Refinery Operations

PS3000: REFINERY OPERATIONS SIMULATOR
REFINERY OPERATIONS SIMULATOR
The PS3000 is a simulation software package is rigorous and detailed

simulation models of Refinery process plants.
The package consists of the following modules:
PS-3001 Atmospheric Distillation Unit

PS-3002 Vacuum Distillation Unit
PS-3003 Fluid Catalytic Cracking Unit
PS-3004 Hydrogen Generation Unit
PS-3005 Hydrodeslphurization Unit
PS-3006 Catalytic Reforming Unit
PS-3007 Continuous Catalytic Regeneration Unit
PS-3008 Hydrocracking Unit
PS-3009 Sulphur Recovery Unit
PS-3010 Amine Treating Unit
PS-3011 Delayed Coker Unit
PS-3012 Diesel Hydrotreater Unit
PS-3013 Naptha Hydrotreating Unit
PS-3014 Kerosene Hydrotreating Unit
PS-3015 Isomerization Unit
Plant familiarization: Simulator offers the best platform for learning process
plant configuration, instrumentation, control system, critical parameters and
their design values and normal plant operations.
Ensure Smooth Start Ups: Plant Simulator allows operators to become

familiar with operation while they increase their familiarity with the controls
and graphical scenes. Continued training ensures increasingly smooth start-ups
in the future.
Reduce Incidents and Downtime: Training personnel in a non-destructive

environment enable you to validate emergency controls before actual use.
Testing modifications to compressor controls can avoid damage from surges.
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SIM INFOSYSTEMS PVT LTD, 11, 1 Cross Street, Nehru Nagar, Kottivakkam, Chennai 600 041, INDIA
Phone: +91-44-24542617, Email: [email protected]. Website: www.siminfosystems.com
One can purposely trigger malfunctions (such as a trip) to test operator

reactions and improve response reactions.
Maximize Performance: The Simulators are based on rigorous first-principles

models and actual controls, allowing you to troubleshoot actual process and
control problems. They unlock the fundamental understanding required to
modify, test, and improve processes and maximize plant performance.
Benefits to Academic Institutions: The Dynamic Simulator helps to teach the

students the fundamentals as well as complex process operations. It provides
opportunity for the chemical / instrumentation engineering students to know
what is happening in the industry. Simulator trained students will have edge
over their counterparts in the competitive scenario with respect to their
knowledge in Instrumentation & Control and Process operations.
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PS3001: ATMOSPHERIC DISTILLATION UNIT
PROCESS DESCRIPTION
In Preheat I section, crude is heated by a series of heat exchangers with kerosene,
Diesel and Pump around as a heating medium In Desalter, the impurities such as salt
and other contaminants are removed from crude by the desalting process. In Preheat
II section, the desalted crude is again heated by a series of heat exchangers with
kerosene, Diesel, Pump Around and reduced crude oil as heating medium.
In Crude Heater, the natural draft furnace heats the crude oil to a high temperature
enough to permit separation of components in distillation column. In Crude Column,
the tower contains 49 trays, which facilitates the contact between vapor and liquid
and through fractionation the crude oil components are separated into desired
materials for further processing.
In Product Stripper, the products like Naphtha, Kerosene and Diesel are separated
according to their boiling range. Three pump around systems namely, Top, Middle and
Bottom Pump around are employed to maintain the desired temperature gradient in
the tower.
The stabilizer unit is designed to stabilize the naphtha from the feed coming from
the overhead accumulator of a crude distillation unit. Stabilized naphtha and LPG are
the products from the stabilizer.
MAJOR EQUIPMENT TRAINING EXERCISES

Feed pump and preheat exchangers Crude feed pump failure
Desalter Booster pump failure
Pre heat exchangers RCO Pump failure
Crude heater Reflux pump failure
Atmospheric Distillation Tower Stabilizer Reflux Pump failure
Pump around systems Steam failure
Products strippers Power failure
Product coolers Instrument Air failure
Overhead condenser and reflux drum Fin Fan failure
Stabilizer Atomizing Steam Indication failure
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TRAINING BENEFITS
This dynamic simulator helps beginners, experienced operators and engineers to

achieve the following objectives:
To teach trainees and to recognize, understand the operating fundamentals of
a Crude Distillation using dynamic simulation.
To describe about the operation of a Crude Distillation.
To Startup and shutdown of the process using documented procedures.
To respond safely and efficiently to disturbances and malfunctions in the
process.
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PS3002: VACUUM DISTILLATION UNIT
PROCESS DESCRIPTION
In the vacuum Distillation Unit model, the bottom reduced crude oil (RCO) from the
atmospheric column is distilled into the following products: Light Vacuum Gas Oil
(LVGO), Medium Vacuum Gas Oil (MVGO) and Heavy Vacuum Gas Oil (HVGO). The
vacuum bottoms exit the process as vacuum residue. The vacuum Distillation Unit
simulator, the entering feed passes through a preheat furnace where partial
vaporization occurs before the feed enters the distillation column. Vacuum column
operates below atmospheric conditions. The vacuum product cooling section consists
of steam generation facilities and tempered water cooling facilities. Vacuum is
maintained by a two stage ejector system. The vacuum column overhead vapor flows
to the pre-condensers where steam & products are condensed out. The balance vapor
passes through the first stage ejector. The discharge from the first stage goes to
the inlet condenser and the non-condensed vapors are sent to the second stage. The
discharge of the second stage goes to the after condenser and the non-condensable
are routed to atmosphere. Condensate is routed to the hot well, from which it is
pumped to the desalting water drum by sour water pumps. The condensed steam and
the slop oil are let into the Hot well from where it is pumped away.

Vacuum Furnace Feed failure
Vacuum Distillation Column Coil steam failure
Product stripper Heater fuel failure
Product cooling Cooling Water failure
Overhead ejector system Vacuum failure
Hot well Pump Failures
Change in Heater Efficiency
Change in Steam Jet Ejector Efficiency
Change in Circulating Reflux
Change in Internal Reflux
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TRAINING BENEFITS
The Vacuum Distillation Unit simulator helps beginners, experienced operators and
engineers to achieve the following objectives:
To teach trainees and to recognize, understand the operating fundamentals of
a Vacuum Distillation unit using dynamic simulation.
To describe about the operation of a Vacuum Distillation unit.
To Startup and shutdown of the process using documented procedures.
To respond safely and efficiently to disturbances and malfunctions in the
process.
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PS3003: FLUID CATALYTIC CRACKING UNIT
PROCESS DESCRIPTION
FCC unit simulator consists of the following major sections:
Feed and pumping section

Reactor and Regenerator section
Fractionation section
Gas concentration section
The Fluidized Catalyst Cracking Unit (FCCU) upgrades relatively heavy hydrocarbon
to high grade lighter products via fluidized catalytic cracking and fractionation. The
heavy hydrocarbon oil makes contact with hot powdered catalyst under selected
conditions of time, temperature and pressure. The unit cracks the heavy hydrocarbon
oil into fuel gas, LPG, Gasoline, TCO and CLO. In Preheater section, feed is preheated
through heat exchanger with the help of slurry from fractionator bottom.
In Reactor/Stripper section, the oil feed enters the base of the reactor risers in a
liquid or partially vaporized state, and is then completely vaporized by contact with
the hot regenerated catalyst dropping from the regenerator standpipes into the
riser lines. In Regenerator section, the coke deposits accumulated on the catalyst in
the reactor are burned off at high temperature in the presence of air In
Fractionator section, it separates the reactor vapor effluent into a wide range of
cracked hydrocarbons as product streams.
In Gas concentration section, Dry gas, LPG and Stabilized gasoline are separated
from wet gas and unstabilized gasoline. The gas concentration section mainly consists
of Wet Gas Compressor (WGC), Primary Absorber, Sponge Absorber, C2 Stripper and
Debutanizer.
UNITS SIMULATED TRAINING EXERCISES

Feed Surge drum and preheat exchangers Feed failure
Riser, Reactor, stripper Air blower failure
Regenerator WGC failure
Flue gas waste recovery Cooling water failure
Air Blower Power failure
Fractionator Furnace Instrument air failure
Main Fractionator Fail stack slide valve
Slurry Steam generators Fail spent catalyst slide valve
Product Strippers Fail regenerator standpipe slide valve
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Wet Gas Compressor Pump Failures
High Pressure Separator Valves failures
Primary Absorber Change in catalyst activity
Sponge Absorber Water in feed
C2 Stripper Change in feed CONCARBON Number
Debutanizer Heat exchanger / cooler / reboiler fouling
Passing of FG in DFAH
Passing of torch oil to regenerator
Passing of BFW in regenerator
TRAINING BENEFITS
The Fluid Catalytic Cracking Unit simulator helps beginners, experienced operators
and engineers to achieve the following objectives:
To teach trainees and to recognize, understand the operating fundamentals of a
Fluidised Catalytic Cracking using dynamic Simulation.
To identify the main equipment and operations associated with Fluidised Catalytic
Cracking
To Startup and shutdown of the process using documented procedures
To respond safely and efficiently to disturbances and malfunctions in the process.
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PS3004: HYDROGEN GENERATION UNIT
PROCESS DESCRIPTION
The Hydrogen unit is designed for a capacity of 4754 kg/hr of Hydrogen. The feed to the
unit is Naphtha. The Hydrogen unit is divided into five main sections:
Desulphurization
Reforming
CO conversion (shift section)
Separation of H2 (excluding PSA unit)
Steam Generation
Desulphurisation unit consists of three reactors, Hydrogenator R401 followed by two H2S
absorbers R402 A/B in series. In reforming section, the hydrocarbon feed is converted into
synthesis gas consisting mainly of H2, CO and CO2, besides a minor amount of CH4.
In Shift section, CO is converted to CO2 by reaction with H2O hereby generating H2. At
startup and during upsets it is possible to bypass the shift section at the expense of a
reduced H2 production. In Separation of H2, the shifted process gas contains H2, CO2 and
steam, besides a minor amount of CO and a slip of methane. The produced H2 is separated in
the PSA unit (Pressure Swing Adsorption) which also treats HCU off-gas as a feedstock. In
Steam generation section, 42 kg/cm2 steam is produced in the H2 generation plant can be
used as process steam for heat transfer within the unit and for steam export.

Feed drum and preheat exchangers Feed failure
Desulphurization Reactors Pump failures
Pre reformer BFW failure
Tubular reformer IF, FD fan failures
Medium Temperature Shift converter Cooling water failure
Low Temperature Shift converter Power failure
Recycle compressors Fail Recycle Hydrogen compressor
Deaerator and BFW pumps Start-up N2 compressor
BFW preheaters Reformer trip
Process Condensate separators PSA trip
Reforming plugging
H2 gas leak
Fouling of heat exchangers
Sulpur in feed naphtha
Feed naphtha temperature
Desulphurization reactor catalyst activity
ZnO bed catalyst activity
Reformer catalyst activity
MTSC / LTSC catalyst activity
PSA Efficiency
Ambient air temperature
Cooling water temperature
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PS3005: HYDRODESLPHURIZATION UNIT
PROCESS DESCRIPTION
HydroDesulphurization unit Simulator is a dynamic simulation model with following
sections:
Feed Section Heavy gas Oil along with the recycle stream enters into the
Feed Drum which is then sent to Preheaters for Preheating.
Preheat Section and Heater Feed is heated in series of exchangers and in

Fired Heater before entering the Reactor.
Reactor System - The hot Hydrogen charged feedstock stream enters the top
of Reactor for Substitution reactions to occur, removing Sulfur from the
Hydrocarbon chains and replacing it with Hydrogen.
High Pressure Accumulator system -
Product Section - The liquid process stream from the Cold Flash Drum, and
Hot Flash Drum are stripped in Product Stripper to strip out remaining
Hydrogen sulfide and the other contaminants from the petroleum product.

Feed drum and preheat exchangers Makeup compressor failure
Fired heater Recycle compressor failure
Reactor Pump failures
HP Accumulator Reactor feed heater air preheater
Medium Temperature Shift converter Fan failures
Low Temperature Shift converter Cooling water failure
Recycle compressors Power failure
Deaerator and BFW pumps Fail reactor feed heater fuel gas flow
BFW preheaters Fouling of heat exchangers
Process Condensate separators Reactor catalyst activity
Maximum DEA supply rate
Hydrogen supply pressure
Hydrogen supply purity
Fresh feed olefin content
Fresh feed sulfur content
Reactor feed heater tube rupture
Reactor no. 1 plugging
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PS3006: CATALYTIC REFORMING UNIT
PROCESS DESCRIPTION
The Catalytic Reforming unit treats sweet naphtha from the naphtha hydrotreating
unit to produce high octane reformate, naphtha and hydrogen rich gas. The Catalytic
Reforming reactions involve aromatization, dehydrocyclisation of napthenes,
isomerisation and hydrocracking to a certain extent. The Catalytic Reforming unit has
four sections, namely, Feed preheat section, Reactor section, Product separator
section, Debutaniser section.
In Feed Preheat section, Feed is preheated with the help of heat exchangers
In Reactor section, it comprises of a reactor and the interstage heaters

where an endothermmic reaction takes place and further it is heated through
interstage heaters.
In Product Separator section, the two-phase mixture from the condenser

flows to the separator. The vapors rich in hydrogen are separated,
compressed and recycled back to the CFE.
In Debutaniser section, it processes the hydrocarbon liquids which contains

the maximum constituents of reformate naphtha and LPG from the separator
section.

Feed tank Feed Naphtha supply Pressure
Combined feed exchanger Feed Naphtha supply Temperature
Product condenser Pump failures
Charge heater Cooling water failure
Catalytic reformer 3 stage reactors Power failure
Inter Heater 2 & 3 Fuel gas failure
Separator Recycle gas compressor failure
Debutaniser Ambient Temperature
Fouling of heat exchangers
FO, PG supply pressure
Catalyst Activity
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PS3007: CONTINUOUS CATALYST REGENERATION UNIT
PROCESS DESCRIPTION
The CCR regeneration section performs two functions, namely, Catalyst transfer and
Catalyst Regeneration
In catalyst Transfer, it is transferred from the Catalytic reforming reactors to the

Regenerator and back again to regenerate the catalyst.
In Catalyst regeneration, the coke is burned off at a high temperature and low
oxygen concentration and the catalyst passes into the Chlorination Zone where it is
oxidized at high temperature and high oxygen concentration (18 to 20 mole %)
The "Logic" is divided into the following:

1. Master Controller
2. Lock Hopper No.1 Controller
3. Lock Hopper No.2 Controller
4. Miscellaneous Logic
Master controller logic contains the logic for the following:

1. Emergency Stop System
2. Regenerator Run-Stop Circuit
3. Catalyst Flow Controller
4. Chemical Selector System
5. Heater Shutdown System
6. Lift Gas Interlock
7. Lock Hopper Selector System
8. Verification
CONTROL SCHEME TRAINING EXERCISES

Purge gas Flow Controller Lock Hopper failure
Lift Gas Flow Controller Pressure Differential Controller failure
Hopper Pressure Controller Chloride Flow failure
Air Heater Outlet Temperature Controller Downstream failure
Regenerator Heater Outlet Temp Controller Regeneration Heater Trip
Air Flow Controller
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PS3008: HYDROCRACKER UNIT
PROCESS DESCRIPTION
The Hydrocracking process is a versatile process for catalytically hydrocracking
heavy petroleum fractions into lighter, more valuable products.
The simulated plant processes a feedstock of vacuum gas oil from the vacuum
distillation Column. The feed is converted into lower molecular weight components
namely sour gas, heavy naphtha, light naphtha, diesel oil and kerosene. The desired
degree of hydrocracking takes place as the feed is processed over a fixed bed of
catalyst at elevated hydrogen pressure and temperature. The amount of catalyst
required per volume of fresh feed and the pressure level required depend on the
nature of the feed and the products desired. When the feed and hydrogen contact
the catalyst, nitrogen compounds are converted to ammonia and hydrocarbons, sulfur
compounds are converted to hydrogen sulfide and hydrocarbons, and the hydrocarbon
feed is hydrocracked into the lower molecular weight products. The effluent from
the reactors is sent to the fractionation section where the products and bottoms are
separated. The simulated plant is divided into two major sections to accomplish the
hydro cracking process:
A Reactor section, in which the feedstock is processed through two hydrogen-
charged catalytic bed reactors namely lead reactor and main reactor.
A Fractionator section, in which the reaction product is separated into several

grades of hydrocarbon products, some of which go on to further treatment
and some to storage.

Feed preheat exchangers and surge drum Pump failures
Lead and Main reactors Cooling water failure
HP, LP Hot Separators Power failure
HP, LP Cold Separators Fuel gas failure
H2S absorber Recycle gas compressor failure
Recycle Gas compressor MUG compressor failure
Makeup Hydrogen compressor trains Ambient Temperature
Fractionator furnace Fouling of heat exchangers
Main Fractionator FO, PG supply pressure
Product strippers Catalyst Activity for R1, R2
Make-up H2 Purity
Heat Exchangers fouling
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PS3009: SULPHUR RECOVERY UNIT
PROCESS DESCRIPTION
The process consists of controlled combustion of a hydrogen sulfide gas stream,
followed by a (catalytic or thermal) reaction between hydrogen sulfide and sulfur
dioxide to produce sulfur as a vapor. The vapor is collected and condensed, and the
liquid is collected in the sulfur pit. The objectives of the unit operation are not only
the production of sulfur, but also the reduction of undesirable gases (such as SO2)
being released into the atmosphere. These objectives must be achieved in spite of
changes in feedstock properties and upsets to the various operating conditions.

Feed gas knockout drums Pump failures
Combustion chamber Cooling water failure
Reaction furnace Power failure
Sulfur condenser 1,2,3, 4 Fuel gas failure
Steam re-heater 1,2,3 BFW failure
Catalytic converter 1,2,3 Plugged S Line To Coalescer
Sulphur pit Fouling of heat exchangers
Feed gas composition
Feed gas temperature
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PS3010: AMINE TREATING UNIT
PROCESS DESCRIPTION
In Amine plant, CO2 present in the feed synthesis gas is reduced from 54.0% to
0.06% by selective absorption using MEA (Mono Ethanol Amine). Gas handling
capacity of the simulated amine plant is 114 TPH of synthesis gas.
Amine plant consists of the following three sections:

Absorber Section
Turbines and Pumps Section
Stripper Section

Absorber Column Pump failures
K.O Drum Power failure
Lean Amine Cooler Blow absorber relief valve
Lean Amine Heat Exchanger Blow stripper relief valve
Amine Guard Inhibitor system High CO2 in feed gas
Lean Solvent Pump A - Motor Driven Fouling of heat exchanger
Lean Solvent Pump B - Turbine Driven Cooling water temperature
Hydraulic Turbine Feed gas temperature
Stripper Column Exchanger fouling
Flash Drum Stripper efficiency
Reflux Drum (D-02) Absorber efficiency
Lean Solvent Exchanger 1 FOAMING IN STRIPPER
Stripper Overhead Condenser
Steam Reboiler
Hot Oil Reboiler
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PS3011: DELAYED COKER UNIT
PROCESS DESCRIPTION
The Delayed Coking Process is a thermal cracking process for upgrading heavy
petroleum residues into lighter gaseous and liquid products and solid coke (green
coke). The petroleum residue feedstock is heated in a specially designed heater to
high temperature with a brief residence time. The thermal cracking reactions start
in the heater coils and are completed in Coke Drums (accumulator vessels with long
residence time). The thermal cracking reactions in the heater are carefully
controlled to minimize coke build up in the heater coils. The solid product (Green
Coke) is retained in the Coke Drums. Coke Drum effluent vapor is quenched to arrest
further cracking reactions and then fractionated into various distillate and light end
products.

Coker furnace
Fractionator Failure of heater charge pump
Coke drums FD fan failure
Pre heat exchangers ID fan failure
ID, FD fans HP Steam failure
MP Steam failure
Air preheater fouling
Heater efficiency
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PS3012: DIESEL HYDROTREATER UNIT
PROCESS DESCRIPTION
Hot and Cold feed are filtered and taken into feed surge drum. The feed is mixed
with recycle gas, antifouling and sulphiding agent, preheated by reactor effluent
exchangers and heater to the required reactor temperature. The Reactor R-001
operates at moderate temperature and pressure, under mixed phase. The olefins
saturation, desulphurization, denitrogenation and aromatics saturation reactions
occurring on the catalyst are highly exothermic. Thus quenching line, derived from
the recycle gas, is installed between the first and second reactor beds in order to
limit the overall exotherm and so to operate the catalyst beds in an optimized
temperature range. In order to ensure the mandatory near to perfect gas/liquid
distribution for this very severe service, Equiflow gas/liquid distributors are
installed at the top of each bed.
The reacted hot vapor is first cooled in 1st Cold liquid preheater against HC liquid
from LP separator drum, then cooled in recycle gas preheater against recycle gas,
then cooled 2nd Cold liquid preheater against HC liquid from LP separator drum. The
cooled hot separator vapor is mixed with washing water and partially condensed in
the Hot separator vapor Air Cooler. The mixture after cooling down in the Hot
Separator Vapor Air Cooler is collected in the HP Separator where three phases are
separated. Pressure of the HP separator drum, which dictates the hydrogen partial
pressure at the outlet of the reactor, is controlled by actuating first on the spill-
back control valves of the Make-Up Compressors and, if required, on the H.P purge
valve located on the line at the HP amine absorber outlet (override at higher set
point). The recycle gas passes in the Recycle Compressor KO Drum and is then
compressed in the centrifugal Recycle Compressor. HC and sour water from Cold HP
separator drum are routed to Cold LP separator drum under level control. In this
Cold LP Separator, three phases are separated:

Feed Coalescer Pump failures
Feed surge Drum Air cooler failure
Reactor feed heater Recycle gas compressor failure
DHDT Reactor H2 makeup gas compressor failure
Cold HP Separator Power failure
Cold LP Separator Fouling of heat exchanger
Makeup gas KOD and compressor Cooling water temperature
Recycle gas compressor
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PS3013: NAPHTHA HYDROTREATER UNIT
PROCESS DESCRIPTION
The purpose of this Naphtha Hydrotreater unit is to protect the Reforming and
Isomerization catalysts by eliminating or reducing to an acceptable level the
impurities of the naphthas. Impurities, which are considered detrimental to the
catalyst activity such as, sulfur, nitrogen, water, halogens, diolefins, olefins, mercury,
arsenic and other metals. The treating process is achieved by passing the naphtha
over a fixed bimetallic catalyst bed in adiabatic reactors in the presence of
hydrogen. There are principally hydrorefining & hydrogenation reactions occurring in
the rector.
Hydrotreating is performed in two steps: the first step consists in transformation of

diolefins into olefins in reactor R-001 and the second one corresponds to olefins
hydrogenation, desulfuration and denitrification of the whole feedstock in reactor R-
002. Naphtha feed and a part of make-up H2 are preheated against reactor R-002
effluent, and are injected into 1st hydrotreater reactor R-001. The diolefins and a
part of the olefins present in the feed are hydrogenated at low temperature in the
liquid phase and with a moderate temperature increase. The effluent is then mixed
with the balance of H2 make-up and the recycle gas from K-001 A/B, heated in heat
exchangers against reactor R-002 effluent and in Feed heater F-001. Then, it is
injected into 2nd hydrotreating reactor R-002. . The temperature increase in R-002
is mainly due to olefin hydrogenation. In case of much higher T than expected in
the second reactor (due to feed composition modification), there is the possibility to
quench the inlet of second catalytic bed. The R-002 effluent is cooled down, before
being sent to separator drum V-002. The major part of the vapor phase is used as
recycle and sent to recycle compressor K-001. Prior to the air condenser A-001,
washing water is intermittently injected to dissolve any chloride, sulfide and
ammonium salts, which precipitate at low temperature. Water is mainly recovered in
the boot of the separator drum V-002. The separated hydrocarbon liquid is routed
under level control to the stripping section.
In the stripping section, the separator liquid is preheated first in stripper

feed/bottoms exchangers to enter the stripper column C-001.The column C-001 is
reboiled by one HP steam reboilers. Overheads from the column are partially
condensed in stripper overheads air condenser and then collected in the stripper
reflux drum. The liquid is pumped under Level control to C-001 as reflux. The
stripper bottom of Heavy Napahtha is cooled in the stripper feed/bottoms
exchangers and then routed under level control to the splitter C-002.
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Feed surge Drum Pump failures
Reactor feed heater Fan failure
Lead and main Reactors Power failure
Hot Separator Fouling of heat exchanger
Recycle gas compressor Reactor catalyst Activity
Naphtha stripper
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PS3014: KEROSENE HYDROTREATER UNIT
PROCESS DESCRIPTION
Catalytic desulphurization is a method for removal of sulphur compounds from

petroleum distillates. Under suitable conditions of temperature, pressure and in the
presence of catalyst and hydrogen atmosphere, organic suphur compounds are
converted to hydrogen sulphide and saturated hydrocarbons. During
hydrodesulphurization apart from desulphurization, hydronitrogenation, oxygen
removal, metal removal etc. are taking place as these compounds are also present in
petroleum. The production process takes place through the following three main
sections
Feed and Furnace Section
Reactor Section
Stripper Section

Reactor heater Coil leak
Hydrotreater reactor Steam failure
Stripper Cooling water failure
Power failure
Fouling of heat exchanger
Reactor catalyst Activity
Instrumentation failure
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PS3015: ISOMERIZATION UNIT
PROCESS DESCRIPTION
Butane feed from the Alkylation Unit is sent to the isomerization feed surge drum.
Then it is pumped by isomerization feed pump to enter down flow in the feed dryers
in order to remove water and sulfur from the feed. Two drums operate in series in
order to protect the isomerization catalyst from irreversible damage with water or
sulfur compounds, which is extremely poisonous to the reactor catalyst.
The dry hydrogen is then mixed with the purified feed. The hydrocarbon feed is
under flow control and the hydrogen make-up is under flow ratio control with the
feed. This combined two phase feed is first preheated in the isomerization
feed/second reactor effluent exchangers, then in the first reactor feed/effluent
exchanger. Finally it is heated to the required inlet isomerisation reactor
temperature by desuperheated MP steam in the first reactor feed heater. The feed
enters into the first isomerization reactor from the top. The isomerization
reaction occurs in the reactor. This reaction is slightly exothermic. Therefore the
reactor effluent leaving the first isomerization reactor has to be cooled down
before entering the second isomerization reactor. The inlet temperature of the
second isomerization reactor is controlled by the bypass of the first reactor
feed/effluent exchanger. The isomerization reaction is completed in the second
reactor. The effluent is then routed to the stabilizer section under pressure control.
Isomerization reactor effluent feeds the stabilizer column. The purpose of
the stabilizer is to reduce C3- rate in the isomerization reactor effluent. The
stabilizer operating pressure is optimized to strip out light ends from the reactor
effluent, while minimizing the C4 hydrocarbon vent losses.

H2 makeup compressor Compressor failure
Feed dryer Power failure
Hydrogen dryer Fouling of heat exchanger
Isomerization reactors Reactor catalyst Activity
Stabilizer Instrumentation failure
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What are some of the modules covered in the refinery operations simulator?

What are some of the modules covered in the refinery operations simulator?

What are some of the benefits of using a refinery operations simulator for training?

What are some of the benefits of using a refinery operations simulator for training?

PS3000: REFINERY OPERATIONS SIMULATOR

REFINERY OPERATIONS SIMULATOR

The PS3000 is a simulation software package is rigorous and detailed

The package consists of the following modules:

PS-3001 Atmospheric Distillation Unit

Ensure Smooth Start Ups: Plant Simulator allows operators to become

Reduce Incidents and Downtime: Training personnel in a non-destructive

One can purposely trigger malfunctions (such as a trip) to test operator

Maximize Performance: The Simulators are based on rigorous first-principles

Benefits to Academic Institutions: The Dynamic Simulator helps to teach the

PS3001: ATMOSPHERIC DISTILLATION UNIT

MAJOR EQUIPMENT TRAINING EXERCISES

This dynamic simulator helps beginners, experienced operators and engineers to

PS3002: VACUUM DISTILLATION UNIT

MAJOR EQUIPMENT TRAINING EXERCISES

PS3003: FLUID CATALYTIC CRACKING UNIT

FCC unit simulator consists of the following major sections:

Feed and pumping section

UNITS SIMULATED TRAINING EXERCISES

PS3004: HYDROGEN GENERATION UNIT

UNITS SIMULATED TRAINING EXERCISES

PS3005: HYDRODESLPHURIZATION UNIT

Preheat Section and Heater Feed is heated in series of exchangers and in

High Pressure Accumulator system -

UNITS SIMULATED TRAINING EXERCISES

PS3006: CATALYTIC REFORMING UNIT

In Reactor section, it comprises of a reactor and the interstage heaters

In Product Separator section, the two-phase mixture from the condenser

In Debutaniser section, it processes the hydrocarbon liquids which contains

UNITS SIMULATED TRAINING EXERCISES

PS3007: CONTINUOUS CATALYST REGENERATION UNIT

In catalyst Transfer, it is transferred from the Catalytic reforming reactors to the

The "Logic" is divided into the following:

Master controller logic contains the logic for the following:

CONTROL SCHEME TRAINING EXERCISES

PS3008: HYDROCRACKER UNIT

A Fractionator section, in which the reaction product is separated into several

MAJOR EQUIPMENT TRAINING EXERCISES

PS3009: SULPHUR RECOVERY UNIT

MAJOR EQUIPMENT TRAINING EXERCISES

PS3010: AMINE TREATING UNIT

Amine plant consists of the following three sections:

MAJOR EQUIPMENT TRAINING EXERCISES

PS3011: DELAYED COKER UNIT

MAJOR EQUIPMENT TRAINING EXERCISES

PS3012: DIESEL HYDROTREATER UNIT

MAJOR EQUIPMENT TRAINING EXERCISES

PS3013: NAPHTHA HYDROTREATER UNIT

Hydrotreating is performed in two steps: the first step consists in transformation of

In the stripping section, the separator liquid is preheated first in stripper

MAJOR EQUIPMENT TRAINING EXERCISES

PS3014: KEROSENE HYDROTREATER UNIT

Catalytic desulphurization is a method for removal of sulphur compounds from

MAJOR EQUIPMENT TRAINING EXERCISES

PS3015: ISOMERIZATION UNIT