Rompetrol Rafinare has completed the first stage in implementing a modern training system for operators at Petromidia – OTS (Operator Training Simulator), developed by a company specialized in industrial simulators, in collaboration with the internal project team made up of process engineers and unit supervisors.
The OTS system facilitates the development of technical skills for DCS (Distributed Control System) operators, including trainees, as well as the training of process engineers, foremen, and field operators.
“One of our strategic directions is ensuring operational efficiency under the strictest safety and occupational health conditions. Integrating the OTS simulator, a state-of-the-art technical system, will allow our operators to continuously improve and test themselves by simulating scenarios they don’t normally encounter in day-to-day activities. This is a commitment that shows responsibility toward employees, both those working in the Command and Control Center and those in the field”, said Sorin Graure, General Manager of Rompetrol Rafinare.
The main goal of the project is for the system to become a permanent training tool, contributing to safe operations, minimizing human errors, and strengthening response abilities in critical situations.
The first simulation module was developed for the Atmospheric and Vacuum Distillation (DAV) unit, for which 1,500 measurement and control points were configured and graphically represented across 21 screens. While testing is ongoing for the DAV unit, the simulator is also being expanded to other units within the refinery, with priority given to those with a significant impact on production yields: Catalytic Cracking, Delayed Coking, and Mild Hydrocracking.
The integration of the simulator supports new employees in training, allowing them to acquire essential knowledge of the technological process and how to respond to various deviations, without affecting the real operation of the unit. At the same time, experienced DCS operators will have the opportunity to reinforce their knowledge by simulating various scenarios: disturbances and anomalies within the unit, their management, and monitoring the process through alarms and trends.
Additionally, the system enables testing and updating of work instructions that can improve unit operation and reduce simulated unit startup/shutdown times, as well as ensure operator readiness for daily tasks and unforeseen situations: accidental shutdowns/startups or fluctuations in technological parameters.
The simulator also includes an evaluation component, with operator testing to be conducted in phases. This will provide an overview of how operators assimilate knowledge and develop the skills required for optimal unit operation.
In the first half of this year, the units at Petromidia processed nearly 2.8 million tons of raw materials, resulting in 845,000 tons of gasoline and 1.44 million tons of diesel and jet fuel – marking increases of 101% and 49%, respectively, compared to the same period last year.
The main shareholders of Rompetrol Rafinare SA are KMG International (54.63% – directly and indirectly) and the Romanian State, through the Ministry of Energy (44.7%).