DISTILLATION with DYNAMIC PROFITABILTY ANALYSIS
Distillation Tower Graphic with Sub-Systems Overview:
The Distillation Program is representative of "intermediate" type Standard Programs and is useful in a wide variety of refining, petrochemical, and chemical plant applications.
Training Objectives:
Typical training objectives include:
- Improving skill levels in the operation of standard refinery or chemical Distillation processes for new and experienced operators
- Providing well-managed, controlled "hands on" experience in:
- Start-ups
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- Normal operations
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- Shut downs
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- Emergency upsets
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- Providing operators/supervisors with understanding the impact of process variables and operation on process profitability. The profitability analysis provides quantitative performance criteria for individual operators against individ
ual "scores," group averages and/or other performance standards.
- Minimizing costs and maximizing profitability through an in-depth understanding of the Distillation process and related engineering principals
- Increasing confidence levels of new and experienced operators in new processes, operating conditions, instrumentation, and control schemes
Process Description:
Representative of a standard industrial Distillation tower, this process is designed to separate a two component mixture in a low-pressure environment. The multiple-tray tower provides fractionation with boil-up provide by
a steam reboiler. The overhead system includes a total condenser and an overhead receiver. They system provided for a range of feed composition and temperature.
The Dynamic Profitability Analysis feature provides user-driven process economics and displays both "instantaneous" and "accumulated" profitability. This information can be historically trended against standard process variabl
es for determining optimum operating conditions and procedures
.
Instrumentation:
The tower base level controller maintains the bottom product rate. The overhead product rate is controlled by the overhead accumulation level. The base temperature is maintained by measuring the temperature of the bottoms
tray and controlling the reboiler steam rate. Systems pressure is maintained by the split range pressure controller at the overhead receiver. Reflux can be cascaded with the top tray temperature or be controlled manually.
Equipment:
- Seven-tray column
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- Shell and tube overhead condenser
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- Overhead receiver
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- Feed pump, spare
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- Kettle-type steam reboiler
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- Bottoms pump, spare
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- Reflux pump, spare
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- Condensate pump, spare
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Upsets and Malfunctions:
The following upsets and malfunctions can be introduced by an instructor via a pre-programmed set of Training Exercises. At the end of the training session, these upsets and malfunctions can be used to test and operator’s ability to troubleshoot - r
ecognize and correct problems - while safely and efficiently returning the process to design or normal conditions.
- Pump failures
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- Steam supply failure
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- Valve failures
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- Cooling water failure
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- Blocked vent
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- Condenser fouling
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- Reboiler fouling
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- Power failure
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- Varied feed rate
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- Varied product specification
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Student Performance Analysis:
A comprehensive set of recording, testing, and evaluation tools included with the Distillation Program provide important training documentation and scores.
"Student Performance Analysis" is the name for this entire "testing/evaluation/records package. Key components include:
- "What If" -- provides the ability to create questions about process response, and record the correct answer to a file. When a student takes the "What If" test, their answers are graded against the correct answers, and their "scores" sent to a
file. Other features include being able to add a "weighting" to each question that will be reflected in the grade, and "categorizing" of the questions so that "weaknesses" and recommendations can be made during the grading process.
- Event Log Processor -- records all Simulator "events" (Setpoint changes, Alarms, Alarm Acknowledgement, Display changes, etc.) and records these into a file. At the end of a Training Exercise, a specific events can be selected (e.g. Alarms an
d Setpoint changes) for review and evaluation.
- Trend File Processor - Saves all of the Trends to a file. At the end of a Training Exercise, provides the facility to display, analyze, and "grade" these Trends. Grading information will include:
- Deviation from Setpoint. This can be weighted based on % deviation.
- Time in alarm, in terms of % time and number of times in HA/LA.
- Weighting factor for each instrument.
- Statistical information:
- Standard deviation
- Average
- Derivation
Complete Training Package:
Simulation Solutions' Standard Programs are complete training packages.
Each Program comes with live process graphics, printer reporting functions,
and many other features. Also provided are comprehensive on-line training
manuals.
The complete training package includes the following:
- A comprehensive Instructor Training Course. This course not only covers
the features of the Simulator and Programs, but also provides useful
information and advice on how to implement a successful
Simulator-Based-Training Course.
- Comprehensive documentation for both Trainees and Instructors. This
includes detailed Training Exercises, Start-Up and Shut-Down instruction,
and more.
- An illustration of the versatility of the Simulator. The Simulator itself
can be useful for training new and experienced operators, instrument
technicians, and new engineers. It can also be used as an effective tool to
screen for new hires.
The built-in Dynamic Profitability Analysis Tool:
This tool, visible to both the operator and instructor, automatically up-dates every second. It tracks and records the dollar impact that the process control changes made by the operator have upon the efficiency of the operation.
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