Book Image

Operator Training Simulator Handbook

By : Joseph Philip
Book Image

Operator Training Simulator Handbook

By: Joseph Philip

Overview of this book

Operator training simulators in the process industry have been around since the 1970s, but you may not find a book that documents the development of these systems and the standard best practices. The Operator Training Simulator Handbook covers best practices for OTS engineering and OTS training development and delivery, starting from the basic the jargon and the different types of OTS systems. It will take you through the best approaches to project specification as well as building, maintenance, planning, and delivering these systems by sharing real-life experiences and dos and don’ts. As you advance, you'll uncover the various challenges in the planning and delivery of operator training models and understand how to address those by working through real-world projects. This book helps in specifying the best fit for purpose, choosing a cost-effective system when acquiring an OTS. You'll also learn how you can turn your OTS projects into digital twins before finally learning all about documentation in a typical OTS project, covering the sample structure that you can use as a starting point in your projects. By the end of the book, you'll have learned best practices for developing operator training simulator systems and have a reference guide to overcome common challenges.
Table of Contents (11 chapters)
1
Section 1: Introduction, Definitions, and Classifications
3
Section 2: Best Practices for the Development of OTS Systems
6
Section 3: OTS' Future, Training Model, and Reference Documents

Project 4

Project type: Prepolymerization (PP) plant, Germany

ICSS emulation: Emulated – Foxboro IA®

Model fidelity: High fidelity – Honeywell OTISS®

This project was a greenfield PP plant in Germany. The main reason for using the OTS was to train the operator and do some process engineering studies. The contractor could not wait until the ICSS was completed to be used in the OTS, so the ICSS emulation was the way to go. All control and safety logic was built into the simulator using Honeywell's emulation tools from interlock, control, and safety documentation.

The delivery needed to be on a mobile system (on laptops) as well as on desktops in an office in Finland. The mobile system was to be flown to Germany and other places around the world to train operators.

In this case, an ICSS emulation worked nicely but needed full cooperation between the contractor and the supplier to achieve a good result. The final delivery was very successful...