Operator Training Simulators for Recovery Boilers. Presented by: Robert Zwick, M.A.Sc., P.Eng, President, Automan Controls Inc.
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1 Operator Training Simulators for Recovery Boilers Presented by: Robert Zwick, M.A.Sc., P.Eng, President, Automan Controls Inc.
2 Automan Controls Inc. is about Operations Technology. The focus is Delivery of projects and opportunities on time and budget which Maximizes automation revenues, and Minimizes plant disruptions. Our goal is for the Customer to realize the true potential of their operations and release its tremendous latent value. Page 2
3 Agenda Using Operator Training Simulators to enhance rapid learning of your complex process and control interactions. Leveraging a simulator effectively into a wider training program Utilizing the latest in cloud computing to simplify training complexity and increase accessibility through Software Simulation as a Service (SSaaS) and Training as a Service (TaaS) Retaining and rapidly transferring experiential knowledge Justifying the investment in building competency in operators. Page 3
4 The Cost of Operational Errors Findings by the Chemical Safety Topical Committee (funded by DOE) reveal an average of one chemical incident/day. Average cost to comply with ORPS process is estimated at $2M per incident*. Average cost per major incident related to Operator error exceeds $80M. Dollar Loss per Major Incident (by cause) Source: J&H Marsh & McLennan ORPS USA Dept of Energy Occurrence Reporting and Processing System (ORPS)
5 The Cost of Operational Errors
6 What is a Simulator? PLANT CONTROLS HMI OPERATOR Simulation Real Dynamic Simulation DCS PLC Software Emulation Same / Similar HMI Hardware Trainee Page 6
7 Simulation Usage in Training An ideal Training Simulator will: Give a realistic look and feel to the control environment, for the trainee to have a realistic experience. The process model behaves realistically so that the Trainee actions result in realistic outcomes The simulator can be easily kept current on any of the control system changes. Page 7
8 Simulation Usage in Training Train on normal and abnormal conditions. Develop best-practices in operational procedures (startup & shutdown). Train on scenarios that rarely appear in the plant. Increase startup/shutdown training frequency. HIGH RESPONSE SKILLS END OF INITIAL TRAINING AND PRACTICE WITH PRACTICE OF SIMULATED UPSETS WITH NO FURTHER PRACTICE Training of operators and testing of control applications prior to start-up. Test bed for controls and process changes. LOW TIME Page 8
9 Simulation Effectiveness as a Training Modality Simulation 78% Job Shadowing 30% Reading 10% Classroom Instruction 5% Simulator is 7 times more effective than traditional methods
10 Why Competent Operators? Billion $ Assets Safety, Profitability, Efficiency, and Asset Performance Highly Dependent on Pilot Confidential Property of Schneider Electric Sophisticated Process & Automation Systems
11 Operational Complexity Complexity in identifying an operations issue Purdue Reference Model (PRM) Level 5 - Business Systems Level 4 - Plant Level (ERP, MRP, and MES) Level 3 - Operation Unit Level (APC) Level 2 - Machine/Process Automation Level 1 - Controller Level Level 0 - Sensor/Actuator Level Process Dynamics Mis-identifying source(s) of issue can lead to further upsets Page 11
12 Shift in Training Needs Page 12
13 The Aging Workforce Case Study - Age Profile, Ammonia Plant in Europe Experience Know how Seen it before The Human Resource Experience Crisis Page 13
14 Industry Wide Problem Source: QER Report: Energy Transmission, Storage, and Distribution Infrastructure April 2015 Page 14
15 Simulation as Part of a Wider Training Program Operating Procedures & Manuals Learning Management System (LMS) Classroom Training All modalities of learning can be augmented by simulation: Reinforce Concepts Practice New Content Test Knowledge Capture Discuss, and Review Different Approaches to a Problem Review, Test, and Improve SOPs Job Shadowing
16 Transferring Experiential Knowledge Experience Classroom Training Know how Seen it before Operating Procedures & Manuals Simulation Scenarios can easily be recorded showing best practices and know how from years of experience. Establishing Initial Conditions (ICs) can easily expand the platform to practice those same proficiencies. Simulation Learning Management System (LMS) Page 16
17 Integrated Training Programs Complete Trainee Performance Tracking Packages Custom Training Content Scenarios and Malfunctions Instructor-led Operations Training Programs Self Study Training Programs with Trainee Evaluation Integrated Learning Management (LMS) Computer Based Training (CBT) for Fundamentals
18 Industry Shift Cloud Simulation Software as a Service (SSaaS) Cloud deployments reduces the total cost of ownership No hardware procurement and upgrades No corporate IT dependency Simple payment schemes pay as you go or utility pricing New advantages for Cloud based simulation applications Collaboration real time online Scale run as many instances of a simulation as needed Convenience your instructors, students and support can connect and collaborate from anywhere on any device Security Cloud offerings are designed from the ground up around security Cloud-based Simulation and Training Platform Page 18
19 Building a Simulator Business Case Learning Efficiency Approach Training Simulator is 7 times more effective than traditional methods: Training $ Value and Retention: Maximizing the value of training time spent (training seat time) through simulation Training Effectiveness: Providing measurement operator competency through development of point-based performancebased activities Production Goals: Beating production goals through increased competency Operator Competency as a Key Performance Indicator (KPI)
20 Building a Simulator Business Case: Risked-Based Benefits Analysis Likelihood/Risk/Consequence: Establish likelihood of an event that affects: Production Environmental incident Maintenance event Catastrophic event Lost opportunities A good rule of thumb is a 20% 30% consequence reduction Establish the monetary consequence for each of those events within an established time horizon Determine what a properly-trained Operator can avoid wrt to the consequences
21 Successful Simulator Projects Simulator projects are composed of the following costs: Software licenses Hardware Engineering of the process model Owner s cost Trainer time Model Acceptance Test Factory Acceptance Test Site Acceptance Test Support (sustainability) Model Fidelity
22 Summary Managing process complexity, societal expectations, asset performance, and profit while exceeding regulatory compliance have become highly dependent on operator competency. Training Simulators have become a crucial training tool for the complexity found in operations today. Training Simulators are 7 times more effective than traditional methods. New technology such as Virtual Reality, SSAAS, TAAS, can assist in immersion, availability, and transfer of knowledge. A simulator is the easiest tool available to rapidly gather knowledge from experienced employees to share and practice among trainees. Training Simulators can be justified Page 22
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