Hyperion developed simulations for the Diesel Hydrotreater Unit, Sulphur Recovery Unit and Hydrogen Production Unit, which are now being used to train operators using scenarios already developed by their process engineers and supervisors (See Figure below).FIGURE: OPERATOR TRAINING SIMULATOR
Some complex simulations were provided, including the modelling of the Hydrogen Pressure Swing Adsorption (PSA) Unit, a complex arrangement of packed beds designed to purify the hydrogen final product using a specific timed step logic, and the integration of the Sulphur Recovery Unit ESD Logic, which consisted of complex ignition sequences for both furnaces. The OTS simulations also included DCS and ESD integration with Yokogawa CS3000 and Triconex databases.
The OTS is located in the control room of the refinery allowing operators immediate access to the training system and speeding up the training process. The OTS will provide a reduced start-up time for the three new units, by ensuring that the operators are fully trained prior to the initial commissioning. Subsequently the OTS will be used for process analyses and de-bottlenecking in addition to running refresher courses.
Dean Jones, vice president for Modelling & Simulation Solutions at Hyperion said, Hyperions experience in delivering complex modelling and simulation solutions, coupled with in-depth understanding of Saudi Aramcos requirements, has enabled us to deliver the OTS system several months in advance of commissioning, allowing time for effective operator training before start-up."