AXION Energy revolutionizes operator training with virtual reality technology
AXION Energy has introduced the use of virtual reality headsets for training their operators at the Campana refinery, which was recognized in 2023 as the most modern in Latin America. This initiative will create immersive spaces to resolve issues in real-time, including the selection and use of tools and enhancing the learning experience.
This innovative system was developed as an initiative to leverage the potential of new technologies and improve the quality of training for employees, who are currently trained under the highest international standards to play a crucial role in the refinery's daily operations.
"The incorporation of virtual reality into our training programs represents a significant step forward in the innovation of our operator training. This technology allows us to simulate real and critical situations, providing an immersive experience and a unique practical differential," stated Diego Mouriño, VP Downstream Operations of AXION Energy.
A dedicated team implemented 360-degree video recording throughout the AXION Energy refinery, providing a faithful and panoramic representation of the facility's interior, closely mimicking real scenarios. Additionally, useful information, FAQs, and significant milestones of the refinery have been integrated into the virtual space, allowing users to access real situations and learn the best practices to address them.
The plant employs 230 operators plus supervisory staff in shifts. Training for entrants lasts between 3 to 6 months, depending on the job's complexity. In this context, technical headsets enable training in atypical situations, such as the startup of complex compressors, circuit alignment maneuvers during shutdowns and startups, thus challenging the staff's knowledge through the simulation of control variables outside the operational window.
"Safety is always our top priority, which is why we are committed to providing the best training tools for our team. With the implementation of virtual reality systems, we further elevate the quality of our training and prepare our workers to face any contingency," expressed Mouriño of AXION Energy.
The virtual reality systems are launched as part of a medium-term plan that projects the development of 7 to 10 exercises per year to enrich the model and deepen the training of operators. One of the next steps includes enabling a multi-user function to allow teamwork during simulations.
It is noteworthy that in 2023, the AXION Energy's Campana Refinery was awarded best of the year in Latin America by the World Refining Association among 30 competitors during the Latin American Refining Technology Conference (LARTC) held in Rio de Janeiro. The award highlighted its best practices, environmental commitment, and operational optimization.
Implementation of technology within the refinery. AXION Energy is constantly seeking to innovate in its operations. In Campana, we have a digital roadmap with short, medium, and long-term projections. Examples of its advancements include the incorporation of augmented reality headsets in 2020 for maintenance work within the AXION Energy refinery, which allowed specialists to connect and show live what their eyes were seeing while exchanging online conversations with technology centers worldwide. This technology is now also used by Hygiene and Safety professionals to conduct remote task inspections, sharing with different work groups what is happening inside the plant.
Another example is the use of Artificial Intelligence (AI) in monitoring the operation of compressors, pumps, furnaces, and reactors. This AI processes thousands of variables simultaneously, providing early alerts to engineers and specialists who can anticipate actions to achieve optimal plant performance, prevent shutdowns, and thus optimize production.
Additionally, "digital twin" technology is used in the delayed coking units of the Campana refinery, allowing performance monitoring of material stresses in the units during each cycle to quickly identify improvement opportunities, extending the units' lifespan and reducing the possibility of operational incidents.
In terms of energy efficiency, during 2023, the Campana Refinery developed software that allows real-time analysis of the refinery's Energy Balance and suggests operational actions to reduce energy consumption, informing the carbon emission savings for each adjustment made. This new digital tool continuously maintains the refinery's optimal energy balance.
AXION Energy's Campana refinery holds 15% of Argentina's installed capacity, with a 16% share in the fuel market, and is the only one in the country which can produce ultra-low sulfur diesel. It has a daily production capacity of 2700 m³ of gasoline, 1200 m³ of jet fuel, and 6500 m³ of middle distillates, among other products. Additionally, it participates in the lubricant business through the Castrol brand.
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