highly detailed, web-based process training for the mid- stream industry phil rutledge western gas...
TRANSCRIPT
Highly Detailed, Web-Based Highly Detailed, Web-Based Process Training for the Mid-Process Training for the Mid-
Stream IndustryStream Industry
Phil RutledgePhil RutledgeWestern Gas Resources, Inc.Western Gas Resources, Inc.
Midland TXMidland TX
Mark RoopMark RoopeSimulation, Inc.eSimulation, Inc.
Houston, TXHouston, TX
DisclaimerDisclaimer
THIS PRESENTATION IS NEITHER INTENDED THIS PRESENTATION IS NEITHER INTENDED AS AN ENDORSEMENT OF THE AS AN ENDORSEMENT OF THE ESIMULATION PRODUCT, NOR IS IT ESIMULATION PRODUCT, NOR IS IT INTENDED TO BE AN EXHAUSTIVE INTENDED TO BE AN EXHAUSTIVE INSTRUCTIONAL TUTORIAL ON THE USE OF INSTRUCTIONAL TUTORIAL ON THE USE OF THE ESIMULATION PRODUCT. RATHER, THE ESIMULATION PRODUCT. RATHER, THIS PRESENTATION IS INTENDED ONLY THIS PRESENTATION IS INTENDED ONLY TO PROVIDE A PARTIAL SUMMARY OF TO PROVIDE A PARTIAL SUMMARY OF WESTERN GAS RESOURCE’S LIMITED WESTERN GAS RESOURCE’S LIMITED EXPERIENCE WITH THE ESIMULATION EXPERIENCE WITH THE ESIMULATION PRODUCT. YOUR EXPERIENCE MAY VARY.PRODUCT. YOUR EXPERIENCE MAY VARY.
Business IssuesBusiness Issues• Wide variance in operator competency
levels• Risk of inappropriate or inexperienced
operator responses– Safety– Environmental– Production losses– Reduced economic operating efficiency
• Operators retiring – new untrained staff
Mid-Stream Training ChallengeMid-Stream Training Challenge
• Geographically diverse assets
• Small number of operators
• Working shifts
• Limited no. of competent trainers
• Lots of equipment training courses, but not a lot of detailed process training options
RWD TechnologiesRWD Technologies
• Plant specific operator training programs for refining, petrochemical, and chemical industries
• Procedural documentation services
• Generic web-based refinery courses
• Approached eSimulation about building courses for mid-stream
BUSINESS IMPROVEMENT TECHNOLOGIES
RWD’s Learning Model
Competency
Training Capital(time and resources)
Learning Curve
15-20%
40-50%
70 - 80%
90-100%
30-40%
Equipment SavvyIntuitive Feel forEquipment Operationand Basic Principles
General Qualitative AnalysisAble to Analyze DirectionalChanges on Common Processes
Unit-Specific Quantitative AnalysisSystematic Analysis of Direction, Magnitudeand Response Time of Changes
Experience, Procedural, and Intuitive Based Analysis
Industry average operator competency
Unit-Specific Qualitative AnalysisAble to Analyze DirectionalChanges on Unit-Specific Processes
eSimTrainer Competency Target
Western GasWestern Gas
• Challenged with the delivering process training and refresher training to their operators
• Realized need to train new personnel quickly to backfill for retiring operations staff
• Was very receptive to eSimulation’s and RWD’s web-based approach
Project DescriptionProject Description
• WGR awarded contract for development of eSimTrainer courses– Cryogenic Gas Plant Course– Fractionation Course– Propane Refrigeration Course
• Used one of WGR’s plant as the basis
• Project kickoff – Dec 03
Project Description (cont.)Project Description (cont.)
• Courses delivered – August 04
• Quality issues – Course withdrawn
• Cryo Course - Re-released in Feb 05
• Fractionation and Propane Refrigeration courses - Summer 05
• Courses enhanced based on industry feedback
CoursesCourses• Cryogenic Gas Plant
– Stabilization, amine treating, amine regeneration, dehydration, turbo/expander, demethanizer, residue compression
• Fractionation Course– Depropanizer
• Propane Refrigeration– Stabilization, amine treating, amine regeneration,
dehydration, propane refrigeration loop, compression
• SRU / Amine Treating – in-progress
Modular DesignModular Design
• Orientation
• Overview of gas processing– Different for each course
• Analysis tools training
• Fundamental concepts
• Operations and control
• Troubleshooting
DemonstrationDemonstration
Phil RutledgePhil RutledgeWestern Gas Resources, Inc.Western Gas Resources, Inc.
Deployment StrategyDeployment Strategy
• WGR deploys product in multiple ways– Onsite orientation (make them feel
comfortable) – 1 day– Web-based orientation using Net meeting or
Goto meeting
• Different intervals - Review discussion on course progress
Deployment StrategyDeployment Strategy
• Kept students active and positive and encouraged them to participate
• Put time limit on courses30 – 40 hours for Cryo
11 – 20 hours for Fractionation
11 – 20 hours for Propane Refrigeration
• Started with easier course first to build confidence
Strategic ValueStrategic Value
• Improved operator productivity• Reduced safety and environmental risk
by reducing inappropriate operator responses
• Improved competency to allow operators to consistently achieve operational directives
SummarySummary
• Western Gas has a tool to improve and maintain operator competency
• Western Gas is in the process of a corporate deployment of eSimTrainer across all assets