FCCU Toolkit · Hi-Spec Solutions Honeywell Hi-Spec Solutions • 16404 N. Black Canyon Hwy. •...

Hi-Spec Solutions

FCCU Toolkit

TP-SWFCCURevision 2.2

2/98

AP13-200

Hi-Spec Solutions

Hi-Spec Solutions

FCCU Toolkit

TP-SWFCCURevision 2.2

2/98

AP13-200

Copyright, Notices, and Trademarks

Printed in U.S.A. – © Copyright 1999 by Honeywell Inc.

While this information is presented in good faith and believed to be accurate,Honeywell disclaims the implied warranties of merchantability and fitness for a

particular purpose and makes no express warranties except as may be stated inits written agreement with and for its customer.

In no event is Honeywell liable to anyone for any indirect, special or consequentialdamages. The information and specifications in this document are subject to

change without notice.

TDC 3000 and TotalPlant are U. S. registered trademarks of Honeywell Inc.

Other product names are trademarks of their respective owners.

HoneywellIndustrial Automation and Control

2500 West Union HillsPhoenix, AZ 85023

(602) 313-4788

Table of Contents

Catalyst Circulation Rate Calculation .........................................................................................1

Measured Conversion Calculation ..............................................................................................2

Octane Number Calculation ........................................................................................................3

Product Yield Calculation ...........................................................................................................4

Severity Calculation ....................................................................................................................5

Hi-Spec Solutions

Honeywell Hi-Spec Solutions • 16404 N. Black Canyon Hwy. • Phoenix, AZ 85023

Advanced Control Package

FCCU Catalyst Circulation RateCalculation

CONTROLLED

Jan 1997Revision 2.2

Hi-Spec Solutions

Proprietary Notice

This work contains valuable confidential and proprietary information and is subject to anyconfidentiality or nondisclosure agreements between Honeywell and The Customer. Disclosure, use,or reproduction of Honeywell material outside of The Customer is prohibited except as authorized inwriting by Honeywell. Disclosure, use, or reproduction of The Customer material outside ofHoneywell is prohibited except authorized in writing by The Customer.

This unpublished work is protected by the laws of the United States and other countries. The workwas created in 1995. If publication occurs, the following notice shall apply:

© 1995, Honeywell Hi-Spec Solutions. All rights reserved.

TDC 3000 is a trademark of Honeywell, Inc.

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Contents

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Contents

Table of ContentsProprietary Notice.....................................................................................................................................1

Overview.........................................................................................................................................1

Acronym List ..................................................................................................................................2

Hardware and Software Requirements ...........................................................................................3

Instrumentation (Process Inputs) ....................................................................................................4

Process Diagram .............................................................................................................................5

Detailed Description .......................................................................................................................6

Point Structure ..................................................................................................................7

Process Inputs ...................................................................................................................8

Configuration Inputs .......................................................................................................10

Calculation Outputs ........................................................................................................13

Error Codes ...................................................................................................................................16

Diagnostic Error Codes...................................................................................................17

Array Location Error Codes............................................................................................20

Molecular Weight Error Codes .......................................................................................21

Hydrocarbon Enthalpy Error Codes................................................................................22

Superheated Steam Enthalpy Error Codes ......................................................................23

Configuration and Tuning.............................................................................................................24

Biases in the FCCU Catalyst Circulation Rate Program ................................................25

Algorithms ....................................................................................................................................27

Installation Procedure ...................................................................................................................30

Preparation for Installation .............................................................................................31

Custom Data Segment (CDS) and Parameter List (PL) Installation...............................32

Building FCCU Catalyst Circulation Rate Calculation Point.........................................33

Configuration Graphics Installation..............................................................................................34

Configure Calculation Point .........................................................................................................35

Point Configuration Using Graphic CCR_CFG .............................................................36

Point Configuration through Direct CDS Entry..............................................................42

Link CL Programs...........................................................................................................48

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Overview

1

Overview

Definition. The FCCU Catalyst Circulation Rate is the mass flow rate of catalystcirculating between the Regenerator and Reactor sections.

Application. The catalyst circulation rate is an important performance parameter for anFCCU. This rate is also an important input for cracking severity and yield models.

Calculation. The Catalyst Circulation Rate program calculates the catalyst circulationrate based on a riser heat and material balance using input process temperatures,pressure, and flows. The program also calculates combined riser feed properties.:

• Processinputs:

Temperatures, pressures, and flows

• Characterizationinputs:

Watson K and specific gravity

• Calculatedvalues:

Molecular weight, enthalpy of hydrocarbon andsteam streams, and Catalyst Circulation Rate.

Incentive. 1. To provide an on-line estimate of catalyst circulation.

2. To provide inputs for cracking severity calculations.

3. To provide inputs for product yield calculations.

4. To provide a real-time input for use in advanced control applications.

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FCFCU Catalyst Circulation Rate Calculation Acronym List

2

Acronym List

Term Acronym

Application Module AM

Local Control Network LCN

Universal Station US

control language CL

process variable PV

custom data segment CDS

pounds per square inch psi

Parameter List PL

CL object code file extension AO

thousand barrels per day MBPD

pounds per hour PPH

Fluidized Catalytic Cracking Unit FCCU

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FCFCU Catalyst Circulation Rate Calculation Hardware and Software Requirements

3

Hardware and Software Requirements

Requirement Description

Hardware Platform TDC 3000 AM

Special Boards None

Other Computing Systems None

LCN Release Release 300 or later

AM Load Modules None

US Load Modules None

Other Packages None

Other Control Applications None

Software Inputs Specific gravities and Watson K factors for the input riser feed streammust exist as points on the LCN

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FCCU Catalyst Circulation Rate Calculation Instrumentation (Process Inputs)

4

Instrumentation (Process Inputs)

Process Input1 Required Recommended

Riser feed flow rate(s) X

Riser steam flow rate(s) X

Riser feed temperature(s) X

Riser steam temperature X

Regenerator bed temperature X

Reaction temperature X

Riser steam pressure X

Reactor pressure X

Regenerator bed pressure X

1 Required inputs can sometimes be obtained by inference. However, calculations based upon inferred data can be less accurate than calculations based upon direct readings.

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Catalyst Circulation Rate Calculation Process Diagram

5

Process Diagram

R i s e r

Regenerator

Reactor

Regenerated Catalyst

Feed

Spent Catalyst

Reaction Products

Heat and Material Balance

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FCCU Catalyst Circulation Rate Calculation Detailed Description

6

Detailed Description

The tables in this section describe the following Catalyst Circulation Rate programarchitecture:

• Point Structure

• Process Inputs

• Configuration Inputs

• Calculation Outputs.

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FCCU Catalyst Circulation Rate Calculation Point Structure

7

Point Structure

Point Structure

Point Type AM Regulatory, CL

PV_Type CL

CTL_Type Any

Custom Data Segment CAT_CDS.CL

Algorithm CAT_CIRC.CL

Insertion Point PV_ALG

Slot 5

Output The calculated catalyst circulation rate is displayed as the point’s PV

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FCCU Catalyst Circulation Rate Calculation Process Inputs

8

Process Inputs

Process Inputs

Critical2

Parameter Description Units Yes No

FLOW_PT(1) Tagname of riser feed 1 flow rate Any flow unitsX





FLOW_PT(6) Tagname of riser steam 1 flow rate Any flow unitsX





TEMP_PT(1) Tagname of riser feed stream 1temperature

°F or °CX


°F or °CX


°F or °CX


°F or °CX


°F or °CX

TEMP_PT(6) Tagname of riser steam input temperature °F or °CX

TEMP_PT(7) Tagname of Regenerator bed temperature °F or °CX

TEMP_PT(8) Tagname of reaction temperature °F or °CX

PRESS_PT(1) Tagname of reactor pressure Any pressure unitsX

PRESS_PT(2) Tagname of riser steam pressure Any pressure unitsX

GRAV_PT(1) Tagname of riser feed stream 1 gravity °API or none (S.G.)

Continued

2 Critical indicates that a bad input causes the output of the calculation to be set BAD.

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FCCU Catalyst Circulation Rate Calculation Process Inputs

9

Process Inputs (Continued)

Process Inputs

Critical


GRAV_PT(2) Tagname of riser feed stream 2 gravity °API or none (S.G.)X




WATK_PT(1) Tagname of riser feed stream 1 Watson K NoneX





CALC_PT(1) Tagname of riser feed stream 1 nitrogencontent

Wt %X


Wt %X


Wt %X


Wt %X


Wt %X

CALC_PT(6) Tagname of riser feed stream 1 sulfurcontent

Wt %X


Wt %X


Wt %X


Wt %X


Wt %X

CALC_PT(11) Tagname of measured mass percentconversion of feed

Wt %X

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Configuration Inputs

10

Configuration Inputs


Parameter Description Units

T_BIAS(1) Additive bias to riser feed stream 1 temperature Same units asTEMP_PT(1)





T_BIAS(6) Additive bias to riser steam temperature Same units asTEMP_PT(6)

T_BIAS(7) Additive bias to Regenerator bed temperature Same units asTEMP_PT(7)

T_BIAS(8) Additive bias to reaction temperature Same units asTEMP_PT(8)

P_BIAS(1) Additive bias to reactor pressure Same units asPRESS_PT(1)

P_BIAS(2) Additive bias to riser steam pressure Same units asPRESS_PT(2)

ENGPAR(1) Number of riser feed flow inputs (O < ENGPAR(1) ≤ 5) N/A

ENGPAR(2) Number of riser steam flow inputs (O < ENGPAR(2) ≤ 5) N/A

ENGPAR(3) Reference reaction temperature °F

ENGPAR(4) Reference Regenerator bed temperature °F

ENGPAR(5) Reference mass percent conversion of feed Wt %

ENGPAR(6) A1; Scaler heat of reaction coefficient None

ENGPAR(7) A2; Reaction temperature heat of reaction coefficient None

ENGPAR(8) A3; Regenerator temperature heat of reaction coefficient None

ENGPAR(9) A4; Mass conversion heat of reaction coefficient None

ENGPAR(10) Flag to force calculation BAD( 0 => Do not set BAD; 1 => Set calculation BAD)

N/A

ENGPAR(11) Convective riser heat loss MBtu/hr

CONV_FAC(1) Input temperature unit flag; 0 => °F; 1 => °C

N/A

CONV_FAC(2) Input gravity type flag:0 => API ; 1 => Specific gravity

N/A

Continued

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11

Configuration Inputs (Continued)



CONV_FAC(3) Riser feed flow rate (FLOW_PT(1..5)) multiplicativeconversion factor

From input unitsto MBPD

CONV_FAC(4) Input pressure (PRESS_PT(1..2)) multiplicative conversionfactor

From input unitsto psi

CONV_FAC(5) Riser steam flow rate (FLOW_PT(6..10)) multiplicativeconversion factor

From input unitsto PPH

CONV_FAC(6) Output catalyst circulation rate multiplicative conversionfactor

From (shortton)/min todesired units

FILTER(1) Filter time for riser feed 1 flow input Minutes





FILTER(6) Filter time for riser steam 1 flow input Minutes





FILTER(11) Filter time for riser feed 1 gravity Minutes





FILTER(16) Filter time for riser feed 1 Watson K factor Minutes





FILTER(21) Filter time for riser feed 1 nitrogen content Minutes





FILTER(26) Filter time for riser feed 1 sulfur content Minutes


Continued

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12







FILTER(31) Filter time for riser feed 1 temperature input Minutes





FILTER(36) Filter time for riser steam temperature input Minutes

FILTER(37) Filter time for Regenerator bed temperature input Minutes

FILTER(38) Filter time for reaction temperature input Minutes

FILTER(39) Filter time for reaction pressure input Minutes

FILTER(40) Filter time for reactor steam pressure input Minutes

FILTER(41) Filter time for measured mass conversion Minutes

LAB_BIAS(1) Multiplicative bias to calculated catalyst circulation rate N/A

LAB_BIAS(2) Additive bias to calculated catalyst circulation rate Same units asCALC_VAL(1)

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Calculation Outputs

13

Calculation Outputs

Calculation Outputs


PVCALC Calculated catalyst circulation rate User units

CALC_VAL(1) Calculated catalyst circulation rate User units

CALC_VAL(2) Calculated οAPI gravity of combined riser feed streams οAPI

CALC_VAL(3) Calculated mass flow rate of combined riser feed streams MPPH

CALC_VAL(4) Calculated Watson K factor of combined riser feed streams None

CALC_VAL(5) Calculated molecular weight of combined riser feedstreams

lb/lb-mole

CALC_VAL(6) Mass fraction of riser feed stream 1 None





CALC_VAL(11) Calculated temperature of combined riser feed streams οF

CALC_VAL(12) Calculated nitrogen content of combined riser feed streams Wt %

CALC_VAL(13) Calculated sulfur content of combined riser feed streams Wt %

CALC_VAL(14) Calculated enthalpy of riser liquid hydrocarbon feed MMBtu/hr

CALC_VAL(15) Calculated enthalpy of riser feed vapor product MMBtu/hr

CALC_VAL(16) Calculated enthalpy of riser steam input streams MMBtu/hr

CALC_VAL(17) Calculated enthalpy of riser steam output stream MMBtu/hr

CALC_VAL(18) Total calculated heat entering riser MMBtu/hr

CALC_VAL(19) Calculated heat of reaction MMBtu/hr

CALC_VAL(20) Calculated catalyst specific heat Btu/lb/οF

MOLWT(1) Calculated molecular weight of riser feed stream 1 lb/lb-mole





FILT_VAL(1) Filtered value of riser feed 1 flow rate Input units




Continued

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14

Calculation Outputs (Continued)

Calculation Outputs



FILT_VAL(6) Filtered value of riser steam 1 flow rate Input units





FILT_VAL(11) Filtered value of riser feed 1 gravity input Input units





FILT_VAL(16) Filtered value of riser feed 1 Watson K factor Input units





FILT_VAL(21) Filtered value of riser feed 1 nitrogen content Input units

FILT_VAL(22) Filtered value or riser feed 2 nitrogen content Input units




FILT_VAL(26) Filtered value of riser feed 1 sulfur content Input units




FILT_VAL(30) Filtered value or riser feed 5 sulfur content Input units

FILT_VAL(31) Filtered value of riser feed 1 temperature input Input units


Continued

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15

Calculation Outputs

Calculation Outputs





FILT_VAL(36) Filtered value of riser steam temperature input Input units

FILT_VAL(37) Filtered value of Regenerator bed temperature input Input units

FILT_VAL(38) Filtered value of reaction temperature input Input units

FILT_VAL(39) Filtered value of reactor pressure input Input units

FILT_VAL(40) Filtered value of riser steam pressure input Input units

FILT_VAL(41) Filtered value of measured mass conversion Input units

STATUS(1) Diagnostic indication of location and possible causes ofprogram error

N/A

STATUS(2) Diagnostic indication of array location or subroutine error N/A

REV_NO Program revision number N/A

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Error Codes

16

Error Codes

The tables in this section describe the following program error codes:

• Diagnostic error codes

• Array Location error codes

• Molecular weight error codes

• Hydrocarbon enthalpy error codes

• Superheated steam enthalpy error codes.

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Diagnostic Error Codes

17

Diagnostic Error Codes


Parameter Value Meaning

STATUS(1)3 0.0 No errors

1.0 Set calculation BAD flag on [ENGPAR(10)<>0]

2.0 Input number of riser feed streams is outside the range 1 to 5[ENGPAR(1)]

3.0 Input number of riser steam flows is outside the range 1 to 5[ENGPAR(2)]

4.0 FLOW_PT(1..5) has a null point entered (see STATUS(2) in"Array Location Error Codes")

5.0 FLOW_PT(1..5) has a bad PV (see STATUS(2) in "ArrayLocation Error Codes")

6.0 GRAV_PT(1..5) has a null point entered (see STATUS(2) in"Array Location Error Codes")

7.0 GRAV_PT(1..5) has a bad PV (see STATUS(2) in "ArrayLocation Error Codes")

8.0 GRAV_PT(1..5) is outside specific gravity range of 0.5 to 1.2 (seeSTATUS(2) in "Array Location Error Codes")

9.0 WATK_PT(1..5) has a null point entered (see STATUS(2) in"Array Location Error Codes")

10.0 WATK_PT(1..5) has a bad PV (see STATUS(2) in "ArrayLocation Error Codes")

11.0 WATK_PT(1..5) is outside Watson K factor range of 7 to 15 (seeSTATUS(2) in "Array Location Error Codes")

12.0 CALC_PT(1..5) has a bad PV (see STATUS(2) in "ArrayLocation Error Codes")

13.0 CALC_PT(6..10) has a bad PV (see STATUS(2) in "ArrayLocation Error Codes")

14.0 TEMP_PT(1..5) has a null point entered (see STATUS(2) in"Array Location Error Codes")

15.0 TEMP_PT(1..5) has a bad PV (see STATUS(2) in "ArrayLocation Error Codes")

16.0 Error in calculating MOLWT(1) (see STATUS(2) in "MolecularWeight Error Codes")



Continued

3 STATUS(1) indicates errors in the calculation.

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18

Diagnostic Error Codes (Continued)



STATUS(1) 19.0 Error in calculating MOLWT(4) (see STATUS(2) in "MolecularWeight Error Codes")


21.0 Mass flow rate of combined riser feed streams is<= 0.1 MPPH

22.0 FLOW_PT(6..10) has a null point entered (see STATUS(2) in"Array Location Error Codes")

23.0 FLOW_PT(6..10) has a bad PV (see STATUS(2) in "ArrayLocation Error Codes")

24.0 TEMP_PT(6) has a null point entered

25.0 TEMP_PT(6) has a bad PV





30.0 PRESS_PT(1) has a null point entered

31.0 PRESS_PT(1) has a bad PV

32.0 PRESS_PT(2) has a null point entered

33.0 PRESS_PT(2) has a bad PV

34.0 CALC_PT(11) has a null point entered

35.0 CALC_PT(11) has a bad PV

36.0 Error in calculating riser feed 1 stream enthalpy (see STATUS(2)in "Hydrocarbon Enthalpy Error Codes")





41.0 Error in calculating molecular weight of combined riser feedstreams (see STATUS(2) in "Molecular Weight Error Codes")

42.0 Calculated molecular weight of combined riser feed streams is<= 0.1 lb/lb mole

Continued

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19

Diagnostic Error Codes (Continued)



STATUS(1) 43.0 Error in calculating exiting riser feed stream enthalpy (seeSTATUS(2) in "Hydrocarbon Enthalpy Error Codes")

44.0 Error in calculating input riser steam enthalpy (see STATUS(2) in"Superheated Steam Enthalpy Error Codes")

45.0 Error in calculating exiting riser steam enthalpy (see STATUS(2)in "Superheated Steam Enthalpy Error Codes")

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Array Location Error Codes

20

Array Location Error Codes



STATUS(2) 4 0.0 No errors

1.0 An error occurred in processing the first element in theSTATUS(1) defined array

2.0 An error occurred in processing the second element in theSTATUS(1) defined array

3.0 An error occurred in processing the third element in theSTATUS(1) defined array

4.0 An error occurred in processing the fourth element in theSTATUS(1) defined array

5.0 An error occurred in processing the fifth element in theSTATUS(1) defined array

4 STATUS(2) indicates the array location of the STATUS(1) error returned.

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Molecular Weight Error Codes

21

Molecular Weight Error Codes

Molecular Weight Error Codes



1.0 Calculated molecular weight has a bad value

2.0 Input specific gravity has a bad value

3.0 Input Watson K has a bad value

-1.0 Input specific gravity or Watson K is equal to or less than 0.0

5 STATUS(2) indicates errors returned by the molecular weight calculation subroutine.

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FCCU Catalyst Circulation Rate Calculation Hydrocarbon Enthalpy Error Codes

22

Hydrocarbon Enthalpy Error Codes

Hydrocarbon Enthalpy Error Codes



1.0 Calculated hydrocarbon stream enthalpy has a bad value

2.0 Riser hydrocarbon stream temperature has a bad value

3.0 Input reactor pressure has a bad value

4.0 Riser hydrocarbon stream Watson K has a bad value

5.0 Riser hydrocarbon stream specific gravity has a bad value

6.0 Riser hydrocarbon stream type has a bad value

7.0 Input atmospheric pressure (psi) has a bad value

8.0 Riser hydrocarbon stream temperature is outside the allowablerange of 0 to 1200 οF

6 STATUS(2) indicates errors returned by the hydrocarbon enthalpy calculation subroutine.

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FCCU Catalyst Circulation Rate Calculation Superheated Steam Enthalpy Error Codes

23

Superheated Steam Enthalpy Error Codes

Superheated Steam Enthalpy Error Codes



1.0 Calculated superheated steam enthalpy has a bad value

2.0 Riser steam temperature has a bad value

3.0 Riser steam pressure has a bad value

4.0 Calculated saturated steam enthalpy has a bad value

-1.0 Riser steam temperature (οK) is equal to or less than 0.0 or theriser steam absolute pressure (psia) is less than 1.0

7 STATUS(2) indicates errors returned by the superheated steam enthalpy calculation subroutine.

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Configuration and Tuning

24

Configuration and Tuning

This section describes the parameters and values used to configure and tune the packageto a specific application.

Biases

• Temperature Bias

• Pressure Bias

• Catalyst Circulation Bias.

Tuning

There are no user tuning parameters associated with the FCCU Catalyst CirculationRate Calculation.

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Biases in the Catalyst Circulation Rate Program

25

Biases in the FCCU Catalyst Circulation Rate Program

The FCCU Catalyst Circulation Rate program is equipped with the following additivebiases:

• Temperatures for the riser steam flows, riser feed stream flows, and the Regeneratorbed.

• Pressures for the riser steam and Reactor.

• Multiplicative and additive biases for the circulation rate

Bias Parameters

Parameter Description

T_BIAS(1..5) Additive bias to input riser feed stream temperatures TEMP_PT(1..5)

T_BIAS(6) Additive bias to input riser steam temperature TEMP_PT(6)

T_BIAS(7) Additive bias to input Regenerator temperature TEMP_PT(7)

T_BIAS(8) Additive bias to input reaction temperature TEMP_PT(8)

P_BIAS(1) Additive bias to input Reactor pressure PRESS_PT(1)

P_BIAS(2) Additive bias to input riser steam pressure PRESS_PT(2)

LAB_BIAS(1) Multiplicative bias to calculated catalyst circulation rate

LAB_BIAS(2) Additive bias to calculated catalyst circulation rate

Pressure and Temperature Bias. The pressure biases (P_BIAS(1..2)) andtemperature biases (T_BIAS(1..8)) are added to the input values before performance ofthe unit conversions and should be entered in the same units as the input pressure andtemperatures.

The T_BIAS parameters are used when there is a known error in the input temperatures[TEMP_PT(1..8)] indication. Similarly, the P_BIAS parameters are used when there isa known error in the pressure [PRESS_PT(1..2)] indication.

Multiplicative and Additive Biases. The Catalyst Circulation Rate program biasesthe calculated circulation rate using the multiplicative parameter LAB_BIAS(1) and theadditive parameter LAB_BIAS(2) for biasing.

The multiplicative bias, LAB_BIAS(1), is used as a proportional bias. This bias isoptional and is manually entered when used. If this bias is not used it must be set to1.0.

The additive bias, LAB_BIAS(2), is used to correct offset. If this bias is not used itmust be set to 0.

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Biases in the Catalyst Circulation Rate Program

26

Biases in the FCCU Catalyst Circulation Rate Program (Continued)

Both PVCALC and CALC_VAL(1) contain the biased calculated catalyst circulationrate.

The unbiased circulation rate results if LAB_BIAS(1) = 1.0 and LAB_BIAS(2) = 0.0.It can also be calculated through the following equation:

unbiasPVCALC LAB BIAS

LAB BIAS= − _

_ ( )1

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FCCU Catalyst Circulation Rate Calculation Algorithms

27

Algorithms

Conversion of Engineering Units. The input process flows can have any units, but theconversion factors must be configured to yield thousands of barrels per day (MBPD) forriser feed streams and pounds per hour (PPH) for riser steam flows as shown inEquation 1:

flow(i) = FLOW_PT(i).PV * CONV_FAC(i)

Where:

flow(i) = Process flow i converted to MBPD or PPH for internaluse

FLOW_PT(i).PV = Input process flow i in any unitsCONV_FAC(i) = Conversion for flow i from input units to MBPD or PPH

Equation 1

The input process pressure can have any units, however, the conversion factor must beconfigured to yield pounds per square inch (psi), as shown in Equation 2:

press = ( PRESS_PT(i).PV + P_BIAS(i)) * CONV_FAC(7)

Where:

press = Process pressure converted to psi for internal usePRESS_PT(i).PV = Process pressure i in any gauge unitsP_BIAS(i) = Bias to input pressure i in input gauge unitsCONV_FAC(6) = Conversion factor for pressure from input units to psi

Equation 2

Continued

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28

Algorithms (Continued)

Heat of Reaction Coefficients. The heat of reaction is calculated using coefficientsalong with input reaction and Regenerator bed temperatures, reference reaction andRegenerator bed temperatures, and the measured and reference mass conversion asshown in Equation 3. The resulting heat of reaction is then used in calculating thecatalyst circulation rate.

heat_rx = Function[A1 + A2*f(reaction temperature) +A3*f(regenerator bed temperature) +A4*f(mass conversion)]

Where:

heat_rx = Heat of reactionA1 = Scaler heat of reaction coefficient (ENGPAR(6))A2 = Reaction temperature heat of reaction coefficient (ENGPAR(7))A3 = Regenerator bed temperature heat of reaction coefficient (ENGPAR(8))A4 = Mass conversion heat of reaction coefficient (ENGPAR(9))f(reaction temperature) = Function of input and reference reaction temperaturef(regenerator bed temperature) = Function of input and reference Regenerator bed

temperaturef(mass conversion) = Function of input and reference mass conversion

Equation 3

FCCU Catalyst Circulation Rate Calculation. The catalyst circulation rate iscalculated from process inputs using the Honeywell Catalyst Circulation RateCalculation, as shown in Equation 4:

CCR = Function[ (Qin + Qrx + Qloss)/(CPcat * (Trg-Trx))]Where:

CCR = Catalyst circulation rateQin = Net heat added by riser feed and steam streamsQrx = Heat or reactionQloss = Radiant and convective riser heat loss (ENGPAR(11))CPcat = Specific heat of catalystTrg = Regenerator bed temperatureTrx = Reaction temperature

Equation 4Continued

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29


Biasing. A multiplicative and additive bias are provided to reduce the offset betweenthe calculated and actual circulation rate. This correction is shown in Equation 5.

Bias_CCR = CCR * LAB_BIAS(1) + LAB_BIAS(2)

Where:

Bias_CCR = Biased catalyst circulation rateCCR = Calculated catalyst circulation rateLAB_BIAS(1) = Multiplicative biasLAB_BIAS(2) = Additive bias

Equation 5

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FCCU Catalyst Circulation Rate Calculation Installation Procedure

30

Installation Procedure

This document describes the installation procedure for the FCCU Catalyst CirculationRate calculation program (CAT_CIRC) on the TDC 3000 System AM.

This section covers the following topics:

• Preparation for Installation

• Custom Data Segment (CDS) and Parameter List (PL) Installation

• Building Catalyst Circulation Rate Calculation Point

• Configuration Graphics Installation.

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FCCU Catalyst Circulation Rate Calculation Preparation for Installation

31

Preparation for Installation

Step Action

Gather media Gather the following items:

• Removable media containing the directory CCR

• Commissioning Worksheet

Make media backup Make a backup copy of media/directory on a US with drives n and mconfigured as follows:

Media:FCOPY $Fn $Fm

Directory only:CD $Fm>vol_dir> CCRCOPY $Fn>CCR>*.* $Fm>CCR>= -V -D

Where $Fn is the drive with the source media and $Fm is the drive withthe target media.

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FCCU Catalyst Circulation Rate Calculation CDS and PL Installation

32

Custom Data Segment (CDS) and Parameter List (PL) Installation

This procedure must be done once per LCN installation.

Step Action

Set volumepathnames

From Modify Volume Paths display:

CL CUSTOM GDF: NET>CDSG

Compile

CAT_PL.CL

From the Command Processor Display, compile the CDS file, CAT_PL:CL $Fn>CCR>CAT_PL.CL -UL

If it is necessary to change the Parameter List due to a software revision,refer to the Application Module Data Control Language/Application ModuleData Entry.

CompileCAT_CDS.CL

From the Command Processor Display, compile the CDS file, CAT_CDS:CL $Fn>CCR>CAT_CDS.CL -UL

If it is necessary to change the CDS due to a software revision, refer to theApplication Module Data Control Language/Application Module Data Entry

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Building FCCU Catalyst Circulation Rate Calculation Point

33

Building FCCU Catalyst Circulation Rate Calculation Point

A regulatory point is required for the calculated catalyst circulation rate.

Step Action

Modify ExceptionBuild file,CCR_PNT.EB

From the Command Processor Display:

ED $Fn>CCR>CCR_PNT.EB [ENTER]

Edit template as follows:

&N point name

UNIT = unit number

PTDESC = “point descriptor text"

KEYWORD = "keyword"

PERIOD = as required

Load EB file. From the Builder Commands Display:

Select the EXCEPTION BUILD target.

Fill in ports as:

REFERENCE PATH NAME: $Fn>CCR

Load Entities (select target)

Pathname for SOURCE file: CCR_PNT

Pathname for IDF file: CCR_PNT

[ENTER]

Verify load When the load is complete, verify point loading by calling the point detailfrom the [DETAIL] button.

Hi-Spec Solutions

Catalyst Circulation Rate Calculation Configure Calculation Point

34

Configuration Graphics Installation

Graphics must be compiled and installed once per LCN.

Step Action

Go to Picture Editor Enter the Picture Editor, one of two ways:From the Engineering Main Menu select the Pictureeditor target OR From the Command Processorcommand line type PE [ENTER]

Load DDB Load Global variable definition file, DDB:

L $Fn>PICS>DDB [ENTER]

Read CCR_CFG Read in the picture file, CCR_CFG

R $Fn>CCR>CCR_CFG [ENTER]

Verify and Compile Verify picture:

VER [ENTER]

When the verification is complete Compile the picture:

COM [ENTER]

Copy CCR_CFG.DOto graphics directory


COPY $Fn>CCR>CCR_CFG.DO NET>pic_dir>= -D [ENTER]

Where pic_dir is the picture source directory specified in the SchematicSearch Path

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FCCU Catalyst Circulation Rate Calculation Configure Calculation Point

35

Configure Calculation Point

Configuration of the catalyst circulation rate point can be done either through thegraphic CCR_CFG or through direct entry to the CDS ports on the Point Detail display.Use of the configuration graphic is recommended.

• Point Configuration Using Graphic CCR_CFG

• Point Configuration through Direct CDS Entry

• Link CL Programs.

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Catalyst Circulation Rate Calculation Point Configuration Using Graphic CCR_CFG

36

Point Configuration Using Graphic CCR_CFG

Each entry port on the catalyst circulation rate configuration graphic, CCR_CFG, isdescribed below:

CCR_PNT

TEMP_PNT

TEMP_PNT

PRES_PNT

1

1

1.000.00

1.00000

1.00000

1.00000

4000

0

0

0

0.00

0.00

0.00

1.00000

FEED_PNT TEMP_PNT GRAV_PNT WATK_PNT S2_PNT N2_PNT STM_PNT0.00

0 0 0 0 0 0 0

Graphic CCR_CFG

Continued

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37

Point Configuration Using Graphic CCR_CFG (Continued)

Selection Port Parameter Description

Calculation Point N/A Enter the FCCU Catalyst Circulation Rate (CCR)calculation point name.

Multiplicative Bias LAB_BIAS(1) Enter the CCR multiplicative bias. This is theproportional bias and should be set to 1.0 (default)if not used.

Additive Bias LAB_BIAS(2) Enter the CCR additive bias. This value is adynamic value and an associated lab package writethe calculated bias value to a numeric point.

Riser Feed Flows ENGPAR(1) Enter the number of riser feed flow streams.

Feed Conv Factor CONV_FAC(3) Enter the conversion factor to convert from inputunits to MBPD.

Riser Steam Flows ENGPAR(2) Enter the number of riser steam flow streams.

Steam Conv Factor CONV_FAC(5) Enter the conversion factor to convert from inputunits to PPH.

Cat Circ Conv Factor CONV_FAC(6) Enter the conversion factor to convert from shorttons per minute to desired output units.

Conv Riser Heat Loss ENGPAR(11) Enter the convective riser heat loss. Default valueis 4000 MBtu/hr.

Gravity Units[API] [SPGR]

CONV_FAC(2) Select the input gravity units.

Temperature Units[DEG F] [DEG C]

CONV_FAC(1) Select the input temperature units. All inputtemperatures will have the same units.

Reaction Temp Pnt TEMP_PT(8) Enter the reaction temperature point tagname.

Reaction Temp Bias T_BIAS(8) Enter the reaction temperature bias. Inputtemperature units must be used.

Reaction Temp Filter FILTER(38) Enter the reaction temperature filter time (min).

Reg Bed Temp Pnt TEMP_PT(7) Enter the regenerator bed temperature pointtagname.

Reg Bed Temp Bias T_BIAS(7) Enter the regenerator bed temperature bias. Inputtemperature units must be used.

Reg Bed Temp Filter FILTER(37) Enter the regenerator bed temperature filter time(min).

Reactor Press Pnt PRESS_PT(1) Enter the reactor pressure point tagname.

Rx Press Bias P_BIAS(1) Enter the reactor pressure bias. Input pressure unitsmust be used.

Rx Press Filter FILTER(39) Enter the reactor pressure filter time (min).

Rx Press Conv Factor CONV_FAC(4) Enter the conversion factor to convert from inputunits to psi.

Continued

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38


The graphic utilizes a configuration zone, located at the bottom of the main graphic, toconfigure up to five flow stream pages, a Measured Conversion / Steam Informationpage, and a Heat of Reaction / Reference page. The page forward and back keys on theTDC 3000 keyboard step through the different configuration pages.

The configuration zone indexes off of the Riser Feed Flows and the Riser SteamFlows parameter entries. The number of stream configuration pages is determined bythe greater of the two entries. Note, if the defined number of riser feed flow streams isgreater, the entry ports associated with the non-defined riser steam flow streams will bereplaced by dashes. The opposite holds true if the defined number of riser steam flowsis greater.

If the Riser Feed Flows or the Riser Steam Flows parameter entries are changed at anypoint, the configuration zone will display the following message: “Press Page Forwardor Page Back to Initialize Stream Zone”. Pressing the page forward or page back keyswill display page 1.

In the configuration zone, the flow stream being displayed for configuration is locatedin the upper left hand corner above the word “Point”. This number will range from 1 to5. In addition, the lower right hand corner of the configuration zone displays paginginformation. The first number indicates the displayed page while the second numberdenotes how many configuration pages require data entry. The second number willchange depending on the Riser Feed Flows and Riser Steam Flows parameter entries.

FEED_PNT TEMP_PNT GRAV_PNT WATK_PNT S2_PNT N2_PNT STM_PNT0.00

0 0 0 0 0 0 0


Point [Feed Pnt] FLOW_PT(1) Enter first riser feed stream point tagname.

Filter [Feed Pnt] FILTER(1) Enter first riser feed stream filter time (min).

Point [Temp Pnt] TEMP_PT(1) Enter first riser feed stream temperature pointtagname.

Bias [Temp Pnt] T_BIAS(1) Enter first riser feed stream temperature bias. Inputtemperature units must be used.

Filter [Temp Pnt] FILTER(31) Enter first riser feed stream temperature filter time(min).

Continued

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39



Point [Grav Pnt] GRAV_PT(1) Enter first riser feed stream gravity point tagname.

Filter [Grav Pnt] FILTER(11) Enter first riser feed stream gravity filter time (min).

Point [Watk Pnt] WATK_PT(1) Enter first riser feed stream Watson K factor pointtagname.

Filter [Watk Pnt] FILTER(16) Enter first riser feed stream Watson K factor filtertime (min).

Point [S2 Pnt] CALC_PT(6) Enter first riser feed stream sulfur content pointtagname.

Filter [S2 Pnt] FILTER(26) Enter first riser feed stream sulfur content filter time(min).

Point [N2 Pnt] CALC_PT(1) Enter first riser feed stream nitrogen content pointtagname.

Filter [N2 Pnt] FILTER(21) Enter first riser feed stream nitrogen content filtertime (min).

Point [Stm Pnt] FLOW_PT(6) Enter first riser steam flow point tagname.

Filter [Stm Pnt] FILTER(6) Enter first riser steam flow filter time (min).

Streams 2 through 5 have the same format as stream 1.

Continued

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40


CONV_PNT STM_PNT STM_PRES0.000.00

0 0 0


Point [Mes Conv] CALC_PT(11) Enter the FCCU Measured Conversion CalculationPoint tagname.

Filter [Mes Conv] FILTER(41) Enter the FCCU Measured Conversion filter time(min).

Point [Stm Temp] TEMP_PT(6) Enter the riser steam temperature point tagname.

Bias [Stm Temp] T_BIAS(6) Enter the riser steam temperature bias. Inputtemperature units must be used.

Filter [Stm Temp] FILTER(36) Enter the riser steam temperature filter time (min).

Point [Stm Pres] PRESS_PT(2) Enter the riser steam pressure point tagname.

Bias [Stm Pres] P_BIAS(2) Enter the riser steam pressure bias. Input pressureunits must be used.

Filter [Stm Pres] FILTER(40) Enter the riser steam pressure filter time (min).

128960

0.00

541

2056

9001370

72.5

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41


xSelection Port Parameter Description

A1 ENGPAR(6) Enter the scaler heat of reaction coefficient. Defaultvalue is 128960.

A2 ENGPAR(7) Enter the reaction temperature heat of reactioncoefficient. Default value is 0.

A3 ENGPAR(8) Enter the regenerator bed temperature heat ofreaction coefficient. Default value is 541.

A4 ENGPAR(9) Enter the measured conversion heat of reactioncoefficient. Default value is 2056.

Reaction Ref Temp ENGPAR(3) Enter the reference reaction temperature. Defaultvalue is 900 ΟF.

Reg Bed Ref Temp ENGPAR(4) Enter the reference regenerator bed temperature.Default value is 1370 ΟF.

Cnvrsn Ref Val ENGPAR(5) Enter the reference measured conversion value.Default value is 72.5.

Note: The FCCU Toolkit consists of five configuration graphics. If all fiveconfiguration graphics are installed on the LCN, the Display Forward and DisplayBack keys on the TDC 3000 keyboard step through these graphics in the followingorder:

1. FCCU Measured Conversion Configuration Graphic (CONV_CFG)

2. FCCU Catalyst Circulation Rate Configuration Graphic (CCR_CFG)

3. FCCU Severity Configuration Graphic (SEV_CFG)

4. FCCU Product Yield Configuration Graphic (YLD_CFG)

5. FCCU Octane Number Configuration Graphic (OCT_CFG).

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FCCU Catalyst Circulation Rate Calculation Point Configuration through Direct CDS Entry

42

Point Configuration through Direct CDS Entry

If the configuration graphic is not used, then the configuration data must be entereddirectly onto the calculation point. The required calculation point information andassociated parameters are listed below.

Parameter Description Comments

FLOW_PT(1) Tagname of first riser feed flow rate Must have one riser feed stream.

FLOW_PT(2) Tagname of second riser feed flow rate Required only if more than 1 riserfeed streams exist.

FLOW_PT(3) Tagname of third riser feed flow rate Required only if more than 2 riserfeed streams exist.

FLOW_PT(4) Tagname of fourth riser feed flow rate Required only if more than 3 riserfeed streams exist.

FLOW_PT(5) Tagname of fifth riser feed flow rate Required only if more than 4 riserfeed streams exist.

FLOW_PT(6) Tagname of first riser steam flow rate Must have one riser steam stream.

FLOW_PT(7) Tagname of second riser steam flow rate Required only if more than 1 risersteam stream exist.

FLOW_PT(8) Tagname of third riser steam flow rate Required only if more than 2 risersteam streams exist.

FLOW_PT(9) Tagname of fourth riser steam flow rate Required only if more than 3 risersteam streams exist.

FLOW_PT(10) Tagname of fifth riser steam flow rate Required only if more than 4 risersteam streams exist.

TEMP_PT(1) Tagname of first riser feed temperature Use bias in T_BIAS(1) if thetemperature is not located in thefeed stream.

TEMP_PT(2) Tagname of second riser feedtemperature

Use bias in T_BIAS(2) if thetemperature is not located in thefeed stream.

TEMP_PT(3) Tagname of third riser feed temperature Use bias in T_BIAS(3) if thetemperature is not located in thefeed stream.

TEMP_PT(4) Tagname of fourth riser feedtemperature

Use bias in T_BIAS(4) if thetemperature is not located in thefeed stream.

TEMP_PT(5) Tagname of fifth riser feed temperature Use bias in T_BIAS(5) if thetemperature is not located in thefeed stream.

TEMP_PT(6) Tagname of riser steam temperature Use bias in T_BIAS(6) if thetemperature is not located in thesteam stream.

Continued

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43

Point Configuration through Direct CDS Entry (Continued)


TEMP_PT(7) Tagname of Regenerator bedtemperature

Use bias in T_BIAS(7) if thetemperature is not on theRegenerator bed.

TEMP_PT(8) Tagname of reaction temperature Use bias in T_BIAS(8) if thetemperature is not on the reaction.

PRESS_PT(1) Tagname of reactor pressure Use bias in P_BIAS(1) if thepressure is not located in thebottom of the reactor.

PRESS_PT(2) Tagname of riser steam pressure Use bias in P_BIAS(2) if thepressure is not located in the steamstream.

GRAV_PT(1) Tagname of riser feed 1 gravity If an on-line gravity is notavailable, bring in an estimatethrough an AM numeric point.This is gravity at standardconditions.





Continued

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44



WATK_PT(1) Tagname of riser feed 1 Watson K factor Build an AM numeric point tohold a manually input value.

Or the Watson K can be calculatedusing the 10;50;90 points andgravity. This requires an AMREG_PV point and the WATKcode block.









T_BIAS(1) Additive bias to riser feed 1 temperature Same units as TEMP_PT(1).



Continued

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45





T_BIAS(6) Additive bias to riser steam temperature Same units as TEMP_PT(6).

T_BIAS(7) Additive bias to Regenerator bedtemperature

Same units as TEMP_PT(7).

T_BIAS(8) Additive bias to reaction temperature Same units as TEMP_PT(8).

P_BIAS(1) Additive bias to reactor pressure Same units as PRESS_PT(1).

P_BIAS(2) Additive bias to riser steam pressure Same units as PRESS_PT(2).

ENGPAR(1) Number of riser feed stream inputs(0 < ENGPAR(1) ≤ 5)

Number of riser feed streams mustmatch number of entered reflectedin FLOW_PT(1..5)

ENGPAR(2) Number of riser steam flow inputs(0 < ENGPAR(2) ≤ 5)

Number of product flows mustmatch number of entries reflectedin FLOW_PT(6..10).

ENGPAR(3) Reference reaction temperature Units must be in οF.

ENGPAR(4) Reference Regenerator bed temperature Units must be in οF.

ENGPAR(5) Reference mass conversion Units in Wt %.

ENGPAR(6) A1; Scaler heat of reaction coefficient Heat of reaction calculation factor.

ENGPAR(7) A2; Reaction temperature heat ofreaction coefficient

Heat of reaction calculation factor.

ENGPAR(8) A3; Regenerator temperature heat ofreaction coefficient


ENGPAR(9) A4; Mass conversion heat of reactioncoefficient


ENGPAR(10) Flag to set calculation BAD;

0 => Do not set BAD;

1 => Set calculation BAD

This input allows the calculationto be set bad by Engineeringrequest.

ENGPAR(11) Heat loss across riser due to ambientlosses

Units must be in MBtu/hr

LAB_BIAS(1) Multiplicative bias to calculated catalystcirculation rate

Used to bias proportionally.

LAB_BIAS(2) Additive bias to calculated catalystcirculation rate

Same units as desired output units.

CONV_FAC(1) Input temperature unit flag:0 => °F; 1 => °C

Default is 0 (°F).

Continued

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46



CONV_FAC(2) Input gravity type flag0 => API; 1 => Specific gravity

Default is 0 (API).

CONV_FAC(3) Riser feed stream (FLOW_PT(1..5))multiplicative flow conversion factor

Convert input units to MBPD.

CONV_FAC(4) Pressure (PRESS_PT(1..2))multiplicative conversion factor

Convert input units to psi.

CONV_FAC(5) Riser steam (FLOW_PT(6..10))multiplicative flow conversion factor

Convert input units to PPH.

CONV_FAC(6) Catalyst circulation rate desired unitconversion factor

Convert from short ton/min todesired units.
















FILTER(16) Filter time for riser feed 1 Watson Kfactor

Minutes


Minutes


Minutes


Minutes


Minutes

FILTER(21) Filter time for riser feed 1 nitrogencontent

Minutes


Minutes

Continued

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47




Minutes


Minutes


Minutes






FILTER(31) Filter time for riser feed 1 temperatureinput

Minutes


Minutes


Minutes


Minutes


Minutes

FILTER(36) Filter time for riser steam temperatureinput

Minutes

FILTER(37) Filter time for Regenerator bedtemperature input

Minutes


FILTER(39) Filter time for reactor pressure input Minutes

FILTER(40) Filter time for riser steam pressure input Minutes

FILTER(41) Filter time for measured massconversion

Minutes

Hi-Spec Solutions

FCCU Catalyst Circulation Rate Calculation Appendix A Engineer’s Detailed Description

48

Link CL Programs

Step Action

Link CAT_CIRC From the Command Processor Display:

LK $Fn>CCR>CAT_CIRC point_name [ENTER]

Activate point Call up the point detail and activate the point or activate from CCR_CFGgraphic.

Verify Operation Verify that CAT_CIRC is running without any CL errors.

Hi-Spec Solutions



FCCU Measured Conversion Calculation

CONTROLLED


Hi-Spec Solutions

Proprietary Notice

This work contains valuable confidential and proprietary information and is subject to anyconfidentiality or nondisclosure agreements between Honeywell and The Customer. Disclosure, use,or reproduction of Honeywell material outside of The Customer is prohibited except as authorized inwriting by Honeywell . Disclosure, use, or reproduction of The Customer material outside ofHoneywell is prohibited except authorized in writing by The Customer.




Hi-Spec Solutions

FCCU Measured Conversion Calculation Revision History

Hi-Spec Solutions

FCCU Measured Conversion Calculation Contents


Overview.........................................................................................................................................1

Acronym List ..................................................................................................................................2



Process Diagram .............................................................................................................................5


Point Structure ..................................................................................................................7

Process Inputs ...................................................................................................................8

Configuration Inputs .........................................................................................................9


Error Codes ...................................................................................................................................12




Algorithms ....................................................................................................................................16




Building FCCU Measured Conversion Calculation Point ..............................................20



Point Configuration Using Graphic CONV_CFG ..........................................................23


Link CL Programs...........................................................................................................31

Hi-Spec Solutions

FCCU Measured Conversion Calculation Overview

1

Overview

Definition. The Fluidized Catalytic Cracking Unit (FCCU) Measured ConversionCalculation represents the fraction of FCCU feed that has been converted materiallighter than Light Cycle Oil (LCO).

Application. The measured conversion of the riser feed is an important specificationbecause it notifies the user of both the efficiency of the catalytic cracking reaction andproduct separation in the Main Fractionator.

Calculation. The Measured Conversion program calculates the conversion of riser feedto material lighter than LCO based on:

• Processinputs:

Temperatures and flows


Specific gravity


Total feed mass, total product mass, andconversion (mass or volumetric).

Incentive. 1. To measure the extent of the catalytic cracking reaction.

2. To provide a bias for predicted conversion.

Hi-Spec Solutions

FCCU Measured Conversion Calculation Acronym List

2

Acronym List

Term Acronym




control language CL

process variable PV



Parameter List PL


thousands of pounds per hour MPPH


Hi-Spec Solutions

FCCU Measured Conversion Calculation Hardware and Software Requirements

3




Special Boards None





Other Packages None


Software Inputs Specific gravities for the riser feed and product flows must exist aspoints on the LCN

Hi-Spec Solutions

FCCU Measured Conversion Calculation Instrumentation (Process Inputs)

4



Riser feed flow rate(s) X

Product flow rate(s) X

Heavy Naphtha ASTM D86 90% PointTemperature

X


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FCCU Measured Conversion Calculation Process Diagram

5

Process Diagram

R i s e r

Regenerator

Reactor Main Fractionator


Saturated Gas, C3, C4, Heavy Naphtha

LCO

HCO

DCO

Riser Feed

Conversion = [1 - (LCO + HCO + DCO) / (Riser Feed)] * 100

Spent Catalyst

Hi-Spec Solutions

FCCU Measured Conversion Calculation Detailed Description

6


The tables in this section describe the following Measured Conversion programarchitecture:

• Point Structure

• Process Inputs



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FCCU Measured Conversion Calculation Point Structure

7

Point Structure

Point Structure

Point Type AM Regulatory

PV_Type CL

CTL_Type Any

Custom Data Segment MCONVCDS.CL

Algorithm MEASCONV.CL


Slot 5

Output The calculated measured conversion (mass% or vol. %) is displayed asthe point’s PV

Hi-Spec Solutions

FCCU Measured Conversion Calculation Process Inputs

8

Process Inputs

Process Inputs

Critical2


FLOW_PT(1) Tagname of product 1 flow rate (Must beLCO)

Any flow units X

FLOW_PT(2) Tagname of product 2 flow rate Any flow units X




FLOW_PT(6) Tagname of riser feed 1 flow rate Any flow units X





TEMP_PT Tagname for Heavy Naphtha ASTM D8690% temperature

°F or °C X

GRAV_PT(1) Tagname for product stream 1 gravity °API or none (S.G.)X





GRAV_PT(6) Tagname for riser feed stream 1 gravity °API or none (S.G.)X





.


Hi-Spec Solutions

FCCU Measured Conversion Calculation Configuration Inputs

9




ENGPAR(1) Desired output setting

( 0 => Wt %; 1 => Vol% ) Must be set to 0 (wt%) ifprogram is to be used in the FCCU toolkit.

% Conversion

ENGPAR(2) Number of product flows (0.0 < ENGPAR(2) <= 5.0)

Any

ENGPAR(3) Number of riser feed flows (0.0 < ENGPAR(3) <= 5.0)

Any

ENGPAR(4) Flag to force calculation BAD( 0 => Do not set BAD; 1 => Set calculation BAD)

None

ENGPAR(5) Heavy Naphtha ASTM D86 90% point referencetemperature

°F

ENGPAR(6) Heavy Naphtha D86 90% compensation coefficient None

CONV_FAC(1) Product 1 (FLOW_PT(1)) multiplicative flow conversionfactor










CONV_FAC(6) Riser feed 1 (FLOW_PT(6)) multiplicative flow conversionfactor








CONV_FAC(10) Riser feed 5 (FLOW_PT(10)) multiplicative flowconversion factor


CONV_FAC(11) Input temperature unit flag; 0 => °F; 1 => °C

N/A

CONV_FAC(12) Input gravity type flag:0 => API; 1 => Specific gravity

N/A

Continued

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FCCU Measured Conversion Calculation Configuration Inputs

10




FILTER(1) Filter time for product 1 flow input Minutes










FILTER(11) Filter time for Heavy Naphtha ASTM D8690% temperature

Minutes

FILTER(12) Filter time for product 1 gravity Minutes










Hi-Spec Solutions

FCCU Measured Conversion Calculation Calculation Outputs

11

Calculation Outputs

Calculation Outputs


PVCALC Calculated measured riser feed conversion Wt or Vol %

CALC_VAL(1) Calculated measured riser feed conversion Wt or Vol %

CALC_VAL(2) Calculated measured riser feed conversion Wt %

CALC_VAL(3) Calculated measured riser feed conversion Vol %

CALC_VAL(4) Calculated total product mass flow rate MPPH

CALC_VAL(5) Calculated total riser feed mass flow rate MPPH

CALC_VAL(6) Calculated total product volume flow rate MBPD

CALC_VAL(7) Calculated total riser feed volume flow rate MBPD

FILT_VAL(1) Filtered value of input product 1 flow rate Input units





FILT_VAL(6) Filtered value of input riser feed 1 flow rate Input units





FILT_VAL(11) Filtered value of Heavy Naphtha ASTM D8690% temperature

Input units

FILT_VAL(12) Filter time for product 1 gravity input Input units





FILT_VAL(17) Filter time for riser feed 1 gravity input Input units






N/A

STATUS(2) Diagnostic indication of array location error N/A


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FCCU Measured Conversion Calculation Error Codes

12

Error Codes



• Array Location error codes.

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FCCU Measured Conversion Calculation Diagnostic Error Codes

13






2.0 Input number of product streams is outside the range 1 to 5[ENGPAR(2)]

3.0 Input number of riser feed streams is outside the range 1 to 5[ENGPAR(3)]

4.0 FLOW_PT(1..5) has a null point entered (See “Array LocationError Codes”)

5.0 FLOW_PT(1..5) has a bad PV (See “Array Location ErrorCodes”)

6.0 GRAV_PT(1..5) has a null point entered (See “Array LocationError Codes”)

7.0 GRAV_PT(1..5) has a bad PV (See “Array Location ErrorCodes”)

8.0 FLOW_PT(6..10) has a null point entered (See “Array LocationError Codes”)

9.0 FLOW_PT(6..10) has a bad PV (See “Array Location ErrorCodes”)

10.0 GRAV_PT(6..10) has a null point entered (See “Array LocationError Codes”)

11.0 GRAV_PT(6..10) has a bad PV (See “Array Location ErrorCodes”)

12.0 TEMP_PT has a null point entered

13.0 TEMP_PT has a bad PV


Hi-Spec Solutions

FCCU Measured Conversion Calculation Array Location Error Codes

14





1.0 An error has occurred in processing the first element in theSTATUS(1) defined array

2.0 An error has occurred in processing the second element in theSTATUS(1) defined array

3.0 An error has occurred in processing the third element in theSTATUS(1) defined array

4.0 An error has occurred in processing the fourth element in theSTATUS(1) defined array

5.0 An error has occurred in processing the fifth element in theSTATUS(1) defined array


Hi-Spec Solutions

FCCU Measured Conversion Calculation Configuration and Tuning

15



Biases

There are no user accessible biases associated with the FCCU Measured ConversionCalculation.

Tuning

There are no user tuning parameters associated with the FCCU Measured ConversionCalculation.

Hi-Spec Solutions

FCCU Measured Conversion Calculation Algorithms

16

Algorithms

Conversion of Engineering Units. The input process flows can have any units, but theconversion factors must be configured to yield MBPD as shown in Equation 1. Theflow rates are internally converted to MPPH to calculate a mass based conversion, asshown in the following equation:

flow(i) = FLOW_PT(i).PV * CONV_FAC(i) * f_spgr(i) * liq_conv

Where:

flow(i) = Process flow i converted to MPPH for internal useFLOW_PT(i).PV = Input process flow i in any unitsCONV_FAC(i) = Conversion of flow i from input units to MBPDf_spgr(i) = Input process flow i specific gravityliq_conv = Conversion from MBPD to MPPH (14.59146)

Equation 1

This unit conversion procedure is used for both the riser feed and Main Fractionatorproduct streams.

Measured Conversion Calculation. The measured conversion is calculated fromprocess inputs using the Honeywell FCCU Measured Conversion Calculation, asshown in Equation 2:

meas_conv = Function[prod_fl, feed_fl, prod_gr, feed_gr, hvy90]

Where:

meas_conv = Calculated measured conversionprod_fl = Total product flowfeed_fl = Total riser feed flowprod_gr = Product stream gravityfeed_gr = Riser feed stream gravityhvy90 = Input Heavy Naphtha ASTM D86 90% point temperature

Equation 2

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FCCU Measured Conversion Calculation Installation Procedure

17


This document describes the installation procedure for the FCCU Measured ConversionCalculation program (MEASCONV) on the TDC 3000 System AM.




• Building Measured Conversion Calculation Point


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FCCU Measured Conversion Calculation Preparation for Installation

18


Step Action


• Removable media containing the directory CONV



Media:FCOPY $Fn $Fm

Directory only:CD $Fm>vol_dir> CONVCOPY $Fn>CONV>*.* $Fm>CONV>= -V -D


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FCCU Measured Conversion Calculation CDS and PL Installation

19



Step Action

Set volumepathnames


CL CUSTOM GDF: NET>CDSG>

CompileMCONVCDS.CL

From the Command Processor display, compile the CDS file, MCONVCDS:CL $Fn>CONV>MCONVCDS.CL -UL


Parameter list There is no parameter list for the standard Measured Conversion Calculationpackage

Hi-Spec Solutions

FCCU Measured Conversion Calculation Building FCCU Measured Conversion Calculation Point

20

Building FCCU Measured Conversion Calculation Point

A regulatory point is required for the calculated riser feed conversion.

Step Action

Modify ExceptionBuild file,CONV_PNT.EB

From the Command Processor display:

ED $Fn>CONV>CONV_PNT.EB [ENTER]


&N point name

UNIT = unit number


KEYWORD = "keyword"


Load EB file. From the Builder Commands display:


Fill in ports as:

REFERENCE PATH NAME: $Fn>CONV


Pathname for SOURCE file: CONV_PNT

Pathname for IDF file: CONV_PNT

[ENTER]


Hi-Spec Solutions

FCCU Measured Conversion Calculation Configuration Graphics Installation

21



Step Action




Read CONV_CFG Read in the picture file, CONV_CFG

R $Fn>CONV>CONV_CFG [ENTER]


VER [ENTER]


COM [ENTER]

CopyCONV_CFG.DO tographics directory


COPY $Fn>CONV>CONV_CFG.DO NET>pic_dir>= -D [ENTER]


Hi-Spec Solutions

FCCU Measured Conversion Calculation Configure Calculation Point

22


Configuration of the measured conversion point can be done either through the graphicCONV_CFG or through direct entry to the CDS ports on the Point Detail display. Useof the configuration graphic is recommended.

• Point Configuration Using Graphic CONV_CFG



Hi-Spec Solutions

FCCU Measured Conversion Calculation Point Configuration Using Graphic CONV_CFG

23

Point Configuration Using Graphic CONV_CFG

Each entry port on the measured conversion configuration graphic, CONV_CFG, isdescribed below:

D86_PNT

CONV_PNT

400.00 0.2

0

1.00000 1.00000

0 0 0 0PROD_PNT GRV_PNT FEED_PNT GRV_PNT

Graphic CONV_CFG

Continued

Hi-Spec Solutions


24

Point Configuration Using Graphic CONV_CFG (Continued)


Calculation Point N/A Enter tagname of the measured conversioncalculation point.

Desired Output Units[WT%] [VOL%]

ENGPAR(1) Select the desired output units.If the Measured Conversion calculation point isto be used as part of the FCCU Toolkit, thisparameter must be set to [WT%].


CONV_FAC(11) Select the desired input temperature units.


CONV_FAC(12) Select the desired input gravity units.

Product Flows ENGPAR(2) Enter the number of product flow streams.

Feed Flows ENGPAR(3) Enter the number of riser feed flow streams.

The following data ports are related specifically to the Heavy Naphtha ASTM D86 90%point temperature.


Point N/A Enter tagname of the Heavy Naphtha ASTM D8690% point temperature.

Ref Temp ENGPAR(5) Enter the Heavy Naphtha ASTM D86 90% pointreference temperature (°F). The default value is400 °F.

Comp Coef ENGPAR(6) Enter the Heavy Naphtha ASTM D86 90% pointtemperature compensation coefficient. The defaultvalue is 0.2.

Filter FILTER(11) Enter the Heavy Naphtha ASTM D86 90% pointtemperature filter time (min).

Hi-Spec Solutions


25


The graphic utilizes a configuration zone, located at the bottom of the main graphic, toconfigure up to five product and riser feed streams. The page forward and page backkeys on the TDC 3000 keyboard step through the five possible configurable streams.

The configuration zone indexes off of the Product Flows and the Feed Flowsparameter entries. The number of stream configuration pages is determined by thegreater of the two entries. Note, if the defined number of product flow streams is thegreater of the two, the data ports associated with the non-defined riser feed flow streamswill be replaced by dashes. The opposite holds true if the defined number of riser feedflow streams is greater.

If the Product Flows or the Feed Flows parameter entries are changed at any point, theconfiguration zone will display the following message: “Press Page Forward or PageBack to Initialize Stream Zone”. Pressing the page forward or page back key willdisplay page 1.

In the configuration zone, the flow stream being displayed for configuration is locatedin the upper left hand corner above the word “Point”. This number will range from 1 to5. In addition, the lower right hand corner of the configuration zone displays paginginformation. The first number indicates the displayed page while the second numberdenotes how many configuration pages require data entry. The second number willchange depending on the Product Flows and Feed Flows parameter entries.

1.00000 1.00000

0 0 0 0PROD_PNT GRV_PNT FEED_PNT GRV_PNT

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26



Point [Prod Pnt] FLOW_PT(1) Enter product flow 1 tagname.

Filter [Prod Pnt] FILTER(1) Enter product flow 1 filter time (min).

Cnvrsn [Prod Pnt] CONV_FAC(1) Enter conversion factor to convert input units toMBPD.

Point [Prod Grv] GRAV_PT(1) Enter product stream 1 gravity tagname.

Filter [Prod Grv] FILTER(12) Enter product stream 1 gravity filter time (min).

Point [Feed Pnt] FLOW_PT(6) Enter riser feed flow 1 tagname.

Filter [Feed Pnt] FILTER(6) Enter riser feed flow 1 filter time (min).

Cnvrsn [Feed Pnt] CONV_FAC(6) Enter conversion factor to convert input units toMBPD.

Point [Feed Grv] GRAV_PT(6) Enter riser feed stream 1 gravity tagname.

Filter [Feed Grv] FILTER(17) Enter riser feed stream 1 gravity filter time (min).

Streams 2 through 5 have the same format as stream 1.

Note: The FCCU Toolkit consists of five configuration graphics. If all five graphicsare installed on the LCN, the Display Forward and Display Back keys on the TDC 3000keyboard step through these graphics in the following order:






Hi-Spec Solutions

FCCU Measured Conversion Calculation Point Configuration through Direct CDS Entry

27


If the configuration graphic is not used, then the configuration data must be entereddirectly onto the measured conversion point. The required information and associatedparameters are listed below.


FLOW_PT(1) Tagname of first product flow rate Must be LCO product stream.

FLOW_PT(2) Tagname of second product flowrate

Required only if more than 1 productstream exists.

FLOW_PT(3) Tagname of third product flowrate


FLOW_PT(4) Tagname of fourth product flowrate


FLOW_PT(5) Tagname of fifth product flow rate Required only if more than 4 productstream exists.

FLOW_PT(6) Tagname of first riser feed flowrate

Must have one feed stream.

FLOW_PT(7) Tagname of second riser feed flowrate

Required only if more than 1 feedstream exists.

FLOW_PT(8) Tagname of third riser feed flowrate


FLOW_PT(9) Tagname of fourth riser feed flowrate


FLOW_PT(10) Tagname of fifth riser feed flowrate


TEMP_PT Tagname of Heavy NaphthaASTM D86 90% pointtemperature

If the 90% point temperature is notavailable, bring in an estimate throughan AM numeric point.

GRAV_PT(1) Tagname of product stream 1gravity

If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.





Continued

Hi-Spec Solutions


28







GRAV_PT(6) Tagname for riser feed stream 1gravity










ENGPAR(1) Desired output setting

( 0 => Wt %; 1 => Vol% )

This should be configured to the user’spreference. However, if this applicationis to be used in the FCCU Toolkit, thepoint must be configured to 0 (wt%).

ENGPAR(2) Number of product flows (0.0 < ENGPAR(2) <= 5.0)

Number of product flows must match #of entries reflected in FLOW_PT(1..5).

ENGPAR(3) Number of riser feed flows (0.0 < ENGPAR(3) <= 5.0)

Number of feed flows must match # ofentries reflected in FLOW_PT(6..10).

ENGPAR(4) Flag to set calculation BAD:0 => Do not set BAD;1 => Set calculation BAD

This input allows the calculation to beset bad by Engineer request.

ENGPAR(5) Heavy Naphtha ASTM D86 90%point reference temperature

Must be in °F

Continued

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29



ENGPAR(6) Heavy Naphtha D86 90% pointcompensation coefficient

Default value is set to 0.2.

CONV_FAC(1) Product 1 (FLOW_PT(1))multiplicative flow conversionfactor










CONV_FAC(6) Riser feed 1 (FLOW_PT(6))multiplicative flow conversionfactor











Default is 0 (°F).

CONV_FAC(12) Input gravity type flag0 => API; 1 => Specific gravity

Default is 1 (SPGR).

FILTER(1) Filter time for product 1 flowinput

Minutes


Minutes

Continued

Hi-Spec Solutions


30




Minutes


Minutes


Minutes

FILTER(6) Filter time for riser feed 1 flowinput

Minutes


Minutes


Minutes


Minutes


Minutes

FILTER(11) Filter time for Heavy NaphthaASTM D86 90% temperatureinput

Minutes











Hi-Spec Solutions

FCCU Measured Conversion Calculation Link CL Programs

31

Link CL Programs

Step Action

Link MEASCONV From the Command Processor display:

LK $Fn>CONV>MEASCONV point_name [ENTER]

Activate point Call up the point detail and activate the point or activate from CONV_CFGgraphic.

Verify Operation Verify that MEASCONV is running without any CL errors.

Hi-Spec Solutions

FCCU Measured Conversion Calculation

32

Hi-Spec Solutions



FCCU Octane Number Calculation

CONTROLLED


Hi-Spec Solutions

Proprietary Notice




TDC 3000™ is a trademark of Honeywell, Inc.

Hi-Spec Solutions

FCCU Octane Number Calculation

Hi-Spec Solutions

FCCU Octane Number Calculation Contents


Overview.........................................................................................................................................1

Acronym List ..................................................................................................................................2



Process Diagram .............................................................................................................................5


Point Structure ..................................................................................................................7

Process Inputs ...................................................................................................................8

Configuration Inputs .........................................................................................................9


Error Codes ...................................................................................................................................11



Biases in the Octane Number Program...........................................................................14

Algorithms ....................................................................................................................................15




Building FCCU Octane Number Calculation Point........................................................20



Point Configuration Using Graphic OCT_CFG .............................................................23


Link CL Programs...........................................................................................................29

Hi-Spec Solutions

FCCU Octane Number Calculation Overview

1

Overview

Definition. Octane number is a measure of a hydrocarbon stream self-ignition point ata given compression ratio.

Application. The octane number of a hydrocarbon fraction is an importantspecification in the production of gasoline. It indicates the efficiency of an engine at agiven compression ratio.

Calculation. The Octane Number calculation program calculates the octane number ofa hydrocarbon product based on:

• Processinputs:

Temperatures and pressures


Octane prediction parameters


Biased and unbiased octane number

Incentive. 1. To indicate how closely a hydrocarbon stream is meeting the octanenumber specification.

2. To eliminate dead time associated with laboratory analysis and on-lineanalyzers.


4. For use in product value optimization.

Hi-Spec Solutions

FCCU Octane Number Calculation Acronym List

2

Acronym List

Term Acronym




control language CL

process variable PV



Parameter List PL


Universal Control Network UCN


Fluidized Catalytic Cracked FCC

Reid Vapor Pressure RVP

Hi-Spec Solutions

FCCU Octane Number Calculation Hardware and Software Requirements

3




Special Boards None





Other Packages None


Software Inputs The Honeywell Profimatics Catalyst Circulation Rate and Severitycalculation points must exist on the LCN

Hi-Spec Solutions

FCCU Octane Number Calculation Instrumentation (Process Inputs)

4




Gasoline ASTM D86 90% Point Temperature X

Gasoline RVP X


Hi-Spec Solutions

FCCU Octane Number Calculation Process Diagram

5

Process Diagram

N/A

Hi-Spec Solutions

FCCU Octane Number Calculation Detailed Description

6


The tables in this section describe the following Octane Number program architecture:

• Point Structure

• Process Inputs



Hi-Spec Solutions

FCCU Octane Number Calculation Point Structure

7

Point Structure

Point Structure


PV_Type CL

CTL_Type Any

Custom Data Segment OCT_CDS.CL

Algorithm OCT_PRED.CL


Slot 5

Output The calculated octane number is displayed as the point’s PV

Hi-Spec Solutions

FCCU Octane Number Calculation Process Inputs

8

Process Inputs

Process Inputs

Critical2


TEMP_PT(1) Tagname for reaction temperature °F or °CX

TEMP_PT(2) Tagname for gasoline ASTM D86 90%point temperature

°F or °CX

PRESS_PT Tagname for gasoline RVP Any pressure unitsX

CALC_PT Tagname for the Honeywell ProfimaticsSeverity point

Wt %X

CATCIRC Tagname for Honeywell ProfimaticsCalculated Catalyst Circulation Rate

Short ton/minX

CATCIRC.CALC_VAL(2)

Tagname for Honeywell Profimaticscalculated API gravity of the combinedriser feed in the catalyst circulation ratecalculation

NoneX

CATCIRC.CALC_VAL(4)

Tagname for Honeywell Profimaticscalculated Watson K factor of thecombined riser feed in the catalystcirculation rate calculation

NoneX

.


Hi-Spec Solutions

FCCU Octane Number Calculation Configuration Inputs

9




ENGPAR(1) Research or Motor Octane number setting0 => RON ; 1 => MON

N/A

ENGPAR(2) Flag to force calculation BAD(0 => Do not set BAD; 1 => Set calculation BAD)

N/A

ENGPAR(3) Catalyst additive None


ENGPAR(5) Reference API gravity value of combined riser feed °API

ENGPAR(6) Reference Watson K value of combined riser feed None

CONV_FAC(1) Input temperature unit flag;0 => °F; 1 => °C

N/A

CONV_FAC(2) Gasoline RVP multiplicative conversion factor From input unitsto psi

FILTER(1) Filter time for reaction temperature Minutes

FILTER(2) Filter time for gasoline ASTM D86 90% point temperature Minutes

FILTER(3) Filter time for gasoline RVP Minutes

FILTER(4) Filter time for the octane number multiplicative bias term(LAB_BIAS(1))

Minutes

FILTER(5) Filter time for the octane number additive bias term(LAB_BIAS(2))

Minutes

LAB_BIAS(1) Octane number multiplicative bias term None

LAB_BIAS(2) Octane number additive bias term None

X(1) K1; Constant None

X(2) K2; Reaction temperature coefficient None

X(3) K3; API gravity coefficient None

X(4) K4; Watson K value coefficient None

X(5) K5; RVP coefficient None

X(6) K6; Severity coefficient None

X(7) K7; Gasoline ASTM D86 90% point temperaturecoefficient

None

X(8) K8; Catalyst additive coefficient None

Hi-Spec Solutions

FCCU Octane Number Calculation Calculation Outputs

10

Calculation Outputs

Calculation Outputs


PVCALC Calculated biased octane number None

CALC_VAL(1) Calculated biased octane number None

CALC_VAL(2) Calculated uncorrected octane number None

FILT_VAL(1) Filtered value of reaction temperature Input units

FILT_VAL(2) Filtered value of gasoline ASTM D86 90% point temperature Input units

FILT_VAL(3) Filtered value of RVP Input units

FILT_VAL(4) Filtered value of LAB_BIAS(1) Input units

FILT_VAL(5) Filtered value of LAB_BIAS(2) Input units


N/A

STATUS(2) Diagnostic indication of subroutine error N/A


Hi-Spec Solutions

FCCU Octane Number Calculation Error Codes

11

Error Codes


• Diagnostic error codes.

Hi-Spec Solutions

FCCU Octane Number Calculation Diagnostic Error Codes

12










6.0 PRESS_PT has a null point entered

7.0 PRESS_PT has a bad PV

8.0 CALC_PT has a null point entered

9.0 CALC_PT has a bad PV

10.0 CATCIRC has a null point entered

11.0 CATCIRC has a bad PV

12.0 Uncorrected octane number calculation returned a bad value


Hi-Spec Solutions

FCCU Octane Number Calculation Configuration and Tuning

13



Biases

• Laboratory Bias.

Tuning

There are no user accessible tuning parameters associated with the octane numbercalculation. The model uses coefficients regressed from a specific FCCU’s operatingdata. If significant unit modifications are made, the coefficients may need to be updatedby Honeywell Profimatics.

Hi-Spec Solutions

FCCU Octane Number Calculation Biases in the Octane Number Program

14

Biases in the Octane Number Program

The Octane Number program is equipped with the following additive biases:

• Additive and multiplicative laboratory biases for the octane number.

Bias Parameters


LAB_BIAS(1) Multiplicative laboratory bias to calculated octane number

LAB_BIAS(2) Additive laboratory bias to calculated octane number

Additive and Multiplicative Laboratory Biases. The Octane Number programbiases the calculated octane number using the parameters LAB_BIAS(1) formultiplicative and LAB_BIAS(2) for additive biasing.

Only the additive bias, LAB_BIAS(2), is used dynamically and is expected to beupdated manually or with a laboratory results interface package.

The multiplicative bias, LAB_BIAS(1), is used as a proportional bias. This bias isoptional and is manually entered when used. If this bias is not used it must be set to1.0.

Hi-Spec Solutions

FCCU Octane Number Calculation Algorithms

15

Algorithms

Conversion of Engineering Units. The input RVP can have any units. However, theconversion factor must be configured to yield psi, as shown in Equation 1:

RVP = PRESS_PT.PV * CONV_FAC(2)

Where:

RVP = RVP converted to psig for internal usePRESS_PT.PV = Input RVP in any gauge unitsCONV_FAC(2) = Conversion factor for pressure from input units to psi

Equation 1

Octane Number Calculation. The octane number is calculated from process inputsusing the Honeywell Profimatics octane number calculation, as shown in Equation 1:

oct_num = Function[srx_t, s_api, s_watk, rvp, severity, gas90, cat_add]

Where:

oct_num = Calculated Research or Motor octane numbersrx_t = Scaled reaction temperatures_api = Scaled API gravitys_watk = Scaled Watson K factorrvp = RVPseverity = Severity from the Honeywell Profimatics Severity Calculationgas90 = Gasoline ASTM D86 90% point temperaturecat_add = Catalyst additive

Equation 2

Hi-Spec Solutions

FCCU Octane Number Calculation Algorithms

16


Biasing. Two filtered bias factors are provided to reduce the offset between thecalculated octane number and a laboratory or on-line analysis-determined octanenumber. A multiplicative bias and an additive bias are used, as shown in Equation 3:

bias_oct = oct_num * LAB_BIAS(1) + LAB_BIAS(2)

Where:

bias_oct = Biased octane numberoct_num = Calculated octane numberLAB_BIAS(1) = Filtered multiplicative laboratory biasLAB_BIAS(2) = Filtered additive laboratory bias

Equation 3

Hi-Spec Solutions

FCCU Octane Number Calculation Installation Procedure

17


This document describes the installation procedure for the FCCU Octane Numberprogram (OCT_PRED) on the TDC 3000 System AM.




• Building Octane Number Calculation Point


Hi-Spec Solutions

FCCU Octane Number Calculation Preparation for Installation

18


Step Action


• Removable media containing the directory OCT



Media:FCOPY $Fn $Fm

Directory only:CD $Fm>vol_dir> OCTCOPY $Fn>OCT>*.* $Fm>OCT>= -V -D


Hi-Spec Solutions

FCCU Octane Number Calculation CDS and PL Installation

19



Step Action

Set volumepathnames



CompileOCT_CDS.CL

From the Command Processor Display, compile the CDS file, OCT_CDS:CL $Fn>OCT>OCT_CDS.CL -UL


Parameter list There is no parameter list for the standard octane calculation package

Hi-Spec Solutions

FCCU Octane Number Calculation Building FCCU Octane Number Calculation Point

20

Building FCCU Octane Number Calculation Point

A calculation point is required for each hydrocarbon octane number calculated

Step Action

Modify ExceptionBuild file,OCT_PNT.EB


ED $Fn>OCT>OCT_PNT.EB [ENTER]


&N point name

UNIT = unit number


KEYWORD = "keyword"




Fill in ports as:

REFERENCE PATH NAME: $Fn>OCT


Pathname for SOURCE file: OCT_PNT

Pathname for IDF file: OCT_PNT

[ENTER]


Hi-Spec Solutions

Octane Number Calculation Configrue Graphics Installation

21



Step Action




Read OCT_CFG Read in the picture file, OCT_CFG

R $Fn>OCT>OCT_CFG [ENTER]


VER [ENTER]


COM [ENTER]

Copy OCT_CFG.DOto graphics directory


COPY $Fn>OCT>OCT_CFG.DO NET>pic_dir>= -D [ENTER]


Hi-Spec Solutions

FCCU Octane Number Calculation Configure Calculation Point

22


Configuration of the octane number point can be done either through the graphicOCT_CFG or through direct entry to the CDS ports on the Point Detail display. Use ofthe configuration graphic is recommended.

• Point Configuration Using Graphic OCT_CFG



Hi-Spec Solutions

Octane Number Calculation Point Configuration Using Graphic OCT_CFG

23

Point Configuration Using Graphic OCT_CFG

Each entry port on the octane number configuration graphic, OCT_CFG, is describedbelow:

OCT_PNT

CCR_PNT

SEV_PNT

1.000

0.000

TEMP_PNT

0

D86_PNT

0

RVP_PNT

0 1.00000

0.00900.0

20.010.0

Graphic OCT_CFG

Continued

Hi-Spec Solutions


24



Calculation Point N/A Enter the FCCU Octane Number calculation pointname.

Cat Circulation Pnt N/A Enter the FCCU Catalyst Circulation Ratecalculation point name.

Pred Conversion Pnt N/A Enter the FCCU Severity calculation point name.

Mult Octane Bias LAB_BIAS(1) Enter the octane number multiplicative bias. Thisis the proportional bias and should be set to 1.0(default) if not used.

Mult Bias Filter FILTER(4) Enter the octane number multiplicative bias filtertime (min).

Add Octane Bias LAB_BIAS(2) Enter the octane number additive bias. This valueis a dynamic value and an associated lab packagewrite the calculated bias value to a numeric point.

Add Bias Filter FILTER(5) Enter the octane number additive bias filter time(mini).

RON or MONCalculation[RON] [MON]

ENGPAR(1) Enter the desired octane number calculation.[RON] => Research Octane Number; [MON] =>Motor Octane Number.


CONV_FAC(1) Select the input temperature units. All inputtemperature will have the same units.



Gas ASTM D86 90%Pnt

TEMP_PT(2) Enter the gasoline ASTM D86 90% pointtemperature tagname.

ASTM D86 90% Filter FILTER(2) Enter the gasoline ASTM D86 90% pointtemperature filter time (min).

Gas RVP Pnt PRESS_PNT Enter the Gasoline Reid Vapor Pressure pointtagname.

Gas RVP Filter FILTER(3) Enter the Gasoline Reid Vapor Pressure filter time(min).

Gas RVP Conv Fact CONV_FAC(2) Enter the conversion factor to convert from inputpressure units to psi.

Catalyst Additive ENGPAR(3) Enter the catalyst additive. The default value is 0.

Ref Reaction Temp ENGPAR(4) Enter the reference reaction temperature. Thedefault value is 900 ΟF.

Ref API Gravity ENGPAR(5) Enter the reference API gravity. The default valueis 20.

Ref Watson K Factor ENGPAR(6) Enter the reference Watson K Factor. The defaultvalue is 10.

Continued

Hi-Spec Solutions


25

Point Configuration Using Graphic OCT_CFG (Continued)

The graphic utilizes a configuration zone, located at the bottom of the main graphic, toconfigure two prediction parameter pages. The page forward and back keys on theTDC 3000 keyboard step through these to configuration pages.

The lower right hand corner of the configuration zone contains paging information.The first number indicates the displayed page while the second number denotes howmany configuration pages require data entry.


Wat K Factor Coef X(4) Enter the octane number Watson K Factorcoefficient.

Reaction Temp Coef X(2) Enter the octane number Reaction Temperaturecoefficient.

API Gravity Coef X(3) Enter the octane number API Gravity coefficient.

Constant Coef X(1) Enter the octane number constant coefficient.

Continued

Hi-Spec Solutions


26

Point Configuration Using Graphic OCT_CFG (Continued)


Gas D86 90% Pt Coef X(7) Enter the octane number gasoline D86 90% pointcoefficient.

Catalyst Add Coef X(8) Enter the octane number catalyst additivecoefficient.

Severity Coef X(6) Enter the octane number FCCU Severity coefficient.

RVP Coef X(5) Enter the octane number Reid Vapor Pressurecoefficient.







Hi-Spec Solutions

FCCU Octane Number Calculation Point Configuration through Direct CDS Entry

27




TEMP_PT(1) Tagname for reaction temperature None

TEMP_PT(2) Tagname for gasoline ASTM D8690% point temperature

If this temperature is not available,bring in an estimate through an AMnumeric point

PRESS_PT Tagname for gasoline RVP If the gasoline RVP is not available,bring in an estimate through an AMnumeric point

CALC_PT Tagname for the predicted massconversion

This is the Honeywell ProfimaticsSeverity calculation point

CATCIRC Tagname for HoneywellPromfimatics’ calculated catalystcirculation rate

This is the Honeywell ProfimaticsCatalyst Circulation Rate point

ENGPAR(1) Research or Motor OctaneNumber setting0 => RON ; 1 => MON

This entry serves as a quick reference todetermine which octane number is beingcalculated


This input allows the calculation to beset bad by Engineering request

ENGPAR(3) Catalyst additive None

ENGPAR(4) Reference reaction temperature Default value is 900 οF

ENGPAR(5) Reference API gravity value ofcombined riser feed

Default value is 20

ENGPAR(6) Reference Watson K factor valueof combined riser feed

Default value is 10


Default is 1 (°C).

CONV_FAC(2) Gasoline RVP multiplicativeconversion factor

From input units to psi

FILTER(1) Filter time for reactiontemperature

Minutes

FILTER(2) Filter time for gasoline ASTMD86 90% point temperature

Minutes

FILTER(3) Filter time for gasoline RVP Minutes

FILTER(4) Filter time for the octane numbermultiplicative bias term(LAB_BIAS(1))

Minutes

Continued

Hi-Spec Solutions

FCCU Octane Number Calculation Point Configuration through Direct CDS Entry

28



FILTER(5) Filter time for the octane numberadditive bias term(LAB_BIAS(2))

Minutes

LAB_BIAS(1) Multiplicative laboratory bias tocalculated octane number

Used to bias proportionally

LAB_BIAS(2) Additive laboratory bias tocalculated octane number

Used to bias additively


X(2) K2; Reaction temperature factor None

X(3) K3; API gravity factor None

X(4) K4; Watson K value factor None

X(5) K5; RVP factor None

X(6) K6; Severity factor None

X(7) K7; Gasoline ASTM D86 90%point temperature factor

None

X(8) K8; Catalyst additive factor None

Hi-Spec Solutions

FCCU Octane Number Calculation Link CL Programs

29

Link CL Programs

Step Action

Link OCT_PRED From the Command Processor Display:

LK $Fn>OCT>OCT_PRED point_name [ENTER]

Activate point Call up the point detail and activate the point or activate from OCT_CFGgraphic.

Verify Operation Verify that OCT_PRED is running without any CL errors.

Hi-Spec Solutions

FCCU Octane Number Calculation Appendix A Engineer’s Detailed Description

30

Hi-Spec Solutions



FCCU Product Yield Calculation

CONTROLLED


Hi-Spec Solutions

Proprietary Notice

This work contains valuable confidential and proprietary information and is subject to anyconfidentiality or nondisclosure agreements between Honeywell Profimatics and The Customer.Disclosure, use, or reproduction of Honeywell Profimatics material outside of The Customer isprohibited except as authorized in writing by Honeywell Profimatics. Disclosure, use, or reproductionof The Customer material outside of Honeywell is prohibited except authorized in writing by TheCustomer.




16404 North Black Canyon Hiway • Phoenix, AZ 85023325 Rolling Oaks Dr • Thousand Oaks, CA 91361-1200

10333 Richmond, Suite 1110 • Houston, TX 77042Chilworth Research Centre • Southampton, United Kingdom SO1 7NP

Hi-Spec Solutions

FCCU Product Yield Calculation Revision HistoryRevision 2.0

Hi-Spec Solutions

FCCU Product Yield Calculation Contents

Revision 2.0

Table of Contents

Overview.........................................................................................................................................1

Acronym List ..................................................................................................................................2



Process Diagram .............................................................................................................................5


Point Structure ..................................................................................................................7

Process Inputs ...................................................................................................................8



Error Codes ...................................................................................................................................14




Biases in the FCCU Product Yield Program...................................................................18

Algorithms ....................................................................................................................................19




Building FCCU Product Yield Calculation Point...........................................................24



Point Configuration Using Graphic YLD_CFG .............................................................27


Link CL Programs...........................................................................................................40

Hi-Spec Solutions


Revision 2.0

Table of Contents (Continued)

Appendix A Engineer’s Detailed Description ............................... Error! Bookmark not defined.

Calculation Overview ..................................................... Error! Bookmark not defined.

Calculation Details.......................................................... Error! Bookmark not defined.

Previous Installations ...................................................... Error! Bookmark not defined.

Installation Tips .............................................................. Error! Bookmark not defined.

References....................................................................... Error! Bookmark not defined.

Attachments .................................................................... Error! Bookmark not defined.

Hi-Spec Solutions


Revision 2.0

Hi-Spec Solutions

FCCU Product Yield Calculation Overview

1

Overview

Definition. The FCCU Product Yield calculation predicts the yield of C2 minus, C3,C4, C5 plus, LCO, DCO, or coke products based on the Honeywell Profimatics Severitymodel and unit operating temperatures. The parameterization of the HoneywellProfimatics model is completed using data specific to an individual FCCU.

Application. The product yields are important operating variables for an FCCU.Often, these product yields are downstream constraints to unit operation. The productyield predictions are suitable for use in multivariable control schemes or for HoneywellProfimatics’ product value optimization.

Calculation. The Product Yield Calculation program calculates the desired productyield based on Reactor/Regenerator input process temperatures, pressures, flows, andcracking severity.

• Processinputs:



Watson K and specific gravity


Product yield bias term, biased yield, anduncorrected product yield.

Incentive. 1. To provide inputs for product value optimization.


Hi-Spec Solutions

FCCU Product Yield Calculation Acronym List

2

Acronym List

Term Acronym




control language CL

process variable PV



Parameter List PL




pounds per square inch gauge psig

thousands of standard cubic feet per hour MSCFPH

thousands of barrels per day MBPD

Catalyst Circulation Rate CCR

Hi-Spec Solutions

FCCU Product Yield Calculation Hardware and Software Requirements

3




Special Boards None





Other Packages None


Software Inputs Honeywell Profimatics Catalyst Circulation Rate and SeverityCalculation points must exist on the LCN

Hi-Spec Solutions

FCCU Product Yield Calculation Instrumentation (Process Inputs)

4



Measured product flow rates X

Product gravity X

Predicted conversion (from HoneywellProfimatics Severity package)

X


Calculated catalyst circulation rate (fromHoneywell Profimatics CCR package)

X


Hi-Spec Solutions

FCCU Product Yield Calculation Process Diagram

5

Process Diagram

Reactor Main Fractionator

C2

C3

C5+

LCO

HCO

DCO

COKE

C4

Hi-Spec Solutions

FCCU Product Yield Calculation Detailed Description

6


The tables in this section describe the following FCCU Product Yield programarchitecture:

• Point Structure

• Process Inputs



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FCCU Product Yield Calculation Point Structure

7

Point Structure

Point Structure


PV_Type CL

CTL_Type Any

Custom Data Segment YLD_CDS.CL

Algorithm YLD_PRED.CL


Slot 5

Output The calculated product yield is displayed as the point’s PV

Hi-Spec Solutions

FCCU Product Yield Calculation Process Inputs

8

Process Inputs

Process Inputs

Critical2


FLOW_PT(1) Tagname of product 1 flow rate Any flow unitsX




FLOW_PT(5) Tagname of total riser steam flow rate Any flow unitsX


TEMP_PT(2) Tagname for Regenerator bed temperature °F or °CX

PRESS_PT Tagname for Reactor pressure Any pressure unitsX

GRAV_PT(1) Tagname for NC3 to DCO gravity οAPI or none X

CALC_PT(1) Tagname for FCCU predicted conversion(Honeywell Profimatics Severitycalculation point)

Wt %X

CALC_PT(2) Feed con carbon point Wt %X

CALC_PT(3) Tagname of Reactor stripping steam tocatalyst ratio point

(lb steam)/ (Mlbcatalyst)

X

CATCIRC Tagname for Honeywell Profimatics’Catalyst Circulation Rate calculation point

User UnitsX

CATCIRC.CALC_VAL(2)

Calculated οAPI Gravity of the combinedriser feed

οAPI X

Continued


Hi-Spec Solutions

FCCU Product Yield Calculation Process Inputs

9


Process Inputs

Critical


CATCIRC.CALC_VAL(3)

Calculated mass flow of the combinedriser feed

Mlb/hrX

CATCIRC.CALC_VAL(4)

Tagname for Honeywell Profimatics’Calculated Watson K factor of thecombined riser feed

NoneX

CATCIRC.CALC_VAL(5)

Calculated molecular weight of thecombined riser feed

Lb/Lb-moleX

CATCIRC.CALC_VAL(13)

Calculated sulfur content of the combinedriser feed

Wt %X

.

Hi-Spec Solutions

FCCU Product Yield Calculation Configuration Inputs

10




ENGPAR(1) Desired product yield prediction settings;

H2 => 0.0; H2S => 0.1; C1 => 1.0

NC2 => 2.0; C2= => 2.1; NC3 => 3.0

C3= => 3.1; NC4 => 4.0; C4= => 4.1

IC4 => 4.2; C5P => 5.0; LCO => 6.0

DCO => 7.0; coke => 8.0

N/A

ENGPAR(2) Number of product streams N/A

ENGPAR(3) Set calculation BAD flag (0 => Do not set BAD;1 => Set calculation BAD)

N/A

ENGPAR(4) Calibrate on point restart (0 => no calibration;1 for calibration)

N/A

ENGPAR(5) Discrete filter time for bias between predicted and measuredproduct yields

Minutes

ENGPAR(6) First catalyst additive None

ENGPAR(7) Second catalyst additive None

ENGPAR(8) Material balance coefficient None


ENGPAR(10) Reference Regenerator bed temperature riser °F

ENGPAR(11) Reference °API value of combined riser feed °API

ENGPAR(12) Reference Watson K factor of combined riser feed None

ENGPAR(13) Catalyst surface area Any

ENGPAR(14) Catalyst micro activity None

ENGPAR(15) Number of predicted yield delay intervals N/A


From input unitsto: MBPD forNC3-DCO;

MSCFPH for H2-C2=;

Mlb/hr for coke


Same as CONV-FAC(1)


Same as CONV-FAC(1)


Same as CONV-FAC(1)

Continued

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CONV_FAC(5) Steam flow (FLOW_PT(5)) multiplicative flow conversionfactor

From input unitsto lb/hr

CONV_FAC(6) Desired output product yield multiplicative flow conversionfactor

MBPD to desiredunits for NC3-DCO;

MSCFPH todesired units forH2-C2;=;

Mlb/hr to desiredunits for coke

CONV_FAC(7) Input temperature unit flag; (0 => °F; 1 => °C)

N/A

CONV_FAC(8) Reactor stripping steam to catalyst ratio multiplicativeconversion factor

Input units to (lbstm)/(Mlbcatalyst)

CONV_FAC(9) Reactor pressure multiplicative conversion factor Input unit to psi

CONV_FAC(10) Input gravity type flag:

(0 => οAPI; 1 => SPGR)

οAPI or None





FILTER(5) Filter time for product gravity input Minutes

FILTER(6) Filter time for Reactor stripping steam to catalyst ratio Minutes



FILTER(9) Filter time for Reactor pressure input Minutes

FILTER(10) Filter time for riser steam flow input Minutes


X(2) K2; Inverse natural log predicted severity coefficient None

Continued

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X(3) K3; Exponential predicted severity coefficient None

X(4) K4; Reaction temperature coefficient None

X(5) K5; οAPI feed gravity coefficient None

X(6) K6; Watson K value coefficient None

X(7) K7; Catalyst micro activity coefficient None

X(8) K8; Catalyst surface area coefficient None

X(9) K9; First catalyst additive coefficient None

X(10) K10; Second catalyst additive coefficient None

X(11) K11; Reactor pressure coefficient None

X(12) K12; Riser steam flow coefficient None

X(13) K13; Regenerator bed temperature coefficient None

X(14) K14; Feed sulfur content coefficient None

X(15) K15; Feed con carbon coefficient None

X(16) K16; Reactor stripping steam ratio coefficient None

X(17) Catalyst characterization factor None

Hi-Spec Solutions

FCCU Product Yield Calculation Calculation Outputs

13

Calculation Outputs

Calculation Outputs


PVCALC Calculated biased product yield prediction Desired Units

CALC_VAL(1) Calculated biased product yield prediction Desired Units

CALC_VAL(2) Calculated uncorrected product yield Mass %

CALC_VAL(3) Calculated bias term for product yield prediction Desired Units

CALC_VAL(4) Predicted product yield delay interval N/A

N(1..250) Delayed predicted yield values N/A

FILT_VAL(1) Filtered value of product 1 flow rate Input units




FILT_VAL(5) Filtered value of product gravity None

FILT_VAL(6) Filtered value of Reactor stripping steam to catalyst ratio (lb steam)/ (Mlbcatalyst)

FILT_VAL(7) Filtered value of reaction temperature Input units

FILT_VAL(8) Filtered value of Regenerator bed temperature Input units

FILT_VAL(9) Filtered value of Reactor pressure Input units

FILT_VAL(10) Filtered value of total riser steam flow rate Input units



N/A

STATUS(2) Diagnostic indication of array location or subroutine error N/A

Hi-Spec Solutions

FCCU Product Yield Calculation Error Codes

14

Error Codes



• Array Location error codes.

Hi-Spec Solutions

FCCU Product Yield Calculation Diagnostic Error Codes

15






2.0 Input number of product streams is greater than the upper limit of4 [ENGPAR(2)]

3.0 Setting for desired product type is outside the allowable range of 0to 8 [ENGPAR(1)]

4.0 GRAV_PT(1) has a null point entered

5.0 GRAV_PT(1) has a bad PV

6.0 FLOW_PT(1..4) has a null point entered (see “Array LocationError Codes”)

7.0 FLOW_PT(1..4) has a bad PV

( See “Array Location Error Codes”)












19.0 TEMP_PT(2) has bad PV

20.0 PRESS_PT has a null point entered

21.0 PRESS_PT has a bad PV

22.0 FLOW_PT(5) has a null point entered

23.0 FLOW_PT(5) has a bad PV

24.0 Uncorrected product yield calculation returned a bad value


Hi-Spec Solutions

FCCU Product Yield Calculation Array Location Error Codes

16


Filter Error Codes








Hi-Spec Solutions

FCCU Product Yield Calculation Configuration and Tuning

17



Biases

• Additive Bias

• Catalyst Characterization Factor.

Tuning

There are no user accessible tuning parameters associated with the Product YieldCalculation. The model uses coefficients regressed from a specific FCCU’s operatingdata. If significant unit modifications are made, the coefficients may need to be updatedby Honeywell Profimatics.

Hi-Spec Solutions

FCCU Product Yield Calculation Biases in the FCCU Product Yield Program

18

Biases in the FCCU Product Yield Program

The Yield program is equipped with the following biases:

• Additive bias for product yield.

• Catalyst characterization factor.

Bias Parameters


ENGPAR(5) Filter time for bias between predicted and measured yield

X(17) Catalyst characterization factor

Additive Biases. In most processes, a change in the FCCU process inputs will shift theproduct yields; however, the yield changes will not be noticed until a later time. Wewill call this time lapse the dead time of the process. For this reason, a delayedpredicted product yield term takes the dead time into account and produces a pseudoreal-time bias term. This additive bias term is automatically updated to reconcile themeasured and delayed predicted yields. The reconciliation is done using a first orderdiscrete filter whose filter time is stored in the parameter ENGPAR(5). The discretefilter time is entered in minutes. The resulting bias parameter is used to keep theproduct yield model reconciled with plant operation.

The predicted product yields are stored into a predefined array, N, whose size isconfigured using ENGPAR(15). The predicted yield’s are stored throughout the yieldcalculation point’s operation. For example, if the dead time is two hours and the yieldcalculation point is being processed every minute, ENGPAR(15) should be configuredto 120. The program will store one hundred and twenty predicted yield values. Thenext time the point is processed, the first yield value stored (120 minutes ago) isretrieved and used to calculate a yield bias. The current predicted yield take the place ofthe retrieved yield value in the N array. Until the dead time is reached, a non-biasedpredicted yield is displayed as the point’s PV.

Catalyst Characterization Factor. If discrepancies exist between actual catalyst dataand data supplied for yield model parameterization, the measured and predicted yieldsmay not match exactly. Therefore, a catalyst characterization factor (X(17)) isprovided. This factor is calculated by the program upon restart, if ENGPAR(4) is set to1.0. The value of X(17) is a multiplier which causes the calculated and measured yieldsto be equal.

If the catalyst characterization factor is updated upon restart, the process should be atsteady state.

Hi-Spec Solutions

FCCU Product Yield Calculation Algorithms

19

Algorithms

Conversion of Engineering Units. The input process flows can have any units, but theconversion factors must be configured to yield MBPD, MSCFPH, Mlb/hr, or PPHdepending on process flow and desired product yield setting. See ENGPAR(1) andCONV_FAC(1..5) for details. Conversion is shown in Equation 1:


Where:

flow(i) = Process flow i converted to desired units for internal use (As explained above)

FLOW_PT(i).PV = Input process flow i in any unitsCONV_FAC(i) = Conversion for flow i from input units to desired units

(As explained above)

Equation 1

The input process pressure can have any gauge units, but the conversion factor must beconfigured to yield psi. The input pressure is then converted internally to absoluteatmospheres as shown in Equation 2

press = (PRESS_PT.PV * CONV_FAC(9) +14.696)/14.696

Where:

press = Process pressure converted to abs. atm. for internal usePRESS_PT.PV = Input process pressure in any gauge unitsCONV_FAC(9) = Conversion factor for pressure from input units to psig

Equation 2

Continued

Hi-Spec Solutions

FCCU Product Yield Calculation Algorithms

20


Product Yield Calculation. The product yield is calculated from process inputs usingthe Honeywell Profimatics product yield calculation, as shown in Equation 3:

prod_yld = Function[FeedProp, CatProp, OpParam]

Where:

prod_yld = Cracking product yieldFeedProp = Feed characterizationCatProp = Catalyst properties including surface area and micro-activityOpParam = Operating parameters including, catalyst circulation rate, and

reaction temperature

Equation 3

Measured Reactor/Regenerator variables and model coefficients are used in the productyield model. The parameterization of the model coefficients is completed by regressingdata specific to the unit. These model coefficients must be calculated by HoneywellProfimatics.

Biasing. An additive bias term is provided to reduce the offset between the calculatedand measured product yields. The correction is shown in Equation 4.

b_prod_yld = prod_yld + prod_yld_bias

Where:

b_prod_yld = Biased product yieldprod_yld = Calculated product yieldprod_yld_b = Filtered additive product yield bias term

Equation 4

Hi-Spec Solutions

FCCU Product Yield Calculation Installation Procedure

21


This document describes the installation procedure for the FCCU Product YieldCalculation program (YLD_PRED) on the TDC 3000 System AM.




• Building Product Yield Calculation Point


Hi-Spec Solutions

FCCU Product Yield Calculation Preparation for Installation

22


Step Action


• Removable media containing the directory YLD



Media:FCOPY $Fn $Fm

Directory only:CD $Fm>vol_dir> YLDCOPY $Fn>YLD>*.* $Fm>YLD>= -V -D


Hi-Spec Solutions

FCCU Product Yield Calculation CDS and PL Installation

23



Step Action

Set volumepathnames



CompileYLD_CDS.CL

From the Command Processor display, compile the CDS file, YLD_CDS:CL $Fn>YLD>YLD_CDS.CL -UL


Parameter list There is no parameter list for the standard yield calculation package

Hi-Spec Solutions

FCCU Product Yield Calculation Building FCCU Product Yield Calculation Point

24

Building FCCU Product Yield Calculation Point

A regulatory point is required for each product yield calculated

Step Action

Modify ExceptionBuild file,YLD_PNT.EB


ED $Fn>YLD>YLD_PNT.EB [ENTER]


&N point name

UNIT = unit number


KEYWORD = "keyword"


Load EB file. From the Builder Commands display:


Fill in ports as:

REFERENCE PATH NAME: $Fn>YLD


Pathname for SOURCE file: YLD_PNT

Pathname for IDF file: YLD_PNT

[ENTER]


Hi-Spec Solutions

FCCU Product Yield Calculation Configuration Graphics Installation

25



Step Action




Read YLD_CFG Read in the picture file, YLD_CFG

R $Fn>YLD>YLD_CFG [ENTER]


VER [ENTER]


COM [ENTER]

Copy YLD_CFG.DOto graphics directory


COPY $Fn>YLD>YLD_CFG.DO NET>pic_dir>= -D [ENTER]


Hi-Spec Solutions

FCCU Product Yield Calculation Configure Calculation Point

26


Configuration of the product yield point can be done either through the graphicYLD_CFG or through direct entry to the CDS ports on the Point Detail display. Use ofthe configuration graphic is recommended.

• Point Configuration Using Graphic YLD_CFG



Hi-Spec Solutions

FCCU Product Yield Calculation Configuration Using Graphic YLD_CFG

27

Point Configuration Using Graphic YLD_CFG

Each entry port on the product yield configuration graphic, YLD_CFG, is describedbelow:

LCO _PNT

1.000000

0

CCR_PN TCO NV_PNT

FC C _PNT

GR AV_PNT

0

PRES_PN T0

1.00000

TEMP_PNT0

TEMP_PNT0

HO NEYW ELL YIELD CO NFIGU RATION

Graphic YLD_CFG

Continued

Hi-Spec Solutions


28

Point Configuration Using Graphic YLD_CFG (Continued)


Calculation Point N/A Enter the Product Yield calculation point tagname.

Yield Conv Factor CONV_FAC(6) Enter the conversion factor to convert from internalunits to desired output units. See CONV_FAC(6) in“Configuration Inputs”.

Delay Increments ENGPAR(15) Enter the number of delay increments for biasing.One delay increment is equal to one executionperiod.

Product Flows ENGPAR(2) Enter the number of product flows.

Calibrate on “Re-Start”[No] [Yes]

ENGPAR(4) Select initiation mode of the catalystcharacterization correction factor [X(17)]

Cat Circulation Pnt CATCIRC Enter the Catalyst Circulation Rate calculation pointname.

Pred Conversion Pnt CALC_PT(1) Enter the Severity (predicted conversion)calculation point tagname.

Feed con Carbon Pnt CALC_PT(2) Enter the feed con carbon point tagname.


CONV_FAC(10) Select the desired gravity units. All input gravitieswill have the same units.

Product Grav Pnt GRAV_PT(1) Enter the product gravity point tagname.

Product Grav Filter FILTER(5) Enter the product gravity filter time (min).

Reactor Press Pnt PRESS_PT Enter the reactor pressure point tagname.


Rx Press Conv Fact CONV_FAC(9) Enter the conversion factor to convert from inputunits to psi.

Temperature Units[Deg F] [Deg C]

CONV_FAC(7) Select the input temperature units. All inputtemperatures must have the same units.



Reg Bed Temp Pnt TEMP_PT(2) Enter the regenerator bed temperature pointtagname.

Reg Bed Temp Filter FILTER(8) Enter the regenerator bed temperature filter time(min).

Continued

Hi-Spec Solutions


29


The graphic utilizes a configuration zone, located at the bottom of the main graphic, toconfigure a desired product setting page, a product information page, a steaminformation page, three prediction parameter pages, a yield equation data page, and ayield equation reference value page. The page forward and back keys on the TDC 3000keyboard step through the different configuration pages.

The lower right hand corner of the configuration zone contains paging information.The first number indicates the displayed page while the second number denotes howmany configuration pages require data entry.

The Desired Product Settings page shown below allows the user to select which productyield is being calculated.

For the product flow information page shown below, the number of configured flowsmust equal the Product Flows parameter entry, n. All four product flows can beconfigured; however, only the first n number of flows will be used by the YLD_PREDcode block. If less than n number of product flows are configured, the code block willreturn a status error when the point is activated.

Continued

Hi-Spec Solutions


30


The conversion factor units displayed will change automatically depending on whichproduct yield setting was chosen.

PROD_PNT PROD_PNT PROD_PNT PROD_PNT0 0 0 0

1.00000 1.00000 1.00000 1.00000


Point [PROD #1] FLOW_PT(1) Enter the first product flow point tagname.

Filter [PROD #1] FILTER(1) Enter the first product flow filter time (min).

Cnvrsn [PROD #1] CONV_FAC(1) See CONV_FAC(1) in “Configuration Input”.

Point [PROD #2] FLOW_PT(2) Enter the second product flow point tagname.

Filter [PROD #2] FILTER(2) Enter the second product flow filter time (min).


Point [PROD #3] FLOW_PT(3) Enter the third product flow point tagname.

Filter [PROD #3] FILTER(3) Enter the third product flow filter time (min).


Point [PROD #4] FLOW_PT(4) Enter the fourth product flow point tagname.

Filter [PROD #4] FILTER(4) Enter the fourth product flow filter time (min).


Continued

Hi-Spec Solutions


31


SSR_PNT0 0

1.00000 1.00000

STM_PNT


Stripping Steam Ratio CALC_PT(3) Enter the reactor stripping steam to catalyst ratiopoint tagname.

Stripping Stm Filter FILTER(6) Enter the reactor stripping steam to catalyst ratiofilter time (min).

Stm/Cat Ratio Cnvrsn CONV_PT(8) Enter the conversion factor to convert from inputunits to (lb steam)/(Mlb catalyst)

Riser Steam Flow FLOW_PT(5) Enter the riser steam flow point tagname. If morethan one steam flow exists, an AM regulatory pointwith PV algorithm summer should be used.

Riser Steam Filter FILTER(10) Enter the riser steam flow filter (min).

Riser Steam Cnvrsn CONV_FAC(5) Enter the conversion factor to convert from inputunits to PPH.


Constant Coef X(1) Enter the yield calculation constant coefficient.

Inv ln Pred Sev Coef X(2) Enter the inverse natural log predicted severitycoefficient.

Exp Pred Sev Coef X(3) Enter the exponential predicted severity coefficient.

Reaction Temp Coef X(4) Enter the reaction temperature coefficient.

API Gravity Coef X(5) Enter the API gravity coefficient.

Watson K Factor Coef X(6) Enter Watson K coefficient.

Continued

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32



Cat Micro-Act Coef X(7) Enter the catalyst micro activity coefficient.

Cat Surface Area Coef X(8) Enter the catalyst surface area coefficient.

First Cat Add Coef X(9) Enter the first catalyst additive coefficient.

Second Cat Add Coef X(10) Enter the second catalyst additive coefficient.

Reactor Press Coef X(11) Enter the reactor pressure coefficient.

Riser Steam Coef X(12) Enter the riser steam flow coefficient.


Reg Bed Temp Coef X(13) Enter the regenerator bed temperature coefficient.

Sulfur on Feed Coef X(14) Enter the feed sulfur content coefficient.

Feed con Carbon Coef X(15) Enter the feed con carbon coefficient.

Strppng Stm Rat Coef X(16) Enter the stripping steam ratio coefficient.

Catalyst Char Coef X(17) Enter the catalyst characterization factor.

Continued

Hi-Spec Solutions


33


0.00

1.00

0.00

0

0.000.00


First Cat Additive ENGPAR(6) Enter the first catalyst additive. Default value is 0.

Second Cat Additive ENGPAR(7) Enter the second catalyst additive. Default value is0.

Material Bal Coef ENGPAR(8) Enter the material balance coefficient. Default valueis 1.

Cat Surface Area ENGPAR(13) Enter the catalyst surface area (m2/gr). Defaultvalue is 0.

Cat Micro-Activity ENGPAR(14) Enter the catalyst micro activity. Default value is 0.

Yield Bias Filter ENGPAR(5) Enter the bias filter time (min) between thepredicted and measured product yield.

900.00 1250.00

20.00 10.00


Ref Reaction Temp ENGPAR(9) Enter the reference reaction temperature. Defaultvalue is 900 ΟF.

Ref Reg Bed Temp ENGPAR(10) Enter the reference regenerator bed temperature.Default value is 1250 ΟF.

Ref API Gravity ENGPAR(11) Enter the reference API gravity. Default value is 20.

Ref Watson K Factor ENGPAR(12) Enter the reference Watson K Factor. Default valueis 10.

Hi-Spec Solutions


34








Hi-Spec Solutions

FCCU Product Yield Calculation Point Configuration through Direct CDS Entry

35


If the configuration graphic is not used, then the configuration data must be entereddirectly onto the calculation point. The required calculation point information andassociated parameter are listed below.


FLOW_PT(1) Tagname for first product flowrate

CL program allows the calculation pointconfiguration with no product flows.

FLOW_PT(2) Tagname for second product flowrate


FLOW_PT(3) Tagname for third product flowrate

Required only if more than 2 productstreams exist.

FLOW_PT(4) Tagname for fourth product flowrate

Required only if more than 3 productstreams exist.

FLOW_PT(5) Tagname for total riser steam flowrate

This point should represent the totalsteam flow entering the riser.

TEMP_PT(1) Tagname for reaction temperature None

TEMP_PT(2) Tagname for Regenerator bedtemperature

None

PRESS_PT Tagname for Reactor pressure None

GRAV_PT(1) Tagname for NC3 to DCO gravity If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.

CALC_PT(1) Tagname for the predicted massconversion

This is the Honeywell Profimatics’Severity calculation point

CALC_PT(2) Tagname for carbon content onentering riser feed

If this reading is not available, bring inan estimate through an AM numericpoint.

CALC_PT(3) Tagname for Reactor strippingsteam to catalyst ratio

This is the ratio of stripping steam flowrate to catalyst circulation rate

Continued

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36



CATCIRC Tagname for HoneywellProfimatics’ Catalyst CirculationRate point

If no point is configured or theconfigured point has a bad value, theseverity output value will be set bad

ENGPAR(1) Desired product yield predictionsettings;

H2 => 0.0 ; H2S => 0.1 ; C1=> 1.0

NC2 => 2.0 ; C2= => 2.1 ;NC3 => 3.0

C3= => 3.1 ; NC4 => 4.0 ;C4= => 4.1

IC4 => 4.2 ; C5P => 5.0 ;LCO => 6.0

DCO => 7.0 ; coke => 8.0

Product yield configuration affectsinternal calculation settings.

ENGPAR(2) Number of input product streams(0.0 ≤ENGPAR(2) ≤ 4.0)

Number of product flows must match #of entries reflected in FLOW_PT(1..4).

ENGPAR(3) Flag to set calculation BAD:0 => Do not set BAD ;1 => Set calculation BAD

This input allows the calculation to beset bad by Engineering request.

ENGPAR(4) Calibration upon restart ofcalculation point

( 0 => Do Not Calibrate )

( 1 => Calibrate )

Parameter calibrates X(17) upon restartof the Honeywell Profimatics’ Severitycalculation point

ENGPAR(5) Discrete filter time for biasbetween predicted and measuredproduct yield

Value is dependent upon processcharacteristics

ENGPAR(6) First catalyst additive Default value is 0.0

ENGPAR(7) Second catalyst additive Default value is 0.0

ENGPAR(8) Material balance coefficient Default value is 1.0

ENGPAR(9) Reference reaction temperature Default value is 900 °F

ENGPAR(10) Reference Regenerator bedtemperature

Default value is 1250 °F

ENGPAR(11) Reference API gravity ofcombined riser

Default value is 20

ENGPAR(12) Reference Watson K factor ofcombined riser

Default value is 10

ENGPAR(13) Catalyst surface area Default value is 0.0

Continued

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37



ENGPAR(14) Catalyst micro-activity Default value is 0.0

ENGPAR(15) Number of predicted yield delayintervals

This signifies the number of pointexecution intervals necessary for theeffect of a change inReactor/Regenerator operation onproduct yields to be recognized at agiven downstream position


Converts input units to: MBPD for NC3-DCO;

MSCFPH for H2-C2=;

Mlb/hr for coke


Same as CONV_FAC(1)


Same as CONV_FAC(1)


Same as CONV_FAC(1)

CONV_FAC(5) Riser steam flow (FLOW_PT(5))multiplicative flow conversionfactor


CONV_FAC(6) Product flow desired outputmultiplicative flow conversionfactor

MBPD to desired units for NC3-DCO;

MSCFPH to desired units for H2-C2=;

Mlb/hr to desired units for coke

CONV_FAC(7) Input temperature unit flag:0 => °F ; 1 => °C

Default is 1 (°C).

CONV_FAC(8) Reactor stripper steam to catalystratio multiplicative conversionfactor

Converts input units to (lb stm) / (Mlbcatalyst)

CONV_FAC(9) Reactor pressure (PRESS_PT)multiplicative conversion factor

Converts input Reactor pressure frominput units to psi

CONV_FAC(10) Input gravity type flag0 => API ; 1 => Specific gravity

Default is 1 (SPGR).

FILTER(1) Filter time for product flow 1input

Minutes


Minutes

Continued

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38




Minutes


Minutes

FILTER(5) Filter time for product gravityinput

Minutes

FILTER(6) Filter time for Reactor strippingsteam to catalyst ratio

Minutes

FILTER(7) Filter time for reactiontemperature input

Minutes


Minutes

FILTER(9) Filter time for Reactor pressureinput

Minutes

FILTER(10) Filter time for riser steam flowinput

Minutes


X(2) K2; Inverse natural log predictedseverity coefficient

None

X(3) K3; Exponential predicted severitycoefficient

None

X(4) K4; Reaction temperaturecoefficient

None

X(5) K5; οAPI feed gravity coefficient None

X(6) K6; Watson K factor coefficient None

X(7) K7; Catalyst micro activitycoefficient

None

X(8) K8; Catalyst surface areacoefficient

None

X(9) K9; First catalyst additivecoefficient

None

X(10) K10; Second catalyst additivecoefficient

None

X(11) K11; Reactor pressure coefficient None

X(12) K12; Riser steam flow coefficient None

X(13) K13; Regenerator bed temperaturecoefficient

None

X(14) K14; Feed sulfur contentcoefficient

None

X(15) K15; Feed con carbon coefficient None

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39

X(16) K16; Reactor stripping steam tocatalyst ratio coefficient

None


Hi-Spec Solutions

FCCU Product Yield Calculation Appendix A Engineer’s Detailed Description

40

Link CL Programs

Step Action

Link YLD_PRED From the Command Processor Display:

LK $Fn>YLD>YLD_PRED point_name [ENTER]

Activate point Call up the point detail and activate the point or activate from YLD_CFGgraphic.

Verify Operation Verify that YLD_PRED is running without any CL errors.

Hi-Spec Solutions



FCCU Severity Calculation

CONTROLLED


Hi-Spec Solutions


Hi-Spec Solutions

FCCU Severity Calculation Revision History

1

Proprietary Notice



© 1995, Honeywell Hi-Spec Solution. All rights reserved.

TDC 3000™ is a trademark of Honeywell, Inc.

Hi-Spec Solutions

FCCU Severity Calculation Contents


Overview.........................................................................................................................................1

Acronym List ..................................................................................................................................2



Process Diagram .............................................................................................................................5


Point Structure ..................................................................................................................7

Process Inputs ...................................................................................................................8

Continued..........................................................................................................................8

Process Inputs (Continued) ...............................................................................................9


Configuration Inputs (Continued)...................................................................................11


Continued........................................................................................................................12

Calculation Outputs (Continued) ....................................................................................13

Error Codes ...................................................................................................................................14


Continued........................................................................................................................15




Biases in the FCCU Severity Program............................................................................19

Biases in the FCCU Severity Program (Continued) .......................................................20

Algorithms ....................................................................................................................................21

Algorithms (Continued) ..................................................................................................22

Algorithms (Continued) ..................................................................................................23




Building FCCU Severity Calculation Point....................................................................27


Hi-Spec Solutions



Point Configuration Using Graphic SEV_CFG..............................................................30

Continued........................................................................................................................30

Point Configuration Using Graphic SEV_CFG (Continued)..........................................31





Continued........................................................................................................................35



Continued........................................................................................................................37

Point Configuration through Direct CDS Entry (Continued) .........................................38

Continued........................................................................................................................38


Continued........................................................................................................................39


Link CL Programs...........................................................................................................41

Hi-Spec Solutions


Hi-Spec Solutions

FCCU Severity Calculation Overview

1

Overview

Definition. The FCCU Severity calculation uses the Honeywell Profimatics FCCUSeverity model. The parameterization of the model coefficients is completed using dataspecific to an individual FCCU. The cracking severity directly relates to the conversionof fresh feed.

Application. The severity calculation provides the predicted weight percent conversionof the fresh feed. This is an important performance parameter for a FCCU and issuitable for use in advanced control application. The predicted conversion is also animportant input for Honeywell Profimatics’ product yield model, octane model, andproduct value optimization.

Calculation. The Severity calculation program calculates the severity of a hydrocarbonstream based on:

• Processinputs:



Severity prediction parameters


Catalyst circulation rate, Catalyst to oil ratio.

Incentive. 1. To provide inputs for predicted product yield calculations.

2. To provide inputs for predicted octane number calculation.

3. To provide a real-time input for use in advanced control.

Hi-Spec Solutions

FCCU Severity Calculation Acronym List

2

Acronym List

Term Acronym




control language CL

process variable PV



Parameter List PL




pounds per hour PPH


atmospheres atm

Hi-Spec Solutions

FCCU Severity Calculation Hardware and Software Requirements

3




Special Boards None





Other Packages None


Software Inputs Honeywell Profimatics catalyst circulation rate calculation must existon the LCN.

Hi-Spec Solutions

FCCU Severity Calculation Instrumentation (Process Inputs)

4



Riser steam flow rates X


Reactor pressure X

Regenerator bed temperature X

Regenerator pressure X


Hi-Spec Solutions

FCCU Severity Calculation Process Diagram

5

Process Diagram

R i s e r

Regenerator

Reactor Chamber

Main Fractionator


Saturated GAs, C3, C4, Heavy Naphtha

LCO

HCO

DCO

Riser Feed

Spent Catalyst

Hi-Spec Solutions

FCCU Severity Calculation Detailed Description

6


The tables in this section describe the following Severity program architecture:

• Point Structure

• Process Inputs



Hi-Spec Solutions

FCCU Severity Calculation Point Structure

7

Point Structure

Point Structure

Point Type AM Regulatory, CL

PV_Type CL

CTL_Type Any

Custom Data Segment SEV_CDS.CL

Algorithm SEV_PRED.CL


Slot 5

Output The calculated wt% conversion is displayed as the point’s PV

Hi-Spec Solutions

FCCU Severity Calculation Process Inputs

8

Process Inputs

Process Inputs

Critical2


FLOW_PT(1) Tagname for riser steam 1 flow rate Any mass flowunits

X


X


X


X


X


TEMP_PT(2) Tagname for Regenerator bed temperature °F or °CX

PRESS_PT(1) Tagname for Regenerator pressure Any pressure unitsX

PRESS_PT(2) Tagname for Reactor pressure Any pressure unitsX

CALC_PT(1) Tagname Honeywell Profimatics’Measured Conversion calculation point

Weight %X

CALC_PT(2) Tagname for Regenerator oxygen Volume %X

CALC_PT(3) Tagname for Reactor level AnyX

CATCIRC Tagname for Honeywell Profimatics’Catalyst Circulation Rate calculation point

AnyX

CATCIRC.CALC_VAL(2)

Calculated API gravity of the combinedriser feed

°API X

CATCIRC.CALC_VAL(3)

Calculated mass flow of the combinedriser feed

Mlb/hrX

Continued


Hi-Spec Solutions

FCCU Severity Calculation Process Inputs

9


Process Inputs

Critical


CATCIRC.

CALC_VAL(4)

Calculated Watson K factor of thecombined riser feed

NoneX

CATCIRC.

CALC_VAL(5)

Calculated molecular weight of thecombined riser feed

Lb/Lb-moleX

CATCIRC.

CALC_VAL(13)

Calculated sulfur content of the combinedriser feed

Wt %X

.

Hi-Spec Solutions

FCCU Severity Calculation Configuration Inputs

10




T_BIAS(1) Additive bias to the reaction temperature Same units asTEMP_PT(1)

T_BIAS(2) Additive bias to the Regenerator bed temperature Same units asTEMP_PT(2)

P_BIAS(1) Additive bias to the Regenerator pressure Same units asPRESS_PT(1)

P_BIAS(2) Additive bias to the Reactor pressure Same units asPRESS_PT(2)

ENGPAR(1) Number of riser steam flow inputs (0 < ENGPAR(1) ≤ 5) N/A

ENGPAR(2) Calibrate on point restart ( 0 => no calibration;1 => for calibration )

N/A

ENGPAR(3) Discrete filter time for bias between predicted and measuredseverity

Minutes

ENGPAR(4) Set calculation BAD flag(0 => Do not set BAD;1 => Set calculation BAD)

N/A

ENGPAR(5) Reference Regenerator bed temperature οF

ENGPAR(6) Reference οAPI gravity value of combined riser feed οAPI

ENGPAR(7) Reference Watson K factor of combined riser feed None

ENGPAR(8) Number of predicted severity delay intervals N/A

CONV_FAC(1) Riser steam 1 flow rate (FLOW_PT(1)) multiplicativeconversion factor

From input unitsto Lb/hr









CONV_FAC(6) Input temperature unit flag;(0 => °F; 1 => °C)

N/A

CONV_FAC(7) Pressure input (PRESS_PT(i)) multiplicative conversionfactor

From input unitsto psi

CONV_FAC(8) Reactor level (CALC_PT(3)) multiplicative conversionfactor

From input unitsto inches H2O

CONV_FAC(9) Catalyst circulation rate multiplicative conversion factor From input unitsto short tons/min



Continued

Hi-Spec Solutions

FCCU Severity Calculation Configuration Inputs

11









FILTER(8) Filter time for Regenerator pressure input Minutes

FILTER(9) Filter time for Reactor pressure input Minutes

FILTER(10) Filter time for measured conversion of feed Minutes

FILTER(11) Filter time for volume percent of Regenerator oxygen Minutes

FILTER(12) Filter time for Reactor level input Minutes

X(1) Geometry coefficient None

X(2) Vorhes coefficient None

X(3) Reaction temperature coefficient None

X(4) Feed gravity coefficient None

X(5) Feed Watson K coefficient None

X(6) Feed sulfur content coefficient None

X(7) Catalyst surface area coefficient None

X(8) Catalyst micro activity coefficient None

X(9) Catalyst to oil ratio coefficient None

X(10) First catalyst additive coefficient None

X(11) Second catalyst additive coefficient None

X(12) Reactor level coefficient None

X(13) Carbon on catalyst coefficient None

X(14) Coefficient for averaging reaction temperature None

X(15) Riser feed expansion coefficient None

X(16) Riser volume Any

X(17) Catalyst surface area Any

X(18) Catalyst micro activity Any

X(19) Catalyst slip factor Any

X(20) First catalyst additive None

X(21) Second catalyst additive None

X(22) Carbon on catalyst additive coefficient None

X(23) Carbon on catalyst temperature coefficient None

X(24) Carbon on catalyst O2 coefficient None

X(25) Carbon on catalyst gain coefficient None

X(26) Carbon on catalyst pressure coefficient None


Hi-Spec Solutions

FCCU Severity Calculation Calculation Outputs

12

Calculation Outputs

Calculation Outputs


PVCALC Calculated biased weight conversion prediction Mass %

CALC_VAL(1) Calculated biased weight conversion prediction Mass %

CALC_VAL(2) Calculated catalyst to oil ratio None

CALC_VAL(3) Calculated scaled reaction temperature None

CALC_VAL(4) Calculated scaled Regenerator bed temperature None

CALC_VAL(5) Calculated scaled feed οAPI gravity οAPI

CALC_VAL(6) Calculated scaled feed Watson K factor None

CALC_VAL(7) Calculated scaled catalyst surface area Input Units

CALC_VAL(8) Calculated scaled Reactor level factor inches H2O

CALC_VAL(9) Calculated geometric factor None

CALC_VAL(10) Calculated feed characterization factor None

CALC_VAL(11) Calculated feed sulfur factor None

CALC_VAL(12) Calculated carbon on catalyst factor Mass

CALC_VAL(13) Calculated catalyst factor None

CALC_VAL(14) Calculated reaction temperature factor None

CALC_VAL(15) Calculated expansion factor None

CALC_VAL(16) Calculated reaction temperature factor None

CALC_VAL(17) Calculated reaction pressure factor None

CALC_VAL(18) Calculated Reactor level factor None

CALC_VAL(19) Calculated catalyst additive factor None

CALC_VAL(20) Calculated numerator of severity calculation None

CALC_VAL(21) Calculated denominator of severity calculation None

CALC_VAL(22) Calculated raw severity None

CALC_VAL(23) Calculated biased severity None

CALC_VAL(24) Measured severity None

CALC_VAL(25) Measured conversion Wt%

CALC_VAL(26) Filtered severity bias term None

CALC_VAL(27) Calculated difference between measured and predictedseverity

None

CALC_VAL(28) Predicted severity delay interval N/A

N(1...250) Delayed predicted severity values None

FILT_VAL(1) Filtered value of input riser steam 1 flow rate Input units





Continued

Hi-Spec Solutions

FCCU Severity Calculation Calculation Outputs

13

Calculation Outputs (Continued)

Calculation Outputs


FILT_VAL(6) Filtered value of reaction temperature input Input units

FILT_VAL(7) Filtered value of Regenerator bed temperature input Input units

FILT_VAL(8) Filtered value of Regenerator pressure input Input units

FILT_VAL(9) Filtered value of Reactor pressure input Input units

FILT_VAL(10) Filtered value of measured conversion of feed Input units

FILT_VAL(11) Filtered value of volume percent of Regenerator oxygen Input units

FILT_VAL(12) Filtered value of Reactor level input Input units

REV_NO Program revision number None


None

STATUS(2) Diagnostic indication of array location or subroutine error None

Hi-Spec Solutions

FCCU Severity Calculation Error Codes

14

Error Codes



• Array location error codes.

Hi-Spec Solutions

FCCU Severity Calculation Diagnostic Error Codes

15






2.0 Input number of steam flows is outside the range of 1 to 5[ENGPAR(1)]

3.0 FLOW_PT(1..5) has a null point entered (see “Array LocationError Codes”)

4.0 FLOW_PT(1..5) has a bad PV (see “Array Location ErrorCodes”)

5.0 Sum of input steam flows [ΣFLOW_PT(i)]= 0.0

6.0 TEMP_PT(i) has a null point entered (see “Array Location ErrorCodes”)

7.0 TEMP_PT(i) has a bad PV (see “Array Location Error Codes”)

8.0 PRESS_PT(i) has a null point entered (see “Array Location ErrorCodes”)

9.0 PRESS_PT(i) has a bad PV (see “Array Location Error Codes”)



12.0 Measured conversion (CALC_PT(1)) is outside the range of 0 to <100



15.0 Reactor level (CALC_PT(3)) is < 0



18.0 Catalyst circulation rate (CATCIRC) < 0

19.0 CATCIRC.CALC_VAL(2) is outside the range of 10 to 35

20.0 CATCIRC.CALC_VAL(3) is equal to 0.0

21.0 CATCIRC.CALC_VAL(4) is outside the range of 10 to 14 or lessthan ENGPAR(7)

22.0 CATCIRC.CALC_VAL(5) is outside the range of 100 to 700

Continued


Hi-Spec Solutions

FCCU Severity Calculation Diagnostic Error Codes

16




23.0 (PRESS_PT(2) + P_BIAS(2)) = -14.696 or X(16) is equal to 0which has caused the denominator term of the severity calculationto become infinite

24.0 Catalyst slip factor (X(19)) is equal to 0.0 which has caused thedenominator term of the severity calculation to become equal to 0

25.0 Uncorrected severity calculation returned a bad value.

26.0 Biased severity calculation is equal to -1.0 which has caused thepredicted mass conversion to become infinite

Hi-Spec Solutions

FCCU Severity Calculation Array Location Error Codes

17


Filter Error Codes







5.0 An error has occurred in processing the fifth element in theSTATUS(1) defined array


Hi-Spec Solutions

FCCU Severity Calculation Configuration and Tuning

18



Biases

• Temperature Biases

• Pressure Biases

• Additive Bias

• Catalyst Characterization Factor.

Tuning

There are no user accessible tuning parameters associated with the FCCU SeverityCalculation. The severity model uses coefficients parameterized from a specificFCCU’s operating data. If significant unit modifications are made, the coefficients mayneed to be updated by Honeywell Profimatics.

Hi-Spec Solutions

FCCU Severity Calculation Biases in the FCCU Severity Program

19

Biases in the FCCU Severity Program

The FCCU Severity program is equipped with the following biases:

• Reaction and Regenerator bed temperature biases.

• Reactor and Regenerator pressure biases.

• Additive bias for the severity.

• Catalyst characterization factor for the severity.

Bias Parameters


T_BIAS(1) Additive bias to input reaction temperature TEMP_PT(1)

T_BIAS(2) Additive bias to input Regenerator bed temperatureTEMP_PT(2)

P_BIAS(1) Additive bias to input Regenerator pressure PRESS_PT(1)

P_BIAS(2) Additive bias to input Reactor pressure PRESS_PT(2)

ENGPAR(3) Discrete filter time for bias between predicted and measuredseverity

X(27) Catalyst characterization factor

Pressure and Temperature Bias. The pressure biases (P_BIAS(1..2)) andtemperature biases (T_BIAS(1..2)) are added to the input values before performance ofunit conversions and should be entered in the same units as the input pressures andtemperatures.

The T_BIAS parameters are used when there is a known error in either the reaction orRegenerator bed temperature indication. The P_BIAS parameter is used when theactual Reactor or Regenerator pressure is not available as an input to the calculation.

Example. If the Reactor overhead pressure is used for PRESS_PT, then P_BIAS is setequal to the pressure change between the Reactor overhead and the Riser.

Hi-Spec Solutions

FCCU Severity Calculation Biases in the FCCU Severity Program

20

Biases in the FCCU Severity Program (Continued)

Additive Biases. In most processes, a change in the FCCU process inputs will shift theoverall severity and consequently, the conversion; however, these changes will not benoticed until a later time. We will call this time lapse the dead time of the process. Forthis reason, a delayed predicted severity term takes the dead time into account andproduces a pseudo real-time bias term. This additive bias term is automatically updatedto reconcile the measured and delayed predicted severities. The reconciliation is doneusing a first order discrete filter whose filter time is stored in the parameterENGPAR(3). The discrete filter time is entered in minutes. The resulting biasparameter is used to keep the severity model reconciled with plant operation.

The predicted severities are stored into a predefined array, N, whose size is configuredusing ENGPAR(8). The predicted severities are stored throughout the severitycalculation point’s operation. For example, if the dead time is two hours and theseverity calculation point is being processed every minute, ENGPAR(8) should beconfigured to 120. The program will store one hundred and twenty predicted severityvalues. The next time the point is processed, the first severity value stored (120 minutesago) is retrieved and used to calculate a severity bias term. The current predictedseverity takes the place of the retrieved severity value in the N array. Until the deadtime is reached, a non-biased predicted conversion is displayed as the point’s PV. IfENGPAR(8) is configured to zero, a real-time, not delayed bias, is used.

Catalyst Characterization Factor. If discrepancies exist between actual catalyst dataand data supplied for severity model parameterization, the calculated severity andmeasured severity may not match exactly. Therefore, a catalyst characterization factor(X(27)) is provided. This factor is calculated by the program upon restart, ifENGPAR(2) is set to 1.0. The value of X(27) is a multiplier which causes thecalculated and measured severities to be equal.

Hi-Spec Solutions

FCCU Severity Calculation Algorithms

21

Algorithms

Conversion of Engineering Units. The input riser steam flows can have any units, butthe conversion factors must be configured to yield PPH shown in Equation 1:


Where:

flow(i) = Process flow i converted to PPH internal useFLOW_PT(i).PV = Input process flow i in any unitsCONV_FAC(i) = Conversion for flow i from input units to PPH

Equation 1

The input process pressure can have any gauge units. However, the conversion factormust be configured to yield psi, as shown in Equation 2:

press = ((PRESS_PT(i).PV + P_BIAS(i)) * CONV_FAC(7) + 14.696) / 14.696

Where:

press = Process pressure converted to absolute atmospheres for internal use

PRESS_PT(i).PV = Input process pressure in any gauge unitsP_BIAS(i) = Bias to input pressure in input unitsCONV_FAC(7) = Conversion factor for pressure from input units to psi

Equation 2

The input Reactor level and catalyst circulation rate are converted in a similar mannerto the flows and pressures using CONV_FAC(8) and CONV_FAC(9). Final units forthe Reactor level and catalyst circulation rate are inches of H2O and short tons perminute, respectively.

Continued

Hi-Spec Solutions


22


Severity Calculation. The severity is calculated from process inputs using theHoneywell Profimatics severity model as shown in Equation 3.

Severity = Function[FeedProp, CatProp, OpParam]

Where:

Severity = Cracking severityFeedProp = Feed characterization propertiesCatProp = Catalyst properties including surface area and micro-activityOpParam = Operating parameters including catalyst circulation rate and

reaction temperature

Equation 3

Many measured Reactor/Regenerator variables and severity model coefficients are usedin the severity model. The parameterization of the model coefficients is completed byregressing data specific to the unit. These model coefficients must be calculated byHoneywell Profimatics.

Biasing. An additive bias term is provided to reduce the offset between the calculatedand measured severities. The correction is shown in Equation 4.

b_severity = severity + sev_bias

Where:

b_severity = Biased severityseverity = Calculated severitysev_bias = Filtered additive severity bias term

Equation 4

Hi-Spec Solutions


23


The severity is related to the weight percent conversion as shown in Equation 5.

Conv = 100*(Severity/(1+Severity))

Where:

Conv = Conversion of fresh feedSeverity = Cracking severity

Equation 5

Hi-Spec Solutions

FCCU Severity Calculation Installation Procedure

24


This document describes the installation procedure for the FCCU Severity Calculationprogram (SEV_PRED) on the TDC 3000 System AM.




• Building Severity Calculation Point


Hi-Spec Solutions

FCCU Severity Calculation Preparation for Installation

25


Step Action


• Removable media containing the directory SEV



Media:FCOPY $Fn $Fm

Directory only:CD $Fm>vol_dir> SEVCOPY $Fn>SEV>*.* $Fm>SEV>= -V -D


Hi-Spec Solutions

FCCU Severity Calculation CDS and PL Installation

26



Step Action

Set volumepathnames



CompileSEV_CDS.CL

From the Command Processor display, compile the CDS file, SEV_CDS:CL $Fn>SEV>SEV_CDS.CL -UL


Parameter List There is no parameter list for the standard severity calculation package

Hi-Spec Solutions

FCCU Severity Calculation Building Severity Calculation Point

27

Building FCCU Severity Calculation Point

A regulatory point is required for each severity calculated.

Step Action

Modify ExceptionBuild file,SEV_PNT.EB


ED $Fn>SEV>SEV_PNT.EB [ENTER]


&N point name

UNIT = unit number


KEYWORD = "keyword"




Fill in ports as:

REFERENCE PATH NAME: $Fn>SEV


Pathname for SOURCE file: SEV_PNT

Pathname for IDF file: SEV_PNT

[ENTER]


Hi-Spec Solutions

FCCU Severity Calculation Configuration Graphics Installation

28



Step Action




Read SEV_CFG Read in the picture file, SEV_CFG

R $Fn>SEV>SEV_CFG [ENTER]


VER [ENTER]


COM [ENTER]

Copy SEV_CFG.DOto graphics directory


COPY $Fn>SEV>SEV_CFG.DO NET>pic_dir>= -D [ENTER]


Hi-Spec Solutions

FCCU Severity Calculation Configure Calculation Point

29


Configuration of the severity point can be done either through the graphic SEV_CFG orthrough direct entry to the CDS ports on the Point Detail display. Use of theconfiguration graphic is recommended.

• Point Configuration Using Graphic SEV_CFG



Hi-Spec Solutions


30

Point Configuration Using Graphic SEV_CFG

Each entry port on the severity configuration graphic, SEV_CFG, is described below:

SEV_PNT

CCR_PNT 1.00000

PRES_PNT

0

PRES_PNT

0

1.000001.00000

0 0 0 0STM_PNT STM_PNT STM_PNT STM_PNTSTM_PNT

1.00000 1.00000 1.00000 1.00000 1.00000

0

1.00000

0

0

1250.00

20.0010.00

TEMP_PNT

TEMP_PNT

1

0

0.00

0.00

0.00

0.00

HONEYWELL SEVERITY CONFIG

Delay Increments

Graphic SEV_CFG


Calculation Point N/A Enter the Severity calculation point name.

Cat Circ Pnt CATCIRC Enter the Catalyst Circulation Rate calculation pointname.

Cat Circ Conv Fact CONV_FAC(9) Enter conversion factor to convert from input unitsto (short ton)/min.

Calibrate on “Re-Start”[No] [Yes]

ENGPAR(2) Select initiation mode of the catalystcharacterization correction factor [X(27)]

Reactor Press Pnt PRESS_PT(2) Enter the reactor pressure point tagname.

Rx Press Bias P_BIAS(2) Enter the reactor pressure bias. Input pressure unitsmust be used.


Reg Press Pnt PRESS_PT(1) Enter the regenerator pressure point tagname.

Continued

Hi-Spec Solutions


31

Point Configuration Using Graphic SEV_CFG (Continued)


Reg Press Bias P_BIAS(1) Enter the regenerator pressure bias. Input pressureunits must be used.

Reg Press Filter FILTER(8) Enter the regenerator bed filter time (min).

Press Conv Fact CONV_FAC(7) Enter the conversion factor to convert from inputpressure units to psig.

Rx Level Conv Fact CONV_FAC(8) Enter the conversion factor to convert from inputunits to inches of H2O.

Temperature Units[Deg F] [Deg C]

CONV_FAC(6) Select the input temperature units. All inputtemperatures must have the same units.


Reaction Temp Bias T_BIAS(1) Enter the reaction temperature bias. Inputtemperature units must be used.


Riser Steam Flows ENGPAR(1) Enter the number of riser steam flows.

Delay Increments ENGPAR(8) Enter the number of delay increments for biasing.One delay increment is equal to one executionperiod.

Ref Reg Bed Temp ENGPAR(5) Enter the reference regenerator bed temperature.Default value is 1250 ΟF.

Ref API Gravity ENGPAR(6) Enter the reference API gravity. Default value is 20.

Ref Watson K Factor ENGPAR(7) Enter the reference Watson K Factor. Default valueis 10.

The graphic utilizes a configuration zone, located at the bottom of the main graphic, toconfigure a riser steam flow information page, a calculation point page, and fiveseverity equation data pages. The page forward and back keys on the TDC 3000keyboard step through the different configuration pages.

The lower right hand corner of the configuration zone displays paging information.The first number indicates the displayed page while the second number denotes howmany configuration pages require data entry.

For the riser steam flow information page shown below, the number of configuredsteam flows must equal the Riser Steam Flows parameter entry, n. All five steamflows can be configured; however, only the first n number of riser steam flows will beused by the SEV_PRED code block. If the number of steam flows configured is lessthan n, the code block will return a status error when the point is activated.

Continued

Hi-Spec Solutions


32


0 0 0 0STM_PNT STM_PNT STM_PNT STM_PNTSTM_PNT

1.00000 1.00000 1.00000 1.00000 1.00000

0


Point [STM #1] FLOW_PT(1) Enter the first riser steam flow point tagname.

Filter [STM #1] FILTER(1) Enter the first riser steam flow filter time (min).

Cnvrsn [STM #1] CONV_FAC(1) Enter conversion factor to convert from flow inputunits to PPH.

Point [STM #2] FLOW_PT(2) Enter the second riser steam flow point tagname.

Filter [STM #2] FILTER(2) Enter the second riser steam flow filter time (min).


Point [STM #3] FLOW_PT(3) Enter the third riser steam flow point tagname.

Filter [STM #3] FILTER(3) Enter the third riser steam flow filter time (min).


Point [STM #4] FLOW_PT(4) Enter the fourth riser steam flow point tagname.

Filter [STM #4] FILTER(4) Enter the fourth riser steam flow filter time (min).


Point [STM #5] FLOW_PT(5) Enter the fifth riser steam flow point tagname.

Filter [STM #5] FILTER(5) Enter the fifth riser steam flow filter time (min).


Continued

Hi-Spec Solutions


33


CONV_PNTO2_PNT

LVL_PNT

00

0


Mass Conversion Pnt CALC_PT(1) Enter Mass Conversion calculation point tagname.

Mass Conv Filter FILTER(10) Enter mass conversion filter time (min).

Regenerator O2 Pnt CALC_PT(2) Enter regenerator O2 point tagname.

Regen O2 Pnt FILTER(11) Enter regenerator O2 filter time (min).

Reactor Level Pnt CALC_PT(3) Enter reactor level point tagname.

Rx Level Filter FILTER(12) Enter reactor level filter time (min).

0.00 0.00

3.00

0.00 0.00

1.00


Feed Grav Coef X(4) Enter the riser feed gravity coefficient. Defaultvalue is 0.

Feed WatK Coef X(5) Enter the riser feed Watson K factor coefficient.Default value is 0.

Feed Expan Coef X(15) Enter the riser feed expansion coefficient. Defaultvalue is 3.

Riser Volume X(16) Enter the riser volume. Default value is 0.

Reaction Temp Coef X(3) Enter the reaction temperature coefficient. Defaultvalue is 0.

Catalyst Char Factor X(27) Enter the catalyst characterization factor. Defaultvalue is 1.

Continued

Hi-Spec Solutions


34


0.00 0.00

0.00

0.00

0.00


CRC Temp Coef X(23) Enter the CRC temperature coefficient. Defaultvalue is 0.

CRC Press Coef X(26) Enter the CRC pressure coefficient. Default value is0.

CRC O2 Coef X(24) Enter the CRC O2 coefficient. Default value is 0.

CRC Gain Coef X(25) Enter the CRC gain coefficient. Default value is 0.

CRC Additive Coef X(22) Enter the CRC additive coefficient. Default value is0.

0.00

0.00

0.800.00

0.00

0.00


CRC Coef X(13) Enter the carbon on catalyst coefficient. Defaultvalue is 0.

Catalyst SURF Coef X(7) Enter the catalyst surface area coefficient. Defaultvalue is 0.

Catalyst MAT Coef X(8) Enter the catalyst micro activity coefficient.Default value is 0.

Catalyst Slip Factor X(19) Enter the catalyst slip factor. Default value is 0.8.

Catalyst Surf Area X(17) Enter the catalyst surface area. Default value is 0.

Cat Micro Activity X(18) Enter the catalyst micro activity. Default value is 0.

Continued

Hi-Spec Solutions


35


0.00

0.00

0.00 0.000.00

0.00


Feed Sulf Coef X(6) Enter the feed sulfur content coefficient. Defaultvalue is 0.

1st Cat Additive X(20) Enter the first catalyst additive. Default value is 0.

2nd Cat Additive X(21) Enter the second catalyst additive. Default value is0.

Rx Level Coef X(12) Enter the reactor level coefficient. Default value is0.

1st Cat Add Coef X(10) Enter the first catalyst additive coefficient. Defaultvalue is 0.

2nd Cat Add Coef X(11) Enter the second catalyst additive coefficient.Default value is 0.

0.00

0

0.000.000.00


Cat Geometry Coef X(1) Enter the catalyst geometry coefficient. Defaultvalue is 0.

Ave Rx Temp Coef X(14) Enter the coefficient for averaging reactiontemperature. Default value is 1.

Sev Bias Filter ENGPAR(3) Enter the bias filter time (min) between thepredicted and measured severity.

Cat/Oil Ratio Coef X(9) Enter the catalyst to oil ratio coefficient. Defaultvalue is 0.

Vorhes Coef X(2) Enter the vorhes coefficient. Default value is 0.

Continued

Hi-Spec Solutions


36








Hi-Spec Solutions

FCCU Severity Calculation Point Configuration through Direct CDS Entry

37




FLOW_PT(1) Tagname for first riser steam flowrate

Must have one riser steam flow.

FLOW_PT(2) Tagname for second riser steamflow rate

Required only if more than 1 riser steamflow exists.

FLOW_PT(3) Tagname for third riser steamflow rate

Required only if more than 2 riser steamflows exist.

FLOW_PT(4) Tagname for fourth riser steamflow rate


FLOW_PT(5) Tagname for fifth riser steam flowrate


TEMP_PT(1) Tagname for reaction temperature Use bias in T_BIAS(1) if thetemperature is not located at the riseroutlet.

TEMP_PT(2) Tagname for Regenerator bedtemperature

Use bias in T_BIAS(2) if thetemperature is not located on theRegenerator catalyst bed.

PRESS_PT(1) Tagname for Regenerator pressure Use bias in P_BIAS(1) if the pressure isnot located on the Regenerator catalystbed.

PRESS_PT(2) Tagname for Reactor pressure Use bias in P_BIAS(2) if the pressure isnot located on the riser outlet.

CALC_PT(1) Tagname for the measured massconversion

This is Honeywell Profimatics’Measured Conversion calculation point

CALC_PT(2) Tagname for the O2 Regeneratorflue gas

Units should be in volume percent

CALC_PT(3) Tagname for the Reactor level This term will later be converted toinched of H2O

CATCIRC Tagname for HoneywellProfimatics’ Catalyst CirculationRate calculation point

If no point is configured or theconfigured point has a bad value, theseverity calculated will be set bad

T_BIAS(1) Additive bias to the reactiontemperature


T_BIAS(2) Additive bias to Regenerator bedtemperature


Continued

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P_BIAS(1) Additive bias to the Regeneratorpressure

Same units as PRESS_PT(1).

P_BIAS(2) Additive bias to the Reactorpressure

Same units as PRESS_PT(2).

ENGPAR(1) Number of input riser steam flows(0.0 < ENGPAR(1) <= 5.0)

Number of riser steam flows mustmatch # of entries reflected inFLOW_PT(1..5)

ENGPAR(2) Calibration upon restart ofcalculation point

( 0 => Do Not Calibrate )

( 1 => Calibrate )

Parameter allows calibration withmeasured conversion upon restart of theSeverity calculation point if requested

ENGPAR(3) Discrete filter time for biasbetween predicted and measuredseverity

Value is dependent upon processcharacteristics


This input allows the calculation to beset bad by Engineering request.

ENGPAR(5) Reference Regenerator bedtemperature

Default value is 1250 °F

ENGPAR(6) Reference API gravity ofcombined feed

Default value is 20 °API

ENGPAR(7) Reference Watson K factor ofcombined feed

Default value is 10

ENGPAR(8) Number of predicted severitydelay intervals

This signifies the number of pointexecution intervals necessary for theeffect of a change inReactor/Regenerator operation onseverity to be recognized at a givendownstream position.

CONV_FAC(1) Riser steam 1 (FLOW_PT(1))multiplicative flow conversionfactor








Continued

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39






Default is 1 (°C).

CONV_FAC(7) Process pressure(PRESS_PT(1..2)) multiplicativeconversion factor

Convert input units to psi.

CONV_FAC(8) Reactor level multiplicativeconversion factor

Convert input units to inches H2O

CONV_FAC(9) Catalyst Circulation Ratemultiplicative conversion factor

Convert input units to short ton perminute

FILTER(1) Filter time for riser steam 1 flowinput

Minutes


Minutes


Minutes


Minutes


Minutes

FILTER(6) Filter time for reactiontemperature input

Minutes


Minutes

FILTER(8) Filter time for Regeneratorpressure input

Minutes

FILTER(9) Filter time for Reactor pressureinput

Minutes

FILTER(10) Filter time for measured massconversion of feed

Minutes

FILTER(11) Filter time for volume percent ofRegenerator oxygen

Minutes

FILTER(12) Filter time for Reactor level input Minutes

X(1) Geometry coefficient Default value is 0.0

X(2) Vorhes coefficient Default value is 0.0

X(3) Reaction temperature coefficient Default value is 0.0

X(4) Feed gravity coefficient Default value is 0.0

X(5) Feed Watson K coefficient Default value is 0.0

Continued

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40



X(6) Feed sulfur content coefficient Default value is 0.0

X(7) Catalyst surface area coefficient Default value is 0.0

X(8) Catalyst micro activity coefficient Default value is 0.0

X(9) Catalyst to oil ratio coefficient Default value is 0.0

X(10) First catalyst additive coefficient Default value is 0.0

X(11) Second catalyst additivecoefficient

Default value is 0.0

X(12) Reactor level coefficient Default value is 0.0

X(13) Carbon on catalyst coefficient Default value is 0.0

X(14) Coefficient for averaging reactiontemperature


X(15) Riser feed expansion Default value is 3.0

X(16) Riser volume Default value is 0.0

X(17) Catalyst surface area Default value is 0.0

X(18) Catalyst micro activity Default value is 0.0

X(19) Catalyst slip factor Default value is 0.8

X(20) First catalyst additive Default value is 0.0

X(21) Second catalyst additive Default value is 0.0

X(22) Carbon on catalyst additivecoefficient


X(23) Carbon on catalyst temperaturecoefficient


X(24) Carbon on catalyst O2 coefficient Default value is 0.0

X(25) Carbon on catalyst gain coefficient Default value is 0.0

X(26) Carbon on catalyst pressurecoefficient


X(27) Catalyst characterization factor Default value is 1.0

Hi-Spec Solutions

FCCU Severity Calculation Appendix A Engineer’s Detailed Description

41

Link CL Programs

Step Action

Link SEV_PRED From the Command Processor display:

LK $Fn>SEV>SEV_PRED point_name [ENTER]

Activate point Call up the point detail and activate the point or activate from SEV_CFGgraphic..

Verify Operation Verify that SEV_PRED is running without any CL errors.

Hi-Spec Solutions

FCCU Severity Calculation Appendix A Engineer’s Detailed Description

42

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