cloud-based training simulators martin ross 27 oct 2016 · responsible for leading the delivery of...

Unleashing New Opportunities

CLOUD-BASED TRAINING SIMULATORSMartin Ross

27 Oct 2016

Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.

The Presenter

Martin RossUniSim Competency Suite Product Manager

Martin Ross is currently a Senior Product Manager at Honeywell Process Solutions.

Martin is responsible for UniSim® Competency Suite.

Martin joined the marketing team in 2012 after spending nearly 20 years in

Honeywell’s simulation projects and after-market services organisation where he was

responsible for leading the delivery of major operator training simulation projects and

service activities for customers in EMEA. Educated at Imperial College in London

with BSc and PhD degrees in Chemical Engineering Martin is a member of the UK

Institution of Chemical Engineers and is Six Sigma Green Belt certified.


Agenda

• Benefits Review

• Review of people challenges related to operator competency

• Reality check

- What we know today

- Challenges faced by many organizations today

• Response to the challenges

- Cloud hosted simulator based courses

- Cloud hosted custom models

• Short demonstration Video

• Q&A


Cloud Based Training Potential Benefits

Potential Benefits

• Save Time and Money

• Contribute to safety, reliability and process performance goals

• Improve knowledge and skills transfer

• Achieve your competency management goals

• Stay current

• Achieve training investment ROI

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© 2015 by Honeywell International Inc. All rights reserved.

Operator Competency – People Challenges

Balancing the beam

Opportunity Challenge

Localisation

Attrition

Evolution

Complexity

Better Morale

Fewer accidents

Lower cycle times

Better HSE performance



Operator Competency Current Reality

Simulation is effective

• Operator competency directly impacts safe, reliable and profitable

process operations.

• Simulator training is one of

the most effectively tools to

safely and consistently

develop and maintain

competent operators.

Rete

ntion R

ate



Operator Competency Current Reality

The problem of access

• Access to training simulators is

constrained by roadblocks to

access.

- Compelling Investment

requirement

- Lifecycle Commitment

- Supply Constraint: Difficult to

scale for peak demands; One

person or team at a time

- Fixed Location – limits use to local

team

By HurwiczRocks - Own work, CC BY-SA 3.0,

https://commons.wikimedia.org/w/index.php?curid=2929407



Reality Check

Simulator Based Training via the Cloud

• Competent Operators Need

• Developing Operator Competency Challenge

• Operator Training Simulator Solution

• Simulator Training Accessibility Problem

Reality

Check

Ahead


Requirements

• Readily accessible simulator training

- Not constrained by location - Where and When Needed, Available 24/7

- Not constrained by resources – Instructorless, Self paced

- Not constrained by Infrastructure – Scale up when needed

• Right and Fast

- Ready when you are

- Leverage economies of scale

- Share best practices and lessons learned

- Credible, realistic and safe simulator training experiences

- Current and relevant curriculum

- Easy to use

Readily Accessible, Right and Fast


Cloud Hosted Console Operator Training –

Benefits to organization

Save Time and Money

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• Industry leading softwareBased on UniSim

• Corresponds to real world

• Effective Knowledge TransferHigh Fidelity Simulation

• Workbooks guide trainee through a lesson planStructured

• Easy access via internet

• Easy enrolment onlineAutomation College

• Enroll 1 to N traineesScalable

• Only need a PC and access to internet

• Nothing installed locallyMinimum Footprint

• Train at convenient time at your own paceAccess On Demand


Cloud Hosted Console Operator Training -

Benefits to trainee

Right and Fast

10

• Gain knowledge through practical application exercisesKnowledge

• Experience key process interactionsUnderstanding

• Respond and recover from abnormal situationsSkills

• Practice tackling realistic real world challengesConfidence

• Interactive feedback confirms knowledge and understandingFeedback

• Courses completion certificationCredit



Outline

Structured lesson plans and multiple choice quizzes

11

Overview and

Introduction

Key process interactions

Recovery from

abnormal situations

Practice start-up and shut-down



Example

• Uses Honeywell’s UniSim Operations Operator Training Simulator (OTS)

technology.

- Cold Start and Steady State Snapshots

- Simulation Training Exercises

- Console Emulation: Trends, Alarming,

Graphics, Face Plates, etc.

• Typical Course Structure:

1. Introduction to Process Model

2. Process Variables and Controls

3. Process Disturbances and Malfunctions

4. Start-up and Shut-down

• The course duration is typically 40 hours

• Access to the training is available 24/7

Structured Lesson Plan


Lesson 1: Introduction to the Process

Model

• This training unit is designed to familiarize trainees with the process flow,

equipment and process controls of the target process model.

• The lesson provides the following information regarding the model:

- Model Scope

- Process Equipment

- Process Flow Description

- Instrumentation and Control

Introduction to the process


Lesson 2: Key Process Variables

• In this lesson, the trainee will adjust key operating variables using the

simulation model, and observe the process response to the change.

• The lesson consists of the following exercises:

1. 11TC10 – Debutanizer Tray 2 Reboiler

2. 11FC01 – Debutanizer Heavy Feed

3. 11PC16 – Debutanizer Reflux Drum Pressure Control

4. 11AC12 – Debutanizer Composition Control

5. 11TC11 – Debutanizer Tray 3 Temperature Control

6. 11PC19 – Depropanizer Reflux Drum Pressure Control

7. 11AC17 – Depropanizer Composition Control

Process responses


Lesson 3: Process Disturbances

• In this lesson, the trainee will adjust operating strategy to adapt to process

disturbances and malfunctions.


8. Ambient Air Temperature

9. Loss of Cooling Water

10. Heavy Feed Temperature Decrease

11. Fouling of Reboiler (E-100)

12. Plugged Debutanizer Level Transmitter (11LT14)

13. Plugged Depropanizer Pressure Transmitter (11PT18)

14. Plugged Overhead C5 Analyzer (11AT12)

15. Pump Failure (P-62)

16. Condenser Fan Failure (11HS14A/B)

Recover from disturbance


Lesson 4: Startup and Shutdown

• In this lesson, the trainee will safely practice startup and shutdown

of the plant using detailed operating procedures.


- Process Unit Startup

- Process Unit Shutdown

Startup and Shutdown


Short demonstration Video


Custom Models in the Cloud

Cloud

Spot Local

SolutionsSustainable Centralized

Solution

Trainee Instructor Computer

Reduce infrastructure and increase productivity

Honeywell


Cloud Based Operator Training Summary

Achieve goals

• Save Time and Money

• Achieve competency management goals

• Sustain training investment ROI

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cloud-based training simulators martin ross 27 oct 2016 · responsible for leading the delivery of...

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