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Training

Training simulator: the better share of knowledge and increased safety in the chemical production site

Project title Training simulator: the better share of knowledge and increased safety in the chemical production site
User company name BP Chemicals
Industry sector Chemicals
Production process type Carbon monoxide (as part of the acetic acid process) and ammonia processes, continuous
Application area Training Simulator
Employees 2000+
Year the project started 2003
Tool(s) Aspen Virtual Plant Simulators, Aspen Plus
Vendor of the tool AspenTech
Pay-back time in months N/A
Type of simulation used
 Dynamic Continuous Modelling
Short description of the project At BP Hull site a project to create a common control environment was started. The purpose was to improve operator efficiency and flexibility as well as increase plant efficiency, safety and reliability. It was recognised that operator training and share of best operating practice would be in great help to reach these goals. Aspen Plus was used to create steady-state models and Aspen Virtual Plant Simulator to represent plants behaviour by using first principles engineering and thermodynamic relations. Simulator is also used for testing of control schemes and testing of plant modifications prior to implementation.
Soft Benefits The benefits are increased safety and environmental protection, increased reliability and savings in production. The use of simulator also reduces maintenance costs due to fewer trips and enhances recovery time from plant trips.
Public quantitative benefits For each plant simulators can save lost production due six plant trips per year and save one weeks lost production due to faster startups.
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