CC-03-144 Operator Training Simulator For DSM Agro Ammonia Plant

Description:

The success of plant operations is greatly dependent on the field and control room operators competence and performance under the pressures of day to day production demands. As plants and control systems become more sophisticated (with advanced process controls and optimization features), effective operator training is needed to ensure safe working conditions and efficient operation. Additionally, reliable operator training is also required to maintain expertise on critical but infrequent operations such as startups, temporary or total shutdowns and for the handling of emergencies. Well-structured simulator based training programs are proving to be highly effective in mediating practical experience with classroom training. Simulator based training bridges the gap between the theoretical backgrounds obtained in class room training and the required plant operating skill. This motivates many plant administrations to opt for operator training programs using simulators for operators to constantly hone their skills in handling not only abnormal (sometimes rare) plant upset situations but also the routine day to day operations, shut down and start up procedures. An Operator Training Simulator (OTS) consists of a dynamic model of a plant connected to training DCS consoles. It provides a means to satisfy all of the above desired objectives by presenting a hands-on, realistic environment, which closely mimics a real plant operation without, in any way, disrupting the actual plant functioning. Both experienced and inexperienced operators can be frequently and repetitively trained on events they would face in the live plant. OTS training satisfies OSHA 1910 guidelines, provides savings in training schedule and time required to bring new operators up to speed, and decreases plant commissioning and turnaround times. In addition to these, OTS allows operators become completely familiar with the DCS controls and display screens, controls and logic loop checkout for plant equipment and control prior to startup, refresher training and operator performance evaluation.