(31a) Utilization of Dynamic Simulation for New Steam Cracker Start-up Activities
AIChE Spring Meeting and Global Congress on Process Safety
2022
2022 Spring Meeting and 18th Global Congress on Process Safety Proceedings
Topical 4: The 34th Ethylene Producers Conference
Ethylene Plant Operations
Monday, April 11, 2022 - 2:05pm to 2:30pm
Dynamic simulation as a training tool for increasing operator competency is not a new concept in the
ethylene industry and continues to see advancement in both areas of application and use of new
technology. Training often focuses on response to non-routine situations such as startup/shutdown and
emergency events. Simulation software capability can be enhanced by DCS integration that connects
the dynamic behavior of the model to controls and graphics that match the production system.
In addition to increasing operator competency, further value can be captured when applied to
greenfield project start-ups. As with simulations of existing plants, superior console training accelerates
operator proficiency in lieu of many years of experience. Dynamic simulations can provide greenfield
steam crackers the opportunity to test procedures for clarity and completeness, perform DCS and safety
logic application reviews, familiarize the operators with process behaviors ahead of the actual plant
startup and even allow qualifying console operators on a new process flowsheet. First time startup
procedures can also be crosschecked and validated in greater detail than possible with tabletop
exercises. Further, in the area of process control engineering support, validating schematic operability,
checking design of process control applications, and tuning controls pre-startup can be readily
accomplished. Finally, focal areas such as techniques to minimize flaring and time to on spec can also be
confirmed pre-startup.
In this presentation, we will review how a dynamic simulation can be successfully implemented during a
greenfield start-up by using general examples from industry and specific examples from two recent
ExxonMobil start-ups. Ultimately, the use of dynamic simulation can contribute significantly to the
overall success and timeliness of a greenfield steam cracker startup.
ethylene industry and continues to see advancement in both areas of application and use of new
technology. Training often focuses on response to non-routine situations such as startup/shutdown and
emergency events. Simulation software capability can be enhanced by DCS integration that connects
the dynamic behavior of the model to controls and graphics that match the production system.
In addition to increasing operator competency, further value can be captured when applied to
greenfield project start-ups. As with simulations of existing plants, superior console training accelerates
operator proficiency in lieu of many years of experience. Dynamic simulations can provide greenfield
steam crackers the opportunity to test procedures for clarity and completeness, perform DCS and safety
logic application reviews, familiarize the operators with process behaviors ahead of the actual plant
startup and even allow qualifying console operators on a new process flowsheet. First time startup
procedures can also be crosschecked and validated in greater detail than possible with tabletop
exercises. Further, in the area of process control engineering support, validating schematic operability,
checking design of process control applications, and tuning controls pre-startup can be readily
accomplished. Finally, focal areas such as techniques to minimize flaring and time to on spec can also be
confirmed pre-startup.
In this presentation, we will review how a dynamic simulation can be successfully implemented during a
greenfield start-up by using general examples from industry and specific examples from two recent
ExxonMobil start-ups. Ultimately, the use of dynamic simulation can contribute significantly to the
overall success and timeliness of a greenfield steam cracker startup.