Watford UK, 23d March 2005. Hyperion Systems Engineering Ltd, which provides high quality custom made solutions and services to process industries worldwide, has announced the successful implementation of a Training Simulator at the Haradh Natural Gas Plant for Saudi Aramco.
Haradh Gas Plant has significant advanced control strategies with a complex ESD system, which is designed such that the plant can run as close to its maximum throughput as possible, in the safest manner. Effective implementation of an operator training system was essential to ensure a safe and smooth start-up of this major project.
In operation for over a year, the Training Simulator provides a model of the whole plant including simulated interfacing to DCS control systems and the Emergency Shut-Down (ESD) system. Hyperion specialists were responsible for the complete implementation of the Training Simulator including DCS and ESD integration, modeling of all the different areas of the plant, through to site training of the system operators. A particular achievement was the modeling of the very complex advanced control systems of the GE Mark V Steam Turbine Control System. Additional benefits during implementation were the verification of the plant start-up and shut-down procedures and the identification of the need for changes to the DCS, and other operations, as a result of the simulations.
Saleh M. AI-Ghamdi, Process Engineering Unit at Haradh Gas Plant, Saudi Aramco, said "I am very pleased by the experience that Hyperion demonstrated in implementing the Training Simulator, which contributed towards one of the smoothest and error-free start-ups ever made in Saudi Aramco. The implementation was completed 7 weeks ahead of schedule, which provided time for plenty of hands-on experience prior to the start-up and helped minimize the time to bring the plant online."
Operator Training Systems are critical to the operation of complex process plants and result in fewer operating errors and quicker and safer startups and shutdowns. They improve plant reliability due to improved response to abnormal situations, optimize throughput and product quality, and provide the basis for evaluation of control strategies. At Haradh, Saudi Aramco trained a large number of operators well in advance of the start-up of the plant, and the system continues in use for refresher training and for training new operators. It is currently being updated to reflect changes in the real plant after the start-up.