A SELF-CONTAINED TRAINING SYSTEM FOR LNG RECEIVING TERMINAL

1
Takuji Takahashi
1. Energy Production Department, Tokyo Gas Co., Ltd., Japan

Keywords: 1. training for operation; 2. LNG receiving terminal; 3. training simulator; 4.self-conatined
training; 5. high efficiency

1. Introduction

The Sodegaura LNG receiving terminal of Tokyo Gas is one of the largest terminals in the world,
producing city gas from LNG for 35 years. During this period, the operators in our terminal have gained a
great deal of experience and accumulated know-how for operation. However, because the operators are
small in number and their average age is rising rapidly, it is strongly required to improve younger
operators ability quickly and effectively. In particular, operators must learn important operations,
including responses to emergencies such as power station failure and diffusion of gas, because they
have a serious influence on terminal operation. However, there are not enough opportunities to
experience such occurrences under normal operating conditions. Thus, operators must secure the
amount of time necessary to learn unique and important tasks from instructors and managers. Therefore,
we have established a self-contained training system for newly-installed simulators so that the trainees
would be able to learn by themselves. Concretely speaking, we have prepared learning materials that
involve know-how for control systems and field operations. Moreover, automatic and quantitative
evaluation of diverse indexes has been instituted.
In this report we describe this self-contained training system and the results of this new training system.
In section 2, the concept of our self-contained training system is introduced. The features of this training
systemnamely, learning texts and evaluation of indexesare described in section 4 and section 5. The
results of this training system are reported in section 7.

2. The concept of the self-contained training system

Our self-contained training system greatly improves the effectiveness of training. The point is that
operators are able to learn by themselves, even if instructors and managers may be absent.
Usually, operators improve their ability by repeating the cycle of learning, training, and evaluation. Our
training system enables operators to make progress with this cycle independently with our training
simulator, as shown in Fig1. Operators are able to learn, train, and undergo evaluation at anytime they
want, and thus they improve their ability quickly and effectively.

Fig. 1 Concept of self-contained training system

3. Our training simulator

We installed the simulator in the Sodegaura LNG receiving terminal in 2007, which has the following
features. Our self-contained training system is achieved by the use of these functions and features.
 (1) Easy to access for operators
This simulator is located in the training room adjacent to the Central Control Room (CCR). Thus, it
is ready for use at all times during the day and operators are able to utilize it at their own
convenience.

(2) Highly realistic sensation

The simulator console and tones (including alarms and voices) are made to appear exactly the
same as those of a real control system. Thus, trainees are able to train with highly realistic
sensations.

(3) Process behavior similar to reality

Because the simulator has highly detailed and accurate models, its behavior is very similar to real
situations, such as LNG pressure changes during the starting or stopping of pumps in tanks.

(4) Accurate simulation of field

Our simulator includes field systems and field equipment in its model, such as power stations and
manual valves. Thus, the field operations, such as opening manual valves, are reflected in the
simulator. As a result, not only the operations of plant control system but also field operations are
reflected with the training simulator.

(5) A variety of malfunctions

Our training simulator recreates various accidents, from slight trouble to serious obstacles.

4. Virtual movie text learning material

We create virtual movie texts as learning materials that contain know-how regarding the control system
and field operations. Because these texts contain points of operation and they are easy to understand,
trainees are able to learn by themselves efficiently.

(1) Example operations video

Virtual movie texts are mainly made from screen captures of experts operations on the simulator.
We record screens that appear when experts operate the learning content on simulator and edit
them with comments. (See Fig. 2) Because it is difficult to produce disastrous conditions in
actuality, the simulator is useful for recreating emergency states.

Examples include details of expert operations, such as opening screens and confirming process
status. Additionally the simulator console and tones (including alarms and voices) are made to
appear in exactly the same way as those of the real operation system. Thus, virtual movie texts
allow for much more realistic sensations than are possible merely with textbooks, and trainees are
able to understand the details of example operations.

Recorded screens (Comments)

Fig. 2 Virtual movie texts

(2) Operational know-how

 The important points of operation are displayed during these examples with balloons and voice
guidance. (See Fig. 3)

They are determined based on thorough debate with experienced operators. Namely, they
represent collective know-how that has been accumulated over 35 years of experience. Thus,
these virtual movie texts are used for not only for training but also for inheritance of operational
know-how.

With balloons and

voice guidance

Fig. 3 Important points of operation in virtual movie texts

(3) Inclusion of field operation

CCR control system operations should be intimately linked with field operations. Particularly in case
of accidents, operators are not able to handle situations properly unless they understand field
operations. Additionally, operators might have to take action in the field. Therefore, we include field
operations in the virtual movie texts. (See Fig. 4)

Fig. 4 Field operations in virtual movie texts

(4) Portability
Virtual movie texts are saved to CDs and trainees can watch them using Internet Explorer. They
are portable and trainees are able to watch them whenever and wherever they choose.

5. Diversification of evaluation indexes

(1) Necessity of confirmation of process status

The results of operation training are often evaluated based on operation content and operation
stability. In many cases, the former misses a number of operations and the latter results in a number
of avoidable alarms under training. In our training system, operation content is evaluated by
comparing the operation content of experts with that of trainees, as shown in Fig. 5. Namely, our
training system calculates the number of missing operations of trainees. Operation stability is
calculated based on the number of alarms during training.
 No. 1 index (operation content) No. 2 index (operation stability)
Example operation Training results Alarm history
Operation history Operation history 13 01 52 CP019 gauge pressure LO
OPEN NO.8 valve START LP Pump 13 03 28 CN091 LPG BO G pressure LO
START LP Pump 13 09 12 VT211 2VGA HDR tem preture HI
OPEN NO.8 valve
13 11 54 TL520 B-5TL LNG levelHI
STOP NO.3 VAP STOP NO.3 VAP 13 12 56 3VEA LNG flow LO

Calculate the number of

Comparison with example operation alarms during training

Fig. 5 Evaluation method

The learning level of trainees is evaluated based on these evaluation indexes to some degree.
However, all operations, and in particular, emergency responses, must be decided based on current
process status, such as level of tank, flow of LNG, and pressure of sending out gas. Specifically,
operators should confirm the process status before starting operations. Thus, we have added this
factor in evaluation indexes for our training.

We install the latest voice-recognition and record software on the simulator. The simulator records
voices of trainees undergoing training, as shown in figure 6. This index is judged based on checking
key words in trainees voices, for example, No. 8 VAP and start / stop.

Records voice of trainee with latest

voice-recognition and record software

Records the operation history

and alarm

Fig. 6 Situation of training

(2) Quantitative and automatic evaluation of all indexes

The aforementioned confirmation of process status is evaluated automatically. Concretely, the
simulator determines the missing number of confirmation points to be checked. (See Fig. 7) Other
indexes are also evaluated automatically and quantitatively with the simulator function of recording
operation history and alarms during training. As a result, trainees accurately understand their
weaknesses and perform in a self-contained training system.

No. 3 index (missing number of process confirmations)

Procedure of operation Confirmation Points to be checked

pressure of NG (sending out line) Determine and record the missing
Start No.3 VAP the number of running LP Pumps number of confirmations to be
checked with voice recognition

Fig. 7 Evaluation of process confirmation

 6. System configuration

These training systems are accomplished with a simple configuration. (See Fig. 8) As described so far,
each step of "cycle ability improvement" could be performed with simple configuration. Namely example
operations videos are made by our training simulator and trainees are able to watch them with individual
PCs. Additionally, trainees are able to train and evaluate with a training simulator in the training room next
to CCR.

Operation CD-R
For trainers Simulator For instructors PC
screen

Capture examples Edit examples

Train Evaluate Learn

Training Evaluation Learning
by oneself by oneself by oneself

Fig. 8 System configuration

7. Results

We will examine the results of this self-contained training system.

(1) Effectiveness of training

Trainees are able to master the required abilities in a shorter time than before. Figure 9 shows the
results of the required time to master abilities with traditional training and with the self-contained
training system. In the case of the easy level, there isn't so much difference between the two
methods, because there is not much to study. However, when the difficulty of items is high, it takes
only about 80% of the time to master.

traditionaltraining self-contained training system

120
100 100
100 95
80
tim e [hours]

80

60

40

20

0
easy hard

Fig. 9 Improvement of time for mastering

 (2) Causes of failure
The many causes of failure during training are due to lack of process confirmation (see Table 1). Thus
the evaluation of process confirmation is necessary for proper evaluation of training.

Table 1. Results of operation training

Pass rate of evaluation index
Difficulty level
No.1 No. 2 No. 3
Easy Over 80% Over 80% Over 80%
Medium Over 80% Over 80% 65%
Hard 72% 74% 58%

(3) Securement of time

Because the self-contained training system enables trainees to train whenever they choose, training
time has significantly increased. Trainees are able to secure about 1.2 times as much training time as
before.

8. Conclusions

We create virtual movie texts as learning materials that contain know-how of control system operations
and field operations with highly realistic sensations. Automatic and quantitative evaluation of diverse
indexes is also instituted. Based on these novel methods, a self-contained training system has been
established. This training system enables trainees to train independently even if instructors or managers
are absent. Consequently, trainees improve their ability more effectively and quickly than before.
Additionally, these virtual movie texts represent collective know-how and are able to be used for
inheritance of operational know-how.

Because our method contributes to the quick and effective improvement of operation ability, it leads to
the solution of issues occurring in many terminals, such as generational change in operators and
education in newly built terminals.