Operator Training Simulators (OTS) train operators on fundamental plant operations and improve their ability to optimize plant performance with the same simulation tool. Its accurate and realistic simulations allow engineers to stretch the limits of a plant’s capability and identify operational and physical constraints in a safe, theoretical environment. It facilitates a thorough, scientific investigation of problems and opportunities for intelligent and fully-supportable decision making. And the same advanced simulation accuracy that makes it the world’s best optimization test bed also makes it the world’s best training simulator! OTS mirrors the exact look and feel of a plant, captures operator best practices, and enables operators to exercise best practices.
Invensys has developed over 80 operator training simulators in the specialty chemicals, oil & gas, and power industries. Many of these simulators use our own OTS software to implement a virtual stimulation design, and others use third-party software. Invensys can build any performance solution to meet your needs. Simulator components typically vary according to requirements:
- Tieback Simulators - Incorporate basic process models and uses simple control loops to simulate the process.
- Medium-Fidelity Simulators - Incorporate a combination of both basic process and comprehensive process models as well as incorporating both simple model based control loops and detailed control system representations to simulate the process.
- High-Fidelity Simulators - Incorporate a comprehensive process model and control system solution for a site-wide specific solution. This Simulator will provide you with a system that will convince your operators that they are actually operating their site.
The Process Model
The process model is the heart of the simulator. A high fidelity simulator accurately simulates the physical process combining rigorous thermodynamics and detailed process models in DYNSIM or DYNSIM-Power or a combination of both!
For a typical plant, many major units must be modeled. These include such boilers, compressors, pumps, fired furnaces, heat exchangers, reactors, and much more. Through the use of SimSci-Esscor's process modeling tools, unit operations are parameterized to match the exact features of the site to produce a real time dynamic representation of the unit.
The Control System Representation
The client's control system can be represented using SimSci-Esscor's control software. The control system representation either simulates the calculations that take place in the vendor's actual control systems or creates a link direct to a representation of the control solution. These systems normally include a Distributed Control System (DCS), Programmable Logic Controllers (PLCs), Emergency Shutdown Systems (ESDs) and hard-wired relay logic.
For a DCS or ESD, the best approach is to use a virtual stimulation product. These solutions include our own products for Foxboro I/A and Triconex TMR to simulate the control with the actual control system code running in the simulation workstation.
The Input/Output Model
Once the process model and control system representation components are in place, they are linked using our cross-reference (XREF) database within SIM4ME, which links a simulation variable in the process model to the corresponding I/O point in the control system representation.This approach enables Invensys to segregate databases for long-term application maintainability and facilitates distribution of CPU loading across multiple parallel processors.
The Operator Interface
With the three systems discussed above in existence - an operational, controllable simulation exists, but an interface for the operation of the simulation is required. This Human Machine Interface (HMI) is analogous to the control room at the site. Ultimately, the best choice for the simulator's operator interface depends on the type of interface at the site. For a DCS-controlled site, the actual DCS hardware is preferred. This is the purpose of our FSIM Plus product.
For hard panel instruments, such as switches lights and strip charts, the most effective solution is to graphically emulate them. This facility is of the utmost importance since the operator interface is the only part of the simulator that the trainee will ever directly touch.
The Instructor Station (I/S)
The Instructor Station (I/S) is the control center of the simulator. The I/S allows access to the simulator's special features, which do not exist at the actual site. These include:
- RUN, FREEZE and RESUME execution of the process model and control system representation in a completely time synchronised manner.
- SAVE and RESTORE model states for future retrieval.
- EXECUTE the model FASTER or SLOWER than real time.
- Introduce malfunctions.
- Initiate scenarios.
- Activate Trainee Performance Montor (TPM) tools
The I/S interface also lets the instructor monitor the progress of the training session with lists and trends of process and control system variables.
Integration of the Simulator Components
Once all the simulator components are integrated with one another, then the information exchange between these components are achieved through a high-speed network. The various components can be distributed and linked across the simulator network – the process model, the control representation and the HMI. If process models are available from other simulation vendors, they can also be linked to one another via SIM4ME.
