Since 2011, ConocoPhillips Australia has been using an Operator Training Simulator (OTS) at the Australia Pacific LNG facility to prepare and upskill facility operators in a realistic, risk-free environment. The digital tool replicates the plant’s control systems and processes, enabling operators to practice everything from routine procedures to complex emergency responses without affecting live operations.
Over the past decade, more than 90 new facility operators have been trained using the simulator, which has become a cornerstone of operational readiness at APLNG. Beyond training, the OTS has also been applied to operational planning. Most recently, the simulator played a key role in a project to address soot fouling issues in the plant’s original Waste Heat Recovery Units. Before the installation of new units, engineers used the simulator to model and validate the design, ensuring its safety and effectiveness. The tool was further leveraged to test, refine, and train operators on the new control systems ahead of commissioning.
Maintaining the simulator as a relevant and effective resource requires ongoing updates. Engineering, operations, and training teams regularly refine the system to reflect changes in plant operations, ensuring its accuracy and reliability.
“The OTS is essential for training new operators and preparing for facility changes, ensuring a smooth and safe transition,” said Mark Nancarrow, training and competency lead at ConocoPhillips Australia.
The simulator is also used for emergency preparedness. According to crisis management and emergency response coordinator David Banford, it provides operators with invaluable experience in managing high-pressure situations. In February 2025, the simulator was central to a large-scale emergency response exercise, where teams practised critical procedures during a staged plant crisis, sharpening their decision-making skills under pressure.
Looking ahead, ConocoPhillips Australia is exploring enhancements to the simulator, including the integration of 3D modelling and virtual reality, to provide even more immersive and effective training experiences for facility operators.
For more information visit www.conocophillips.com
