PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

OPERATOR TRAINING SIMULATOR (OTS) SYSTEM

PROJECT EXECUTION

PTS 20.00.10.38
JANUARY 2011

© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any
form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the
copyright owner.
 PTS Circular
2011-SKG16.4/PTS-001

PTS No: 20.00.10.38

PTS Title: Operator Training Simulator (OTS) System Project Execution

This new PTS 20.00.10.38 – Operator Training Simulator (OTS) System Project Execution
(January 2011, Revision 0) has been developed to ensure effective and consistent OTS System
project execution throughout PETRONAS Groupwide to ensure quality OTS system
implementation, on time delivery and as budgeted cost.
 PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,of
PETRONAS PROJECT OWNERs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based on, or
reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' PROJECT OWNERs in oil and gas production facilities, refineries, gas processing plants,
chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum
technical and economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration and decision
to implement. This is of particular importance where PTS may not cover every requirement or diversity
of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual
operating units to adapt the information set forth in PTS to their own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality
of work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will expect them to follow those design and
engineering practices which will achieve the same level of integrity as reflected in the PTS. If in doubt,
the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the
Principal or its technical advisor.

The right to use PTS rests with three categories of users:

1) PETRONAS and its affiliates.

2) Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users
referred to under 1) and 2) which requires that tenders for projects, materials supplied or -
generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users,
PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death)
suffered by any company or person whomsoever as a result of or in connection with the use,
application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this
disclaimer shall inure in all respects to PETRONAS and/or any company affiliated to PETRONAS that
may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users
to any company or person whomsoever and the PTS shall be used exclusively for the purpose they
have been provided to the user. They shall be returned after use, including any copies which shall only
be made by users with the express prior written consent of PETRONAS.

The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and
PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how
users implement this requirement.
 TABLE OF CONTENTS

1. INTRODUCTION ............................................................................................................................................... 1 
1.1 SCOPE ............................................................................................................................................................... 1 
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .............................................................. 1 
1.3 DEFINITIONS ..................................................................................................................................................... 1 
1.3.1 GENERAL DEFINITIONS .............................................................................................................................. 1 
1.3.2 ABBREVIATIONS ........................................................................................................................................ 1 
1.4 CROSS REFERENCES .......................................................................................................................................... 2 
2. INTRODUCTION TO OTS SYSTEM ...................................................................................................................... 3 
2.1 EMULATION ...................................................................................................................................................... 4 
2.2 DIRECT CONNECT/STIMULATION ...................................................................................................................... 4 
3. OTS PROJECT EXECUTION STAGES .................................................................................................................... 4 
3.1 ITB SCOPE OF WORK PREPARATION .................................................................................................................. 5 
3.2 BIDDING – TECHNO‐COMMERCIAL EVALUATION .............................................................................................. 6 
3.3 PROJECT KICK‐OFF MEETING (KOM) .................................................................................................................. 6 
3.4 FUNCTIONAL DESIGN SPECIFICATION (FDS) DEVELOPMENT AND APPROVAL .................................................... 7 
3.5 SIMULATOR DESIGN AND CONFIGURATION ...................................................................................................... 7 
3.6 MODEL ACCEPTANCE TEST ................................................................................................................................ 8 
3.7 FACTORY ACCEPTANCE TEST ............................................................................................................................. 8 
3.8 SITE ACCEPTANCE TEST ..................................................................................................................................... 9 
3.9 USER TRAINING ................................................................................................................................................. 9 
3.10 INITIAL ACCEPTANCE AND WARRANTY PERIOD ............................................................................................... 9 
3.11 FINAL ACCEPTANCE ....................................................................................................................................... 10 
REFERENCE ......................................................................................................................................................... 10 
 LIST OF FIGURES

Figure 2- 1: Emulation OTS System ............................................................................................................ 3

Figure 2- 2: Stimulation/Direct Connect OTS System .................................................................................. 3

Figure 3- 1: Emulation vs Stimulation Typical Schedule .............................................................................. 5

LIST OF TABLES

Table 2- 1: OTS Configuration Comparison ................................................................................................. 4

 PTS 20.00.10.38
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1. INTRODUCTION

1.1 SCOPE

This PTS provides guidance on the project execution of an Operator Training Simulator (OTS) System.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorized by PETRONAS, the distribution of this PTS is confined to companies forming
part of PETRONAS or managed by a Group company, and to
Contractors nominated by them.

This PTS is intended for use in oil refineries, gas plants, chemical plants, exploration and production
facilities and where applicable, supply/marketing installations. When PTSs are applied, a Management of
Change (MOC) process should be implemented. This is of particular importance when existing facilities
are to be modified.

If national and/or local regulations exist in which some of the requirements may be more stringent than in
this PTS, the Contractor shall determine by careful scrutiny which of the requirements are the more
stringent and which combination of requirements will be acceptable as regards to safety, environmental,
economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the
requirements of this PTS which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the authorities concerned with the object of obtaining
agreement to follow this PTS as closely as possible.

1.3 DEFINITIONS

1.3.1 GENERAL DEFINITIONS

The Contractor is the party that carries out all or part of the design, engineering, procurement,
construction, commissioning or management of a project or operation of a facility. The Principal may
undertake all or part of the duties of the Contractor.

The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform
the duties specified by the Contractor.

The Principal is the party that initiates the project and ultimately pays for its design and construction. The
Principal will generally specify the technical requirements. The Principal may also include an agent or
consultant authorized to act for, and on behalf of, the Principal.

The word shall indicates a requirement.

The word should indicates a recommendation.

1.3.2 ABBREVIATIONS

OTS Operator Training Simulator

DCS Distributed Control System
SOW Scope Of Work
KOM Kick-Off Meeting
FDS Functional Design Specification
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TP Technical Professional
ITB Invitation To Bid
MAT Model Acceptance Test
FAT Factory Acceptance Test
SAT Site Acceptance Test
PC Personal Computer

1.4 CROSS REFERENCES

Where cross-references to other parts of this PTS are made, the referenced section number is shown in
brackets. Other documents referenced by this PTS are listed in (4).
 PTS 20.00..10.38
Januaryy 2011
Pa
age 3

2.
2 INTRODUC
CTION TO OT
TS SYSTEM

OTS syste em is a comp puter based training system m aimed to provide

p “Live” training to th
he Panel Ope erators
and otherr operation peersonnel by replicating
r thee actual plantt dynamic behavior and DCSD interface. The
system is utilized to fa
amiliarize the panel operattors with the plant’s Startu
up and Shutdown sequencces as
well as to train the ope
erators on thee proper mitigation responsses when certain plant up psets or emerrgency
condition arises in the plant’s operating condition. Due to t increased plant stabiliity, longer ru untime
between Turnaround and the imp plementation of Advance Process Control (APC) system, the panel
operators and operatio onal personne el have lesser exposure and reduced e experience on n Plant Startu
up and
Shutdown n and more importantly, plantp upsets.. This can leadl to loss of process control
c knowledge,
improper response to plant
p condition and longer response tim me to plant upssets.

The OTS system can be

b customized d in 2 differen
nt configuratio
ons:
- Emulation
- Direct Conne
ect/Stimulation
n

Fig
gure 2- 1: Em
mulation OTS System

Figure 2- 2: Stimulation//Direct Conn

nect OTS Sys
stem
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2.1 EMULATION

Emulation configuration is where the DCS graphics and controller algorithm are emulated inside the OTS
software running in a standard PC. 95% of the DCS functionality can be emulated with the remaining 5%
non-emulated functionality which covers DCS system configuration and diagnostic tool (not crucial for
operator training). DCS graphics and controller functionalities are 100% emulated as per the actual
system.

2.2 DIRECT CONNECT/STIMULATION

Direct Connect configuration is where the OTS dynamic model engine is connected to the actual DCS
system hardware and software. The common connections utilized are via Ethernet, TCP/IP, OPC etc.
The actual DCS console (not linked to the plant control network) will function as the Operator Station while
the Instructor Station will run on the OTS PC Server. The actual DCS graphics and DCS controller
algorithm will be utilized.

The table below lists the comparison between the Emulation and Direct Connect configuration.

Table 2- 1: OTS Configuration Comparison

EMULATION DIRECT CONNECT

DCS graphics and control algorithm Actual DCS graphics and control algorithm used
emulated/replicated in OTS software
Operator Station hardware is standard PC (lower Operator Station hardware is actual DCS console
capital cost) (higher capital cost)
Dynamic model and control algorithm in the same Dynamic model and control algorithm resides in
software (easier and more stable synchronization separate software (more difficult synchronization of
of model speed (freeze, fast speed, slow speed) model speed which may lead to system
crash/hang)
Limited emulated DCS functionality (training is Full DCS functionality (training can be extended to
limited to Operation Personnel) DCS/Instrument Personnel)
OTS System easier to maintain since only involved OTS System is more difficult to maintain esp. on
PC (IT personnel is capable to maintain the system the DCS Hardware (need support from DCS
with assistance from OTS vendor) engineer)
Project duration is longer since extra time is Project duration is shorter (pending on DCS
required to develop the graphics and configure the console delivery time from DCS vendor) since
controllers graphics and controller configuration already
available.

3. OTS PROJECT EXECUTION STAGES

The OTS Project execution typically shall consist on the following items:
a) ITB Scope of Work (SOW) Preparation
b) Bidding – Techno-Commercial Evaluation
c) Project KOM
d) FDS Development and Approval
e) Simulator Design and Configuration
f) Model Acceptance Test
g) Factory Acceptance Test
h) Site Acceptance Test
i) User Training
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j) Initial Acceptance and Warranty Period
k) Final Acceptance

The duration of the project will range from 10 to 15 months depending on the plant complexity and fidelity
of the OTS system required.

Figure 3- 1: Emulation vs Stimulation Typical Schedule

3.1 ITB SCOPE OF WORK PREPARATION

PROJECT OWNER needs to develop the OTS SOW document which covers but not limited to the
following items:

1. GENERAL
a) Scope of work
b) Terminology
c) List of abbreviation
d) Extent of Supply

2. GENERAL REQUIREMENTS
a) Environmental Requirements
b) Power Supply
c) System cables
d) Diagnostic
e) Security provision

3. DOCUMENTATION
a) PROJECT OWNER documentation
b) CONTRACTOR documentation
c) Functional Design Specification
d) CONTRACTOR Drawings and Documents
e) CONTRACTOR Manuals

4. TECHNICAL SPECIFICATION
a) Introduction
b) Overview
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c) Definitions
d) Hardware
e) Software
f) Simulator Features
g) Functionality Test

5. CONTRACTOR’S SERVICE
a. Project Plan
b. Project Time Schedule
c. Test and Certifications
d. OTS Room
e. Packing
f. Training
g. Pre-Commissioning and Commissioning
h. Warranty
i. Annual Maintenance Service Contract
j. Housekeeping
k. Schedule of Price

For detail content on the ITB section, please refer to related PTS on OTS system ITB/FDS (PTS
20.00.10.39).

The draft ITB SOW shall be reviewed by GTS Process Simulation TPs before it can be issued to potential
bidders to ensure adequate technical content.

Typical Duration = 1 month

3.2 BIDDING – TECHNO-COMMERCIAL EVALUATION

During the Technical Evaluation and clarification stage, the OTS vendor Technical Proposal shall be
evaluated against the ITB SOW to determine whether the proposed OTS system meets the required
PROJECT OWNER’s specification. Execution or non-conformance to the SOW needs to be evaluated
against the overall functionality of the OTS system. It is required that PROJECT OWNER engages GTS
Process Simulation TPs to ensure the OTS technical requirement shall be fulfilled by the vendor. In
addition, GTS Process Simulation TPs shall validate the vendor’s proposed OTS software to ensure
reliable and robust system.

Typical Duration = 1 week

3.3 PROJECT KICK-OFF MEETING (KOM)

During the Project KOM, the following items must be discussed to ensure clear project execution plan:
a) Project Schedule
b) Project Milestones
c) Project Organization Structure
d) Roles and Responsibilities (PROJECT OWNER, OTS Vendor, GTS)
e) Document/Data Delivery Date
f) P&ID Markup (to determine OTS modeling scope)

It is required that PROJECT OWNER engages GTS Process Simulation TPs to ensure the OTS project
execution plan is realistic and to advise PROJECT OWNER during the P&ID Markup exercise.

Typical Duration = 1 week

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3.4 FUNCTIONAL DESIGN SPECIFICATION (FDS) DEVELOPMENT AND APPROVAL

The design of the OTS system shall be detailed out in the FDS document. The minimal content of the
FDS document is listed below:
a) Process Simulator Architecture/Functionalities
b) Hardware Configuration and Specification
c) Process Description
d) Process Model Requirement
e) PFD & P&ID List
f) Data Documentation Requirement
i. Sequence Logic
ii. Interlock Logic
iii. Complex control configuration
iv. Instrument I/O list
g) Malfunction List
h) Graphics Display Architecture/Functionalities
i) Graphics Count List
j) Trainee Evaluation System Requirement
k) Data Historian Requirement
l) Security/Access Level
m) Operating Procedures List
n) Battery Limit Condition List

For detail content on the Functional Detail Specification section, please refer to related PTS on OTS
System ITB/FDS (PTS 20.00.10.39).

This document shall be the basis for the design and configuration of the OTS system and all the
acceptance tests criteria shall be based on this document. It is required that PROJECT OWNER engages
GTS Process Simulation TPs to review and endorse the FDS document prior to PROJECT OWNER’s
approval to ensure the OTS system design shall meet the PROJECT OWNER’s intended requirement
based on the SOW document.

Typical Duration = 2 weeks – 1 month depending on system scope

3.5 SIMULATOR DESIGN AND CONFIGURATION

The following items shall be designed and configured during this stage:
a) Plantwide Steady State using iCON
b) Dynamic Models
c) Interlock System Models
d) DCS Graphic (for emulation configuration)
e) Field Operator/Local Panel Graphic
f) Malfunction Program
g) Trainee Evaluation System (if customized)

PROJECT OWNER is strongly advised to assign one full time engineer to be part of the OTS
development team to gain knowledge on the model design and system architecture. This shall be crucial
to maintain and troubleshoot the system after the Final Acceptance.

Typical Duration = 6 – 8 months depending on plant complexity and emulation/direct connect options
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3.6 MODEL ACCEPTANCE TEST

The Model Acceptance Test (MAT) shall be conducted once the dynamic models have been fully
configured. The models can either be individual models (i.e. subsystem/unit model) or integrated model
(i.e. plant wide). The main objective of the MAT is to test the dynamic response of the models vs. actual
plant behavior/expected behavior. Normally, the models shall be subjected to the Startup and Shutdown
tests as well as certain process upset/malfunction scenarios tests. Experienced panel operators are
required to ensure the models are able to replicate realistic plant dynamic response.

Models’ behavior that does not realistically match the plant’s behavior shall be listed in the MAT Punch
List items for the vendor to rectify prior to the FAT. During the MAT, certain OTS system functionalities
(e.g. safety interlock, DCS graphics, automated malfunction scenarios etc.) might still under development
and might not be able to be tested.

It is required that PROJECT OWNER engages GTS Process Simulation TPs to witness the MAT
execution and verify the MAT Punch List items and to discuss on the proposed solutions to ensure the
OTS system design shall meet the PROJECT OWNER’s intended requirement.

For detail content on the MAT section, please refer to related PTS OTS system QA/QC (PTS
20.00.10.40).

Typical Duration = 1 – 2 weeks depending on plant complexity

3.7 FACTORY ACCEPTANCE TEST

The Factory Acceptance Test (FAT) shall be conducted once all the OTS systems (as per the items in
Section E) have been fully configured. The FAT shall also test the functionality of the actual OTS system
hardware and the communication between the OTS software and hardware.

The FAT activities shall cover the following areas:

a) Initial Conditions Verification
b) Graphic Function Test (Operator, Field Operator Device, Instructor Stations)
c) Steady-State Data Verification (Integrated Model)
d) Process Dynamic Test
• Startup Test (Integrated Model)
• Shutdown Test (Integrated Model)
• Battery Limit Change Test (Integrated Model)
e) ESD/Interlock Test
f) Preconfigured Training Scenario Test

Experienced panel operators are required to ensure the models are able to replicate realistic plant
dynamic response, the graphics functions as per plant DCS and all other OTS functionalities are per the
FDS/SOW document requirement. OTS system functionality that does not meet the FDS/SOW document
specification shall be listed in the FAT Punch List items for the vendor to rectify prior to the SAT.

It is required that PROJECT OWNER engages GTS Process Simulation TPs to witness the FAT
execution and verify the FAT Punch List items and to discuss on the proposed solutions to ensure the
OTS system design shall meet the PROJECT OWNER’s intended requirement.

For detail content on the FAT section, please refer to related PTS on OTS system QA/QC (PTS
20.00.10.40).
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Typical duration = 2 weeks to 1 month depending on plant complexity

3.8 SITE ACCEPTANCE TEST

The Site Acceptance Test (SAT) serves to verify the OTS system functionality after the software and
hardware are shipped from the vendor’s facility and installed at site. In addition, all the FAT Punch List
items shall be verified for closure. If any major tests during the FAT that were not able to be completed
due to system problems, they shall be retested in SAT to ensure proper system functionality. Any items
that do not meet the FDS/ITB SOW documents requirement shall be punch listed and the vendor need to
rectify the issues during the OTS system warranty period.

For detail content on the SAT section, please refer to related PTS on OTS system on QA/QC (PTS
20.00.10.40).

Typical duration = 2 - 3 weeks depending on no. of FAT punch list items (this time also includes the
system installation and commissioning – normally 1 week)

3.9 USER TRAINING

User training on the OTS system shall be provided by the vendor to the users depending on the user level.
Normally, the trainings provided are:

a) Instructor Training – this training is to teach the instructors (normally senior panel operators)
on the system instructor functionality which includes:
i. Starting up and shutting down the OTS system
ii. Loading simulation model and initial conditions
iii. Running, accelerating and freezing the simulator
iv. Activating equipment/instrument malfunctions
v. Loading/Configuring training scenarios
vi. Saving snapshots
vii. Setting up student evaluation criteria

b) Engineer Training – this training is to teach the plant engineers (normally operation/APC
engineer or process technologist) on the dynamic model architecture, model configuration
and system setup. This is to enable the plant engineers to perform minor model modification,
troubleshoot model/system problem and perform system maintenance.

Typical duration = 1 week

3.10 INITIAL ACCEPTANCE AND WARRANTY PERIOD

Initial Acceptance shall be awarded to the OTS vendor once all the FAT punch list items have been
closed and the OTS system is functioning as per FDS/SOW documents requirement.

During the warranty period, the vendor is required to clear all the SAT punch list items as well as to rectify
any problems with the OTS system that was not captured/did not occurred during the FAT and SAT but
within the FDS/SOW documents requirement.

PROJECT OWNER is advised to thoroughly test and utilize the OTS system to ensure all “bugs” and
“defects” are detected and rectified during the warranty period.
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Typical duration = 1 year

3.11 FINAL ACCEPTANCE

At the end of the warranty period, the OTS system maintenance/rectification work shall be considered as
complete and PROJECT OWNER shall award the final acceptance to the OTS vendor. PROJECT
OWNER is advised to plan for the OTS system maintenance schedule to ensure the system is kept up to
date with the plant configuration as well as to ensure the OTS software is updated with the latest version
for improvement.

REFERENCE

1. Fabrice REY (RSI Simcon), Operator Training Simulator: Payback and Risk Mitigation, GasTech’08
2. PASB OTS Project Documentation