How technology powers safe operations at APLNG

KEY POINTS

• Operator Training Simulator (OTS) helps build confident, capable teams by providing realistic, hands-on training in a virtual environment
• Simulator mirrors real-world operations, helping Australia Pacific LNG operators prepare for potential challenges at the Curtis Island plant, enhancing safety and operational excellence
• Training tool reflects business unit's commitment to safety, people and performance

Since 2011, ConocoPhillips Australia has been using a simulator at the Australia Pacific LNG (APLNG) facility to train facility operators, enabling them to practice and refine their skills in a realistic, virtual environment without affecting live operations.

Over the years, ConocoPhillips Australia, which operates the APLNG facility, has used this digital tool, known as an Operator Training Simulator (OTS), to enhance the skills of more than 90 new facility operators.

Replicating the look, feel and behavior of the plant's control systems and processes, the simulator lets operators practice running the plant and handling different situations, from everyday tasks to emergencies.

Recently, the team used the simulator for operational planning, leveraging it for a project to solve soot fouling issues in the plant's original Waste Heat Recovery Units. These units capture heat that would otherwise be lost, putting it to good use elsewhere in the plant.

Before installing new Waste Heat Recovery Units, they modeled and validated the design in the simulator to make sure the new setup would work well and be safe. And prior to starting up the new equipment, the project team used the simulator to train, test and improve the control design.

Maintaining the simulator as a relevant and effective training tool requires continual investment and technical expertise. To this end, engineering, operations and training teams regularly update the simulator so it accurately reflects changes in facility operations.

"The OTS is essential for training new operators and preparing for facility changes, ensuring a smooth and safe transition," said Mark Nancarrow, who leads training and competency at ConocoPhillips Australia.

Crisis Management and Emergency Response Coordinator David Banford said the simulator is also used for emergency response training, enabling teams to act fast and smart when it counts.

For example, during a high-intensity emergency response exercise in February 2025, Banford said operators used the simulator to tackle a staged plant crisis. Inside the simulated control room, they practiced critical procedures and sharpened their decision-making under pressure, building confidence to respond swiftly and safely in case of a real event.

Looking ahead, ConocoPhillips Australia is exploring ways to further enhance its simulator by integrating 3D modeling and virtual reality, providing operators with even more immersive and effective training experiences.