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User Manual
Contents
1. Introduction 2. System requirements (minimum hardware specifications) 3. Installing the Petrospace software 4. Getting started 4.1 Refinery overview 4.2 What can be done? examples 4.3 Choose refinery scenario 4.4 Navigation and orientation in the refinery 4.5 Interacting with equipment 4.6 Menu mode (drop-down menus) 4.7 Visualizations 5. Visualizations - overview 6. Process pumps: demonstration examples 7. Refinery start-up 8. Furnace B404 9. Distillation column D406 10. Steam trap 11. Reciprocating gas compressor G5814 12. Heat exchangers E427, E430 13. Gas separators F404, F5804 14. Tank F401 15. Control valves 16. Battery limit 17. Personal safety equipment 18. Software trouble-shooting
1. Introduction
The Petrospace Desktop Refinery Simulation is a proven and advanced refinery training tool available for the first time as a desktop version. Developed for refinery trainers, it is however of great relevance to all involved in refinery operations and maintenance Petrospace is a collection of refinery plant and equipment linked together as a functioning interactive whole and arranged for maximum training and demonstration opportunities. Users can navigate freely through the virtual refinery using keyboard and mouse, or choose to be transported to key equipment by mouse click. They can choose to see the inner workings of key apparatus via a visualization option: an enormously powerful feature in aiding understanding. Virtual copies of pumps, heat exchangers, column, furnace, gas compressor, tanks, safety equipment, valves, etc. are actual working copies. Most valves, levers and switches can be activated by mouse click, causing the relevant response of that equipment. Users can pre-select various operational parameters, and trigger equipment malfunctions and emergencies (eg. oil leaks and fires), by means of easy-to-use drop-down menus. This manual is not a set of training exercises. Users are free to devise their own demonstration and training content depending upon individual training objectives. This manual serves to explain what is contained in the Petrospace simulation and which training tasks can be accomplished. Users are ultimately responsible for the training content which they devise and deliver to their trainees, and Phenomatics accepts no liability in this respect.
Operating system
Sound
Windows XP with Service Pack 2 or Windows Vista (32 or 64 bit edition) or Windows 7 (32 or 64 bit edition) Onboard sound chip or sound card
3. The Setup Wizard will ask you where to install Petrospace. We recommend to install it in the default folder provided by the Setup Wizard ("C:\Program Files\Phenomatics\Petrospace"). But Petrospace will also work from a different folder. You can also choose how the Setup Wizard shall set the permissions to use Pe4
trospace on this computer ("Everyone" for all users or "Just me"). Click on "Next".
4. The Setup Wizard will finally ask you to confirm the installation settings by clicking on "Next". The installation will start.
5. Users of Windows Vista and Windows 7 may get a warning message by the Windows User Access Control (UAC) during the installation process. Tell UAC to allow Petrospace to install itself on your computer.
4. Getting started
4.1. Refinery overview
top gas condensate steam top product cooling water inlet cooling water return bottom product feedstock fire ext. steam
F 401
E 427 A
E 427 B
G 5814
B 404
Furnace B404 Steam trap 2-stage reciprocating gas compressor G5814 Heat exchangers Gas separator Tank F401 and others
E427A E427B E430A E430B F404, F5804
What can be done? - examples start-up/shut-down seal system (monitor, refill) monitor: pressure, electrics, flow visualization of inner workings of pump and mechanical seal
Malfunctions which can be triggered different leaks in the seal system cavitation motor seizure fire filter congestion hot spots on piping burst of pipe inside furnace (fire) forced shutdown
Furnace
B404
Steam trap
inspect inside start-up/shut-down adjust exhaust and furnace pressure adjust burners monitor: air flow (pressure, oxygen content), gas flow, oil flow, ignition system, flames, piping Visualize furnace interior drain visualization of inner working
steam-hammering flooding
Heat exchanger
E427A E427B E430A E430B
start-up/shut-down lubrication systems -check levels, pressures, -set oil pump -manual lubrication prior to start-up drain load compression stages monitor: electrics, pressures, lubrication, temperatures, gas, drip-feed lubrication visualization of inner working (compressor and gas separator) drain (cooling water) monitor: pressure, temperature, flow visualization of inner working (E427) drain monitor: level visualization of inner-working drain monitor: pressures, temperatures, level visualization of inner working column and evaporator. bypass, water-separator (drain water) monitor: pressure, level bypass drain monitor opening/closing valves on all pipes leading to/from the refinery. hard hat hard hat with visor safety glasses gas mask escape filter gas warning devices walkie-talkie leather gloves rubber gloves
fluid in piston housing defective alarm lamp gas leak forced shutdown (by overfilling of gas separator)
Gas separator
F404 F5804
Distillation column
D406
flooding
Tank
F401
Control valves
Battery limit
Personal equipment
Select Refinery stopped as starting scenario for start-up of the entire refinery. Select Refinery stopped except G401 as starting scenario for start-up of the furnace alone Select Refinery running except gas compressor as starting scenario for start-up of the gas compressor alone Select Refinery running as starting point for demonstration of equipment malfunctions, shut-down of equipment, etc
+/i Space or t or F8 m or F2 n or F1 f or F3
increase/decrease navigation speed show this info screen switch between menu mode and navigation mode show the refinery schematic show the refinery map switch between window and full screen
Navigation mode (N Mode) and Menu mode (M mode) In N mode (default), the user is free to navigate to any point in the refinery using a combination of mouse and keyboard. In M mode, the user can automatically be transported to the equipment of choice. Press space to select M mode. Select the desired piece of equipment. Select go-to to be transported. Press space again to return to N mode.
The home position (h) brings the user always to the same starting position (the exit from the equipment room to the refinery). To activate a schematic refinery plan at any time, press m or F2
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F 401
E 427 A
E 427 B
G 5814
B 404
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Simply navigate the cross-hairs onto the desired valve, switch, lever, etc and hold down the mouse button. On most equipment the rule is Left mouse button to open valves. Right mouse button to close valves. Or single click on the middle mouse button (or wheel) to fully-open or fully-close valves.
Select which parameters are to be set, by choosing from the drop-down menu
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Full navigation in the refinery is only restored when M Mode is quit (press Space again).
4.7 Visualizations
For certain key equipment, it is possible to visualize the interior workings by selecting from the drop-down menus. This is dynamic real-time visualization: the visualization responds immediately to changes in the operating parameters which are set or triggered by the user. When it is no longer necessary to visualize a piece of equipment, the visualization should be de-selected in order to conserve computing power, and maximize the quality of the Petrospace user experience. Visualization of selected equipment can be triggered (drop-down menu):
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(Press space for M Mode. Select desired equipment. Select/deselect visualization as appropriate. Select go-to for automatics transfer to equipment). Press space again to quit
5 Visualizations overview
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Furnace B404
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Steam trap
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Lubrication oil level (can be adjusted in M mode. Press Space. Select pump. Adjust Lubrication oil level. Space again to quit.)
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Sealing oil level G401A, G401B, G414A, G414B Sealing oil level in pump G401 can be adjusted in M mode. Press Space. Select G401. Adjust sealing oil level. Space again to quit.
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Suction pressure
Delivery pressure
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Pump start
Ampere reading
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Leakage at the flanges (triggered in M mode. Press Space. Select pump. Press filter congestion. Press space again to quit)
Leakage at the mechanical seal (triggered in M mode. Press Space. Select pump. Press external leak. Press space again to quit)
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G401
Visualization when visualization on is selected from the drop-down menu, the flow of liquid through the pump is made visible (Pump G401 only) and the inner workings of the mechanical seal are visible.
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Visualization of flow
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Pressurized tandem mechanical seal G412 G413 Thermo-syphon sealing oil system G414
The level and pressure of the mechanical seal supply system reacts automatically when there is a leak.
Opening valve
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The sealing oil level in the pump can be filled from the nearby trolley.
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Manometers
Every manometer can be tested by means of the manometer lever. The correct operation of the manometer can be checked: with the valve leading to the manometer closed, the reading falls when the manometer lever is closed. The reading rises again after the manometer lever and the valve are opened again.
7 Refinery start-up
top gas condensate steam top product cooling water inlet cooling water return bottom product feedstock fire ext. steam
F 401
E 427 A
E 427 B
G 5814
B 404
Opening all lines from battery limit Follow the overhead pipes to locate the battery limit at the refinery perimeter or press Space, select battery limit and press go-to. Press space again to quit.
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To battery limit
To tank F401
Triggering condensation:
The user has to decide on the correct timing to trigger condensation (of top product). Top product appears in the tank F411 only after the user has selected trigger condensation in the distillation column drop-down menu. In the start-up Refinery Scenarios refinery running and refinery running except gas compressor, the condensation is already triggered.
In the start-up Refinery Scenarios refinery stopped and refinery stopped except G401, the furnace may be started-up as below. In start-up Refinery Scenarios refinery running and refinery running except gas compressor, the furnace is already in operation.
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The green lamp for the pilot gas is lit Pressing the pilot gas switch opens the main gas valve XV 401
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When all 4 pilot burners are in operation, the green lamp heating gas lights in addition to pilot gas. Pressing the heating gas switch opens the main gas valve XV 402
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The user can inspect the flames via the inspection flap
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Forced Shutdown
If any of the conditions (interlocks) for start-up (quantity of pump G401, level in gas separator, furnace in under-pressure) are not fulfilled whilst the furnace is in operation, then this causes a forced shut-down of the furnace (automatic shut-off of gas valves XV401 and XV402).
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Liquid level.
Evaporator
For the evaporator to function, the valve steam to E429 must be open at the battery limit .
Visualization
Inner working of the column and evaporator can be visualized. Note that it will take about 60 seconds for the visualization to initialize after selecting it in M Mode. Three malfunctions can be activated: Overheating will overheat the bottom product which will then propagate slowly to the top of the column. This can be noticed by a growing percentage of brown spheres (bottom product) on each tray. Flood at sump will flood the column with liquid starting from the bottom. Flood at tray will flood the column with liquid starting at the second bubble cap tray.
The following can be triggered (drop-down menu): (Press space for M Mode. Select Dist. Column. Select visualization on) Press space again to quit
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inlet
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First - Check condensation at the column is active (and therefore gas is available):
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(Press space for M Mode. Select Distillation column D406. Select trigger condensation) Press space again to quit
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Draining cylinders (lantern housing) First stage. (Liquid levels can also be increased/decreased via the drop-down menu)
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Draining cylinders (lantern housing). Second stage (Liquid levels can also be increased/decreased via the drop-down menu)
Oil pump on
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Compressor start
Power usage
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2. stage
S3 L L R R R S4 L L L L R flow rate 100% 85% 50% 35% 0%
S1 to S4 R L
suction valve 1 to suction valve 4 turn valve right (no flow rate) turn valve left
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Visualizations
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Plate valve
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Gas leak
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Pressure monitoring
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In the equipment room (press h or home) different types of protective clothing and personal equipment can be viewed, and their purpose explained Hard hat Hard hat with visor Safety glasses Gas Mask Escape filter Gas warning devices Walkie-talkie
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Initialization
Some visualizations need time to initialize themselves correctly and reflect the true state of the apparatus after they have been activated. The following table lists the visualizations and the maximum time it takes for them to reflect the true state of the apparatus after activation: apparatus/visualization Pump G401A Furnace inside Steam trap Distillation column and evaporator Heat exchanger E427 Gas compressor (gas flow visualization) Gas separator maximum time for initialization 5 seconds 5 seconds 60 seconds 5 seconds 7 seconds
Graphics/Speed
We recommend using Petrospace with a screen resolution between 1024 x 768 and 1920 x 1200. It will run on higher resolutions, but this will put more strain on your graphics card. It will also work with lower resolutions, but you may experience problems using all functions in the menu mode. It is recommended to close all other applications before starting Petrospace.
dowed mode. To switch back to fullscreen, move your mouse into the Petrospace window (and click the left mouse button to set the Windows focus on Petrospace) and press f again.
Jerky motion
It is normal to experience short stops or jerky motion at the beginning of the simulation, especially when you look into a direction for the first time. This is because Petrospace must load graphics data into the graphics memory. You should not experience stops or jerky motion after this. If you experience jerky motion permanently, it is likely that the PC on which you are running Petrospace is not powerful enough for the simulation.
The application is frozen and will not react to any mouse or keyboard input
In rare cases Petrospace might freeze. This is most likely because of limited resources on your PC or because the PC is not powerful enough to run Petrospace. In this case you will need to hold down the keys Cntrl+Alt+Del at the same time to start the Process Monitor of Windows where you can click on Petrospace and select Kill process. You can also try pressing Alt+Tab to switch to the console window of Petrospace and close this window. Please close all applications running on your PC before starting Petrospace the next time.
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No sound
Please check that sound isnt turned off in the Windows Control Panel and check if you can hear standard systems sounds. If only Petrospace is silent, then you can try the following: 1. Go to the Petrospace install directory (e.g. C:\Program Files\Phenomatics\Petrospace) 2. Go into the subdirectory bin and further into config 3. Locate the file bonfire.cfg and open it in the Windows Notepad 4. Locate the line sound_device "Generic Hardware" 5. Put two slashes at the beginning of this line so that it reads //sound_device "Generic Hardware" 6. Locate the line //sound_device "Generic Software" 7. Remove the two slashes so that it reads sound_device "Generic Software" 8. Start Petrospace
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