Operator training simulator for a

multi-product fuels pipeline

An operator training simulator for a fuel products pipeline system was
developed and delivered before the pipeline was completed to train personnel
Santosh Alladwar, Cordell Chapman, Billy Mayo, Surajit Dasgupta
and Javier Vazquez-Esparragoza KBR
Daniel Vogt Krohne Oil And Gas
Keone Jackman Petroleum Company of Trinidad and Tobago Limited

s part of a larger project to design and system that loads one liquid product immedibuild a new multi-product fuels pipeline ately behind another in a continuous, seamless
system for Trinidad and Tobago, an inno- fashion. The proper operation of the pipeline in
vative operator training simulator (OTS) was this pigless mode is ensured by a leak detection
developed that allows highly realistic training of system (LDS) and batch management system
the pipeline operators in all phases of operations (BMS) from Krohne Oil and Gas, a company
prior to actual startup of the pipeline and for specialising in metering skid solutions and
continuous training after startup. The pipeline, computational pipeline monitoring (CPM) pipeowned by a consortium of Trinidadian entities, line leak detection. The LDS and BMS were
including the Government of Trinidad and integrated into the OTS, which would be used
Tobago, the National Gas Company of Trinidad in tandem with the pipeline control system
and Tobago (NGC), the Trinidad and Tobago (PCS) and the terminal automation system
National
Petroleum
Marketing
Company (TAS) to plan, schedule and track product
(TTNPMC) and Petroleum Company of Trinidad batches, keep track of the feed and product
and Tobago (Petrotrin), is designed to deliver up tanks, as well as provide alarms and/or advice
to 36 000 b/d of multiple fuel products (gaso- to operators on abnormal conditions, and
line, diesel and aviation fuels) at peak by a continuously detect for potential pipeline leaks.
state-of-the-art automated pipeline
system roughly 47 km in length from
the islands Petrotrin West refinery to
a new distribution terminal in Caroni
County in the central part of Trinidad.
Also included in the distribution
system is a new 11 km pipeline to
deliver aviation fuel from the Caroni
terminal to Trinidads Piarco Airport
(see Figure 1).
The pipeline system is being built
to ensure secure and on-time delivery of fuel products to key points on
the island, which otherwise relies on
delivery by trucks. To ensure the
quickest delivery times, the pipeline
also employs a new pigless delivery Figure 1 Pipeline path on Trinidad and Tobago map

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PTQ Q1 2013 1

Dedicated Engineering Server

hosting both the Pipeline &
Terminal SCADA databases

All hardware connected

through Ethernet switch

Printer

Ethernet Switch (LAN)

Engineering and App Station

BMS Simulation connection to OTS

through OPC link

(I-Station)
Simulation PC & Instructor
Station
Dynamic model of Tanks and pipeline
Simulates all physical equipment and
instruments
Includes malfunctions & training
scenarios
Session initialization control logic &
files

Internet Gateway
Switch

Operator Trainee Console

Leak Detection and
Batch Tracking Console
(BMS/LDS)

Displays all controls graphics

and operator displays

Figure 2 Architecture of the operator training simulator

As some of these systems are new and to some

extent custom built for this project, it was
agreed and planned in advance to have an OTS
to aid in the rapid familiarisation and training
of operations personnel.

Process overview

The batch of refined products from Petrotrin

West Refinery storage tanks consisting of
unleaded RON92 gasoline, unleaded RON95
gasoline, diesel and Jet A-1 fuel will be metered
and transferred by pipeline pump using individual booster pumps for each product.
The preliminary batch sequence would be as
follows:
Jet A-1 Diesel RON 92 RON 95 RON 92 Jet A-1

This batch sequence will be transferred to the

Caroni facility, the distribution centre, using a
pipeline pump via an 8in multi-fuels pipeline.
Before transferring to the Caroni facilitys storage tanks, all the fuels will be metered at a
metering skid entering the pipeline. The meter
will be used to control the mainline pumps,
while the tank gauging systems will be used for
custody transfer. The general operation is
designed to run with no pigs; however, an additional pig launcher was built to launch an

2 PTQ Q1 2013

intelligent/batch pig in cases when this operation was needed.

As soon as a batch arrives at the Caroni facility, it will be diverted to the appropriate
destination tank by the operator based on the
interface detection. For batch interface detection, density is the primary parameter used. Two
densitometers are used to detect the interface of
the multi-fuels. The first interface detector is
installed 4.4 km from the Caroni facility to alert
the operator about the product coming in the
pipeline. The operator may use a second interface detector, located at the Caroni centre, to
decide the correct time to switch valves to transfer the product into an appropriate tank.
The liquid fuels interface is one of the most
important parameters to measure at the Caroni
facility in order to transfer the product into an
appropriate tank. When the multi-fuels are
transferred using one pipeline, an interface
mixture is generated. The interface mixture/
off-spec product can be diverted to slop tanks
or to the lower-quality product tank. Two slop
tanks are provided to accommodate the interface a high flash slop tank and a low flash
slop tank. The interface/off-spec product from
the slop tanks is trucked back to the Petrotrin
West refinery for reprocessing.
Fuel from the individual storage tanks is

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Figure 3 Model development screen

transferred to (truck) loading bays using individual transfer pumps for each product.
For the batch control of two grades of gasoline RON 92 gasoline and RON 95 gasoline
their physical properties would be too close
to reliably differentiate the products based on
density alone. Optical interface detectors
(OIDs) are also installed near to the densitometers. The two gasoline grades are dyed for
taxation purposes, resulting in distinct
optical signatures (primarily colour), which the
OID can distinguish and signal to the operator.
Additionally, the flow meter count could be
utilised to guide the operator
An additional dedicated pipeline 8in diameter
and 11.2 km length is installed to transfer the Jet
A-1 from Caroni to the Piarco facility. There are
two isolation valves installed on the pipeline
because of a river crossing, one valve at each
side of the river. A 600-gallon-per-minute
capacity pump can deliver jet fuel from the
Caroni distribution centre to Piarco Airport.

Simulator development
The OTS was designed and delivered by KBRs
Advanced Chemical Engineering group with

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support from the Pipeline and Operations

groups. Overall, the OTS consists of four
components:
A custom dynamic model of the pipeline
system (resembling actual pipeline operation)
and an instructor station to train the operator,
with various features such as operating training
on field devices. The safety instrumented system
(SIS) logic was also implemented in the model.
The SIS hardware/software was not replicated
because it was possible to model its functionality
with the pipeline software. A portion of the pipeline system, the TAS, handling loading on
logistics operations, was not included in the OTS
system. Only some of the main operations
screens were simulated
A BMS and LDS identical to the real pipelines
BMS and LDS systems
A dedicated Emerson DeltaV distributed
control system (DCS) identical to the real pipelines DCS
DeltaV Operator consoles identical to the
actual pipelines consoles.
These OTS components are interfaced through
a standalone local area Ethernet network using
industry-standard OLE for Process Control

PTQ Q1 2013 3

Figure 4 Instructor graphics showing feed and product tanks

(OPC) protocol for communications. Figure 2

shows the architecture of the OTS.
The OTS also includes auxiliary equipment to
ensure the proper working of the integrated
system as a standalone OTS. As such, the OTS
had no physical connections to actual pipelines
PCS or other pipeline systems.

Software
On reviewing the details of the process and
requirements for the modelling of various
process upsets, it was decided to use the Stoner
Pipeline Simulator from GL Noble Denton to
provide the required rigour and accuracy for the
pipeline model.
The Instructor graphics were developed using
Iconics Genesis32 that comes with the Stoner
software.
The BMS, was developed by Krohne Oil and
Gas, and it is used to manage and track the
batching operations. It was fully integrated with
Krohnes LDS, PipePatrol, used for the detection
of leaks along the length of the pipeline.
A dedicated Emerson DeltaV DCS identical to
the actual pipeline Delta V hardware with the
complete PCS and TAS database provides a
highly realistic training environment.

Actual pipeline and associated equipment

modelling
The model included all physical equipment
(pipes, valves, pumps, and so on) in the pipeline
from the feed tanks to final destination tanks
and includes complexities such as truck loading

4 PTQ Q1 2013

racks and loaders. In addition to the physical

equipment available in the software library,
programming was done to define operation of
special equipment like Yarway valves, truck
loading, pig status, and so on. The model also
included the complete safety instrument system
logic resembling the actual SIS system. Figure 3
shows a screen capture of a Stoner Pipeline
Software (SPS) scheme.

Instructor station
Overall control of the OTS is through a special
graphical display system called the instructor
interface, which provides such functionality as
the run/pause of the simulation, load/save of
initial conditions, touch points for failing critical
equipment, and standardised scenarios for operator training. Figure 4 shows a screen capture of
the Instructor interface.

Leak detection and batch tracking management

system
The Krohne leak detection and batch tracking/
management system functionalities are intended
to manage the batching process, to track the
current position of a batch in the pipeline and to
schedule the next batch. Also, operators can be
informed of the likely location of a leak in the
pipeline if it occurs.
Krohne was required to create and test two new
functionalities for the BMS pause/start and
speed-up/slow-down in order to complete the
communication and integration of the OTS
system. Many rounds of further testing had to be

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Figure 5 Batch management system typical display

done to ensure proper two-way communication

between the BMS and the DCS. Figure 5 shows a
screen capture of the batch management system.
Figure 6 shows a screen detail of the status of
pipeline batches and alarms.
The LDS is a real-time transient model
(RTTM) type. It has special parameters that
determine its sensitivity during pumping and
standstill conditions. Also, the parameters that
detect a creeping leak can be set in the system.
A creeping leak is a leak that does not cause
significant pressure drops or pressure waves.
For false alarm-free operation, these parameters have been fine-tuned based on recorded
data to find the best compromise between minimum detectable leak rate and detection time.
Next to the leak detection, which determines
the volume of a leak, this system has two different algorithms based on pipeline pressure and
flow to determine the leaks location.

Modelling and integration

The overall modelling effort for the OTS was

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rigorous and detailed to include the complexity

of the modelling of some equipment, such as the
Yarway valves downstream of the pumps and, in
particular, the prover circuits, the implementation of the logics, the interlock system and the
communications among the OTS components.
Some new functionality and custom features
had to be incorporated into the SPS software in
order to properly implement OTS functionality,
such as pause/resume and save/restore, which
had to be transferred to the DCS and the instructor interface systems. In order to save a run or a
file for the initial condition of a scenario, the
OTS system saves a file in the DeltaV system and
a file in the simulation system simultaneously,
and both files are loaded at the same time when
the instructor restores a saved run. The BMS is a
real-time system that was originally not intended
to perform as an OTS, but the feature of pausing
and restoring the simulation was added successfully; pausing of the signal to the BMS is
available via OPC command but not necessary
because the flow totaliser automatically stops

PTQ Q1 2013 5

Warnings, if valve
switches are due soon

Warnings, if any tank

combination is
inconsistent

Warnings, if tank levels

are off (high and low)
Warnings due to
redundancy state

LDS warnings
Currently
logged-on operator

Figure 6 Overview screen of pipeline, batches and alarm status

counting in the pause mode of

the Stoner simulator.
The DCS database is complex.
Many extra logic points were
required to be developed in the
simulation and connected to
model variables to allow a
complete range of operator
actions from the DCS. The
DeltaV system is capable of
working in simulation mode
when it is not connected to the
real and physical system.
Figure 7 shows a distance plot
of both of the pipelines, from
Petrotrin Refinery to Caroni
Distribution Centre, and from
Caroni to Piarco Airport.
Reverse flow operation had to
be defined and configured
within the operator training
system. This operation occurs
when a substantial amount of

Figure 7 Pipeline distance plot, from the simulation program and displayed on the Instructor station

6 PTQ Q1 2013

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off-spec product is not

accepted at the distribution
Server
Server
Client
centre and has to be sent back
StOPC
DeltaV
OPCMirror
SPS
Stoner
Iconics
graphics
Engineering Station
to the refinery via the pipeSimulation
display
PSC
line. This procedure is a
StOPC
OPCMirror
manual
operation
and
Client
consists of opening a set of
StOPC
DeltaV LAN
OPCMirror
Iconics graphics
display
valves, in the right sequence
Client
and at the right time, from
Client
Krohne
the tank with the off-spec fuel
DeltaV
BMS
to the reverse flow pipeline at
Client
Operator Station
LDS
PCS
Iconics graphics
OPC link
the Caroni Centre. Then,
display
PP_server
operators have to start the
dedicated reverse pump and
PCS Engineering Station system is an OPC server.
continue with the opening of
Stoner Simulation is an OPC server.
PCS DeltaV Operator Station is an OPC client.
the downstream valves to
BMS/LDS system is an OPC client.
direct the flow to the main
Each Iconics graphic instance is an OPC client.
pipeline and let the rejected
OPCMirror is a DeltaV OPC communication tool.
StOPC is a SPS OPC communication tool.
product travel in reverse
motion to the refinery.
Training for this operation Figure 8 Software/OPC communications
procedure
is
important
because it will be done very seldom at the actual interface and the BMS to be able to engineer a
pipeline facilities; therefore, the only means by fully working system.
which the operators can be trained for this evenFigure 8 shows the general OPC connectivity
tuality is the OTS system. By doing this, the architecture within the OPC system components.
operator will be ready when a reverse operation
is needed in the real pipeline.
Operations support
A particular limitation of the model was the Additional support was required from the
OID, which was modelled as though it is driven Commissioning and Startup Services group of
by density due to the absence of an optical char- KBR and the client operations personnel to help
acteristic model in the software.
define and test the training scenarios and to
define the details of the standard operation
Communication using OPC
procedures. In order to have detailed procedures
connectivity
on the standard operations of the pipeline, batch
OPC Mirror, a server-to-server/client communi- startup, batch changing, batch receiving, intercation software utility from the DCS vendor, was face disposal and so on, client personnel and
used to connect OPC servers (pipeline model to KBR Commissioning and Startup Services
DCS and BMS/LDS) on the OTS system and to personnel had several meetings defining and
enable two-way data communication from one simulating the procedures and the exercises to
system to another. In the OTS, the linkage was prepare the training program for the operators.
between the DCS, OPC server and the Instructor Some of those procedures were also taken as
server, StOPC. Additionally, the Instructor server exercises for the final site acceptance test of the
and the Iconics graphics interface communicate system.
with the simulation model variables. The OPC
communication was server-server between the Training
DCS and the Iconics graphical interface, as a Table 1 shows a set of the different scenarios that
client-server between Iconics graphics and the were prepared for training the trainer initially
simulation model, and as a client-server between and for further training of operators. Some of
the OPC mirror and BMS system. The develop- them are related to the OTS as an integrated
ment team had to go through additional system tool and others are related to operations
technical development on the DCS, the graphical procedures.

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PTQ Q1 2013 7

Scenarios for training operators

Scenario
Speed up the OTS

Description
Batching speed is increased for
training purposes

Modelling preparation
Speed factor is increased and then
decreased

Process results
Batches will travel faster through the pipeline

Downstream valve A valve fails closed

A selected valve is closed
failure

Upstream pressure will increase until valve is fixed

and open again (or interlock system works against
the failure)

Truck loading



Leak scenario

The amount of liquid requested is delivered in the

determined time

A RON95 truck is requesting a

certain volume of product at
loading rack

A valve in the model at the loading

racks for RON95 will open and release
the amount of fluid requested

A leak in the pipeline section

A leak flow is defined in that section
between PaP and Caroni will occur of pipeline

The material flow through the pipeline will

decrease and the LDS will create an alarm

Filter swap
A jet fuel filter is plugged
Jet fuel filter E206A is plugged, causing Upstream pressure will increase and material flow

upstream pressure to increase
amount will decrease until the operator switches
to

E206B filter
Equipment and
instrument failure

Densitometer, tank level or

other equipment show a failure

Selected equipment fails and stops

communications with PCS

RON 92 gasoline
batching

Batching of RON92 from

refinery to Caroni performed
as per procedures document and
BMS guide

Prepare and start a RON95 batch,

A Batch of RON95 is dispatched to the Caroni
including starting of auxiliary and main Centre
pumps and opening of corresponding
valves

Batching Jet A-1 to Batching of Jet A-1 from Caroni

Piarco Airport
to Piarco performed as per

procedures document
Receiving RON95

PCS will not receive the selected equipment signal

Prepare and start a jet fuel batch,

A batch of jet fuel is dispatched to the airport tanks
including starting of auxiliary and main
pumps and opening of corresponding valves

Receiving a batch of RON95 at

Prepare tank and valves at Caroni Centre A batch of RON95 is received, metered and directed
Caroni performed as per
for receiving a batch of RON95
to the RON95 tank at the Caroni Centre, BMS
procedures document and BMS
system is used to determine the time to manage
guide
valves and pipeline interface

Table 1

Benefits
While the primary purpose of the OTS is operator training, several benefits accrued to the
project as a result of the early development of
the simulator. It was also beneficial to project
staff who came to the project late as a conceptual tool in understanding the scope and
objectives of the pipeline system.
One of the key benefits was that it was possible to completely check the designs of both the
DCS and BMS systems prior to actual implementation. Several missing details and incomplete
functions were found and corrected, particularly
those relating to the travelling and volume of the
interface along the length of the pipeline and its
properties shown on the systems in real time;
for instance, the distance from the pumps and
length of the interface between two consecutive
batches.
Further, it provided an invaluable platform for
completely testing and validating the operating

8 PTQ Q1 2013

procedures for the pipeline. It was possible for

KBR operations and training experts to run
through each procedure many times to ensure
that all aspects were thoroughly tested. As part
of the testing process, NGC has also already
reaped significant benefits through early familiarisation and training of their operations
supervisors.
By using the OTS in a repeated fashion, it is
envisaged that operators will quickly become
familiar with and learn how to control daily
activities in the pipeline, such as starting a
batch of a specified product, modifying batches,
receiving a batch at the distribution centre,
performing operations such as starting and
shutting down the pipeline system, and
responding to upsets. The company plans to
complete this OTS-based training before the
actual startup of the pipeline so that operators
are completely familiarised with actual operations well in advance.

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Conclusion
This was the first integrated OTS system for
pipeline operations developed by KBR. Close
working relationships between various groups
and support from the client were critical to the
successful completion of the OTS. Acceptance by
the client has been high based on early assessment. Experience showed that such pipeline
systems can derive significant benefit from a
BMS and LDS as standard equipment.
The authors wish to thank the following for their help in developing
the OTS: Ernest Williams, Kendal Lindsay, Terrence N Ramsundar
and Vishard Birusingh of the National Gas Company of Trinidad
and Tobago, Ian Ramoutar of Trinidad and Tobago National
Petroleum Marketing Company Limited, Reiner Jorewitz of Krohne
Oil and Gas, Travis Stripling, David Smith, Celine Thomerson
and David H. Jones of KBR. The technical support from GL Noble
Denton is also appreciated.
Santosh Alladwar is a Senior Technical Professional with KBR
Technology in New Delhi, India. He has seven years experience
in petrochemical, refining and olefins technologies, and holds
bachelors and masters degrees in chemical engineering.
Cordell Chapman was the Engineering Manager with KBR for the
design of the liquid fuels pipeline and terminal facilities, and
wrote the performance specification for the real-time surveillance
software and supervised its development and testing. He holds
a BS in geological engineering from Colorado Mines and a MS in
engineering management from University of Alaska-Anchorage.
Billy Mayo has worked for KBR for 36 years in maintenance and
construction for petrochemical, plastics and speciality chemical

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facilities. For the last five years he has worked in the KBR
Commissioning and Start-up Service group, preparing operating
and maintenance manuals for a variety of projects.
Surajit Dasgupta is the Senior Technology Manager for Advanced
Simulation Applications & Services in KBR and was the Technical
Manager for this OTS. He has almost 35 years experience in
advanced simulation techniques and applications.
Javier Vazquez-Esparragoza is an Engineer in the Advanced
Chemical Engineering group at KBR. He is a registered professional
engineer in Texas, has worked in Process Automation for the last
17 years, and holds a PhD in chemical engineering from Texas
A&M University.
Daniel Vogt works for Krohne in Duisburg, Germany, on leak
detection systems and supervised the development of real-time
surveillance software for this project. He graduated from the
University of Applied Sciences in Gelsenkirchen with a Dipl.Ing.
(FH) EE and MScMT.
Keone Jackman is a Senior Engineer with Petroleum Company of
Trinidad and Tobago. He is a Registered Electrical Engineer with
more than 12 years experience in instrumentation and control
systems, is a Senior Member of the International Society of
Automation (ISA) and former President, former Webmaster and
Executive of the San Fernando, ISA Trinidad Section.

LINKS
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