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TRANSCRIPT
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Dynamic Simulation :
Project and ApplicationSuccesses
Stan Hamilton Howard Jemison,
PhDOperations Trainer OTS ConsultantOPTI Upgrader Team IPS Houston
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Introduction
OPTI Canada Long Lake Upgrader Project
Processes diluted bitumen (Dilbit) from NEXENs SAGD oil sandsproduction
Produces high quality synthetic crude
(39oAPI premium sweet crude)
Phase #1 expected production
70,000 b/d with 4 more phases planned
Located in Fort McMurray, Alberta
Commissioning of Units well under way first oil by Sept, 08
Expect 50% capacity by Jan 2009
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SAGO PROCESSIn the SAGO process. the upper weIJs/eilm 1n1O he deposl..t.ere h.;ses through the oil sands and healS thetlitumen .The hea ted bi tumen /lows withthe eon
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OPTI Canada Objectives
Train operators with limited experience
Shorten startup
Develop an ongoing training program
Improve operator response to abnormal conditions
Familiarize operators with new unit operations
Familiarize operators with DCS and SIS
Familiarize operators with operating procedures
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OTS Project Scope
Process models
OrCrude Unit (OPTI owned process)
Hydrocracker Unit
Gasification Unit
Sulphur Recovery Unit
Air Separation Unit
DCS
Emerson DeltaV operator consoles
Emerson DeltaV SimulatePro controls configuration
SIS logic translated into DeltaV controls
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OPTI CanadaTraining System Architecture
SIM4ME TCP/IP network
DeltaV Control Network
VIRTUALCONTROLSDeltaVSimulatePro)
OPERATORMONITORS
INSTRUCTOR STATION Operator Consolefor Instructor
Printer
contains trainer toolsand remote functions)SIMULATIONCOMPUTERS
contains controldatabases andgraphics)
contains processmodels)
SIMULATOR ROOM COMPUTER RACK
DeltaVWorkstationsASNs and OSNs)
KVM Switch
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OPTI Training Program
Trained 26 Panel operators
Trained 60 Field Operators (BMS)
Full competency training which includes 160 hours ofSimulation Training for all Panel Operators
Competency training for Field Operators on BMS
Simulation Training for Panel Operators make up 40%of over-all training designed to train anyone with verylittle related experience
Process Engineers have also spent time on theSimulator to become familiar with expected outcome.
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Why was OPTI OTS successful?
OTS part of overall OPTI training program
Dedicated trainers
Designed training lesson plans to enable successionplanning for Trainers
System kept current with process and controlschanges
Training is a requirement
Training is performed as a shift
Operators practice, practice, practice
Experience incorporated into OTS
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Additional benefits of OTS
Checkout of DCS and SIS controls
Validation of engineering design
Checkout and improvement of DCS graphics
Validation and refinement of operating procedures
Evaluate control and ESD strategies
Test alarm management
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Questions?
Thank You!!!