Meylan, June 2017 – Atlantic Methanol Production Company LLC (AMPCO) selected RSI to provide the high fidelity Operator Training Simulator (OTS) for its world scale methanol production facility.
AMPCO operates one of the largest and lowest cost methanol plants in the world. Located on Bioko Island in Equatorial Guinea, West Africa, AMPCO has been producing IMPCA-spec methanol since 2001. Owned by Marathon Oil Corporation, Noble Energy, Inc. and SONAGAS, the National Gas Company of Equatorial Guinea, AMPCO produces approximately one million metric tons per year, about 1% of the global market.
The operations group at the AMPCO facility instituted a training program for Equatorial Guinean operators, certifying each individual in working on the Distributed Control System (DCS) as a Control Room (Board) Operator.
To be successful, AMPCO’s training program required the design and implementation of an Operator Training Simulator (OTS) for operating staff working on the DCS as well as continuous training for plant scenarios including emergency response, start up and shutdown.
RSI’s turn-key responsibilities for the OTS project included:
- Delivery of instructor station and IndissPlus® simulation software maintenance license
- Delivery of DeltaV Operator Station (OSN), DeltaV Simulate Professional Plus (PPN) and DeltaV Application (ASN) Stations
- Development of IndissPlus first-principle high-fidelity dynamic process model of the steam reforming and methanol synthesis including
- Natural Gas Receiving, Compression & Desulphurisation
- Pre-reformer, Primary Reformer, Waste Heat Recovery & Reformed Gas Cooling
- Syngas Compression, Synthesis Loop, Methanol Reactor & Methanol Separation
- Topping and Refining Columns, Crude Tank & Purge Gas Loop
- Deaerator, Boiler Feed Water, Steam System & Fuel Gas System
- Development of preconfigured plant specific training scenarios
- Integration of the process model with Emerson DeltaV control system using Simulate Pro
- Commissioning and installation of OTS system at site in Equatorial Guinea
- Process model maintenance training and instructor training courses at site
Vanessa Poyer-Dipnarine (Senior Process Engineer & Interim Technical Manager):
The system was initially installed and handed over to AMPCO in September 2016. The model and simulation interface are a good training mimic of the plant operation. The system has been utilized regularly for the past year by the Operations team for refresher training of senior board operators and for the development of the Equatorial Guinean operators.