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Dynamic Simulation :
Project and Application
Successes
Stan Hamilton Howard Jemison,
PhD
Operations Trainer OTS Consultant
OPTI Upgrader Team IPS Houston
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Introduction
OPTI Canada Long Lake Upgrader Project
Processes diluted bitumen (Dilbit) from NEXENs SAGD oil sands
production
Produces high quality synthetic crude
(39
o
API 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 PROCESS
In the SAGO process. the upper weIJ
s/eilm 1n1O !he deposl..t.ere h
.;ses through the oil sands and healS the
tlitumen. The heated bitumen /lows with
the eon<Iensed I team (Wil ter) 10 lie IorIrIer
hDrirontal wei . and 110m thenI. 1Iows III
the surlace.
Upgrading
===='::VNGAS FUel
<l SVNGAS FUel
GaslfleMion
GasJflcatlon FINAL PRODUCT
"'C
The h i f>renWm Synlhelc Crude
(PSC) produd 1& 39' API g.a-.ity
with vsy low SlAp/lll' and nilrojren
end superior product QUo&ties.
The l ong l ake Project is a joim
venlure Nexen and
OPTI Canada Inc. 10 prodUCA!! a
Premium Syn1hebc Crtlde.
_longlake C8

Click on diagram
IIfTOWS Of UIIJtI to
_ ..
-""''1
-- OOPTI ne.xen
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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 Canada
Training System Architecture
SIM4ME TCP/IP network
DeltaV Control Network
VIRTUAL
CONTROLS
(DeltaV
SimulatePro)
OPERATOR
MONITORS
INSTRUCTOR STATION
Operator Console
for Instructor
Printer
(contains trainer tools
and remote functions)
SIMULATION
COMPUTERS
(contains control
databases and
graphics)
(contains process
models)
SIMULATOR ROOM COMPUTER RACK
DeltaV
Workstations
(ASNs 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 of
Simulation 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 very
little related experience
Process Engineers have also spent time on the
Simulator 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 succession
planning for Trainers
System kept current with process and controls
changes
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!!!