Emerson Exchange 365

One of the most common questions we see from users interested in using simulation for operator training is “How can this be used for training?”. Of course, this varies based on individual goals, but we have seen everything from standard equipment malfunctions to instructors acting as a field operator on a coffee break to train on handling complex situations. Below I have collected some of the solutions Emerson has worked with customers to implement in the past to help answer this question:

• Familiarizing operators with control system interface and control strategies – The digital twin, a simulation of the live process running in parallel with it, allows for new operators to get familiar with existing controls or existing operators to get familiar with new controls, since the control strategies, graphics, and alarms are identical to the production system.

• Training on Standard Operating Procedures – One step beyond familiarization, operators can run through procedures such as startup and shutdown. This is especially beneficial when bringing a new system online or for training on procedures that are encountered infrequently such that there is not a lot of operational experience. Note that while this is can be scripted as an exercise, this is generally only beneficial, if the intention is to track that the operator takes certain steps as outlined in procedures or best practices.

• Identifying and Addressing Equipment Malfunctions and Process Upsets – This type of training is self-explanatory: a malfunction or upset is initiated and an operator must respond. The training consists of both seeing the effect of the malfunction or upset for identification in production and taking appropriate action. Up to this point, the training described has not required decision making. Because of this, we have seen benefits in the instructor pausing the simulator at key decision points for further discussion. Training around equipment malfunctions can be scripted if a specific response is expected, but ad-hoc instructor controls can also be implemented. Often, this type of training flows into a standard operating procedure to shutdown equipment.

• Changing Operational States – This type of training is like training on standard operating procedures with the primary difference being that there may not be strict procedures making this a free environment for operators to understand process dynamics and interactions and how they relate to the operational changes they make. Specifically, operators can learn how the process responds to operational changes from a timing perspective in addition to the frequency and magnitude of operator actions that should be taken. Some examples include a gas to diesel swing, a change from hot to cold feed, or a change in production rates

• Identifying and Responding to Disturbances – As any controls engineer would tell you, the goal of automation is to prevent disturbances, however, this isn’t always possible. Like malfunctions, training on disturbances consists of both seeing the effect of the disturbance for identification in production and taking appropriate action. The primary difference being that there may not be any indication of these disturbances unless operators are carefully watching trends. Understanding how to identify and respond with smaller operational changes, is a key to unlocking operational efficiency. Often these disturbances are caused by boundaries such as process feeds, which can be programmed with noise to simulate realistic process dynamics.

• Identifying and Preventing Process Trips – Unplanned downtime is one of the most expensive operational costs, but often process trips can be prevented if appropriate action is taken. Operators need to be aware of different indicators that a process or piece of equipment is trending in the wrong direction. The initiation of this type of training is like a malfunction or upset, but operators are focusing on identifying and preventing a process trip rather than how to respond after a process trip. For this reason, training typically ends with either a process trip or a prevented process trip.

• Training on Key Process Indicators – Rather than training on process understanding or operator response time, this type of training focuses on key process indicators such as throughput, quality, recovery, or efficiency. The great thing about training on these in a simulator is that you have access to much more information than in production, so metrics like changes to product or reject compositions can be analyzed in real-time rather than waiting on lab data. These metrics can then be tracked and recorded over the course of a training session. This is a more advanced training that focuses on operational goals. While this is generally only used for more experienced operators, some companies allow operators to compete on the simulator for a high score to promote a more fun and engaging training environment.

• Combination of Training Types – As operators gain experience with the simulator, they start to expect the standard training. To prevent this, combining multiple malfunctions together or with KPIs makes operators focus on multiple tasks at the same time and determine how to decouple issues and priorities to make informed decisions. This is ultimately where we would like to see advanced operators.

Note that the training functionality is also largely dependent on the selection of the appropriate fidelity for the specific application. For example, introductions to new DeltaV users or updated graphics may only require a low fidelity simulation without the inclusion of the use of more complex exercises, but this would not be sufficient for more advanced training. More information on the selection of fidelity can be found here.

We are always hearing about new and creative ideas and applications. How have you used simulation for your training needs?