Simulator to train refinery operators

Invensys Process Systems has been awarded an operator training system contract by PetroChina Dushanzi Petrochemical Company.

Invensys Process Systems has been awarded an operator training system contract by PetroChina Dushanzi Petrochemical Company.

The implementation will provide a comprehensive SimSci-Esscor operator training simulator (OTS) for the chemical section of the company's integrated refinery and chemical revamping project, which will process imported sour crude from Kazakhstan.

The contract includes the design, outfit, installation and tuning, and acceptance check of the software/hardware platform for the simulation system.

The scope includes process modelling of the six chemical section units (ethylene, styrene, high density polyethylene, polypropylene, polystyrene and styrene-butadiene rubber/SBS), along with integration with emulators for the distributed control system, safety instrumented systems (SIS) and PLCs.

Related engineering services, such as technical training and support, are also included in the contract.

The operator training system (OTS) implementation employs the Dynsim process simulation solution, for high-fidelity plant modelling in dynamic and steady states.

These models are used to train control room and equipment operators and supervisors on the characteristics and interactions of plant's systems.

The simulation network also includes the Trisim Plus solution for replicating the control logic in the Triconex safety instrumented systems.

In addition, Invensys will also provide a control system human machine interface (HMI) emulation and checkout for a Yokogawa DCS at the plant.

By using the SimSci-Esscor OTS system, PetroChina Dushanzi will be able to: enhance the knowledge and competency of the operator; reduce the startup time and shutdown period; improve quality by reducing off-spec product; improve safety and extend actual safety run-time of equipment; and minimise environmental risk.

Besides being used for operator training, the OTS system will help improve process design, control system checkout, DCS configuration and tuning, diagnosis, startup and shut down, and operation optimisation.

It also incorporates the Trainee Performance Monitor tool, which allows PetroChina Dushanzi to regularly check and evaluate trainee performance.

"Invensys made our shortlist of vendors with the required resources, experience, and knowledge base needed to successfully implement this important OTS project".

"From this list, we ultimately selected Invensys because the company's Dynsim OTS solution is based on rigorous models, and utilises very flexible object-oriented technology with a user-friendly Windows interface".

said the OTS supervisor of PetroChina Dushanzi.

"Furthermore, the SimSci-Esscor simulators will also provide plant engineers with an effective validation tool to test and evaluate new control strategies in a safe, offline environment".

"PetroChina Dushanzi Petrochemical Company's selection of the OTS system shows that our world class rigorous model-based dynamic simulation technologies have been recognised not only by the subsidiaries of multi-national companies in China, but also by leading Chinese companies", said Li Yanjie, Director of Solutions Business for Invensys Process Systems China.

"The petroleum and petrochemical industries in China are growing fast, and we are prepared to meet the demand with our OTS and other solutions and systems".

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