References > Petrochemichals / Chemicals

Petrochemicals / Chemicals

End User	Plant	Simulation Solution	Year
VEOLIA	Campus VEOLIA Environnement	OTS	2006
	Drinking water treatment

Context of the OTS application: RSI has developed a training tool on drinking water treatment, based on dynamic simulation of a model Plant "selected by its educational value". The several steps of the treatment follow on with the flow in a dynamic simulator, among which, the pre-treatment, the clearing, the filtration, the ozonation, the stabilization and the disinfection. About twenty parameters characteizing the water quality are recorded along the production chain: water muddying, organic matters, pH, chlorine, mineral micro-pollutants, etc. Various technologies of clearing and filtration are put forward as well as the choice of chemical reagents. Specific phenomena to water profession was carried out, from documents and technical data from Veolia water and on the basis of feedbacks of Plants operated by Veolia Group. A hundred of training scenarii are provided to be used as progressive and targeted modules. The tool thus integrates the training developments existing with the adult continuing education or the initial education and offers professional situation scenario near the work practice. The operator training simulator is delivered in French, English and Chinese languages for a use as large as possible within VEOLIA Environnement Group.
OMV	Schwechat, Austria	OTS	In progress
	Liquid Cracking Plant (Linde)	ABB Industrial IT Stimulation
		Certification program for operator training
Context of the OTS application: This is a Liquid Cracking Plant. The feedstock is Naphtha with some LPG cracking. The Plant went through a major revamp and expansion by Linde in late 2005: new furnaces (latest Linde design) were added and the rest of the plant was debottlenecked for the added capacity The DCS was completely replaced with the ABB Industrial IT system. When the expansion project was complete, OMV has started the OTS project. RSI Simcon was chosen as the OTS vendor mainly because of the wide experience in providing Ethylene Plant simulators and also because of the good reference that OMV has from RSI Simcon at the OMV Burghausen plant. An integrated process model of the entire plant is being provided. One new furnace type and one old furnace type will be modeled in detail. The other furnaces will be modeled in a simplified way in order to adjust the plant load. OMV in Schwechat is very serious about operator training using process simulators. They already have a number of simulators for their refinery units. Their plan is to eventually have training simulator models for all the major pants in the refinery/petrochemical complex. The Schwechat site has a training center where all the training of operators is performed. The ethylene plant simulator is located at the center. It is used as part of the certification program for operator training. DCS: The DCS is ABB IIT. A soft stimulation of the control is provided by ABB. This product is called ITS. The process simulator interfaces to the ITS package. Also included in the scope is an interface to real panel-mounted lights and switches that mimic the hard-wired panels in the control room.
PCS	Jurong Island, Singapore	OTS	In progress
	Liquid Cracking Plant(Stone and Webster)	Honeywell TPS TDC3000 (Link)
		Certification program for operator training
Context of the OTS application: This is a liquid cracking plant. The feed stock is naphtha. It also co-cracks C4 LPG with Naphtha in some furnaces. After loading of the ethane recycle furnace, the excess ethane and recycle propane are mixed and co-cracked with Naphtha in one furnace. This is an existing plant originally built in the 1970's and revamped over the years. S&W is the process licensor. RSI Simcon provided a simulator to PCS in 1995/1996. It was based on an emulation of TDC-2000. The original purpose was to train the operators in the process and on the DCS. In the past 10 years, there were many process revamps to the plant. Also, the DCS was again upgraded to TDC-3000 TPS/GUS. Therefore, PCS decided to upgrade the simulator to make it up-to-date. Most of the simulator process model will be re-used and updated. This has provided PCS a cost-effective opportunity to modernize their simulator without completely re-doing the model. RSI Simcon's philosophy is to protect the customer's investment in modeling even when there are major improvements to the simulation software (in this case 10 years). The purpose of the simulator is to incorporate it into an overall training program as part of operator training certification. The plant runs for extended periods of time and is very stable because of advanced control. Even the experienced operators no longer have current experience to operator the plant during abnormal circumstances as well as during startup and shutdown. Hence, the training simulator will be used to keep the operators skills sharp. The PCS model is the fully integrated ethylene plant. Includes detailed modeling of all the furnaces (9 furnaces). The model is very large. The model also includes both the propylene and ethylene refrigeration systems. DCS: The DCS is Honeywell TDC-3000 TPS/GUS. There are 4 real Honeywell Gus operator consoles (supplied by RSI Simcon). We connect to the real DCS via a Proconex LCNSIM interface box. Also included in the scope is an a Board Operator Panel in the DCS console. This is a software emulation of the panel-mounted hard-wired switches.
BASF	Antwerp, Belgium	OTS	In progress
	Naphtha Cracking Plant (Linde and ABB Lummus)	Honeywell TPS TDC3000 (Link)
		Certification program for operator training
Context of the OTS application: This is a liquid cracking plant. The feedstock is Naphtha. Some co-cracking of LPG is done. The plant was built in the early 1990's. The process licensor is Linde. In the late 1990's a Lummus furnace was added to expand the plant capacity. There are currently 11 furnaces in the plant. Many of the operators of this plant participated in the original startup and gained their experience as the plant was started and eventually stabilized out over the years. Also, advanced process control was introduced in the plant approximately 7 years ago. This has made the plant even more stable. Now, many of these seasoned operators are reaching retirement age. BASF wants the training simulator to maintain the skills of the older operators and to train the younger operators in the abnormal operations in the plant as well as startup and shutdown. (Note that this plant has run continuously without a major turnaround for 5 years. The next turnaround is being planned for 2007 as part of a plant expansion project.) An integrated process model of the entire plant is being provided. Also in the scope of the integrated model is the aromatics unit of the plant, as well as the utilities section (mainly steam distribution systems). Four furnaces are being simulated in detail. This allows BASF to have a detailed model of all feed/furnace types. Also, in addition to the integrated model, RSI Simcon is providing the ability to run separate, stand-alone sections of the model (Hot, cold, aromatics/utilities). DCS: The DCS is Honeywell TDC-3000 TPS. There are 6 real Honeywell operator consoles. We connect to the real DCS via a Proconex LCNSIM interface box. The simulated DCS database is huge (over 20,000 points). Even before the SAT in mid-2006, BASF is planning to upgrade the simulator model to be in step with the plant expansion that is scheduled to come on line at the end of 2007. New furnaces (latest Linde design) will be added to expand the capacity. Also, the cold section will be significantly debottlenecked. BASF is concerned that even the experienced operators will be unfamiliar with the operation of the plant (especially the interactions of the cold section) when the expanded plant starts up. The operator training simulator will play a key role in getting the operators familiar with the new plant configuration. Also, it helps in debugging the changes that are planned for the DCS.
Middle East Company	Middle East	OTS	2006
	Ethane - Propane steam-cracker (Linde)	Yokogawa CS3000 (Emulation)
		Certification program for operator training

PETRONAS	Malaysia	OTS	2005
PETRONAS	Propane & Naphtha steam cracker (ABB Lummus)	Honeywell TDC3000 emulation	2005
caption 1 caption 2 caption 3 The Operator Training Simulator is dedicated to emulate the Honeywell TDC 3000 Distributed Control System (DCS) for enhanced training and operation issues. Context of the OTS application: The plant is a existing gas cracking plant dated in the late 1990’s. The feed is ethane. The process Units modeled in detail concern the hot section, the cold section and the steam boiler section. Hot section modeling scope includes ethane feed vaporization, amine system, 2 cracking heaters, quench tower, process water stripper, dilution steam system, four-stage cracked gas compressor, steam turbine, caustic system and gas drying. Cold section simulation scope contains chilling train, demethanizer & deethanizer, acetylene hydrogenation, ethylene fractionation, ethylene and propylene refrigeration systems This section consists of three boilers operated with fuel gas. Each boiler is composed of an economizer, a top drum, a lower drum, a steam super-heater and a fan. The simulator includes the deaerators which supply feed water to each boiler, the fuel gas system and the three steam headers. DCS: The control strategy within the simulator is implemented via Honeywell TDC3000 DCS emulation and is ensured by simple, complex and cascade PID control loops. It involves logic sequences and Emergency Shut Down logics (ESD). EMSB - Steam Cracking Unit Success Story
OMV	Burghausen, Germany	OTS	2004
	Naphtha steam-cracker (Combination of process licensors)	Honeywell TPS TDC3000 (Link)
		Operator training for new operators
Context of the OTS application: OMV Burghausen is a liquid cracking plant. It cracks Naphtha. This is an existing plant originally built in the 1970's and revamped over the years. The purpose of the simulator is to train new and experienced operators. As the plant operations have matured, the plant runs in a stable condition for very long times. The older experienced operators can get refresher training with the simulator. Many of the younger operators have never even seen abnormal conditions or participated in startups and shutdowns. More and more of OMV's older operators are retiring. The simulator is used to train the replacements so they don't make mistakes in the real plant. The scope of the model starts at the inlet to the gasoline fractionator (first separation tower after the cracking furnaces). Since the furnaces coke up over time, they are constantly being started up, shut down, de-coked, and started up again. Therefore, the operators get good experience in the real plant in practicing these operations. The model also included both the propylene and ethylene refrigeration systems. There is also a secondary feed to the separation section that comes from a coker. The processing of this feed is in the OMV scope. Project Follow-up: We have used the OMV Burghausen ehtylene plant as a reference site for several potential customers. Our good work on the OMV project in Burghausen led to the award of the latest OMV project in Schwechat, Austria. We are currently working on some model enhancements for Burghausen. Burghausen is also embarking on a 10-year plan to make training simulators a key element of operator training in all plants in the petrochemical complex. We are working hand-in-hand with OMV to assist them in the development of this plan. DCS: The DCS is Honeywell TPS TDC-3000.There are 6 real Honeywell Gus operator consoles (supplied by RSI Simcon). We connect to the real DCS via a Proconex SX003 interface box. Also included in the scope is an interface to real panel-mounted lights and switches that mimic the hard-wired panels in the control room.
Rio Polimeros	Brazil	OTS	2004
	Ethane-Propane (ABB Lummus)	ABB Advant MOD300 (Link)
		Operator training before start-up
Context of the OTS application: The Rio plant is a gas cracking plant (grass roots). It cracks Ethane-Propane. Rio was a grass-roots plant. Therefore, no one had any experience in operating this specific plant. The simulator was used to train not only operators, but also engineers and operating supervisors. It was used as part of an intensive training program for the plant that lasted several months before the startup. If familiarized the personnel with both the DCS operation as well as the process operation. The model was an integrated model of both the furnaces and the separation section connected together. Only 2 furnaces were modeled in detail since the others were identical. The modeling of 2 furnaces allowed Rio to practice startup, shutdown, decoking, and furnace switching (i.e. taking down a coked furnace and starting up a clean furnace to take its place). The model also included both the propylene and ethylene refrigeration systems. There were also a number of generic models that were also provided (Boiler, compressor, distillation, generic process). Before the startup, the training simulator was used to intensively train operators and even engineers / supervisors for several months about the operation of this grass roots plant DCS: The DCS was ABB ADVANT MOD300. There were 2 operator stations plus a historical trending station (AEH). We connect to the real DCS via an interface device called a Turbonode (small DCS controller that has a TCP/IP interface).
TOTAL	Donges refinery, France	OTS	2004
	Highly integrated distillation unit. Crude Switch Model.	Honeywell TDC3000 emulation
		Operator training and Engineering purposes
ERTC Computing Conference, London
TOYO ENGINEERING CORPORATION	Bandar Assalouyeh - Fourth Aromatic Plant	OTS	2004
		Emulation of YOKOGAWA CS3000 DCS
		Huge Simulator modelling the whole Plant.Use of the simulator for initial training of plant operators before refinery start up.
Catalytic Reforming Section The Plant has been split in 7 simulators: Hydrogenation of pyrolysis gasoline Prefractionation and Hydrotreatment of gas condensates Continuous Catalytic Reforming Separation of Reformate and Aromatics Extraction of Benzene and Toluene (Krupp Uhde ) Disproportination and Transalkylation Units (Toray) Xylenes isomerization Bandar Assalouyeh – 4 th Aromatic Plant Success Story
Petrochemical Unit	New 1-butene Unit	OTS	2004
Petrochemical Unit	Ethylene dimerization by a liquid-phase process using a soluble catalyst system	Emulation of YOKOGAWA CS3000 DCS	2004
Providing engineers and operators with experience prior to commissioning Startup and shutdown procedures Unlimited variety of what if situations Dynamics of heat exchanger fouling due to oligomer formation Operation of distillation columns to ensure polymer-garde product specification Emergency situation, fire case. Hydrocarbon Processing
BASF – YPC Company Limited	New Integrated Petrochemical Site - Nanjing , Jiangsu province - East – Central China	3 OTS	2003
BASF – YPC Company Limited	Ethylene Oxide / Ethylene Glycol LDPE Propionic Acid	Partial Stimulation of Emerson DeltaV DCS	2003
Provides a replica of the plant behaviour that enables operators to be familiar with the processes and their different phases such as normal start up, normal shut down, emergency shut down. LDPE Success Story