Training simulators smooth operations

Simulators pay for themselves with fewer trips and incidents, wrinkle-free transitions, knowledge capture and process improvements.

By Janice Abel and Rick Rys, ARC Advisory Group

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One of the earliest applications for simulator-based training was to train airplane pilots.  Today, simulators are used to train people across many professions, including as health care (e.g., for surgeons), aviation, military, aerospace, shipping, nuclear, oil & gas, chemical and many other industries in which workers have high levels of responsibility with the possibility that mistakes could result in harm to people, equipment and/or the environment.

Although a well-rounded program that includes classroom, online and on-the-job training is important, ongoing research indicates that for operations and other personnel in many types of industrial plants and facilities, operator training simulators (OTS) can be particularly beneficial.  This is because simulators enable operators to practice operations in a situational context. Unlike training on live control systems, operator training simulators can be used to practice real-life scenarios (both normal and abnormal) without the risk of adverse consequences. In addition to gaining an understanding how the plant functions, simulators can enable workers to learn how to solve problems and make better and faster decisions.

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Research has shown that companies that have utilized simulation in training have workers that learn faster, retain information longer, and perform much better than workers who have only been trained through more traditional training such as on the job, on-line, or classroom training.

ARC Advisory Group recently conducted a research survey in conjunction with Control to develop a better understanding of how industrial organizations today utilize operator training simulators (OTS) and the specific benefits they accrue.  The survey examined various types of OTS simulation solutions used today, current implementation practices, reasons for implementing, training methods, and specific benefits.

This Insight highlights selected findings from the survey, focusing on the responses received from end users with actual OTS experience.  The majority of participants were from the oil, gas, chemical, and petrochemical industries. The energy and nuclear industries were also represented.  ARC clients will also receive a more detailed report on the survey findings in the near future.

CG1602 OTS1

Top benefits from implementing OTS

The survey examined the top benefits received from implementing OTS.  Survey participants were allowed to choose up to five answers (top choices are shown in graph and all choices are listed in the table).

The top benefits from implementing OTS identified by respondents include:

  • Smoother startups, shutdowns and transitions
  • Fewer abnormal situations, trips, incidence avoidance and  troubleshooting skills
  • Improved process knowledge capture and transfer
  • Improve process safety, & reduce risk & liability
  • Test operational modifications & process control before

CG1602 OTS2

The number one reason given for implementing OTS was to obtain smoother startups, shutdowns, and transitions.  Operations teams today do not always get the hands-on training needed for starting up and shutting down a plant and although technology has made it easier to capture procedures, critical plant information is not always easy to obtain when it counts the most.  For plants that startup and shutdown frequently, just the cost savings from avoiding equipment damage can help justify the OTS purchase. One person ARC interviewed estimated that the savings could be as high as $10,000 to $50,000 per day in a coal-fired power plant.  Another estimate given was that plants can save as much as $300,000 to $400,000 per startup.

Respondents also indicated that improving process safety and reducing risk and liability was another major OTS benefit realized.  Lower risk can mean lower liability and even lower insurance costs in some cases.  Another benefit was to test operational modifications and process control before implementation.  Companies benefit from using an OTS system for factory acceptance testing and checkout and optimizing the process control system prior to and following startup.  One end user told ARC that by using the OTS for testing they were able to obtain a ROI before startup.

How OTS are used

According to respondents, the number one reason for OTS usage is to train operators before startup.  This aligns with the top benefits given.  The number two reason is to respond to abnormal situations.  The third most popular reason give is for troubleshooting.   In fact, some companies have received ROI by identifying potential issues before startup.

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  • Certainly technology has opened wide the door for grater use of Process Simulators. These have varying features depending on their origin and cost structure. Of all those I have studied, I have not found a better system than the Yokogawa, Mirrorplant. I would welcome your collective appraisal of such a system, if possible,


  • I'm sure we all agree here that an OTS utilization lowers the risks in O&G industries; but, Have anyone seen any paper of any Environmental Organization that endorses OTS as the technology to be used to do so? Or is there any official recommendation published by any National Regulation Entity? I was searching for some days now, but it seems something difficult to find. Note: I also posted the same question in LinkedIn OTS groups.


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