Real-time simulator for FCCU operator training

In September 1990, a client refiner undertook a conversion of the pneumatic instrumentation on several units, including FCCU, to a TDC-3000 distributed control system (DCS). In order to train the process operators on the use of the DCS, a real-time dynamic simulation of the FCCU was used. The FCCU simulator consisted of reactor, regenerator, and main fractionator models. The ability of the simulation to reproduce unit performance and an operator interface to the simulator using DCS equipment identical to that for the FCCU provided a realistic tool for operator training in a no risk environment. After review of the simulator-based operator training system, Operations management considered training process operators using the simulator as a prerequisite to switching control to the new DCS. During September, after completion of operator training, the hot cut over from the old pneumatic system to the new DCS was completed, safely, 5 days ahead of schedule. Operator acceptance of and confidence in the new control system are good. Refinery management acknowledges the major contribution of the simulator training system to the successful control system transition and the positive attitude of the process operators. In the future, the simulator will be used for refresher training as well as for new operator training. Also, refinery engineers plan on using the simulator for unit performance studies.