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SS S&T-11 A ExxonMobil Rotterdam Refinery Dynamic Simulations Overview

Sept 26, 2014

Mos, Henk Jan

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Introduction Refinery DYNSIM models Rotterdam Refinery Simulator Room DYNSIM Operator Training Simulator (OTS) training DYNSIM OTS exercises DYNSIM OTS experiences DYNSIM usage by Engineering Value provided by Dynamic Simulation Question?

Agenda

Introduction

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Introduction About me : • 33 years in service for ExxonMobil. • 20 years experience in Operations as a process-operator,

console operator and team-leader • Switched to Technical department as an unit engineer,

application engineer and last 5 years Simulation Coordinator maintaining DCS database and keeping models up-to-date / improving current models

Refinery: • Initial start-up in 1959 • Major expansion in mid 80’s

Refinery Configuration

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• Refinery Onsites is divided in 5 “consoles”

• A Console team has 7 members : 2 console / board operators, 4 unit operators and a teamleader.

• The board /console is operated by 1 Console Operator on duty

• All 5 Onsites Console Operators in 1 control room

• 5 Shifts, 5 Consoles : 50 + Console operators

• 85% of the units have a DYNSIM OTS

Refinery Configuration

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Rotterdam Refinery Control Room

DYNSIM OTS models

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DYNSIM models

• Currently running on DYNSIM 4.5.5, Windows Server 2003

• 6 separate models, some share hardware

• Atmospheric Pipestill, Vacuum Pipestill and HydroTreaters 2 DYNSIM servers, 7 engines 1453 analog IO’s 345 digital IO’s

• Flexicoker 2 DYNSIM servers, 6 engines 891 analog IO’s 1150 digital IO’s ( including complete SafeGuarding system )

• PowerFormer, HydrogenPlant & Refinery Treatgas system 2 DYNSIM servers, 6 engines 1136 analog IO’s 1387 digital IO’s ( including complete SafeGuarding system )

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DYNSIM models ( cont. )

• Utilities ( Refinery wide steam and fuelgas systems ) 1 DYNSIM servers, 2 engines 580 analog IO’s 303 digital IO’s

• Hydrocracker 1 DYNSIM servers, 4 engines 791 analog IO’s 535 digital IO’s

• Sulphur block ( Sulphur Plants, Gastreating units ) 2 DYNSIM servers, 6 engines 902 analog IO’s 466 digital IO’s

• Chemicals : 3 simulator models

DYNSIM OTS training

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Rotterdam Refinery Simulator Room

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• Console Operator Training Simulator :

DCS automation

• Advanced Model Based Control and optimization. • SafePark applications ( Automated SlowDown or Shutdown application )

Much improved / reliable operation of units

DYNSIM OTS training

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• Tailor-made exercises depending on level of experience • Field Operators:

• Show unit operators how unit works and operates

• New console operators Starts with simple exercises like cutpoint change of 5 deg C and see what happens

incl. the use of TPM and standard scenario’s Builds up to Equipment trips / malfunctions, instrument malfunction and emergency

shutdown.

• “Experienced” console operators More complicated exercises like Emergency Shutdowns, Shut-Down and Start-up, Equipment trips / malfunctions, Instrument malfunction based on real plant experiences

• Training is led by instructor ( PowerUser = Experienced Console Operator )

• Every console has 2 PowerUsers and are trained DYNSIM trainers

DYNSIM OTS exercises

DYNSIM OTS experiences

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Examples : • Refluxpump trip on a Debutanizer:

Invensys vs. 100+ years Process incl. Technical experience Workaround installed Until analyzing real event of the same Reflux pump trip Workaround removed

DYNSIM OTS experiences

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DYNSIM OTS experiences ( cont. )

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Examples : • ShutDown & StartUp training prior to Turn around First ShutDown / TA for a number of Trainees Trained for several days on simulator Performed fully confident a successful ShutDown.

• ShutDown procedure on a GastreatingPlant changed after a more

effective procedure was tested on simulator. More effective means a quicker way to get the unit empty and “sweet”.

• SafePark training prior to implementing No alternative.

DYNSIM OTS experiences ( cont. )

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Unit / Contact Engineer: Lot of opportunity for engineering use of simulator – still need to mature

work process Developing & Checking Design Specs Problem solving / Unit troubleshooting Reproduce an upset and improve the requested console operator

response and train the operator on that improvement Energy conservation studies , heat integration studies Check if vessels ( drums ) can be re-used after a big unit throughput

increase by 30% Training of new unit / contact engineer …………

Application Engineer : Development and testing / tuning of new ( complex ) applications like

SafePark Development and testing / tuning of new ( project ) control loops before

completion / turn over. Training of new application engineer …….

DYNSIM usage by Engineering

Value provided by DYNSIM OTS

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Value Provided by Dynamic Simulation

• Value Provided by Dynamic Simulation Accelerated development of training Console Operators Flawless execution of startup and shutdown procedures. Better handling of non-routine or abnormal operations (e.g., fewer/shorter

upsets) Optimization by increasing operator confidence to operate closer to

constraints Offline studies for unit optimization, safety/reliability/feasibility studies,

controls strategies, new application testing & training Provides excellent initial assignment for newer engineers

+ Broad process, control, and operations experience

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Questions?

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