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New Simulation Tools Capture Dynamic Nature of Coking Operations with Highly Detailed Data on Full Process

Sep 10, 2013 | 2013, News

GSE’s EnVision brand e-learning tutorial and real-time simulation tools reduce risk and increase operator competence.

SYKESVILLE, Md. – September 10, 2013 – Refiners know that coking is a highly profitable and indispensable part of their portfolio. Unlike many other refining processes, coking is not a “Set and Forget” operation. Its semi-batch operation demands that unit operators continually interact with the system with precise timing. Complicating matters is the need to handle petroleum in all three phases – vapor, liquid and solid. It’s an operation that, until now, was largely taught through books and on-the-job training.

Global energy service solutions provider, GSE Systems Inc. (NYSE MKT: GVP), now offers a multimedia tutorial and a real-time dynamic simulation for delayed coking units. Part of GSE Systems’ line of EnVision™ e-learning and Universal Simulations, the coking unit tools provide a safe, interactive method for training unit operators on the entire process.

“These tools go far beyond any other coker training tools available today,” said Santosh Joshi, Vice President of GSE Systems. “They use rigorous mathematical process models to provide accurate, dynamic data and response for every part of the process, and include continuous dynamic indication of outage, volatile combustible material, and sponge/shot quality. It helps plant managers improve their bottom line when the operator takes that knowledge to the plant floor.”

The delayed coker products have elicited very positive feedback from customers. One customer’s experienced delayed coker unit operator explained, “Seeing the visual of recycle to the frac[tionator], helped me to ‘get the big picture’ in a way I never had before.” The training advisor for an international refinery was also pleased stating, “I think this would be a great tool for someone who is starting training in the delayed coker.”

Using the simulation trainees are able to practice:

  • Startup and shutdown operations;
  • Drum switching, cutting, unheading and reheading;
  • Blow-down steps (steaming, quenching and warm-up);
  • Emergency shutdown operations; and
  • Troubleshooting and recovery from equipment, instrument and control valve malfunctions.

GSE’s EnVision delayed coking unit tutorial combines audio, video, animation and graphics that goes beyond fundamental control to operating philosophy and safety best practices.

“The dynamic nature of the coking process demands continuous adjustments by the operators, something they get a feel for over time, so it’s not necessarily the best situation for new operator training” said Joshi. “GSE’s tools provide a safe environment for training and eliminate the risk for the plant owner-operator.”

Both the GSE EnVision tutorial and simulation are equipped with their own individual learning management system (LMS), TutAdmin and SimAdmin, respectively, which allows instructors to register trainees and monitor their performance during the education process. The tutorial is available in eight languages and as a web-based application. The simulation is available in Instructor-Trainee and Standalone versions.

For more information on GSE’s EnVision products, including the delayed coking unit tutorial and the simulation tool, go to the GSE EnVision web page.


About GSE Systems, Inc.

GSE is a world leader in real-time high-fidelity simulation, providing a wide range of simulation, training, consulting and engineering solutions to the power and process industries. Its comprehensive and modular solutions help customers achieve performance excellence in design, training and operations.  GSE’s products and services are tailored to meet specific client requirements such as scope, budget and timeline.  The Company has over four decades of experience, more than 1,100 installations, and hundreds of customers in over 50 countries spanning the globe.  GSE Systems is headquartered in Sykesville (Baltimore), Maryland, with offices in Navarre, Florida and Beijing, China.  Information about GSE Systems is available at

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