Rompetrol Rafinare has completed the implementation of the first stage of a modern operator training system at its Petromidia facility. The Operator Training Simulator was developed by a company specialising in industrial simulators, together with the internal project team consisting of process engineers and installation managers, the company said in a release.
The OTS system facilitates the development of technical skills of Distributed Control System operators, including those in training, as well as the training of process engineers, foremen and field operators.
„The integration of the OTS simulator, a state-of-the-art technical system, will allow our operators to improve and test themselves permanently, simulating scenarios they do not normally encounter in their daily activity. It is a commitment that shows responsibility towards employees, both those working in the Command and Control Center and those in the field,” declared Sorin Graure, General Manager of Rompetrol Rafinare.
The main goal of the project is for the system to become a permanent training tool, contributing to safe operations, minimizing human errors, and strengthening response abilities in critical situations.
The first simulation module was developed for the Atmospheric and Vacuum Distillation (DAV) unit, for which 1,500 measurement and control points were configured and graphically represented across 21 screens. While testing is ongoing for the DAV unit, the simulator is also being expanded to other units within the refinery, with priority given to those with a significant impact on production yields: Catalytic Cracking, Delayed Coking, and Mild Hydrocracking.
„The integration of the simulator supports new employees in training, allowing them to acquire essential knowledge of the technological process and how to respond to various deviations, without affecting the real operation of the unit. At the same time, experienced DCS operators will have the opportunity to reinforce their knowledge by simulating various scenarios: disturbances and anomalies within the unit, their management, and monitoring the process through alarms and trends,” the release states.
Additionally, the system enables testing and updating of work instructions that can improve unit operation and reduce simulated unit startup/shutdown times, as well as ensure operator readiness for daily tasks and unforeseen situations: accidental shutdowns/startups or fluctuations in technological parameters.
The simulator also includes an evaluation component, with operator testing to be conducted in phases. This will provide an overview of how operators assimilate knowledge and develop the skills required for optimal unit operation.
DCS operators play an extremely important role in the safety and efficiency of technological operations. They contribute to the optimal functioning of processes and the prevention of technical incidents, all while working in a constantly modernized and automated control center.
The project complements the company’s existing training programs and follows investments aimed at digitizing, developing, and modernizing production assets, carried out during last year’s general turnaround.
In the first half of this year, the units at Petromidia processed nearly 2.8 million tons of raw materials, resulting in 845,000 tons of gasoline and 1.44 million tons of diesel and jet fuel – marking increases of 101% and 49%, respectively, compared to the same period last year.
The main shareholders of Rompetrol Rafinare SA are KMG International (54.63% – directly and indirectly) and the Romanian state, through the Ministry of Energy (44.7%).
AGERPRES
