Improving Operator Effectiveness with Training Simulators

User Group Presentation

October 6-8, 2015

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• What is Dynamic Simulation

• What is a training simulator

• Improved operator effectiveness

• Operator training simulators value

Discussion Topics

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Dynamic SimulationWhat is simulation

• Simulation is the construction and use of a computer- based representation or rigorous model, of somepart of real world as a substitute vehicle for experimental and behavior prediction. Digital simulation isrecognized as a powerful tool for solving the equations that represent a real system. -- Marta S.Basualdo Departamento de Electrónica. FCEIyA. UNR

Differences between Steady State and Dynamic Simulation• In steady state simulation there is no accumulation of material or energy, flows in are equal to flows out

• In dynamic simulation there is an accumulation term, for instance

• Dynamic simulation analysis can be used to predict moments in time where the process may fall outside acceptable limits due to set point or load (disturbances) imposed on the system

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What is a Custom Operator Training SimulatorDetailed Process Model that represents the

dynamic behavior of a specific unit (or portion of a unit)

– Includes same equipment, displays, and tags

– Reflects actual unit heat and material balance,

reaction kinetics, utility interactions, etc.

Application– Teach process concepts, cause/effect

relationships via an effective “hands-on”

mechanism

– Teach operators to handle process upsets and

avoid unplanned unit shutdowns or other

events

– Familiarize trainees with control systems

(keyboard operation, process schematics, tag

groups, etc.)

– Provide tools for control applications training

and testing

Detailed Replica of the Operating Console

– Uses Same Console Hardware

– Uses Operating Schematics

– Uses Same Point Database and Applications

Non-routine and abnormal operations procedures modeled (e.g., start-ups, shutdowns, and loss of feed, utility supply, or major equipment)

Realism enhances training experience

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Examples of Operator Training Simulators• Refinery operations

• Crude towers. • Hydrocrackers • Fluid Catalytic Cracking• Alkylation units. • Catalytic reforming• Fluid/Flexicoking

• Chemical operations• Steamcrackers

Sample training Room

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Operator Training Effectiveness

Value Provided by Dynamic Simulation– Accelerated development of Console Operators

– Repetition of frequent exercises can improve response time to plant upsets

– Can help operator troubleshoot causes of upsets more effectively

– Flawless execution of startup and shutdown procedures

– Allows less experienced operators to practice startups and shutdowns prior to planned events.

– Better handling of non-routine or abnormal operations (e.g., fewer/shorter upsets)

– Optimization by increasing operator confidence to operate closer to constraints

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Why Use Training SimulatorsWhy are training simulators needed

• Plant automation is Two-edged sword.

• Improves plant reliability

• Longer plant runs / fewer startups, and fewer reliability events has led to loss of experience

• Provides a deeper understanding of the process

• Provides confidence to operator; exposed to situations in simulator; quicker reaction

• Allows operators to Anticipate – work more proactively

Additional benefits of simulators• Offline studies for unit optimization, safety/reliability/feasibility studies, controls strategies, new

application testing & training

• Simulators can provide excellent training for newer process and control application engineers

• Provides operational experience of unit

• Provides exposure to unit control philosophy

• Provides deeper understanding cause and effect relationships in unit

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Actual Quote Regarding Value of Operator Training Simulators

“....An emergency occurred, which if not handled properly, would have resulted in a costly unit shutdown.

Equipment failure caused a trip to the oxygen enrichment system.

The operating crew did an excellent job handling the emergency. They quickly and efficiently brought the unit back to normal operating conditions.

The lead operator stated that he had never experienced this situation except during recent simulator training. The simulator training gave them the confidence to respond to this infrequent emergency.”

- ExxonMobil Operations Lead

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Recap

• Simulators

• Provide a cost-effective and safe training environment for new and

experienced operators as well as to process and control application

engineers

• Allow operators to quickly become familiar with complex process

equipment and operating conditions

• Can help operators to gain confidence more quickly

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