Dynamic process simulation system saved money for plant start-up

A petrochemical complex under SINOPEC in east China built a styrene unit and an aromatics unit. The processes with many control variables were very complicated, especially for the mixed phase styrene reactor, which was firstly used in the country. In this case how to train the operators to familiarize the processes, master their features and skillfully operate DCS before factory starting-up was very essential. In collaboration with the factory people, HKD developed training simulators for the two units, which were deployed in site a few weeks before the units going into operation. The use of simulators to train the operators made the factory start-up very successful and made a contribution to saving money for the factory.
According to the factory's statistic, the use of simulators saved factory's actual expenses for plant start-up training, DCS training and other training about $123,457. However, It is of significance that the use of simulators enable the factory people to gain the knowledge for plant operation and for unpredicted or unscheduled shut down, which could retrieve a loss of $2,407,000. The simulation system was awarded the SINOPEC technology certificate.

Dynamic Simulation System Used For Plant Operation

HKD developed a PTA (350MT/y) simulation system and a monitoring system on GPDMS platform for a petrochemical plant under SINOPEC. The dynamic simulation system was used for training recruited and old operators in normal and abnormal/malfunction conditions, and also used for DCS control system design and startup procedure checking.
The use of simulation system and the monitoring system significantly gained profit for the plant.
The operation experience gained by using simulators avoided a lot of abnormal shutdown. The decrease in one hour of unscheduled shut down could retrieve a loss of $29,400.

Dynamic Simulation System Used For DCS System Design Checking And Startup Procedure Study

A petrochemical complex under SINOPEC applied the simulation system developed by HKD to its ethylene unit revamp. The simulation system was successfully used for:

• Control system checking and testing: Engineers of the plant found some problems in compressor system, interlock loop and control loop by using the simulation system, and solved them before startup, so as to reduced risk as the plant went into operation.
• Checking new operation procedure: The simulation system played important role in verifying the interlock scheme, designing startup procedure.
• Training operators: The plant used the dynamic simulation system to train 106 operators in the new ethylene process, startup/shutdown procedures, DCS interface, interlock, etc.