FCCU Toolkit · Hi-Spec Solutions Honeywell Hi-Spec Solutions • 16404 N. Black Canyon Hwy. •...
Transcript of 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.
Hi-Spec Solutions
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
Hi-Spec Solutions
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
Hi-Spec Solutions
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.
Hi-Spec Solutions
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
Hi-Spec Solutions
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(2) Tagname of riser feed 2 flow rate Any flow unitsX
FLOW_PT(3) Tagname of riser feed 3 flow rate Any flow unitsX
FLOW_PT(4) Tagname of riser feed 4 flow rate Any flow unitsX
FLOW_PT(5) Tagname of riser feed 5 flow rate Any flow unitsX
FLOW_PT(6) Tagname of riser steam 1 flow rate Any flow unitsX
FLOW_PT(7) Tagname of riser steam 2 flow rate Any flow unitsX
FLOW_PT(8) Tagname of riser steam 3 flow rate Any flow unitsX
FLOW_PT(9) Tagname of riser steam 4 flow rate Any flow unitsX
FLOW_PT(10) Tagname of riser steam 5 flow rate Any flow unitsX
TEMP_PT(1) Tagname of riser feed stream 1temperature
°F or °CX
TEMP_PT(2) Tagname of riser feed stream 2temperature
°F or °CX
TEMP_PT(3) Tagname of riser feed stream 3temperature
°F or °CX
TEMP_PT(4) Tagname of riser feed stream 4temperature
°F or °CX
TEMP_PT(5) Tagname of riser feed stream 5temperature
°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
Parameter Description Units Yes No
GRAV_PT(2) Tagname of riser feed stream 2 gravity °API or none (S.G.)X
GRAV_PT(3) Tagname of riser feed stream 3 gravity °API or none (S.G.)X
GRAV_PT(4) Tagname of riser feed stream 4 gravity °API or none (S.G.)X
GRAV_PT(5) Tagname of riser feed stream 5 gravity °API or none (S.G.)X
WATK_PT(1) Tagname of riser feed stream 1 Watson K NoneX
WATK_PT(2) Tagname of riser feed stream 2 Watson K NoneX
WATK_PT(3) Tagname of riser feed stream 3 Watson K NoneX
WATK_PT(4) Tagname of riser feed stream 4 Watson K NoneX
WATK_PT(5) Tagname of riser feed stream 5 Watson K NoneX
CALC_PT(1) Tagname of riser feed stream 1 nitrogencontent
Wt %X
CALC_PT(2) Tagname of riser feed stream 2 nitrogencontent
Wt %X
CALC_PT(3) Tagname of riser feed stream 3 nitrogencontent
Wt %X
CALC_PT(4) Tagname of riser feed stream 4 nitrogencontent
Wt %X
CALC_PT(5) Tagname of riser feed stream 5 nitrogencontent
Wt %X
CALC_PT(6) Tagname of riser feed stream 1 sulfurcontent
Wt %X
CALC_PT(7) Tagname of riser feed stream 2 sulfurcontent
Wt %X
CALC_PT(8) Tagname of riser feed stream 3 sulfurcontent
Wt %X
CALC_PT(9) Tagname of riser feed stream 4 sulfurcontent
Wt %X
CALC_PT(10) Tagname of riser feed stream 5 sulfurcontent
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
Configuration Inputs
Parameter Description Units
T_BIAS(1) Additive bias to riser feed stream 1 temperature Same units asTEMP_PT(1)
T_BIAS(2) Additive bias to riser feed stream 2 temperature Same units asTEMP_PT(2)
T_BIAS(3) Additive bias to riser feed stream 3 temperature Same units asTEMP_PT(3)
T_BIAS(4) Additive bias to riser feed stream 4 temperature Same units asTEMP_PT(4)
T_BIAS(5) Additive bias to riser feed stream 5 temperature Same units asTEMP_PT(5)
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
Hi-Spec Solutions
FCCU Catalyst Circulation Rate Calculation Configuration Inputs
11
Configuration Inputs (Continued)
Configuration Inputs
Parameter Description Units
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(2) Filter time for riser feed 2 flow input Minutes
FILTER(3) Filter time for riser feed 3 flow input Minutes
FILTER(4) Filter time for riser feed 4 flow input Minutes
FILTER(5) Filter time for riser feed 5 flow input Minutes
FILTER(6) Filter time for riser steam 1 flow input Minutes
FILTER(7) Filter time for riser steam 2 flow input Minutes
FILTER(8) Filter time for riser steam 3 flow input Minutes
FILTER(9) Filter time for riser steam 4 flow input Minutes
FILTER(10) Filter time for riser steam 5 flow input Minutes
FILTER(11) Filter time for riser feed 1 gravity Minutes
FILTER(12) Filter time for riser feed 2 gravity Minutes
FILTER(13) Filter time for riser feed 3 gravity Minutes
FILTER(14) Filter time for riser feed 4 gravity Minutes
FILTER(15) Filter time for riser feed 5 gravity Minutes
FILTER(16) Filter time for riser feed 1 Watson K factor Minutes
FILTER(17) Filter time for riser feed 2 Watson K factor Minutes
FILTER(18) Filter time for riser feed 3 Watson K factor Minutes
FILTER(19) Filter time for riser feed 4 Watson K factor Minutes
FILTER(20) Filter time for riser feed 5 Watson K factor Minutes
FILTER(21) Filter time for riser feed 1 nitrogen content Minutes
FILTER(22) Filter time for riser feed 2 nitrogen content Minutes
FILTER(23) Filter time for riser feed 3 nitrogen content Minutes
FILTER(24) Filter time for riser feed 4 nitrogen content Minutes
FILTER(25) Filter time for riser feed 5 nitrogen content Minutes
FILTER(26) Filter time for riser feed 1 sulfur content Minutes
FILTER(27) Filter time for riser feed 2 sulfur content Minutes
Continued
Hi-Spec Solutions
FCCU Catalyst Circulation Rate Calculation Configuration Inputs
12
Configuration Inputs (Continued)
Configuration Inputs
Parameter Description Units
FILTER(28) Filter time for riser feed 3 sulfur content Minutes
FILTER(29) Filter time for riser feed 4 sulfur content Minutes
FILTER(30) Filter time for riser feed 5 sulfur content Minutes
FILTER(31) Filter time for riser feed 1 temperature input Minutes
FILTER(32) Filter time for riser feed 2 temperature input Minutes
FILTER(33) Filter time for riser feed 3 temperature input Minutes
FILTER(34) Filter time for riser feed 4 temperature input Minutes
FILTER(35) Filter time for riser feed 5 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
Parameter Description Units
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(7) Mass fraction of riser feed stream 2 None
CALC_VAL(8) Mass fraction of riser feed stream 3 None
CALC_VAL(9) Mass fraction of riser feed stream 4 None
CALC_VAL(10) Mass fraction of riser feed stream 5 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
MOLWT(2) Calculated molecular weight of riser feed stream 2 lb/lb-mole
MOLWT(3) Calculated molecular weight of riser feed stream 3 lb/lb-mole
MOLWT(4) Calculated molecular weight of riser feed stream 4 lb/lb-mole
MOLWT(5) Calculated molecular weight of riser feed stream 5 lb/lb-mole
FILT_VAL(1) Filtered value of riser feed 1 flow rate Input units
FILT_VAL(2) Filtered value of riser feed 2 flow rate Input units
FILT_VAL(3) Filtered value of riser feed 3 flow rate Input units
FILT_VAL(4) Filtered value of riser feed 4 flow rate Input units
Continued
Hi-Spec Solutions
FCCU Catalyst Circulation Rate Calculation Calculation Outputs
14
Calculation Outputs (Continued)
Calculation Outputs
Parameter Description Units
FILT_VAL(5) Filtered value of riser feed 5 flow rate Input units
FILT_VAL(6) Filtered value of riser steam 1 flow rate Input units
FILT_VAL(7) Filtered value of riser steam 2 flow rate Input units
FILT_VAL(8) Filtered value of riser steam 3 flow rate Input units
FILT_VAL(9) Filtered value of riser steam 4 flow rate Input units
FILT_VAL(10) Filtered value of riser steam 5 flow rate Input units
FILT_VAL(11) Filtered value of riser feed 1 gravity input Input units
FILT_VAL(12) Filtered value of riser feed 2 gravity input Input units
FILT_VAL(13) Filtered value of riser feed 3 gravity input Input units
FILT_VAL(14) Filtered value of riser feed 4 gravity input Input units
FILT_VAL(15) Filtered value of riser feed 5 gravity input Input units
FILT_VAL(16) Filtered value of riser feed 1 Watson K factor Input units
FILT_VAL(17) Filtered value of riser feed 2 Watson K factor Input units
FILT_VAL(18) Filtered value of riser feed 3 Watson K factor Input units
FILT_VAL(19) Filtered value of riser feed 4 Watson K factor Input units
FILT_VAL(20) Filtered value of riser feed 5 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(23) Filtered value of riser feed 3 nitrogen content Input units
FILT_VAL(24) Filtered value of riser feed 4 nitrogen content Input units
FILT_VAL(25) Filtered value of riser feed 5 nitrogen content Input units
FILT_VAL(26) Filtered value of riser feed 1 sulfur content Input units
FILT_VAL(27) Filtered value of riser feed 2 sulfur content Input units
FILT_VAL(28) Filtered value of riser feed 3 sulfur content Input units
FILT_VAL(29) Filtered value of riser feed 4 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
FILT_VAL(32) Filtered value of riser feed 2 temperature input Input units
Continued
Hi-Spec Solutions
FCCU Catalyst Circulation Rate Calculation Calculation Outputs
15
Calculation Outputs
Calculation Outputs
Parameter Description Units
FILT_VAL(33) Filtered value of riser feed 3 temperature input Input units
FILT_VAL(34) Filtered value of riser feed 4 temperature input Input units
FILT_VAL(35) Filtered value of riser feed 5 temperature input Input units
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
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")
17.0 Error in calculating MOLWT(2) (see STATUS(2) in "MolecularWeight Error Codes")
18.0 Error in calculating MOLWT(3) (see STATUS(2) in "MolecularWeight Error Codes")
Continued
3 STATUS(1) indicates errors in the calculation.
Hi-Spec Solutions
FCCU Catalyst Circulation Rate Calculation Diagnostic Error Codes
18
Diagnostic Error Codes (Continued)
Diagnostic Error Codes
Parameter Value Meaning
STATUS(1) 19.0 Error in calculating MOLWT(4) (see STATUS(2) in "MolecularWeight Error Codes")
20.0 Error in calculating MOLWT(5) (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
26.0 TEMP_PT(7) has a null point entered
27.0 TEMP_PT(7) has a bad PV
28.0 TEMP_PT(8) has a null point entered
29.0 TEMP_PT(8) 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")
37.0 Error in calculating riser feed 2 stream enthalpy (see STATUS(2)in "Hydrocarbon Enthalpy Error Codes")
38.0 Error in calculating riser feed 3 stream enthalpy (see STATUS(2)in "Hydrocarbon Enthalpy Error Codes")
39.0 Error in calculating riser feed 4 stream enthalpy (see STATUS(2)in "Hydrocarbon Enthalpy Error Codes")
40.0 Error in calculating riser feed 5 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
Hi-Spec Solutions
FCCU Catalyst Circulation Rate Calculation Diagnostic Error Codes
19
Diagnostic Error Codes (Continued)
Diagnostic Error Codes
Parameter Value Meaning
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
Array Location Error Codes
Parameter Value Meaning
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
Parameter Value Meaning
STATUS(2)5 0.0 No errors
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.
Hi-Spec Solutions
FCCU Catalyst Circulation Rate Calculation Hydrocarbon Enthalpy Error Codes
22
Hydrocarbon Enthalpy Error Codes
Hydrocarbon Enthalpy Error Codes
Parameter Value Meaning
STATUS(2) 6 0.0 No errors
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
Parameter Value Meaning
STATUS(2) 7 0.0 No errors
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.
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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.
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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.
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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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FCCU Catalyst Circulation Rate Calculation Algorithms
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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FCCU Catalyst Circulation Rate Calculation Algorithms
29
Algorithms (Continued)
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
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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.
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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
From the Command Processor Display:
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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Catalyst Circulation Rate Calculation Point Configuration Using Graphic CCR_CFG
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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Catalyst Circulation Rate Calculation Point Configuration Using Graphic CCR_CFG
38
Point Configuration Using Graphic CCR_CFG (Continued)
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
Selection Port Parameter Description
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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Catalyst Circulation Rate Calculation Point Configuration Using Graphic CCR_CFG
39
Point Configuration Using Graphic CCR_CFG (Continued)
Selection Port Parameter Description
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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Catalyst Circulation Rate Calculation Point Configuration Using Graphic CCR_CFG
40
Point Configuration Using Graphic CCR_CFG (Continued)
CONV_PNT STM_PNT STM_PRES0.000.00
0 0 0
Selection Port Parameter Description
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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Catalyst Circulation Rate Calculation Point Configuration Using Graphic CCR_CFG
41
Point Configuration Using Graphic CCR_CFG (Continued)
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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FCCU Catalyst Circulation Rate Calculation Point Configuration through Direct CDS Entry
43
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
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.
GRAV_PT(2) Tagname of riser feed 2 gravity If an on-line gravity is notavailable, bring in an estimatethrough an AM numeric point.This is gravity at standardconditions.
GRAV_PT(3) Tagname of riser feed 3 gravity If an on-line gravity is notavailable, bring in an estimatethrough an AM numeric point.This is gravity at standardconditions.
GRAV_PT(4) Tagname of riser feed 4 gravity If an on-line gravity is notavailable, bring in an estimatethrough an AM numeric point.This is gravity at standardconditions.
GRAV_PT(5) Tagname of riser feed 5 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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FCCU Catalyst Circulation Rate Calculation Point Configuration through Direct CDS Entry
44
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
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.
WATK_PT(2) Tagname of riser feed 2 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.
WATK_PT(3) Tagname of riser feed 3 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.
WATK_PT(4) Tagname of riser feed 4 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.
WATK_PT(5) Tagname of riser feed 5 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).
T_BIAS(2) Additive bias to riser feed 2 temperature Same units as TEMP_PT(2).
T_BIAS(3) Additive bias to riser feed 3 temperature Same units as TEMP_PT(3).
Continued
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FCCU Catalyst Circulation Rate Calculation Point Configuration through Direct CDS Entry
45
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
T_BIAS(4) Additive bias to riser feed 4 temperature Same units as TEMP_PT(4).
T_BIAS(5) Additive bias to riser feed 5 temperature Same units as TEMP_PT(5).
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
Heat of reaction calculation factor.
ENGPAR(9) A4; Mass conversion heat of reactioncoefficient
Heat of reaction calculation factor.
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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FCCU Catalyst Circulation Rate Calculation Point Configuration through Direct CDS Entry
46
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
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(1) Filter time for riser feed 1 flow input Minutes
FILTER(2) Filter time for riser feed 2 flow input Minutes
FILTER(3) Filter time for riser feed 3 flow input Minutes
FILTER(4) Filter time for riser feed 4 flow input Minutes
FILTER(5) Filter time for riser feed 5 flow input Minutes
FILTER(6) Filter time for riser steam 1 flow input Minutes
FILTER(7) Filter time for riser steam 2 flow input Minutes
FILTER(8) Filter time for riser steam 3 flow input Minutes
FILTER(9) Filter time for riser steam 4 flow input Minutes
FILTER(10) Filter time for riser steam 5 flow input Minutes
FILTER(11) Filter time for riser feed 1 gravity Minutes
FILTER(12) Filter time for riser feed 2 gravity Minutes
FILTER(13) Filter time for riser feed 3 gravity Minutes
FILTER(14) Filter time for riser feed 4 gravity Minutes
FILTER(15) Filter time for riser feed 5 gravity Minutes
FILTER(16) Filter time for riser feed 1 Watson Kfactor
Minutes
FILTER(17) Filter time for riser feed 2 Watson Kfactor
Minutes
FILTER(18) Filter time for riser feed 3 Watson Kfactor
Minutes
FILTER(19) Filter time for riser feed 4 Watson Kfactor
Minutes
FILTER(20) Filter time for riser feed 5 Watson Kfactor
Minutes
FILTER(21) Filter time for riser feed 1 nitrogencontent
Minutes
FILTER(22) Filter time for riser feed 2 nitrogencontent
Minutes
Continued
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FCCU Catalyst Circulation Rate Calculation Point Configuration through Direct CDS Entry
47
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
FILTER(23) Filter time for riser feed 3 nitrogencontent
Minutes
FILTER(24) Filter time for riser feed 4 nitrogencontent
Minutes
FILTER(25) Filter time for riser feed 5 nitrogencontent
Minutes
FILTER(26) Filter time for riser feed 1 sulfur content Minutes
FILTER(27) Filter time for riser feed 2 sulfur content Minutes
FILTER(28) Filter time for riser feed 3 sulfur content Minutes
FILTER(29) Filter time for riser feed 4 sulfur content Minutes
FILTER(30) Filter time for riser feed 5 sulfur content Minutes
FILTER(31) Filter time for riser feed 1 temperatureinput
Minutes
FILTER(32) Filter time for riser feed 2 temperatureinput
Minutes
FILTER(33) Filter time for riser feed 3 temperatureinput
Minutes
FILTER(34) Filter time for riser feed 4 temperatureinput
Minutes
FILTER(35) Filter time for riser feed 5 temperatureinput
Minutes
FILTER(36) Filter time for riser steam temperatureinput
Minutes
FILTER(37) Filter time for Regenerator bedtemperature input
Minutes
FILTER(38) Filter time for reaction temperature 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
Honeywell Hi-Spec Solutions • 16404 N. Black Canyon Hwy. • Phoenix, AZ 85023
Advanced Control Package
FCCU Measured Conversion Calculation
CONTROLLED
Jan 1998Revision 2.1
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 Measured Conversion Calculation Revision History
Hi-Spec Solutions
FCCU Measured Conversion 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 .........................................................................................................9
Calculation Outputs ........................................................................................................11
Error Codes ...................................................................................................................................12
Diagnostic Error Codes...................................................................................................13
Array Location Error Codes............................................................................................14
Configuration and Tuning.............................................................................................................15
Algorithms ....................................................................................................................................16
Installation Procedure ...................................................................................................................17
Preparation for Installation .............................................................................................18
Custom Data Segment (CDS) and Parameter List (PL) Installation...............................19
Building FCCU Measured Conversion Calculation Point ..............................................20
Configuration Graphics Installation..............................................................................................21
Configure Calculation Point .........................................................................................................22
Point Configuration Using Graphic CONV_CFG ..........................................................23
Point Configuration through Direct CDS Entry..............................................................27
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
• Characterizationinputs:
Specific gravity
• Calculatedvalues:
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.
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FCCU Measured Conversion 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
thousands of pounds per hour MPPH
Fluidized Catalytic Cracking Unit FCCU
Hi-Spec Solutions
FCCU Measured Conversion 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 for the riser feed and product flows must exist aspoints on the LCN
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FCCU Measured Conversion Calculation Instrumentation (Process Inputs)
4
Instrumentation (Process Inputs)
Process Input1 Required Recommended
Riser feed flow rate(s) X
Product flow rate(s) X
Heavy Naphtha ASTM D86 90% PointTemperature
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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FCCU Measured Conversion Calculation Process Diagram
5
Process Diagram
R i s e r
Regenerator
Reactor Main Fractionator
Regenerated Catalyst
Saturated Gas, C3, C4, Heavy Naphtha
LCO
HCO
DCO
Riser Feed
Conversion = [1 - (LCO + HCO + DCO) / (Riser Feed)] * 100
Spent Catalyst
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FCCU Measured Conversion Calculation Detailed Description
6
Detailed Description
The tables in this section describe the following Measured Conversion programarchitecture:
• Point Structure
• Process Inputs
• Configuration Inputs
• Calculation Outputs.
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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
Insertion Point PV_ALG
Slot 5
Output The calculated measured conversion (mass% or vol. %) is displayed asthe point’s PV
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FCCU Measured Conversion Calculation Process Inputs
8
Process Inputs
Process Inputs
Critical2
Parameter Description Units Yes No
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(3) Tagname of product 3 flow rate Any flow units X
FLOW_PT(4) Tagname of product 4 flow rate Any flow units X
FLOW_PT(5) Tagname of product 5 flow rate Any flow units X
FLOW_PT(6) Tagname of riser feed 1 flow rate Any flow units X
FLOW_PT(7) Tagname of riser feed 2 flow rate Any flow units X
FLOW_PT(8) Tagname of riser feed 3 flow rate Any flow units X
FLOW_PT(9) Tagname of riser feed 4 flow rate Any flow units X
FLOW_PT(10) Tagname of riser feed 5 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(2) Tagname for product stream 2 gravity °API or none (S.G.)X
GRAV_PT(3) Tagname for product stream 3 gravity °API or none (S.G.)X
GRAV_PT(4) Tagname for product stream 4 gravity °API or none (S.G.)X
GRAV_PT(5) Tagname for product stream 5 gravity °API or none (S.G.)X
GRAV_PT(6) Tagname for riser feed stream 1 gravity °API or none (S.G.)X
GRAV_PT(7) Tagname for riser feed stream 2 gravity °API or none (S.G.)X
GRAV_PT(8) Tagname for riser feed stream 3 gravity °API or none (S.G.)X
GRAV_PT(9) Tagname for riser feed stream 4 gravity °API or none (S.G.)X
GRAV_PT(10) Tagname for riser feed stream 5 gravity °API or none (S.G.)X
.
2 Critical indicates that a bad input causes the output of the calculation to be set BAD.
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FCCU Measured Conversion Calculation Configuration Inputs
9
Configuration Inputs
Configuration Inputs
Parameter Description Units
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
From input unitsto MBPD
CONV_FAC(2) Product 2 (FLOW_PT(2)) multiplicative flow conversionfactor
From input unitsto MBPD
CONV_FAC(3) Product 3 (FLOW_PT(3)) multiplicative flow conversionfactor
From input unitsto MBPD
CONV_FAC(4) Product 4 (FLOW_PT(4)) multiplicative flow conversionfactor
From input unitsto MBPD
CONV_FAC(5) Product 5 (FLOW_PT(5)) multiplicative flow conversionfactor
From input unitsto MBPD
CONV_FAC(6) Riser feed 1 (FLOW_PT(6)) multiplicative flow conversionfactor
From input unitsto MBPD
CONV_FAC(7) Riser feed 2 (FLOW_PT(7)) multiplicative flow conversionfactor
From input unitsto MBPD
CONV_FAC(8) Riser feed 3 (FLOW_PT(8)) multiplicative flow conversionfactor
From input unitsto MBPD
CONV_FAC(9) Riser feed 4 (FLOW_PT(9)) multiplicative flow conversionfactor
From input unitsto MBPD
CONV_FAC(10) Riser feed 5 (FLOW_PT(10)) multiplicative flowconversion factor
From input unitsto MBPD
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
Configuration Inputs (Continued)
Configuration Inputs
Parameter Description Units
FILTER(1) Filter time for product 1 flow input Minutes
FILTER(2) Filter time for product 2 flow input Minutes
FILTER(3) Filter time for product 3 flow input Minutes
FILTER(4) Filter time for product 4 flow input Minutes
FILTER(5) Filter time for product 5 flow input Minutes
FILTER(6) Filter time for riser feed 1 flow input Minutes
FILTER(7) Filter time for riser feed 2 flow input Minutes
FILTER(8) Filter time for riser feed 3 flow input Minutes
FILTER(9) Filter time for riser feed 4 flow input Minutes
FILTER(10) Filter time for riser feed 5 flow input Minutes
FILTER(11) Filter time for Heavy Naphtha ASTM D8690% temperature
Minutes
FILTER(12) Filter time for product 1 gravity Minutes
FILTER(13) Filter time for product 2 gravity Minutes
FILTER(14) Filter time for product 3 gravity Minutes
FILTER(15) Filter time for product 4 gravity Minutes
FILTER(16) Filter time for product 5 gravity Minutes
FILTER(17) Filter time for riser feed 1 gravity Minutes
FILTER(18) Filter time for riser feed 2 gravity Minutes
FILTER(19) Filter time for riser feed 3 gravity Minutes
FILTER(20) Filter time for riser feed 4 gravity Minutes
FILTER(21) Filter time for riser feed 5 gravity Minutes
Hi-Spec Solutions
FCCU Measured Conversion Calculation Calculation Outputs
11
Calculation Outputs
Calculation Outputs
Parameter Description Units
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(2) Filtered value of input product 2 flow rate Input units
FILT_VAL(3) Filtered value of input product 3 flow rate Input units
FILT_VAL(4) Filtered value of input product 4 flow rate Input units
FILT_VAL(5) Filtered value of input product 5 flow rate Input units
FILT_VAL(6) Filtered value of input riser feed 1 flow rate Input units
FILT_VAL(7) Filtered value of input riser feed 2 flow rate Input units
FILT_VAL(8) Filtered value of input riser feed 3 flow rate Input units
FILT_VAL(9) Filtered value of input riser feed 4 flow rate Input units
FILT_VAL(10) Filtered value of input riser feed 5 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(13) Filter time for product 2 gravity input Input units
FILT_VAL(14) Filter time for product 3 gravity input Input units
FILT_VAL(15) Filter time for product 4 gravity input Input units
FILT_VAL(16) Filter time for product 5 gravity input Input units
FILT_VAL(17) Filter time for riser feed 1 gravity input Input units
FILT_VAL(18) Filter time for riser feed 2 gravity input Input units
FILT_VAL(19) Filter time for riser feed 3 gravity input Input units
FILT_VAL(20) Filter time for riser feed 4 gravity input Input units
FILT_VAL(21) Filter time for riser feed 5 gravity input Input units
STATUS(1) Diagnostic indication of location and possible causes ofprogram error
N/A
STATUS(2) Diagnostic indication of array location error N/A
REV_NO Program revision number N/A
Hi-Spec Solutions
FCCU Measured Conversion Calculation Error Codes
12
Error Codes
The tables in this section describe the following program error codes:
• Diagnostic error codes
• Array Location error codes.
Hi-Spec Solutions
FCCU Measured Conversion Calculation Diagnostic Error Codes
13
Diagnostic Error Codes
Diagnostic Error Codes
Parameter Value Meaning
STATUS(1)3 0.0 No errors
1.0 Set calculation BAD flag on [ENGPAR(4)<>0]
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
3 STATUS(1) indicates errors in the calculation.
Hi-Spec Solutions
FCCU Measured Conversion Calculation Array Location Error Codes
14
Array Location Error Codes
Array Location Error Codes
Parameter Value Meaning
STATUS(2)4 0.0 No errors
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
4 STATUS(2) indicates the array location of the STATUS(1) error returned.
Hi-Spec Solutions
FCCU Measured Conversion Calculation Configuration and Tuning
15
Configuration and Tuning
This section describes the parameters and values used to configure and tune the packageto a specific application.
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
Hi-Spec Solutions
FCCU Measured Conversion Calculation Installation Procedure
17
Installation Procedure
This document describes the installation procedure for the FCCU Measured ConversionCalculation program (MEASCONV) 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 Measured Conversion Calculation Point
• Configuration Graphics Installation.
Hi-Spec Solutions
FCCU Measured Conversion Calculation Preparation for Installation
18
Preparation for Installation
Step Action
Gather media Gather the following items:
• Removable media containing the directory CONV
• 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> CONVCOPY $Fn>CONV>*.* $Fm>CONV>= -V -D
Where $Fn is the drive with the source media and $Fm is the drive withthe target media.
Hi-Spec Solutions
FCCU Measured Conversion Calculation CDS and PL Installation
19
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>
CompileMCONVCDS.CL
From the Command Processor display, compile the CDS file, MCONVCDS:CL $Fn>CONV>MCONVCDS.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
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]
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>CONV
Load Entities (select target)
Pathname for SOURCE file: CONV_PNT
Pathname for IDF file: CONV_PNT
[ENTER]
Verify load When the load is complete, verify point loading by calling the point detailfrom the [DETAIL] button.
Hi-Spec Solutions
FCCU Measured Conversion Calculation Configuration Graphics Installation
21
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 CONV_CFG Read in the picture file, CONV_CFG
R $Fn>CONV>CONV_CFG [ENTER]
Verify and Compile Verify picture:
VER [ENTER]
When the verification is complete Compile the picture:
COM [ENTER]
CopyCONV_CFG.DO tographics directory
From the Command Processor Display:
COPY $Fn>CONV>CONV_CFG.DO NET>pic_dir>= -D [ENTER]
Where pic_dir is the picture source directory specified in the SchematicSearch Path
Hi-Spec Solutions
FCCU Measured Conversion Calculation Configure Calculation Point
22
Configure Calculation Point
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
• Point Configuration through Direct CDS Entry
• Link CL Programs.
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
FCCU Measured Conversion Calculation Point Configuration Using Graphic CONV_CFG
24
Point Configuration Using Graphic CONV_CFG (Continued)
Selection Port Parameter Description
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%].
Temperature Units[DEG F] [DEG C]
CONV_FAC(11) Select the desired input temperature units.
Gravity Units[API] [SPGR]
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.
Selection Port Parameter Description
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
FCCU Measured Conversion Calculation Point Configuration Using Graphic CONV_CFG
25
Point Configuration Using Graphic CONV_CFG (Continued)
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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FCCU Measured Conversion Calculation Point Configuration Using Graphic CONV_CFG
26
Point Configuration Using Graphic CONV_CFG (Continued)
Selection Port Parameter Description
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:
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).
Hi-Spec Solutions
FCCU Measured Conversion Calculation Point Configuration through Direct CDS Entry
27
Point Configuration through Direct CDS Entry
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.
Parameter Description Comments
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
Required only if more than 2 productstream exists.
FLOW_PT(4) Tagname of fourth product flowrate
Required only if more than 3 productstream exists.
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
Required only if more than 2 feedstream exists.
FLOW_PT(9) Tagname of fourth riser feed flowrate
Required only if more than 3 feedstream exists.
FLOW_PT(10) Tagname of fifth riser feed flowrate
Required only if more than 4 feedstream exists.
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.
GRAV_PT(2) Tagname of product stream 2gravity
If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.
GRAV_PT(3) Tagname of product stream 3gravity
If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.
Continued
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FCCU Measured Conversion Calculation Point Configuration through Direct CDS Entry
28
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
GRAV_PT(4) Tagname of product stream 4gravity
If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.
GRAV_PT(5) Tagname of product stream 5gravity
If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.
GRAV_PT(6) Tagname for riser feed stream 1gravity
If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.
GRAV_PT(7) Tagname for riser feed stream 2gravity
If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.
GRAV_PT(8) Tagname for riser feed stream 3gravity
If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.
GRAV_PT(9) Tagname for riser feed stream 4gravity
If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.
GRAV_PT(10) Tagname for riser feed stream 5gravity
If an on-line gravity is not available,bring in an estimate through an AMnumeric point. This is gravity atstandard conditions.
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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FCCU Measured Conversion Calculation Point Configuration through Direct CDS Entry
29
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
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
Convert input units to MBPD.
CONV_FAC(2) Product 2 (FLOW_PT(2))multiplicative flow conversionfactor
Convert input units to MBPD.
CONV_FAC(3) Product 3 (FLOW_PT(3))multiplicative flow conversionfactor
Convert input units to MBPD.
CONV_FAC(4) Product 4 (FLOW_PT(4))multiplicative flow conversionfactor
Convert input units to MBPD.
CONV_FAC(5) Product 5 (FLOW_PT(5))multiplicative flow conversionfactor
Convert input units to MBPD.
CONV_FAC(6) Riser feed 1 (FLOW_PT(6))multiplicative flow conversionfactor
Convert input units to MBPD.
CONV_FAC(7) Riser feed 2 (FLOW_PT(7))multiplicative flow conversionfactor
Convert input units to MBPD.
CONV_FAC(8) Riser feed 3 (FLOW_PT(8))multiplicative flow conversionfactor
Convert input units to MBPD.
CONV_FAC(9) Riser feed 4 (FLOW_PT(9))multiplicative flow conversionfactor
Convert input units to MBPD.
CONV_FAC(10) Riser feed 5 (FLOW_PT(10))multiplicative flow conversionfactor
Convert input units to MBPD.
CONV_FAC(11) Input temperature unit flag:0 => °F; 1 => °C
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
FILTER(2) Filter time for product 2 flowinput
Minutes
Continued
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FCCU Measured Conversion Calculation Point Configuration through Direct CDS Entry
30
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
FILTER(3) Filter time for product 3 flowinput
Minutes
FILTER(4) Filter time for product 4 flowinput
Minutes
FILTER(5) Filter time for product 5 flowinput
Minutes
FILTER(6) Filter time for riser feed 1 flowinput
Minutes
FILTER(7) Filter time for riser feed 2 flowinput
Minutes
FILTER(8) Filter time for riser feed 3 flowinput
Minutes
FILTER(9) Filter time for riser feed 4 flowinput
Minutes
FILTER(10) Filter time for riser feed 5 flowinput
Minutes
FILTER(11) Filter time for Heavy NaphthaASTM D86 90% temperatureinput
Minutes
FILTER(12) Filter time for product 1 gravity Minutes
FILTER(13) Filter time for product 2 gravity Minutes
FILTER(14) Filter time for product 3 gravity Minutes
FILTER(15) Filter time for product 4 gravity Minutes
FILTER(16) Filter time for product 5 gravity Minutes
FILTER(17) Filter time for riser feed 1 gravity Minutes
FILTER(18) Filter time for riser feed 2 gravity Minutes
FILTER(19) Filter time for riser feed 3 gravity Minutes
FILTER(20) Filter time for riser feed 4 gravity Minutes
FILTER(21) Filter time for riser feed 5 gravity 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.
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FCCU Measured Conversion Calculation
32
Hi-Spec Solutions
Honeywell Hi-Spec Solutions • 16404 N. Black Canyon Hwy. • Phoenix, AZ 85023
Advanced Control Package
FCCU Octane Number Calculation
CONTROLLED
Jan 1998Revision 2.1
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 Octane Number Calculation
Hi-Spec Solutions
FCCU Octane Number 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 .........................................................................................................9
Calculation Outputs ........................................................................................................10
Error Codes ...................................................................................................................................11
Diagnostic Error Codes...................................................................................................12
Configuration and Tuning.............................................................................................................13
Biases in the Octane Number Program...........................................................................14
Algorithms ....................................................................................................................................15
Installation Procedure ...................................................................................................................17
Preparation for Installation .............................................................................................18
Custom Data Segment (CDS) and Parameter List (PL) Installation...............................19
Building FCCU Octane Number Calculation Point........................................................20
Configuration Graphics Installation..............................................................................................21
Configure Calculation Point .........................................................................................................22
Point Configuration Using Graphic OCT_CFG .............................................................23
Point Configuration through Direct CDS Entry..............................................................27
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
• Characterizationinputs:
Octane prediction parameters
• Calculatedvalues:
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.
3. To provide a real-time input for use in advanced control applications.
4. For use in product value optimization.
Hi-Spec Solutions
FCCU Octane Number 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
Universal Control Network UCN
Fluidized Catalytic Cracking Unit FCCU
Fluidized Catalytic Cracked FCC
Reid Vapor Pressure RVP
Hi-Spec Solutions
FCCU Octane Number 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 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
Instrumentation (Process Inputs)
Process Input1 Required Recommended
Reaction temperature X
Gasoline ASTM D86 90% Point Temperature X
Gasoline RVP 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.
Hi-Spec Solutions
FCCU Octane Number Calculation Process Diagram
5
Process Diagram
N/A
Hi-Spec Solutions
FCCU Octane Number Calculation Detailed Description
6
Detailed Description
The tables in this section describe the following Octane Number program architecture:
• Point Structure
• Process Inputs
• Configuration Inputs
• Calculation Outputs.
Hi-Spec Solutions
FCCU Octane Number Calculation Point Structure
7
Point Structure
Point Structure
Point Type AM Regulatory
PV_Type CL
CTL_Type Any
Custom Data Segment OCT_CDS.CL
Algorithm OCT_PRED.CL
Insertion Point PV_ALG
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
Parameter Description Units Yes No
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
.
2 Critical indicates that a bad input causes the output of the calculation to be set BAD.
Hi-Spec Solutions
FCCU Octane Number Calculation Configuration Inputs
9
Configuration Inputs
Configuration Inputs
Parameter Description Units
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(4) Reference reaction temperature °F
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
Parameter Description Units
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
STATUS(1) Diagnostic indication of location and possible causes ofprogram error
N/A
STATUS(2) Diagnostic indication of subroutine error N/A
REV_NO Program revision number N/A
Hi-Spec Solutions
FCCU Octane Number Calculation Error Codes
11
Error Codes
The tables in this section describe the following program error codes:
• Diagnostic error codes.
Hi-Spec Solutions
FCCU Octane Number Calculation Diagnostic Error Codes
12
Diagnostic Error Codes
Diagnostic Error Codes
Parameter Value Meaning
STATUS(1)3 0.0 No errors
1.0 Set calculation BAD flag on [ENGPAR(2)<>0]
2.0 TEMP_PT(1) has a null point entered
3.0 TEMP_PT(1) has a bad PV
4.0 TEMP_PT(2) has a null point entered
5.0 TEMP_PT(2) has a bad PV
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
3 STATUS(1) indicates errors in the calculation.
Hi-Spec Solutions
FCCU Octane Number Calculation Configuration and Tuning
13
Configuration and Tuning
This section describes the parameters and values used to configure and tune the packageto a specific application.
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
Parameter Description
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
Algorithms (Continued)
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
Installation Procedure
This document describes the installation procedure for the FCCU Octane Numberprogram (OCT_PRED) 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 Octane Number Calculation Point
• Configuration Graphics Installation.
Hi-Spec Solutions
FCCU Octane Number Calculation Preparation for Installation
18
Preparation for Installation
Step Action
Gather media Gather the following items:
• Removable media containing the directory OCT
• 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> OCTCOPY $Fn>OCT>*.* $Fm>OCT>= -V -D
Where $Fn is the drive with the source media and $Fm is the drive withthe target media.
Hi-Spec Solutions
FCCU Octane Number Calculation CDS and PL Installation
19
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>
CompileOCT_CDS.CL
From the Command Processor Display, compile the CDS file, OCT_CDS:CL $Fn>OCT>OCT_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
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
From the Command Processor Display:
ED $Fn>OCT>OCT_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>OCT
Load Entities (select target)
Pathname for SOURCE file: OCT_PNT
Pathname for IDF file: OCT_PNT
[ENTER]
Verify load When the load is complete, verify point loading by calling the point detailfrom the [DETAIL] button.
Hi-Spec Solutions
Octane Number Calculation Configrue Graphics Installation
21
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 OCT_CFG Read in the picture file, OCT_CFG
R $Fn>OCT>OCT_CFG [ENTER]
Verify and Compile Verify picture:
VER [ENTER]
When the verification is complete Compile the picture:
COM [ENTER]
Copy OCT_CFG.DOto graphics directory
From the Command Processor Display:
COPY $Fn>OCT>OCT_CFG.DO NET>pic_dir>= -D [ENTER]
Where pic_dir is the picture source directory specified in the SchematicSearch Path
Hi-Spec Solutions
FCCU Octane Number Calculation Configure Calculation Point
22
Configure Calculation Point
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
• Point Configuration through Direct CDS Entry
• Link CL Programs.
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
Octane Number Calculation Point Configuration Using Graphic OCT_CFG
24
Point Configuration Using Graphic CCR_CFG (Continued)
Selection Port Parameter Description
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.
Temperature Units[DEG F] [DEG C]
CONV_FAC(1) Select the input temperature units. All inputtemperature will have the same units.
Reaction Temp Pnt TEMP_PT(1) Enter the reaction temperature point tagname.
Reaction Temp Filter FILTER(1) Enter the reaction temperature filter time (min).
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
Octane Number Calculation Point Configuration Using Graphic OCT_CFG
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.
Selection Port Parameter Description
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
Octane Number Calculation Point Configuration Using Graphic OCT_CFG
26
Point Configuration Using Graphic OCT_CFG (Continued)
Selection Port Parameter Description
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.
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).
Hi-Spec Solutions
FCCU Octane Number Calculation Point Configuration through Direct CDS Entry
27
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
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
ENGPAR(2) 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(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
CONV_FAC(1) Input temperature unit flag:0 => °F; 1 => °C
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
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
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(1) K1; Constant None
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
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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.
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FCCU Octane Number Calculation Appendix A Engineer’s Detailed Description
30
Hi-Spec Solutions
Honeywell Hi-Spec Solutions • 16404 N. Black Canyon Hwy. • Phoenix, AZ 85023
Advanced Control Package
FCCU Product Yield Calculation
CONTROLLED
Jan 1998Revision 2.1
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.
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.
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
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 ...................................................................................................................................14
Diagnostic Error Codes...................................................................................................15
Array Location Error Codes............................................................................................16
Configuration and Tuning.............................................................................................................17
Biases in the FCCU Product Yield Program...................................................................18
Algorithms ....................................................................................................................................19
Installation Procedure ...................................................................................................................21
Preparation for Installation .............................................................................................22
Custom Data Segment (CDS) and Parameter List (PL) Installation...............................23
Building FCCU Product Yield Calculation Point...........................................................24
Configuration Graphics Installation..............................................................................................25
Configure Calculation Point .........................................................................................................26
Point Configuration Using Graphic YLD_CFG .............................................................27
Point Configuration through Direct CDS Entry..............................................................35
Link CL Programs...........................................................................................................40
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FCCU Product Yield Calculation Contents
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.
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FCCU Product Yield Calculation Contents
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:
Temperatures, pressures, and flows
• Characterizationinputs:
Watson K and specific gravity
• Calculatedvalues:
Product yield bias term, biased yield, anduncorrected product yield.
Incentive. 1. To provide inputs for product value optimization.
2. To provide a real-time input for use in advanced control applications.
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FCCU Product Yield 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
Universal Control Network UCN
thousands of pounds per hour MPPH
pounds per square inch gauge psig
thousands of standard cubic feet per hour MSCFPH
thousands of barrels per day MBPD
Catalyst Circulation Rate CCR
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FCCU Product Yield 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 Honeywell Profimatics Catalyst Circulation Rate and SeverityCalculation points must exist on the LCN
Hi-Spec Solutions
FCCU Product Yield Calculation Instrumentation (Process Inputs)
4
Instrumentation (Process Inputs)
Process Input1 Required Recommended
Measured product flow rates X
Product gravity X
Predicted conversion (from HoneywellProfimatics Severity package)
X
Reaction temperature X
Calculated catalyst circulation rate (fromHoneywell Profimatics CCR package)
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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FCCU Product Yield Calculation Process Diagram
5
Process Diagram
Reactor Main Fractionator
C2
C3
C5+
LCO
HCO
DCO
COKE
C4
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FCCU Product Yield Calculation Detailed Description
6
Detailed Description
The tables in this section describe the following FCCU Product Yield programarchitecture:
• Point Structure
• Process Inputs
• Configuration Inputs
• Calculation Outputs.
Hi-Spec Solutions
FCCU Product Yield Calculation Point Structure
7
Point Structure
Point Structure
Point Type AM Regulatory
PV_Type CL
CTL_Type Any
Custom Data Segment YLD_CDS.CL
Algorithm YLD_PRED.CL
Insertion Point PV_ALG
Slot 5
Output The calculated product yield is displayed as the point’s PV
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FCCU Product Yield Calculation Process Inputs
8
Process Inputs
Process Inputs
Critical2
Parameter Description Units Yes No
FLOW_PT(1) Tagname of product 1 flow rate Any flow unitsX
FLOW_PT(2) Tagname of product 2 flow rate Any flow unitsX
FLOW_PT(3) Tagname of product 3 flow rate Any flow unitsX
FLOW_PT(4) Tagname of product 4 flow rate Any flow unitsX
FLOW_PT(5) Tagname of total riser steam flow rate Any flow unitsX
TEMP_PT(1) Tagname for reaction temperature °F or °CX
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
2 Critical indicates that a bad input causes the output of the calculation to be set BAD.
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FCCU Product Yield Calculation Process Inputs
9
Process Inputs (Continued)
Process Inputs
Critical
Parameter Description Units Yes No
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
.
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FCCU Product Yield Calculation Configuration Inputs
10
Configuration Inputs
Configuration Inputs
Parameter Description Units
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(9) Reference reaction temperature °F
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
CONV_FAC(1) Product 1 (FLOW_PT(1)) multiplicative flow conversionfactor
From input unitsto: MBPD forNC3-DCO;
MSCFPH for H2-C2=;
Mlb/hr for coke
CONV_FAC(2) Product 2 (FLOW_PT(2)) multiplicative flow conversionfactor
Same as CONV-FAC(1)
CONV_FAC(3) Product 3 (FLOW_PT(3)) multiplicative flow conversionfactor
Same as CONV-FAC(1)
CONV_FAC(4) Product 4 (FLOW_PT(4)) multiplicative flow conversionfactor
Same as CONV-FAC(1)
Continued
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FCCU Product Yield Calculation Configuration Inputs
11
Configuration Inputs (Continued)
Configuration Inputs
Parameter Description Units
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(1) Filter time for product 1 flow input Minutes
FILTER(2) Filter time for product 2 flow input Minutes
FILTER(3) Filter time for product 3 flow input Minutes
FILTER(4) Filter time for product 4 flow input Minutes
FILTER(5) Filter time for product gravity input Minutes
FILTER(6) Filter time for Reactor stripping steam to catalyst ratio Minutes
FILTER(7) Filter time for reaction temperature input Minutes
FILTER(8) Filter time for Regenerator bed temperature input Minutes
FILTER(9) Filter time for Reactor pressure input Minutes
FILTER(10) Filter time for riser steam flow input Minutes
X(1) K1; Constant None
X(2) K2; Inverse natural log predicted severity coefficient None
Continued
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FCCU Product Yield Calculation Configuration Inputs
12
Configuration Inputs (Continued)
Configuration Inputs
Parameter Description Units
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
Parameter Description Units
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(2) Filtered value of product 2 flow rate Input units
FILT_VAL(3) Filtered value of product 3 flow rate Input units
FILT_VAL(4) Filtered value of product 4 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
REV_NO Program revision number N/A
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
Hi-Spec Solutions
FCCU Product Yield Calculation Error Codes
14
Error Codes
The tables in this section describe the following program error codes:
• Diagnostic error codes
• Array Location error codes.
Hi-Spec Solutions
FCCU Product Yield Calculation Diagnostic Error Codes
15
Diagnostic Error Codes
Diagnostic Error Codes
Parameter Value Meaning
STATUS(1)3 0.0 No errors
1.0 Set calculation BAD flag on [ENGPAR(3)<>0]
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”)
8.0 CALC_PT(1) has a null point entered
9.0 CALC_PT(1) has a bad PV
10.0 CALC_PT(2) has a null point entered
11.0 CALC_PT(2) has a bad PV
12.0 CALC_PT(3) has a null point entered
13.0 CALC_PT(3) has a bad PV
14.0 CATCIRC has a null point entered
15.0 CATCIRC has a bad PV
16.0 TEMP_PT(1) has a null point entered
17.0 TEMP_PT(1) has a bad PV
18.0 TEMP_PT(2) has a null point entered
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
3 STATUS(1) indicates errors in the calculation.
Hi-Spec Solutions
FCCU Product Yield Calculation Array Location Error Codes
16
Array Location Error Codes
Filter Error Codes
Parameter Value Meaning
STATUS(2)4 0.0 No errors
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
4 STATUS(2) indicates the array location of the STATUS(1) error returned.
Hi-Spec Solutions
FCCU Product Yield Calculation Configuration and Tuning
17
Configuration and Tuning
This section describes the parameters and values used to configure and tune the packageto a specific application.
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
Parameter Description
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:
flow(i) = FLOW_PT(i).PV * CONV_FAC(i)
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
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FCCU Product Yield Calculation Algorithms
20
Algorithms (Continued)
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
Installation Procedure
This document describes the installation procedure for the FCCU Product YieldCalculation program (YLD_PRED) 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 Product Yield Calculation Point
• Configuration Graphics Installation.
Hi-Spec Solutions
FCCU Product Yield Calculation Preparation for Installation
22
Preparation for Installation
Step Action
Gather media Gather the following items:
• Removable media containing the directory YLD
• 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> YLDCOPY $Fn>YLD>*.* $Fm>YLD>= -V -D
Where $Fn is the drive with the source media and $Fm is the drive withthe target media.
Hi-Spec Solutions
FCCU Product Yield Calculation CDS and PL Installation
23
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>
CompileYLD_CDS.CL
From the Command Processor display, compile the CDS file, YLD_CDS:CL $Fn>YLD>YLD_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
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
From the Command Processor display:
ED $Fn>YLD>YLD_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>YLD
Load Entities (select target)
Pathname for SOURCE file: YLD_PNT
Pathname for IDF file: YLD_PNT
[ENTER]
Verify load When the load is complete, verify point loading by calling the point detailfrom the [DETAIL] button.
Hi-Spec Solutions
FCCU Product Yield Calculation Configuration Graphics Installation
25
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 YLD_CFG Read in the picture file, YLD_CFG
R $Fn>YLD>YLD_CFG [ENTER]
Verify and Compile Verify picture:
VER [ENTER]
When the verification is complete Compile the picture:
COM [ENTER]
Copy YLD_CFG.DOto graphics directory
From the Command Processor Display:
COPY $Fn>YLD>YLD_CFG.DO NET>pic_dir>= -D [ENTER]
Where pic_dir is the picture source directory specified in the SchematicSearch Path
Hi-Spec Solutions
FCCU Product Yield Calculation Configure Calculation Point
26
Configure Calculation Point
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
• Point Configuration through Direct CDS Entry
• Link CL Programs.
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
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FCCU Product Yield Calculation Configuration Using Graphic YLD_CFG
28
Point Configuration Using Graphic YLD_CFG (Continued)
Selection Port Parameter Description
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.
Gravity Units[API] [SPGR]
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 Filter FILTER(9) Enter the reactor pressure filter time (min).
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.
Reaction Temp Pnt TEMP_PT(1) Enter the reaction temperature point tagname.
Reaction Temp Filter FILTER(7) Enter the reaction temperature filter time (min).
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
FCCU Product Yield Calculation Configuration Using Graphic YLD_CFG
29
Point Configuration Using Graphic YLD_CFG (Continued)
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
FCCU Product Yield Calculation Configuration Using Graphic YLD_CFG
30
Point Configuration Using Graphic YLD_CFG (Continued)
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
Selection Port Parameter Description
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).
Cnvrsn [PROD #2] CONV_FAC(2) See CONV_FAC(2) in “Configuration Input”.
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).
Cnvrsn [PROD #3] CONV_FAC(3) See CONV_FAC(3) in “Configuration Input”.
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).
Cnvrsn [PROD #4] CONV_FAC(4) See CONV_FAC(4) in “Configuration Input”.
Continued
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FCCU Product Yield Calculation Configuration Using Graphic YLD_CFG
31
Point Configuration Using Graphic YLD_CFG (Continued)
SSR_PNT0 0
1.00000 1.00000
STM_PNT
Selection Port Parameter Description
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.
Selection Port Parameter Description
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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FCCU Product Yield Calculation Configuration Using Graphic YLD_CFG
32
Point Configuration Using Graphic YLD_CFG (Continued)
Selection Port Parameter Description
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.
Selection Port Parameter Description
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
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FCCU Product Yield Calculation Configuration Using Graphic YLD_CFG
33
Point Configuration Using Graphic YLD_CFG (Continued)
0.00
1.00
0.00
0
0.000.00
Selection Port Parameter Description
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
Selection Port Parameter Description
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.
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FCCU Product Yield Calculation Configuration Using Graphic YLD_CFG
34
Point Configuration Using Graphic YLD_CFG (Continued)
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).
Hi-Spec Solutions
FCCU Product Yield Calculation Point Configuration through Direct CDS Entry
35
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 parameter are listed below.
Parameter Description Comments
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
Required only if more than 1 productstream exists.
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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FCCU Product Yield Calculation Point Configuration through Direct CDS Entry
36
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
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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FCCU Product Yield Calculation Point Configuration through Direct CDS Entry
37
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
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
CONV_FAC(1) Product 1 (FLOW_PT(1))multiplicative flow conversionfactor
Converts input units to: MBPD for NC3-DCO;
MSCFPH for H2-C2=;
Mlb/hr for coke
CONV_FAC(2) Product 2 (FLOW_PT(2))multiplicative flow conversionfactor
Same as CONV_FAC(1)
CONV_FAC(3) Product 3 (FLOW_PT(3))multiplicative flow conversionfactor
Same as CONV_FAC(1)
CONV_FAC(4) Product 4 (FLOW_PT(4))multiplicative flow conversionfactor
Same as CONV_FAC(1)
CONV_FAC(5) Riser steam flow (FLOW_PT(5))multiplicative flow conversionfactor
Convert input units to PPH.
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
FILTER(2) Filter time for product flow 2input
Minutes
Continued
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FCCU Product Yield Calculation Point Configuration through Direct CDS Entry
38
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
FILTER(3) Filter time for product flow 3input
Minutes
FILTER(4) Filter time for product flow 4input
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
FILTER(8) Filter time for Regenerator bedtemperature input
Minutes
FILTER(9) Filter time for Reactor pressureinput
Minutes
FILTER(10) Filter time for riser steam flowinput
Minutes
X(1) K1; Constant None
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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FCCU Product Yield Calculation Point Configuration through Direct CDS Entry
39
X(16) K16; Reactor stripping steam tocatalyst ratio coefficient
None
X(17) Catalyst characterization factor 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
Honeywell Hi-Spec Solutions • 16404 N. Black Canyon Hwy. • Phoenix, AZ 85023
Advanced Control Package
FCCU Severity Calculation
CONTROLLED
Jan 1998Revision 2.1
Hi-Spec Solutions
Honeywell Hi-Spec Solutions • 16404 N. Black Canyon Hwy. • Phoenix, AZ 85023
Hi-Spec Solutions
FCCU Severity Calculation Revision History
1
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 Solution. All rights reserved.
TDC 3000™ is a trademark of Honeywell, Inc.
Hi-Spec Solutions
FCCU Severity 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
Continued..........................................................................................................................8
Process Inputs (Continued) ...............................................................................................9
Configuration Inputs .......................................................................................................10
Configuration Inputs (Continued)...................................................................................11
Calculation Outputs ........................................................................................................12
Continued........................................................................................................................12
Calculation Outputs (Continued) ....................................................................................13
Error Codes ...................................................................................................................................14
Diagnostic Error Codes...................................................................................................15
Continued........................................................................................................................15
Diagnostic Error Codes...................................................................................................16
Array Location Error Codes............................................................................................17
Configuration and Tuning.............................................................................................................18
Biases in the FCCU Severity Program............................................................................19
Biases in the FCCU Severity Program (Continued) .......................................................20
Algorithms ....................................................................................................................................21
Algorithms (Continued) ..................................................................................................22
Algorithms (Continued) ..................................................................................................23
Installation Procedure ...................................................................................................................24
Preparation for Installation .............................................................................................25
Custom Data Segment (CDS) and Parameter List (PL) Installation...............................26
Building FCCU Severity Calculation Point....................................................................27
Configuration Graphics Installation..............................................................................................28
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FCCU Severity Calculation Contents
Configure Calculation Point .........................................................................................................29
Point Configuration Using Graphic SEV_CFG..............................................................30
Continued........................................................................................................................30
Point Configuration Using Graphic SEV_CFG (Continued)..........................................31
Point Configuration Using Graphic SEV_CFG (Continued)..........................................32
Point Configuration Using Graphic SEV_CFG (Continued)..........................................33
Point Configuration Using Graphic SEV_CFG (Continued)..........................................34
Point Configuration Using Graphic SEV_CFG (Continued)..........................................35
Continued........................................................................................................................35
Point Configuration Using Graphic SEV_CFG (Continued)..........................................36
Point Configuration through Direct CDS Entry..............................................................37
Continued........................................................................................................................37
Point Configuration through Direct CDS Entry (Continued) .........................................38
Continued........................................................................................................................38
Point Configuration through Direct CDS Entry (Continued) .........................................39
Continued........................................................................................................................39
Point Configuration through Direct CDS Entry (Continued) .........................................40
Link CL Programs...........................................................................................................41
Hi-Spec Solutions
FCCU Severity Calculation Contents
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:
Temperatures, pressures, and flows
• Characterizationinputs:
Severity prediction parameters
• Calculatedvalues:
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
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
Universal Control Network UCN
Fluidized Catalytic Cracking Unit FCCU
pounds per hour PPH
thousands of pounds per hour MPPH
atmospheres atm
Hi-Spec Solutions
FCCU Severity 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 Honeywell Profimatics catalyst circulation rate calculation must existon the LCN.
Hi-Spec Solutions
FCCU Severity Calculation Instrumentation (Process Inputs)
4
Instrumentation (Process Inputs)
Process Input1 Required Recommended
Riser steam flow rates X
Reaction temperature X
Reactor pressure X
Regenerator bed temperature X
Regenerator 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.
Hi-Spec Solutions
FCCU Severity Calculation Process Diagram
5
Process Diagram
R i s e r
Regenerator
Reactor Chamber
Main Fractionator
Regenerated Catalyst
Saturated GAs, C3, C4, Heavy Naphtha
LCO
HCO
DCO
Riser Feed
Spent Catalyst
Hi-Spec Solutions
FCCU Severity Calculation Detailed Description
6
Detailed Description
The tables in this section describe the following Severity program architecture:
• Point Structure
• Process Inputs
• Configuration Inputs
• Calculation Outputs.
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
Insertion Point PV_ALG
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
Parameter Description Units Yes No
FLOW_PT(1) Tagname for riser steam 1 flow rate Any mass flowunits
X
FLOW_PT(2) Tagname for riser steam 2 flow rate Any mass flowunits
X
FLOW_PT(3) Tagname for riser steam 3 flow rate Any mass flowunits
X
FLOW_PT(4) Tagname for riser steam 4 flow rate Any mass flowunits
X
FLOW_PT(5) Tagname for riser steam 5 flow rate Any mass flowunits
X
TEMP_PT(1) Tagname for reaction temperature °F or °CX
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
2 Critical indicates that a bad input causes the output of the calculation to be set BAD.
Hi-Spec Solutions
FCCU Severity Calculation Process Inputs
9
Process Inputs (Continued)
Process Inputs
Critical
Parameter Description Units Yes No
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
Configuration Inputs
Configuration Inputs
Parameter Description Units
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(2) Riser steam 2 flow rate (FLOW_PT(2)) multiplicativeconversion factor
From input unitsto Lb/hr
CONV_FAC(3) Riser steam 3 flow rate (FLOW_PT(3)) multiplicativeconversion factor
From input unitsto Lb/hr
CONV_FAC(4) Riser steam 4 flow rate (FLOW_PT(4)) multiplicativeconversion factor
From input unitsto Lb/hr
CONV_FAC(5) Riser steam 5 flow rate (FLOW_PT(5)) 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
FILTER(1) Filter time for riser steam 1 flow input Minutes
FILTER(2) Filter time for riser steam 2 flow input Minutes
Continued
Hi-Spec Solutions
FCCU Severity Calculation Configuration Inputs
11
Configuration Inputs (Continued)
Configuration Inputs
Parameter Description Units
FILTER(3) Filter time for riser steam 3 flow input Minutes
FILTER(4) Filter time for riser steam 4 flow input Minutes
FILTER(5) Filter time for riser steam 5 flow input Minutes
FILTER(6) Filter time for reaction temperature input Minutes
FILTER(7) Filter time for Regenerator bed temperature input Minutes
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
X(27) Catalyst characterization factor None
Hi-Spec Solutions
FCCU Severity Calculation Calculation Outputs
12
Calculation Outputs
Calculation Outputs
Parameter Description Units
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
FILT_VAL(2) Filtered value of input riser steam 2 flow rate Input units
FILT_VAL(3) Filtered value of input riser steam 3 flow rate Input units
FILT_VAL(4) Filtered value of input riser steam 4 flow rate Input units
FILT_VAL(5) Filtered value of input riser steam 5 flow rate Input units
Continued
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FCCU Severity Calculation Calculation Outputs
13
Calculation Outputs (Continued)
Calculation Outputs
Parameter Description Units
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
STATUS(1) Diagnostic indication of location and possible causes ofprogram error
None
STATUS(2) Diagnostic indication of array location or subroutine error None
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FCCU Severity Calculation Error Codes
14
Error Codes
The tables in this section describe the following program error codes:
• Diagnostic error codes
• Array location error codes.
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FCCU Severity Calculation Diagnostic Error Codes
15
Diagnostic Error Codes
Diagnostic Error Codes
Parameter Value Meaning
STATUS(1)3 0.0 No errors
1.0 Set calculation BAD flag on [ENGPAR(4)<>0]
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”)
10.0 CALC_PT(1) has a null point entered
11.0 CALC_PT(1) has a bad PV
12.0 Measured conversion (CALC_PT(1)) is outside the range of 0 to <100
13.0 CALC_PT(2) has a null point entered
14.0 CALC_PT(3) has a bad PV
15.0 Reactor level (CALC_PT(3)) is < 0
16.0 CATCIRC has a null point entered
17.0 CATCIRC has a bad PV
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
3 STATUS(1) indicates errors in the calculation.
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FCCU Severity Calculation Diagnostic Error Codes
16
Diagnostic Error Codes
Diagnostic Error Codes
Parameter Value Meaning
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
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FCCU Severity Calculation Array Location Error Codes
17
Array Location Error Codes
Filter Error Codes
Parameter Value Meaning
STATUS(2)4 0.0 No errors
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
4 STATUS(2) indicates the array location of the STATUS(1) error returned.
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FCCU Severity Calculation Configuration and Tuning
18
Configuration and Tuning
This section describes the parameters and values used to configure and tune the packageto a specific application.
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.
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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
Parameter Description
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.
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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.
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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:
flow(i) = FLOW_PT(i).PV * CONV_FAC(i)
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
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FCCU Severity Calculation Algorithms
22
Algorithms (Continued)
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
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FCCU Severity Calculation Algorithms
23
Algorithms (Continued)
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
Installation Procedure
This document describes the installation procedure for the FCCU Severity Calculationprogram (SEV_PRED) 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 Severity Calculation Point
• Configuration Graphics Installation.
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FCCU Severity Calculation Preparation for Installation
25
Preparation for Installation
Step Action
Gather media Gather the following items:
• Removable media containing the directory SEV
• 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> SEVCOPY $Fn>SEV>*.* $Fm>SEV>= -V -D
Where $Fn is the drive with the source media and $Fm is the drive withthe target media.
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FCCU Severity Calculation CDS and PL Installation
26
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>
CompileSEV_CDS.CL
From the Command Processor display, compile the CDS file, SEV_CDS:CL $Fn>SEV>SEV_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
Parameter List There is no parameter list for the standard severity calculation package
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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
From the Command Processor display:
ED $Fn>SEV>SEV_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>SEV
Load Entities (select target)
Pathname for SOURCE file: SEV_PNT
Pathname for IDF file: SEV_PNT
[ENTER]
Verify load When the load is complete, verify point loading by calling the point detailfrom the [DETAIL] button.
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FCCU Severity Calculation Configuration Graphics Installation
28
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 SEV_CFG Read in the picture file, SEV_CFG
R $Fn>SEV>SEV_CFG [ENTER]
Verify and Compile Verify picture:
VER [ENTER]
When the verification is complete Compile the picture:
COM [ENTER]
Copy SEV_CFG.DOto graphics directory
From the Command Processor Display:
COPY $Fn>SEV>SEV_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 Severity Calculation Configure Calculation Point
29
Configure Calculation Point
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
• Point Configuration through Direct CDS Entry
• Link CL Programs.
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FCCU Severity Calculation Configure Calculation Point
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
Selection Port Parameter Description
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.
Rx Press Filter FILTER(9) Enter the reactor pressure filter time (min).
Reg Press Pnt PRESS_PT(1) Enter the regenerator pressure point tagname.
Continued
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FCCU Severity Calculation Configure Calculation Point
31
Point Configuration Using Graphic SEV_CFG (Continued)
Selection Port Parameter Description
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 Pnt TEMP_PT(1) Enter the reaction temperature point tagname.
Reaction Temp Bias T_BIAS(1) Enter the reaction temperature bias. Inputtemperature units must be used.
Reaction Temp Filter FILTER(6) Enter the reaction temperature filter time (min).
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
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FCCU Severity Calculation Configure Calculation Point
32
Point Configuration Using Graphic SEV_CFG (Continued)
0 0 0 0STM_PNT STM_PNT STM_PNT STM_PNTSTM_PNT
1.00000 1.00000 1.00000 1.00000 1.00000
0
Selection Port Parameter Description
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).
Cnvrsn [STM #2] CONV_FAC(2) Enter conversion factor to convert from flow inputunits to PPH.
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).
Cnvrsn [STM #3] CONV_FAC(3) Enter conversion factor to convert from flow inputunits to PPH.
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).
Cnvrsn [STM #4] CONV_FAC(4) Enter conversion factor to convert from flow inputunits to PPH.
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).
Cnvrsn [STM #5] CONV_FAC(5) Enter conversion factor to convert from flow inputunits to PPH.
Continued
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FCCU Severity Calculation Configure Calculation Point
33
Point Configuration Using Graphic SEV_CFG (Continued)
CONV_PNTO2_PNT
LVL_PNT
00
0
Selection Port Parameter Description
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
Selection Port Parameter Description
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
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FCCU Severity Calculation Configure Calculation Point
34
Point Configuration Using Graphic SEV_CFG (Continued)
0.00 0.00
0.00
0.00
0.00
Selection Port Parameter Description
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
Selection Port Parameter Description
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
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FCCU Severity Calculation Configure Calculation Point
35
Point Configuration Using Graphic SEV_CFG (Continued)
0.00
0.00
0.00 0.000.00
0.00
Selection Port Parameter Description
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
Selection Port Parameter Description
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
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FCCU Severity Calculation Configure Calculation Point
36
Point Configuration Using Graphic SEV_CFG (Continued)
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).
Hi-Spec Solutions
FCCU Severity Calculation Point Configuration through Direct CDS Entry
37
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 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
Required only if more than 3 riser steamflows exist.
FLOW_PT(5) Tagname for fifth riser steam flowrate
Required only if more than 4 riser steamflows exist.
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
Same units as TEMP_PT(1).
T_BIAS(2) Additive bias to Regenerator bedtemperature
Same units as TEMP_PT(2).
Continued
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FCCU Severity Calculation Point Configuration through Direct CDS Entry
38
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
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
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 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
Convert input units to PPH.
CONV_FAC(2) Riser steam 2 (FLOW_PT(2))multiplicative flow conversionfactor
Convert input units to PPH.
CONV_FAC(3) Riser steam 3 (FLOW_PT(3))multiplicative flow conversionfactor
Convert input units to PPH.
CONV_FAC(4) Riser steam 4 (FLOW_PT(4))multiplicative flow conversionfactor
Convert input units to PPH.
Continued
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FCCU Severity Calculation Point Configuration through Direct CDS Entry
39
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
CONV_FAC(5) Riser steam 5 (FLOW_PT(5))multiplicative flow conversionfactor
Convert input units to PPH.
CONV_FAC(6) Input temperature unit flag:0 => °F; 1 => °C
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
FILTER(2) Filter time for riser steam 2 flowinput
Minutes
FILTER(3) Filter time for riser steam 3 flowinput
Minutes
FILTER(4) Filter time for riser steam 4 flowinput
Minutes
FILTER(5) Filter time for riser steam 5 flowinput
Minutes
FILTER(6) Filter time for reactiontemperature input
Minutes
FILTER(7) Filter time for Regenerator bedtemperature input
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
Hi-Spec Solutions
FCCU Severity Calculation Point Configuration through Direct CDS Entry
40
Point Configuration through Direct CDS Entry (Continued)
Parameter Description Comments
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
Default value is 1.0
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
Default value is 0.0
X(23) Carbon on catalyst temperaturecoefficient
Default value is 0.0
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
Default value is 0.0
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