As operators cultivate understanding of their machinery and
gain quick-response capabilities, they can tangibly improve the
plant’s efficiency, safety and reliability – all of which tangibly
affect the bottom line. In the training simulator, operators use a
replica to learn skills on the human-machine interface (HMI), a
soft controller to study the control system and dynamic
simulation to practice working with the process (see Figure 3).
In a case study using an operator training simulator,
D.K. Lorenzo found that simulation reduced the time needed for
on the job training (OJT) to translate into performance (see
Figure 4).
2
Using simulation, operators were trained before a new
four-stage compressor was installed, and compressor controls
were pre-tuned accurately. At the end of the initial training, all
operators were able to execute solid response skills. Further
practice sessions of simulated upsets enabled operators to
maintain their response skills at a high level, whereas operators
who did not participate in practice sessions began scoring at
much lower skill levels. The result: plant safety improved in
correlation with operator training. Also, the compressor started
up smoothly and reached maximum efficiency in less than half
the time normally required (see Figure 5).
Increase availability
In terms of day-to-day operations, overall availability improves
when engineers use simulation to work out the bugs before the
system ever goes online. Evaluating the control programme
against a dynamic simulation of the local process allows start-up
Figure 3.
Operator training.
Figure 4.
Operator performance over time.
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