Assessment of availability of a Fluid Catalytic Cracking Unit through simulation

This paper presents a systematic approach to estimate the availability of process plants. The study includes a live problem at a Fluid Catalytic Cracking Unit (FCCU) of a refinery requiring high levels of availability for cost-effective operation. The system is modelled as a fault tree which is often used in the analysis of chemical process industries. A numerical evaluation of the fault tree assesses the characertistic safety parameters such as reliability and availability of the system. However, for large and complex systems, such analysis will normally require enormous computational effort, involving the breakdown of the fault tree into minimal cut sets. An alternative approach is to simulate the system using the Monte Carlo method. This paper presents an availability analysis of the Reactor/Regenerator system of the Fluid Catalytic Cracking Unit using the Monte Carlo simulation. The results of the simulation are validated by a comparison with the actual system. The method promises to be a useful tool for assessing the availability of complex systems with alternative configurations.