Refinery HCU Train II OTS

Client: Honeywell 

Location: Thailand 

Thaioil Group operates an oil refinery located near Laem Chabang Port in Sriracha, Chonburi. As part of an expansion of the hydrocracker units (HCU), Honeywell were engaged as a vendor to upgrade the refinery DCS.

Part of the Honeywell scope was to build a complete Operator Training Simulator (OTS) as a training package. This involved transitioning from the existing legacy OTS (Shadow Plant) to UniSim.

The Lima Complex in the Offshore West Java area was experiencing subsidence issues, resulting in a significant reduction in the safe air gap clearance of the platforms relative to sea level. The extent of the subsidence on the Lima Complex had become a safety issue for operations and consequently, a permanent long term solution was established by raising the most critical platforms and facilities and ensure continued safe operations of the Lima Complex for the next 15 years. 

A simultaneous Deck Raising System was implemented to raise the Lima Compression (LCOM), Lima Services (LSER) and Lima Process (LPRO) Platforms as well as the associated bridges and flare by 4 (four) meters. 

Synergy's Scope of Work

Synergy were commissioned by Honeywell to produce the Operator Training Simulator (OTS) for the new HCU Train, as well as to generate the training scenarios and test the system in the field.

The OTS was built in UniSim and included the proprietary processes (e.g. hydrotreater, reaction kinetics) from the technology vendor (Honeywell UOP).

The work scope was executed in Indonesia, Singapore and Thailand.

Key Project Achievements

  1. Developed the operator training simulator for the new HCU train process down to 3% accuracy. 
  2. Integrated the OTS with spare DCS hardware and compressor control systems and field tested the complete system.