2014 Software Global Client Conference - …iom.invensys.com/EN/SoftwareGCC14Presentations/SimSci/SS S_T-03A... · Write Trainee Manual or Handout Analyze ... Sour Water Stripper

2014 Software Global Client Conference

Using Generic

Simulators for

Training in the

Process Industries

SS S&T-03 A

Ian Willetts

Global Practice Director


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Agenda

●Background

●Generic Simulators

●Applications for Generic Simulators


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


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


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


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


GENERIC SIMULATORS


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


Process Model – Generic but Rigorous –

Eg. Continuous Catalytic Reformer and Naphtha Hydrotreater


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


Generic Crude Unit EYESIM Video

EYESIM Virtual Crude Unit - 720p.mp4


APPLICATIONS FOR GENERIC

SIMULATORS


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


TRB Safety

Managemt. Incident


Mitigation

Anaylsis

Hazards


Processes

Equipment


Company Policy


Pyramid Copyright:


pro

gre

ssio

n for

pro

cess s

afe

ty c

om

pete

ncy


TRB Safety

Managemt. Incident


Mitigation

Anaylsis

Hazards


Processes

Equipment


Company Policy


Pyramid Copyright:


pro

gre

ssio

n for

pro

cess s

afe

ty c

om

pete

ncy


TRB Safety

Managemt. Incident


Mitigation

Anaylsis

Hazards


Processes

Equipment


Company Policy


Pyramid Copyright:


pro

gre

ssio

n for

pro

cess s

afe

ty c

om

pete

ncy


TRB Safety

Managemt. Incident


Mitigation

Anaylsis

Hazards


Processes

Equipment


Company Policy

The Competency Pyramid & OTS

Pyramid Copyright:


pro

gre

ssio

n for

pro

cess s

afe

ty c

om

pete

ncy


TRB Safety

Managemt. Incident


Mitigation

Anaylsis

Hazards


Processes

Equipment


Company Policy


Pyramid Copyright:


pro

gre

ssio

n for

pro

cess s

afe

ty c

om

pete

ncy


TRB Safety

Managemt. Incident


Mitigation

Anaylsis

Hazards


Processes

Equipment


Company Policy


Pyramid Copyright:


pro

gre

ssio

n for

pro

cess s

afe

ty c

om

pete

ncy


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


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.


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


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

26 ©2014 Schneider Electric. All Rights Reserved.

All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies or their respective owners.

Documents

2014 Software Global Client Conference - …iom.invensys.com/EN/SoftwareGCC14Presentations/SimSci/SS S_T-03A... · Write Trainee Manual or Handout Analyze ... Sour Water Stripper