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Operator Training Simulator
 
Modern Operator Training Simulators are detailed, high fidelity, real-time simulation systems that are custom-built to match the dynamic behavior of single or multiple plant units and their associated control systems. These powerful systems are utilized for a variety of purposes, including operator training, engineering studies for operational improvements and de-bottlenecking projects.
 
Figure2
 
An operator training simulation system typically consists of (i) a number of process models describing the plant behavior as a function of time, (ii) a complete copy of the distributed control and the emergency shutdown system, including a series of operator consoles, and (iii) the instructor/engineer station, used to control the simulator and the training sessions. Hardware and software must communicate seamlessly.
 
An Operator Training System may be used throughout the plant lifecycle to train operating crews, thus developing and sustaining operations skills. This is because:
  • A simulator is a safe environment for “hands-on” training.
  • All training sessions are reproducible.
  • The operator performance is measurable and verifiable.
Figure3
 
Skills in plant operations are typically considered to be close to average. This alone highlights the potential for improvements and savings. The dark-red bars indicate the performance during start-ups and shutdowns. The light-blue bars indicate the operations performance based on energy conservation, process equipment utilization, and product loss or re-run. These results are based on a recent survey with the question “Rate Your Company’s Training Effort as Reflected in Demonstrated Operator Skill”.
 
Improved operational skills provide the plant management with a competitive advantage, because it leads to:
  • Faster start-up and safe shutdowns.
  • Reliable response to abnormal situations.
  • Consistent performance of the operations team.
  • Agile response to market needs and increased throughput in less time.
  • Improvement in product quality and reduced losses.
A simulator adds more value when the engineering benefits are taken in to account
  • The control design and configuration are validated before startup.
  • The operational procedures are improved and troubleshot.
  • New control strategies can be evaluated.
  • “What-if” scenarios can be efficiently analyzed.


 



   
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