Relevant case studies

Blog post: 29/09/2025 2:19 pm

Author: Spark Team

VR SOP Training for Refining: Turnarounds, Operations & Process Safety

Custom-built simulations for complex units and high-stakes procedures

Refineries run intricate, interdependent units where a single procedural slip can cascade into costly incidents. Spark builds bespoke VR SOP training that mirrors your refinery’s units—hydrocrackers, reformers, FCC, amine, sulphur recovery, tank farms—so operators rehearse start-up, shut-down, line-up, and emergency procedures in a risk-free but realistic environment.

Refinery pain points our VR addresses

• Start-ups & shut-downs: the most hazardous periods requiring precise sequencing.
• Isolation control: mechanical/electrical LOTO, blinds/spades, double-block-and-bleed validation.
• TAR (turnarounds): compressed schedules, multi-contractor coordination, SIMOPS.
• Process safety: line mis-line-ups, overpressure scenarios, flare system limits.
• Competence verification: consistent standards across shifts and units.

Bespoke build approach

1. Discovery: gather SOPs, PFDs, P&IDs, cause-and-effect charts, alarm philosophies.
2. Scenario design: unit-specific start-up/shut-down, pigging, decontamination, nitrogen purging.
3. AI avatar coaching: guides operators with your exact SOC/HSE wording and decision gates.
4. Permit realism: PTW, confined space, hot work, inert entry rehearsals with required PPE and gas tests.
5. Assessment: interlock checks, valve line-ups, correct tagout application, time-to-safe-state metrics.
6. Deployment: training rooms, control-room refreshers, multilingual packs, LMS integration.

Commercial & compliance benefits

• Enhanced process safety culture; fewer start-up deviations.
• More predictable TAR outcomes; better SIMOPS coordination.
• Stronger audit trail for regulators and insurers.
• Reduced rework and downtime through practiced right-first-time execution.

Why Spark

No off-the-shelf shortcuts—our team models your units, instrumentation, alarms, and procedures to deliver a training twin that matches reality.

Discuss a tailored refinery SOP simulator — contact Spark.

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