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TRANSCRIPT
Using Generic
Simulators for
Training in the
Process Industries
SS S&T-03 A
Ian Willetts
Global Practice Director
2014 Software Global Client Conference
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2014 Software Global Client Conference
Agenda
●Background
●Generic Simulators
●Applications for Generic Simulators
2014 Software Global Client Conference
The Challenge – Demographics, Safety & Increasing
Levels of Automation - All Impacting Operations
10
15
20
25
30
1925 1975 2025
Bir
th R
ate
/1
00
0
Pe
op
le Baby Boomers
Retiring
“Based upon information it received, the Panel
believes that at most of BP’s U.S. Refineries,
the implementation of and over reliance on
computer-based training contributes to
inadequate process safety training of refinery
employees” – Baker Report (2007)
Control Loops
per Operator
Operator
Initiated
Moves/Day
2014 Software Global Client Conference
Best
Technology
Right
Services
Game
Changing
Solutions
The Job To Be Done – Raising Operator Competence...
Generic
Operator
Training
Simulators
Traditional Operator
Training Simulators
Immersive Field Operator
Training Simulators
Integrated Operator and Field
Operator Training Simulators
Corporate Operator Training
Simulators
Training
Services
LMS Integration and Hosting
Instructor Training
Write Instructional Objectives
Create Training Outlines and Training Plan
CBT Authoring or Conversion
Write Trainee Manual or Handout
AnalyzeAssess Training Needs
DesignCustomize Training Program
DevelopmentOf Training Materials
ImplementationOf Training Program
EvaluationRefine and Revise Program
Define Learning Objectives for Training Program
Lesson Plans & Evaluation Forms
Refine and Improve Program
Evaluate Trainees
Evaluate Program Effectiveness
2014 Software Global Client Conference
The Benefits – Improved Availability, Profitability &
Safety
An ARC Report (2010) reports
that operator error results in 42
percent of unscheduled plant
shutdowns
Arson/Sabotage
Design Error
Natural Hazard
Process Upsets
Unknown Causes
Operational Error
Mechanical Failure
3
4
7
10
12
26
38
ACCIDENT (Incident) PERCENTAGES
US Health and Safety Executive
reports 26 percent of accidents occur
due to operational error
2014 Software Global Client Conference
Which Solution For My Company?
Generic
Operator
Training
Simulators
Traditional Operator
Training Simulators
Immersive Field Operator
Training Simulators
Integrated Operator and Field
Operator Training Simulators
Corporate Operator Training
Simulators
Training
Services
LMS Integration and Hosting
Instructor Training
Write Instructional Objectives
Create Training Outlines and Training Plan
CBT Authoring or Conversion
Write Trainee Manual or Handout
AnalyzeAssess Training Needs
DesignCustomize Training Program
DevelopmentOf Training Materials
ImplementationOf Training Program
EvaluationRefine and Revise Program
Define Learning Objectives for Training Program
Lesson Plans & Evaluation Forms
Refine and Improve Program
Evaluate Trainees
Evaluate Program Effectiveness
Maybe
Generics
2014 Software Global Client Conference
What are Generic Simulators? ● Standard Process Models of Real Processes
● Capable of startup, shutdown and abnormal operation
● Generic DCS-like operator Human Machine Interface
● Pre-configured Training Documentation and Exercises
● Quick deployment to site. Can be run on a single
PC/Server and will be available on the Cloud soon
● Not specific to “your” plant in terms of controls or
capacity
● However can be a very valuable component of a
training program
2014 Software Global Client Conference
Process Model – Generic but Rigorous –
Eg. Continuous Catalytic Reformer and Naphtha Hydrotreater
2014 Software Global Client Conference
Available Generic Simulators
Hydrocarbon Processes
● Crude Distillation Unit / Vacuum
Distillation Unit (OTS & ITS)
● Fluid Catalytic Cracker
● Naphtha Hydrotreater / Continuous
Catalytic Reformer
● Hydro-Cracker
● Hydrogen Plant
● Diesel Hydrotreater
● Amine Regen / Sulfur Recovery /
Sour Water Stripper
Power
● 690 MW Coal Fired Drum Boiler
● Integrated Gasification & Combined Cycle
(OTS & ITS) ● Coal Preparation
● Air Separation Unit
● Gasifier
● Acid Gas Recovery
● CO2 Capture
● Sulfur Recovery
● Subcritical Steam Cycle
● 200 field operator actions and process
malfunctions
● 30 major malfunctions or accidents
● Standalone Combined Cycle Power Plant
● Supercritical Once Through Power Plant
2014 Software Global Client Conference
Generic Crude Unit EYESIM Video
2014 Software Global Client Conference
TRB Safety
Managemt. Incident
Investigation Emergency Response
Mitigation
Anaylsis
Hazards
Operations and Management
Processes
Equipment
Properties of Hydrocarbons
Company Policy Pyramid Copyright:
John M Campbell and Company
pro
gre
ssio
n for
pro
cess s
afe
ty c
om
pete
ncy
The Safety Competency Pyramid
2014 Software Global Client Conference
TRB Safety
Managemt. Incident
Investigation Emergency Response
Mitigation
Anaylsis
Hazards
Operations and Management
Processes
Equipment
Properties of Hydrocarbons
Company Policy
The Safety Competency Pyramid
Pyramid Copyright:
John M Campbell and Company
pro
gre
ssio
n for
pro
cess s
afe
ty c
om
pete
ncy
2014 Software Global Client Conference
TRB Safety
Managemt. Incident
Investigation Emergency Response
Mitigation
Anaylsis
Hazards
Operations and Management
Processes
Equipment
Properties of Hydrocarbons
Company Policy
The Safety Competency Pyramid
Pyramid Copyright:
John M Campbell and Company
pro
gre
ssio
n for
pro
cess s
afe
ty c
om
pete
ncy
2014 Software Global Client Conference
TRB Safety
Managemt. Incident
Investigation Emergency Response
Mitigation
Anaylsis
Hazards
Operations and Management
Processes
Equipment
Properties of Hydrocarbons
Company Policy
The Safety Competency Pyramid
Pyramid Copyright:
John M Campbell and Company
pro
gre
ssio
n for
pro
cess s
afe
ty c
om
pete
ncy
2014 Software Global Client Conference
TRB Safety
Managemt. Incident
Investigation Emergency Response
Mitigation
Anaylsis
Hazards
Operations and Management
Processes
Equipment
Properties of Hydrocarbons
Company Policy
The Competency Pyramid & OTS
Pyramid Copyright:
John M Campbell and Company
pro
gre
ssio
n for
pro
cess s
afe
ty c
om
pete
ncy
2014 Software Global Client Conference
TRB Safety
Managemt. Incident
Investigation Emergency Response
Mitigation
Anaylsis
Hazards
Operations and Management
Processes
Equipment
Properties of Hydrocarbons
Company Policy
The Competency Pyramid & OTS
Pyramid Copyright:
John M Campbell and Company
pro
gre
ssio
n for
pro
cess s
afe
ty c
om
pete
ncy
2014 Software Global Client Conference
TRB Safety
Managemt. Incident
Investigation Emergency Response
Mitigation
Anaylsis
Hazards
Operations and Management
Processes
Equipment
Properties of Hydrocarbons
Company Policy
The Competency Pyramid & OTS
Pyramid Copyright:
John M Campbell and Company
pro
gre
ssio
n for
pro
cess s
afe
ty c
om
pete
ncy
2014 Software Global Client Conference
Training functionality
> Over 25 control interlocks and malfunctions available in
each generic OTS application, for example.. > Fuel trips to fired heaters
> Failures in fired heater sequences
> Rotating equipment (Compressors, Fans & Pumps) trips
> Catalyst deactivation and changes in reactor operating parameters
> Control valve and transmitter failures
> Heat exchanger fouling
> Distillation column operations (changes in operating pressure, feed, reflux,
bottoms flows
> Drum / vessel operations (high / low level and their impact)
> Power / steam / instrument air / cooling water failures
> Changes in ambient and utility conditions
2014 Software Global Client Conference
Generic Simulators - Industry Usage
> Centre of Excellence: Customers with more than one
manufacturing facility have identified a single Centre of Excellence
for training, where the process models are been hosted and where
employees from different functions are trained
> Augmentation: Customers are able to easily augment the Generic
Models and tailor them to other sites with similar technology and
configuration
> Process Technology Models: Process Licensors are developing
generic models to showcase their Process Technology to End
Users.
2014 Software Global Client Conference
Generic OTS - Industry Usage
> Common Processes: Clients have developed proprietary
generic models of common processes and deployed those
systems across multiple sites providing standardized training
on SOPs
> Early Training: Customers have taken delivery of generic
simulators for early training while awaiting for delivery of a
customized process Operator Training Simulator
2014 Software Global Client Conference
Challenge
● Improve productivity and plant operations, while increasing operator plant understanding, safety and reducing operating costs
Results
● The simulation system has reduced operating costs, while plant understanding and personnel safety have improved
● Assists in providing continuous electricity to 95% of South Africa (around 60% of the total electricity consumed on the African continent)
“We are amazed at how easy the Generic Simulator system is to learn and work with”
Elsabé Pretorius, Eskom Training Manager
Eskom Lethabo Power Station South Africa
Generic Operator Training Simulator Success Story