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Tuesday, 19 Feb 2019

Hyperion Delivers Turn-Key Operator Training Simulator (OTS) for a CCR Unit at Hellenic Petroleum Thessaloniki Refinery, Greece

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Nicosia, Cyprus. 29th June 2011. Hyperion Systems Engineering Ltd. the leading independent solutions provider to the global process announced the successful delivery of a high fidelity Operator Training Simulator (OTS) system for the new CCR Reforming Unit development for the Hellenic Petroleum Refining Complex in Thessaloniki, Greece.

The Thessaloniki refinery is one of the three refineries owned and operated by Hellenic Petroleum in Greece, a fourth one is located in FYROM. The new OTS system consisted of the process models, emergency safety system, DCS, DCS control logics, Instructor/FOD station and local panels.

Hyperion developed a high fidelity dynamic model of the CCR complex which included models of the CCR reactor, Regenerator, Catalyst moving bed transfer, turbine driven centrifugal recycle compressor, Hydrogen compressor, Stabilizer column, Steam generation boiler and the Regeneration loop compressor. The DCS system was an emulation of the Honeywell Experion Human Machine Interface (HMI) to provide the Operator training functions required.

Hyperion’s turn-key responsibilities on the project included:

  • Development of rigorous process models
  • Development of ESD
  • Integrating the process models with an emulation of Honeywell Experion DCS
  • Development of the Instructor and Field-Operator stations
  • Development of appropriate panels
  • Supply of trainee/operator consoles using the actual plant graphics
  • Hardware and software procurements
  • Installation and commissioning at site
  • Provision of appropriate training and documentation (manuals and specifications)


Other technical characteristics of the project included the enchantment of the simulator by adding special malfunctions and other scenarios for daily operational challenges, as well as added functionality around the catalyst circulation batch sequence.

The OTS provided a further in-depth view of the new CCR project and its emergency safety system which allowed Hellenic Petroleum’s newly hired and inexperienced Human resources team to train how to efficiently and effectively operate the plant, through the acquisition of a thorough understanding of the Unit and its daily and abnormal operations

Benefits provided to HELPE Thessaloniki Refinery also came from the provision of a safety system design validation, which allows them to discover a variety of issues.

About Hellenic Petroleum

Hellenic Petroleum is a dynamic Group, with solid foundations and a continuous profitability that holds a leading position in the Greek energy sector as well as in the greater area of Southeast Europe. Owning and operating four oil refineries, the Group’s range of·activities includes crude oil refining and fuel supply and export, oil products retailing in Greece and abroad, production and trading of petrochemicals and chemicals as well as oil & gas exploration and production.

The group is also active in production and trading of power generation through a JV with italy's Edison, has the presence in the natural gas market through its stake DEPA S.A., and in participation in crude oil and products transportation (pipe-lines, sea transportation). For more information visit www.helpe.gr

About Hyperion
Hyperion Systems Engineering (www.hyperionsystems.net) is the world’s leading independent provider of systems engineering solutions and services to the process industries. A privately held company with 16 years’ experience in the Oil and Gas, Petrochemical, Chemical, Pharmaceutical, Food and Beverage, Power, Water and Metals industries, Hyperion has a well-established reputation for groundbreaking innovation, helping clients to drive down costs and dramatically increase operational efficiencies.

Hyperion provides Process Modeling and Simulation, Basic and Advanced Process Control, Manufacturing Execution Systems, Supply Chain Management, and Project Management Consulting, with specialized expertise including Operator Training Simulators, Predictive Emissions Monitoring Systems, Environmental Compliance and Reporting, Laboratory Information Management Systems and Advanced Planning and Scheduling.

Headquartered in Cyprus, Hyperion operates around the world with regional offices in Athens (Greece), Moscow (Russia), Al-Khobar (Saudi Arabia), Pune (India), Shanghai (China), and Singapore. In addition, Hyperion’s wholly owned UK-based subsidiary, Broner Metals Solutions Ltd, is a leading provider of supply-chain management solutions to the international steel and aluminium manufacturing industry.

Hyperion is certified to the ISO 9001:2000 standard, by EuroCert.