![While it is very difficult to quantify “incidents that won’t occur” and “improved
operator performance” the [investigation] team believes that the advantages to the
site from the use of simulator training would be significant. In order to leverage the
use of simulators to their best value, a clear simulator strategy is needed, outlining
most-likely-to-be-realized benefits, and critical success factors. This needs to be
backed by resources to develop meaningful ongoing training and optimization
programs.
John Mogford, Fatal Accident Investigation Report, Isomerization
Unit Explosion Final Report, December 9, 2005
AM08-71 2008 Annual Meeting](https://image.slidesharecdn.com/toolsprocessesandtraining-12562384483843-phpapp03/85/Tools-Processes-And-Training-9-320.jpg)
Tools Processes And Training
- 1. Operator Effectiveness Solutions Presented by David Holden, Business Consulting Director, Invensys Process Systems
- 2. Operator Effectiveness Training AM08-71 2008 Annual Meeting
- 3. The Operator’s Tools Alarm Management DCS / ESD IMPORTANCE APC and RTO KPI’s Reports URGENCY AM08-71 2008 Annual Meeting
- 4. The Operator’s Work Processes Emergency Procedures Safety Management IMPORTANCE Stable Operation Team Communications Economic Optimization Maintenance Management URGENCY AM08-71 2008 Annual Meeting
- 5. The Challenge • Always Be Safe – Process Safety – Personnel Safety • Master Tools and Processes Despite – Infrequent Real Life Application – Turnover • Maintain Tools & Processes AM08-71 2008 Annual Meeting
- 6. Incident Root Cause Analysis ACCIDENT (Incident) PERCENTAGES • Operational errors Mechanical Failure 38 Operational Error 26 • Aging workforce Unknown Causes 12 Process Upsets 10 • Longer runs Natural Hazard 7 between Design Error 4 shutdown • Maintenance Arson/Sabotage 3 AM08-71 2008 Annual Meeting
- 7. The Operator’s Skills General Qualitative Unit-Specific Equipment Savvy Unit-Specific Quantitative Experience, Analysis Qualitative Analysis Intuitive Feel for Analysis Procedural, and Systematic Analysis of Systematic Analysis of Equipment Systematic Analysis of Intuitive Based Directional Directional Changes Operation and Direction, Magnitude and Analysis Changes on Common on Unit-Specific Basic Principles Response Time of Changes Processes Processes 90% Competency 80% Objectives: 50% • Shift competency 30-35% curve • Shift it faster 40% 15% Training Capital (time and resources) 2008 Annual Meeting AM08-71 Source: RWD
- 9. While it is very difficult to quantify “incidents that won’t occur” and “improved operator performance” the [investigation] team believes that the advantages to the site from the use of simulator training would be significant. In order to leverage the use of simulators to their best value, a clear simulator strategy is needed, outlining most-likely-to-be-realized benefits, and critical success factors. This needs to be backed by resources to develop meaningful ongoing training and optimization programs. John Mogford, Fatal Accident Investigation Report, Isomerization Unit Explosion Final Report, December 9, 2005 AM08-71 2008 Annual Meeting
- 10. Why Use Simulation for Training? Capture process knowledge Practice makes perfect Develop best practices AM08-71 2008 Annual Meeting
- 11. FP&L Experience Without Simulators It takes approximately 8-9 years of OJT to make an operator “error free” Number of Incidence (de-rate or trip) 30 25 due to operator error 20 15 Years in J ob 10 Data taken for 5 every operator error where loss of 0 production or damage to 0 1 2 3 4 5 6 7 8 9 Years of Experience equipment was identified AM08-71 2008 Annual Meeting
- 12. What is the Value of a Simulator? EEI Initial Startup (P4 Post Environment. Additions and ERGS) w/o and with Simulator Training Power Plant Error Trips 30 25 Without Simulator Training Number of Trips 20 With Simulator Training 15 10 5 0 1 2 3 Year 4 5 6 Simulator training can provide the equivalent of six (6) years of OJT by focused training for atypical conditions AM08-71 2008 Annual Meeting
- 13. Role of the Simulator in the Learning Curve Operator Training • In-depth Process Knowledge • Troubleshooting • Optimization 90% • Abnormal Situation Management 80% Competency Procedures & Tasks 50% • Plant Startup /Shutdown • Equipment SU/SD • Emergency Response 40% 15% Basic Equipment Knowledge Source: RWD Training Capital (time and resources) 2008 Annual Meeting AM08-71
- 14. OTS Overview • What is OTS? –DCS HMI representation –Controls –Process Models –Instructor Station –Field Operator Stations AM08-71 2008 Annual Meeting
- 15. Operator Training Simulators AM08-71 2008 Annual Meeting
- 16. Different Types of Training Simulators Type of Simulator Generic - Generic Controls - Generic Controls - Process Process Basics Equipment Familiarity Practice Procedures Develop Procedures Troubleshooting ASM Economic Optimization Cost Value AM08-71 2008 Annual Meeting
- 17. Modular Control and Process Simulation Models DCS GUI Process Models Controls DynSim SIM4ME Controls Operator ESD Workstation (any brand) AM08-71 2008 Annual Meeting
- 18. Control Room Controls Plant (DCS, ESD) Outside Operation Instructor & Trainee Controls Models AM08-71 HMI Representation 2008 Annual Meeting
- 19. What are Your Top 4 Objectives for your company has for Operator Training Simulator use. Select the Top Four Objectives that OTS? Avoid Lost Production Avoid Lost Production 13.6 % Increase Process Know ledge Increase Process Knowledge 13.2 % Reduce Unplanned Downtime 11.7 % Improve Safety Improve Safety 9.5 % Avoid Incidents 8.5 % Improve Troubleshooting Skills Improve Troubleshooting Skills 8.3 % DCS Factory Acceptance Test 8.1 % Operator Certification Operator Certification 7.5 % Improve Profit of Plant 5.7 % Promote Best Practices Promote Best Practices 5.1 % Engineering Studies 3.0 % Improve Equipment Runtime Improve Equipment Runtime 2.4 % Improve the Process 2.0 % Protect Environment Protect the Environment 1.4 % 0 10 20 30 40 50 60 70 80 AM08-71 2008 Annual Meeting
- 20. What are the Main Benefits Achieved with Your OTS? • $$ Improved Startups $$ • Enhanced Operator Performance • $$ Trip and Incident Avoidance $$ • DCS Checkout and Factory Acceptance Testing • Test Proposed Operational Changes • Knowledge Capture AM08-71 2008 Annual Meeting
- 21. Initial Startup- CMA Retraining Study S K IL L S HIGH END OF INITIAL TRAINING AND PRACTICE R E S P O N S E WITH PRACTICE OF SIMULATED UPSETS WITH NO FURTHER PRACTICE LOW TIME AM08-71 2008 Annual Meeting
- 22. Key Success Factors for OTS • Appropriate Fidelity • Environment - One tool for many users: Model, Operator, Control, Trainer • Life Cycle Cost – Easy updates and changes • Training Program – OTS is part of Solution AM08-71 2008 Annual Meeting