Invensys Process Systems ( won an operator training system contract by PetroChina Dushanzi Petrochemical Company ( The implementation will provide a SimSci-Esscor operator training simulator (OTS) for the chemical section of the company”s integrated refinery and chemical revamping project, which will process imported sour crude from Kazakhstan.

The contract includes the design, outfit, installation and tuning, and acceptance check of the software/hardware platform for the simulation system. The scope includes process modeling of the six chemical section units (ethylene, styrene, high density polyethylene, polypropylene, polystyrene and styrene-butadiene rubber/SBS), along with integration with emulators for the distributed control system, safety instrumented systems (SIS) and PLCs. Related engineering services, such as technical training and support, are also included in the contract.

The operator training system (OTS) implementation employs the DYNSIM process simulation solution (, for high-fidelity plant modeling in dynamic and steady states. These models are used to train control room and equipment operators and supervisors on the characteristics and interactions of plant”s systems. The simulation network also includes the TRISIM Plus solution for replicating the control logic in the Triconex ( safety instrumented systems. In addition, Invensys will also provide a control system human machine interface (HMI) emulation and checkout for a Yokogawa DCS at the plant.

By using the SimSci-Esscor OTS system, PetroChina Dushanzi is expected to be able to:
• Enhance the knowledge and competency of the operator
• Reduce the startup time and shutdown period
• Improve quality by reducing off-spec product
• Improve safety and extend actual safety run-time of equipment
• Minimize environmental risk

Besides being used for operator training, the OTS system is expected to help improve process design, control system checkout, DCS configuration and tuning, diagnosis, startup and shut down, and operation optimization. It also incorporates the Trainee Performance Monitor tool, which is expected to allow PetroChina Dushanzi to regularly check and evaluate trainee performance.