Strengthening Operational Safety Through Advanced Process Simulation


Operator Training Simulator – steam cracker

Operating a steam cracker requires highly trained personnel capable of managing complex processes and responding effectively to critical situations. For a European facility operated by SABIC, Inprocess, a Quadrante Group company, delivered a hybrid Operator Training Simulator (OTS) designed to strengthen operator capabilities, improve process safety and support more efficient plant operations.

The solution provides a realistic virtual training environment, allowing operational teams to develop practical experience without exposing the physical plant to risk.

The hybrid simulation approach combines process simulation with an accurate representation of the plant’s Distributed Control System (DCS). Using Inprocess’ proprietary IConex software to replicate DCS behaviour, the OTS enables operators to interact with simulated plant processes and control systems under realistic operating conditions.

The simulator supports training across normal operations, start-ups, shutdowns and emergency scenarios, providing opportunities to practise critical procedures that would otherwise be difficult or unsafe to reproduce in a live industrial environment.

Beyond operator training, the platform also serves as a test environment for engineering analysis, supporting the evaluation of operational strategies and the prevention of equipment damage.

Market

PT+MEA

Sector

Digital Twin | Energy

Location

Europe

Client

SABIC Europe

By creating a safe environment for practising complex and high-risk operations, the OTS helps overcome the limited opportunities for hands-on training in an operating petrochemical facility.

The solution strengthens operator preparedness, supports the reduction of operational risks and contributes to more efficient start-up procedures and improved plant performance. Its additional use as an engineering analysis test environment extends the value of simulation beyond training, supporting safer and more informed operational decisions.