Operator Training Simulators
As advanced control and optimization become widely used, the requirements for highly skilled operators has become a key element for a competitive strategy. Human error, particularly due to the erosion of expertise, has largely contributed to production losses. It is now mandatory to provide operators with a training tool that allows them to Gain-Improve-Maintain their skills.
The INDISS™ Operator Training Simulator (Custom OTS) is a High Fidelity Virtual Plant to train operators to master a large variety of process conditions that range from cold start up to emergency shut downs.
Custom OTS that can be either Emulated or Stimulated.
Both solutions are designed to replicate the process and the Plant operator environment and differ in their implementation.
A Plant can be divided into three main categories:
- the process and the field instrumentation
- the Control that is located in the technical facilities
- the DCS operator consoles
| Emulation | Stimulation | |
|---|---|---|
| Process Model | INDISS™ | INDISS™ |
| Process Control Algorithms | INDISS™ | third-party software |
| Logic sequences | INDISS™ | INDISS™ |
| ESD | INDISS™ | INDISS™ or third-party software |
| Graphical Interface | INDISS™ | DCS station |
In both cases, it is an accurate reproduction of the plant equipment and instrumentation & control. The specific equipment data sheets are used to configure the model that is tuned to the Heat & Material Balance. Graphic displays and control strategies as well as logic and ESD are a replica of the plant. The Custom Process OTS is a Real Time Virtual Plant that has the same dynamic as the real process. The fidelity is such that an experienced operator will not see any difference between the OTS and the plant behavior. The Custom OTS will give the Trainee the opportunity to have a custom tailored training program that will allow train him to deal with any particular situation in the plant. Custom OTS is a key factor to the success of a plant startup and largely contributes to maintain and improve the operator skill.
OTS gives operators the opportunity to understand the process behaviour to rapidly gain experience and respond safely, quickly and efficiently to all kinds of process situations such as:
- normal operation
- troubleshooting in daily operation
- specific equipment operation (compressors operation, automatic start up of spare pumps, etc.)
- abnormal situations and emergencies
- start-up and normal shutdown procedures
- control and strategy
- safety philosophy and trips causes and effect analysis
OTS Emulation
The OTS Emulation will reproduce the three main categories:
- the High Fidelity model will simulate the process and the field instrumentation
- the High Fidelity model will emulate the control, the logic and the ESD
- a number of PC will emulate all the main functionality of the DCS operator facility including specific operator key board if any.
A specific PC will usually be dedicated to the ESD functionality. A graphic display will emulated the layout of the ESD panel and access to the information and action is supported by the mouse/keyboard. This PC will indicate any emergency situation and allow the Trainee to initiate when necessary trips in the same manner as in the control room.
Another PC will be dedicated to the Field Operated Devices. The FOD are specific on site commands that are not available in the control room.
OTS Stimulation
The OTS Stimulation will reproduce the three main categories:
- the High Fidelity model will simulate the process and the field instrumentation
- the Virtual Controller Environment will use a copy of the plant data base to control the simulated process
- a trainee console similar to the plant DCS will host and operate a copy of the plant graphic displays.
The Virtual Controller, is a connecting environment between the INDISS™ High Fidelity model and the Trainee Console. It provides process information to the Trainee and will control the process simulated in the OTS server.
The Virtual Controller environment is very specific to each DCS vendor and details are available on each DCS vendor internet site.
Emulation and Stimulation available librairies
| Emulation | Stimulation | |
|---|---|---|
| YOKOGAWA | CS3000 | CS3000 |
| Cetum XL | ||
| FOXBORO | I/A | I/A |
| EMERSON | Delta V | |
| HONEYWELL | Universal Station | |
| TDC2000 | TDC2000 | |
| TDC3000 | TDC3000 | |
| TPS | TGS GUS | |
| Experion PKS | ||
| ABB | ABB INFI 90 | |
| Advant | ||
| Advant MOD 300 | ||
| Advant Master | ||
| ABB PBB | IT | |
| BAILEY | Controls MCS | |
| Micro Z | ||
| Network 90 | ||
| INFI 90 | INFI 90 | |
| Symphony | ||
| FISHER | Rosemount Provox | Rosemount Provox |
| SR90 | ||
| Provue | Provue | |
| Siemens | Teleperm XP | |
| TOSHIBA | CIEMAC | |
| TOSDIC |
Any other DCS replica device may be implemented upon request.
INDISS™ Instructor functionality
All OTS come with a full set of Instructor functions. In addition for Custom OTS INDISS™ can easily be provided with specific Instructor functionality to match any need.
Main Instructor tools are:
- Management of the simulation
- Run/Freeze/Step by step
- Modification of acceleration rate
- Record/Replay simulation runs; configuration of sampling period
- Activation of instrument and equipment malfunctions
- Creation and execution of scenarios and exercises
- Management of users
- Adding/removing users
- Assigning/removing mimic displays to/from users
- Allocation of trainees to exercises
- Training evaluation
Download the Instructor functionalities document for more details.