(104v) Using Simulators to Teach Process Safety and Operations At Petroplus Coryton

Operators jobs are complex and well trained operators are directly related to safe and efficient plant operations.  This work describes Petroplus Cortyon’s efforts to enhance process safety and operations training using simulator technology in a structured classroom environment. The Cortyon refinery site was an early simulator user, and has used a variety of simulators over the past 40 years.  This current training effort using Simulators was driven by a variety of HSE and Operations factors and included substantial union input in the objectives of the course, the course delivery, and the wide ranging operator assessment at the conclusion of the course.  The specific software tools being used include simulations of a heat exchanger and distillation column. Simulation Solutions’ 5 step comprehensive training process called INSTO is being used by small groups of 6-8 trainees in a combination of instructor and trainee led 2 day course where Operators are presented with a series of exercises that cover the following aspects of plant safety and operations:  I – Identification, N – Normal Operations, S – Start-up and Shut-down, T – Troubleshooting, and O – Optimization.  Many exercises involve the trainee making written predictions as to how the heat exchanger and distillation tower work and then trying to validate these predictions through the operation of the simulator.  A great deal of classroom time is spent discussing plant safety and operations.   The heat exchanger and distillation modules are accompanied by a "virtual reality" outside operator view in which the students can locate, monitor, and operate various field devices such hand valves, block valve, pumps, etc. This presentation will focus on our classroom methods, operator assessment, and some of the preliminary feedback from the trainees and local management.