In 2024, a leading midstream operator was facing a dilemma.
Their new gas processing facility designed to handle up to 260 MMSCFD of sour gas was up and running, but they did not have a sustainable way to train the operators.
Both experienced engineers and new hires were struggling to understand how the system was all tied together. With numerous equipment and pipelines spanning across multiple acres, it was simply impossible for operators to digest hundreds of pages of control narratives and P&IDs:
In-person training was also not a viable option due to the facility’s size, its remote location, and the risks associated with getting “hands-on” experience. Between high pressures, live equipment, and a maze of interconnected systems, the company was looking for a safer and more scalable way to bring people up to speed.
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The Solution: A Virtual Training Ecosystem
To address this gap, Wellsite LMS developed a fully interactive digital twin of the gas processing facility. Built from CAD models, P&IDs, control narratives, and additional input from the engineering team, the highly-detailed and interactive training provided a “hands-on” virtual walkthrough that both new and experienced personnel could rely on:
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The Benefits: Scalable, Engaging Training Experience
By learning in an immersive, interactive environment, operators are more engaged and better able to visualize cause-and-effect relationships across the facility.
Instead of pouring over hundreds of pages of static documentation, operators can now navigate the facility to get a full visual understanding of different processes and equipment. Not only are they now able to learn how key units in the facility such as gas sweetening, refrigeration, and condensate stabilization function individually, but they can also see how all of them work together as part of a larger process flow.
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Unlike traditional training methods, operators can also learn at their own pace. Whether reviewing a specific piece of equipment or walking through a full system startup, operators can pause, repeat, or explore topics as needed.
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In addition, this approach enables scalability and consistency in training. Instead of relying on ad hoc mentorship or static manuals, the company now has a centralized, consistent training solution that can evolve with the facility itself.
The browser-based training can also be scaled across multiple initiatives, such as new hire onboarding, cross-training for existing staff, and even annual refresher programs - all while maintaining detailed training records from knowledge checks and exams.
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Ready to Modernize Operator Training?
Wellsite LMS helps energy companies close the knowledge gap with scalable, immersive training built around your actual facilities. From onboarding new hires to building deep system-level understanding among experienced operators, our digital twin training programs deliver faster ramp-up, greater retention, and safer operations.
If your teams are struggling to keep up with complex midstream systems, or if you simply want a better way to train at scale, we would love to help. We’ll work to modernize your training with custom-built, simulation-driven learnings that can transform the way your team learns, retains, and performs.
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Contact us today to schedule a demo or learn more about our digital twin training solutions. Visit www.wellsitelms.com or reach out to us at admin@wellsitelms.com.
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