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Dynamic Simulation :

Project and ApplicationSuccesses

Stan Hamilton Howard Jemison,

PhDOperations Trainer OTS ConsultantOPTI Upgrader Team IPS Houston

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Introduction

OPTI Canada Long Lake Upgrader Project

Processes diluted bitumen (Dilbit) from NEXENs SAGD oil sandsproduction

Produces high quality synthetic crude

(39oAPI 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 PROCESSIn the SAGO process. the upper weIJs/eilm 1n1O he deposl..t.ere h.;ses through the oil sands and healS thetlitumen .The hea ted bi tumen /lows withthe eon

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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 CanadaTraining System Architecture

SIM4ME TCP/IP network

DeltaV Control Network

VIRTUALCONTROLSDeltaVSimulatePro)

OPERATORMONITORS

INSTRUCTOR STATION Operator Consolefor Instructor

Printer

contains trainer toolsand remote functions)SIMULATIONCOMPUTERS

contains controldatabases andgraphics)

contains processmodels)

SIMULATOR ROOM COMPUTER RACK

DeltaVWorkstationsASNs 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 ofSimulation 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 verylittle related experience

Process Engineers have also spent time on theSimulator 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 successionplanning for Trainers

System kept current with process and controlschanges

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!!!