Qatar Petroleum started as a small topping plant in 1958, which has grown over the years into a giant refinery organisation, successfully making the state of Qatar self-sufficient and export-oriented in refined oil and petroleum products. The main finished products are Liquefied Petroleum Gas (LPG), Naptha, Gasoline, Jet Fuel, Diesel and Fuel Oil.
The Gas Recycling Plant in Dukhan was commissioned in 1998 with the objective of recovering condensate and raw NGL from Arab-D Cap gas reservoir. The plant was upgraded in 2003 for the recovery of ethane-rich NGL.
Challenges
After its expansion in Dukhan, QP faced new plant complexities with both processes and technological upgrades. The gas recycling plant is a single train with high demand on plant reliability and availability, and the plant has highly advanced plant protection systems, including automated shutdown and blowdown systems. The company had a shortage of skilled trainers, plus the trainees needed to upgrade their skill level. The company recognized the need for an operator training simulator to train new employees and to aid with resource and skill retention.
The Solution
QP chose to implement Honeywell’s UniSim Operations Suite which included an advanced Instructor Station, a process/control/logic modeling engine, a direct connect DCS interface, and advanced graphics software. It also allows training of existing operators to ensure continued familiarity with the system. The UniSim solution provides highly efficient training because it is interactive and identical to the actual DCS user interface, provides risk-free and repeatable exercises, and trains for “normal” operating situations in addition to specific disturbances.
The simulation model characterize the Dukhan Gas Recycling Plant process and control systems, including ESD and F&G Logistics. The solution uses a direct connect simulator to a Honeywell TPS control system.
The UniSim solution models routine operational scenarios, including start-up operations (cold start), normal shutdown operations, normal steady-state operations and emergency operations. In addition, the system is capable of simulating operations dictated by process disturbances and equipment failures introduced by the instructor. The UniSim operator training solution represents the plant’s DCS, and provides emulation of the Honeywell DCS, Tristation logic, FSC and Triconex Logic systems and basic emulation of turbine controls.
“The involvement of trained operators and process engineers with the development of OTS process model from concept to commissioning resulted in a highly effective and realistic training simulator at Q.P., Gas Recycling Plant,” said Soud Jaleel Al-Ruwaili, assistant manager production operations, Gas Recycling, Qatar Petroleum.
Honeywell and QP developed a comprehensive training program for both existing panel operators, as well as future panel operators, plus a competency certification program was initiated and successfully implemented which has identified clear Qatarization plans of action for new recruits. A career progression path has been established based on various training modules with increasing complexity.
“The UniSim operator training simulator is a highly effective tool and has become an indispensible part of our training program. The hands-on training experience has dramatically shortened the job training period and helped increase the confidence in our operators and other personnel,” commented Soud Al-Ruwaili.
Outcomes
The operational realism of the Honeywell’s UniSim Operations Suite training simulation software allows users to become fully familiar with all aspects of the control system before operating the plant.
Through implementing Honeywell’s UniSim, we have gained a training simulator that provides a accurate representation of its actual DCS system, and it has strongly improved DCS concept and software familiarisation. Additional benefits QP has achieved from UniSim training simulation solution include:
- Comprehensive training program for current and future panel operators
- Shortened the job training period thanks to hands-on experience
- Helped overcome the skills shortage in the oil industry
- Reduced post shutdown start-up time
- Established a career progression path for additional training modules with increasing complexity
- Allows creation of actual plant operational problems for operator training. Ensuring all such problems can be demonstrated to all operational staff.
