Preparing Petrochemical Operations Through Advanced Simulation


Emulated (Early-OTS) and Hybrid OTS – new Isopropyl Alcohol plant

Preparing operators for a new industrial facility requires a thorough understanding of its processes, control systems and operational risks before production begins. For Moeve Chemicals’ new Isopropyl Alcohol (IPA) plant, Inprocess, a Quadrante Group company, developed an advanced Operator Training Simulator (OTS) solution designed to strengthen operational readiness, improve safety and support the transition towards operational excellence.

The project combined early-stage training capabilities with a hybrid simulation environment, allowing operators to become familiar with the plant’s technology and operating procedures ahead of start-up.

Two complementary simulation environments were developed to support operator training throughout the plant’s preparation phase. An Early OTS enabled training to begin while the Distributed Control System (DCS) database was still under development, with the control and safety systems emulated within the dynamic process simulator.

The subsequent Hybrid OTS integrated Aspen HYSYS for dynamic process simulation with Inprocess IConex 300SM for Honeywell DCS simulation, connected through the Inprocess Infrastructure Suite (IIS). This configuration allowed operators to practise normal operations, start-ups, shutdowns, process upsets and emergency scenarios in a realistic virtual environment, without exposing physical equipment to operational risks.

Market

PT+MEA

Sector

Digital Twin | Energy

Location

Europe

Client

Moeve Chemicals

Early access to realistic operational scenarios helps bridge the gap between plant design and operational readiness. By enabling training before the DCS database was finalised, Inprocess supported earlier familiarisation with the new production technology and its control strategies.

The combined Early OTS and Hybrid OTS environments provide a safe setting for developing operator confidence, improving responses to abnormal conditions and strengthening process safety. The solution supports more effective preparation for plant start-up and the pursuit of long-term operational excellence.