge was in the use of a commercially available simulation package designed for operator training, with flexible high-
fidelity modeling objects. For instance, the pressure-flow functions for the closed gas track of the unit, implemented using
basic simulator, were augmented with models of the compressors and a simple reactor kinetics, taking into account the
reactor topology and holdups. The separation block of the unit was simulated using a high fidelity distillation objects,
integrated with the process simulator. The distillation package provided simulation of such features, as a real world
pressure control for various configurations of the column overhead, weeping at the trays, and “heat shock” in the reboiler.
The simulator was successfully used for the plant operator training before the unit start up, as ongoing tool for training in
the critical situations (reactor temperature runaways, equipment and control loop malfunctions, e.t.c.), and for testing,
tuning and fixing the errors of the DCS control strategies. Customer has used the simulator to find hidden issues in the
control strategies that would cause unscheduled downtime as well as certify the operators on the control of the unit.

1. Introduction

Benefits of using Operator Training Systems (OTS) and simulation are proven and compelling. The
benefits include faster project startups and time-to-market, improved product quality, reduced plant
incidents, and improved operator proficiency In most cases the cost of the simulation system is
recovered well before the startup of the process unit, and investment in the simulation software has the
greatest return of any capital investment.

This paper presents a case study on development and implementation of the operator training system
for a green-field Hydrocracker unit at a large North American refinery. The users wanted a realistic
simulation for operator training and automation design validation. The OTS should provide tools [1] that
- Assist in safe, environmentally sound and profitable startups, shutdowns and emergency
response of the new Hydrocracking unit
- Reduce the number and severity of unplanned events
- Help with unit control and optimization
The OTS should allow the Hydrocracker process leads to train on the unit before it started up, and later
be used to implement ongoing training and qualification of new Hydrocracker process leads.

The challenge before the project team was to develop a simulation model that would be adequate to
the purposes of the operator training and provide additional functionality for process control and
optimization.

2. Challenges of the Hydrocracking Process simulation

The dynamic model of the process should meet the goals of the operator training. In this section we will
give a brief description of the simulated process, then consider the operator training situations
(scenarios) user would like to implement, and, finally, evaluate the model functionality and complexity
needed.
2.1 Process description

A Hydrocracking Unit (figure 1) catalytically cracks heavier petroleum fractions in the presence of
hydrogen to make more valuable products. In the Reactor Section the hydrotreating reactions occur
first and remove Sulfur, Nitrogen and the other undesirable components. The hydrocracking reactions
convert some of the feed molecules into the smaller molecules that can be separated into valuable
naphtha product streams. These components are separated then in the Fractionation Section of the
unit into streams that will go into making finished gasoline and distillate products. A Recycle Gas
Compressor returns non-reacted hydrogen to the reactors. A Make up Gas Compressor (reciprocal)
supplies make-up hydrogen to replace the gas, consumed in the reactions.

Compression Section

Light Cycle Oil Reaction Section

Light Gas Oil Recycle

Makeup Hydrogen

Light Gas

Liquefied Petroleum Gas (LPG)

Light Naphtha
Product
Fractionation Heavy Naphtha

Heavy-Heavy Naphtha

Diesel Fuel

Figure 1. A Hydrocracking Unit schematic

The unit liquid feed can be represented by two generalized components, Light Cycle Oil (LCO) and
Light Gas Oil (LGO) having different reactivity and heat of reaction. The unit gas feed, hydrogen, is
used as both, a reagent and a cooling (quenching) agent.

2.2 Operator training scenarios

The user was interested in the development of realistic and effective scenarios for basic operator
training and response to critical situations of the process operation (associated with unit upsets and
malfunctions of equipment or instruments). The list of the upset situations includes:
- Reaction runaway due to the feed disruption or malfunction of the reactor quenching valves
- Recovery of the unit after runaway and depressurizing of the system
- Process upset due to sudden change of the feed composition
In these scenarios the operator should recognize the situation and take the actions to bring the process
to normal operation or to safe shutdown conditions. The simulator can be utilized to train the operations
engineers on basics of operation and control strategies for distillation, heaters, and/or reactors.

2.3 Model functionality and complexity needed

The operator training scenarios, suggested above, define the requirements for process model
functionality and complexity. Particularly, in order to simulate the unit recovery after runaway and
depressurizing the model should contain an adequate description of the hydrogen recycle and make up
tracks, including the compressor models. The simulation of the reaction runaway due to malfunction of
the reactor quenches assumes precise enough modeling of the individual reactor beds, including the
heat of reaction and kinetics. The models of the feed composition propagation through the unit and
kinetics/heat of reaction for the individual components are needed to simulate the process upsets due
to sudden change of the feed composition or feed flow disruption. In order to provide basic operator
training in distillation operation and control (product fractionation area) the multivariable column models
for the main interacting process parameters (pressures, temperatures, and flow rates and compositions
of the inlet/outlet streams) are needed.

A development of these models can require extensive time and resources. However, on this project the
schedule was compressed and the workforce limited. Therefore, the challenge was to find an
appropriate balance between a simple simulation model and sophisticated unit operations modeling
that mirrored the real process.

3. Solutions: Flexible combining of the Process simulation complexity

The solution for this challenge was in the use of a commercially available simulation package designed
for operator training, with flexible high-fidelity modeling objects. A balance of high and medium
complexity models was selectively applied to the unit operations of the process. MiMiC Simulation
Software [2], was used as the simulation solution for the project. MiMiC has utilities for auto generation
of the model skeleton and a variety of embedded functions for simulation of common process unit
operations (heat exchangers, vessels, mixers, flow rates of the vapor and liquid streams, e.t.c). It
provides the tools for fast and easy development of medium complexity process model. The medium
complexity models were augmented with high fidelity models for three main process areas: hydrogen
recycle and make up tracks, reactors, and product separation.

3.1 Hydrogen recycle and make up tracks

The pressure-flow functions for the closed gas track of the unit, implemented in the simulation, were
supplemented with models of the compressors. The Recycle Gas Compressor was simulated by the
special models, employed the centrifugal compressor model using approximations of its design
pressure- flow curves. The models were implemented in the simulation software User Calculation
blocks.

The simulation of the Make up Gas Compressor, which contains several reciprocal compression
stages, consists of a series of User Calculation blocks. Each block includes a model of the polythropical
compression along with the interstage gas conditioning. The model also simulates the stage loading
and unloading functions with realistic compressor performance simulation.
3.2 Reactor section

A number of a high fidelity features, taking into account a simplified reaction kinetics, reactor topology
and holdups, were incorporated in the reactor section model.

The overall reactor model consists of the interacting models for the reactor beds. The model for each
bed contains material and heat balances, which include transformation balances and heat of reactions
for two generalized liquid components, LCO and LGO, and for the hydrogen gas component. The
simplified reaction kinetics was modeled using the piece-linear approximation of the Arrchenius type
equation for rate of reactions in the working interval of temperatures with correction coefficients for the
reactor pressure and liquid holdup. Since the beds different in the roles, hydrotreating or hydrocracking,
the model contains two sets of the reaction equations, respectively.

These equations of the reactor model were implemented using a set of interacting User Calculation
blocks in the simulation software.

3.3 Distillation Package for the Product Fractionation

The Product Fractionation block of the unit was simulated using a high fidelity distillation objects,
integrated with the basic process simulator. These objects were created, initialized, and integrated with
the rest of the process simulation using the MiMiC Distillation Package [3].

The Distillation Package allows the user to build dynamic models for a full-scale distillation column
simulation, including reboiler, condenser, and reflux receiver (figure2). The column can have up to five
feed and side withdraw streams, three tray sections with different diameters, and up to ten components,
separated in the column. The features of the column object include two liquid phase separation in the
reflux receiver, constant or variable options for column pressure and tray pressure drop, tray weeping.

A distinctive feature of the model is the overhead section layout that makes possible simulation of a
variety of the real world pressure control loops (described, for instance, in [4]) used in the distillation.
Particularly, the column pressure can be controlled (see the basic column configuration, figure 2):
- By manipulation of cooling agent flow rate to the condenser
- Using control valve on the vapor bypass around condenser to the reflux drum
- Using directly control valve on the vapor stream to the condenser
- By manipulation of flow rate of the outside vapor stream from/to reflux drum (split range control
commonly used with the partial condenser)

The Distillation Column Package offers to user a convenient interface to each of the objects, providing:
- Creation and configuration of the object
- Initialization and running of the object
- Visualization tools to monitor the object performance
An example of the run time user interface to the Debutanizer object is shown in figure 3. It contains a
real time profile of the column liquid composition, offering a valuable insight into the object.

The distillation column model built with the Distillation Packages has the ability to be initialized and
started from a Cold or Warm (near steady-state) status. User controls within the Distillation Modeling
Package allow the user to perform initialization off-line and then launch the object to run on-line with a
basic simulator.
 A _ V lv 1

C ondenser

Vnt C W O ut C o o lin g w a te r F c w

D is tilla tio n c o lu m n V_D1

R e flu x D ru m

R e flu x L _ R

H e a v y liq u id L _ H v L iq

Feed 2 D is tilla te p ro d u c t L _ D

S id e w ith d ra w 2

Feed 1

S id e w ith d ra w 1

V_B
R e b o ile r
A_v H e a tin g s te a m

H E c o n d e n s a te

L_B + V_B B u tto m p ro d u c t L _ B

Figure 2. Basic Configuration of the Distillation Column with two liquid phase separation in reflux drum

The Distillation Column models for the Product Fractionation section were configured, initialized and
launched on-line using the Distillation Package features, described above. Note, that the package
allows creation and initialization of new models while the others are already running on-line, providing
flexibility in the process of building and tuning of the entire plant model.
Figure 3. Object user interface with graph of the column liquid composition profile

The distillation package provided simulation of such features, as a real world pressure control for
various configurations of the column overhead, weeping at the trays, and “heat shock” in the reboiler.
An example of a complex pressure control scheme of the real process is shown in figure 4. It includes
the column pressure control loop using the valve at the vapor inlet to the condenser and the pressure
difference loop, controlled by the valve on the “hot vapor bypass” around condenser. Due to the
flexibility provided by the Distillation Package, this scheme was implemented in the model without
compromise.

Figure 4. DCS screen of the column with the process controls

The Operator Training Systems for the new Hydrocracking unit was developed by means of combining
of a commercially available simulation package designed for operator training, with flexible high-fidelity
modeling objects. The selective application of high and medium complexity models to the unit
operations of the process, provided simulator functionality that completely met or exceeded the
customer expectations.

The simulator was successfully used for the plant operator training before the unit start up, as ongoing
tool for training in the critical situations (reactor temperature runaways, equipment and control loop
malfunctions, e.t.c.), and for testing, tuning and fixing the errors of the DCS control strategies. The
customer has used the simulator to find hidden issues in the control strategies that would cause
unscheduled downtime as well as certify the operators on the control of the unit.

References

1. Anne Walztoni and Todd Anstine, “The Refinery Behind the Monitor: DeltaV training System for
Greenfield Hydrocracker”, in Proceedings of Technical Conference, 2006 Emerson User Global
Exchange, October 2006, Nashville.

2. MiMiC Product Bulletin, http://www.mynah.com/software_documentation.asp, 2006

3. MiMiC Distillation Package Product Bulletin, http://www.mynah.com/index.asp, 2006

4. Béla G. Lipták, “Instrument Engineers' Handbook, Fourth Edition, Volume Two: Process Control
and Optimization”, ISA, 2005