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Operator Training Simulator Handbook
Operator Training Simulator Handbook

Operator Training Simulator Handbook: Best practices for developing and investing in OTS

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Operator Training Simulator Handbook

Chapter 1: OTS Introduction

It has been a long time since I wanted to write this book, and as always, time was an issue. The coronavirus lockdown in 2020 managed to give me the time needed to do so. I have been working in the Operator Training Simulator (OTS) field for more than 30 years, and I thought it would be good to document this experience in a textbook that will help many stakeholders in this field.

In this chapter, we will introduce OTS in the process industry and provide a classification of these systems. We will discuss who this book is directed toward and who the stakeholders are that will make the most of the information provided. The industry uses a lot of jargon, and in this chapter, we will look at some definitions to set a base to understand these terms.

Finally, we will discuss what is good for the user and give some sample cases from my past experience in this field.

In this chapter, we'll cover the following main topics:

  • Introduction to OTS
  • Who is this book directed toward?
  • OTS – Multi-Purpose Dynamic Simulator (MPDS) or digital twin
  • OTS jargon and definitions
  • The instructor station
  • OTS types
  • Third-party representation
  • Some use cases

Technical requirements

There are no technical requirements for this chapter. Those who will benefit the most would already be involved with OTS projects as suppliers or contractors. Even if you are not involved with OTS, this chapter will be a good introduction to the subject.

Introduction to OTS

We can start with the fact that, for the last 40 years, flight simulators have been providing the aviation industry with training simulators for all their pilots at all stages of their careers. These simulators have evolved over the years, but they have always had the ability to train pilots before they take their first flight.

Providing this training over the years has reduced air traffic accidents and provided pilots with a huge amount of experience in normal and abnormal flight conditions. Flight simulation has also provided the mechanism to practice evolving safety practices and maintain a very high degree of competence.

I have always asked myself why, if aviation pilots always train on simulators (please refer to Figure 1.1, taken from https://www.cae.com/civil-aviation/aviation-simulation-equipment/training-equipment/full-flight-simulators/), the process industry has not fully adopted this practice for their personnel who take responsibility for the control of major assets; the process industry equivalent of pilots being Control Room Operators/Technicians (CROs/CRTs):

Figure 1.1 – A CAE flight simulator

Figure 1.1 – A CAE flight simulator

You could say pilots have, in their hands, the lives of tens, maybe hundreds, of people if they are flying an Airbus 350 or a Jumbo Jet. Similarly, CRTs are running assets with tens of personnel in the plant while they are maintaining the running parameters, which can go into the hundreds, of atmospheric pressure and very high temperatures, along with fuel vessels that carry a heat capacity of far more than what a nuclear bomb would deliver! So, the risks and responsibilities are equally high and can be compared with flying an aircraft. The industry has changed over the last 20 years, and it has evolved with new projects coming that provide training simulators.

This is the evolution that we need in the industry. In Chapter 4, Going Forward Toward Digital Twins I will describe my vision for the 21st century.

Similarly, the nuclear industry has been actively using simulators, and no nuclear reactor operator will work in the control room before getting their training on a simulator first.

Again, you could ask why all nuclear plant operators train on simulators but thermal plant power plants don't get the same treatment. I think the time has come to change this concept. In every project I have delivered, there was a huge benefit to the users, and the companies that invested in these systems got their Return on Investment (ROI) in no time at all. We will look at some of the examples of these benefits in upcoming chapters.

For now, let's explore what an OTS is.

What is an OTS?

Figure 1.2 shows how Inputs/Outputs (IOs) to and from the field communicate with the control system with its Process Automation System (PAS), Safety Instrumented System (SIS), Fire and Gas (F&G), and third-party controllers such as Compressor Control (CC), for example.

The CRTs in the control room can see the status of the plant through their Human Machine Interface (HMI) screens and can control it from the control room:

Figure 1.2 – A real-life plant

Figure 1.2 – A real-life plant

In an OTS environment (Figure 1.3), the HMI in the OTS control room is exactly the same as the one in the real-life plant, so the CRTs will see no difference between operating the OTS and operating a real plant:

Figure 1.3 – The OTS of the plant

Figure 1.3 – The OTS of the plant

The control system in the OTS environment is an emulation of the actual control system, which also matches the same behavior as the real control system. One difference is that while the real system controllers run on a controller where everyone can handle up to any number of IOs (let's say 100), the emulation will run on a virtual/desktop machine that emulates many controllers in one virtual/desktop machine.

The process in the field is modeled using process modeling software (such as AspenTech's HYSYS®, Honeywell's UniSim®, AVEVA'S DYNSIM®, or NAPCON's ProsDS®). Usually, this will be running on another virtual/desktop machine.

Figure 1.4, taken from https://www.fossilconsulting.com/2018/10/01/purchase-a-training-simulator/, shows how the OTS looks very similar to the control room. The operator should not see any difference between the two:

Figure 1.4 – The OTS of the plant is similar to the control room

Figure 1.4 – The OTS of the plant is similar to the control room

Now that we have defined the OTS system that we will address in this book, let's discuss who this book is directed toward.

Who is this book directed toward?

One of the main issues suppliers are faced with is that end users do not know exactly what they want. So, here, I am trying to provide information for end users to help them understand what is best for them. We will start with defining the necessary specification for an OTS for a new project and continue right through to the project cycles, KOM, data collection, and more until Site Acceptance Test (SAT). We will even look beyond this to the training and engineering uses of the OTS.

As I have delivered many simulators over the years with different suppliers and different setups, I will be including a chapter on project execution and best practices, which will help suppliers access my long experience and discover what really worked during project delivery.

Additionally, a chapter showing the benefits of OTS will list a few real-life examples and the benefits that were achieved. This will provide a useful example of real project work on how the OTS was put to use.

Finally, there will be a chapter on training development and execution. When the OTS/MPDS/Digital Twin (DT) is delivered, the assumption from the end user is that it can be used for training straightaway. This concept is incorrect, and many end users forget that there is a period needed to set up the system to be ready for training, which could vary from weeks to months based on the complexity of the project. This is not to say that this cannot be broken down into smaller pieces, and preparation is only needed for the next deliverable training session, for example, an introduction to the OTS, but still, the length of time required is considerable and will need to be catered for.

Another challenge on the training side is what is known as bums on seats! I reckon this is the most challenging task in training as CRTs/CROs have different tasks to do alongside OTS training. This is more difficult on an offshore project for obvious reasons. So, this task will need to be planned and agreed upon with management well in advance of the actual training dates.

To summarize, contractors that are thinking of investing in a simulator will benefit from this book by seeing what the best practices are to specify a simulator that will give you what you want for the investment that you are taking. In addition to this, it will show them how they can benefit from their system and the best ways of using it.

Vendors will benefit from seeing the best practices of executing these projects; an experience spanning 30 years of delivering these systems and challenges will be shared in this book.

A final group of individuals that this book is directed toward is users and engineers who are thinking of getting into this field. They will also be able to see what these projects are about.

The naming of the OTS systems has been evolving over the years. First, we will go through that evolution, and define every term.

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Key benefits

  • Learn OTS project delivery best practices from the author's 30 years of experience
  • Explore use cases to understand how your OTS systems can maximize ROI for users
  • Discover how to best develop OTS training models for developers and users

Description

Operator training simulators in the process industry have been around since the 1970s, but you may not find a book that documents the development of these systems and the standard best practices. The Operator Training Simulator Handbook covers best practices for OTS engineering and OTS training development and delivery, starting from the basic the jargon and the different types of OTS systems. It will take you through the best approaches to project specification as well as building, maintenance, planning, and delivering these systems by sharing real-life experiences and dos and don’ts. As you advance, you'll uncover the various challenges in the planning and delivery of operator training models and understand how to address those by working through real-world projects. This book helps in specifying the best fit for purpose, choosing a cost-effective system when acquiring an OTS. You'll also learn how you can turn your OTS projects into digital twins before finally learning all about documentation in a typical OTS project, covering the sample structure that you can use as a starting point in your projects. By the end of the book, you'll have learned best practices for developing operator training simulator systems and have a reference guide to overcome common challenges.

Who is this book for?

This book is for suppliers who build and deliver OTS systems, OTS buyers, or companies looking to invest in these systems. Anyone with an interest in OTS systems, including university students or graduates who will work on these systems, will find this book useful. Basic knowledge of either OTS systems, ICSS control systems, or process engineering will help you grasp the concepts covered in this book.

What you will learn

  • Become familiar with the OTS jargon to set a base for understanding OTS aspects
  • Implement training planning methods that have been tried and tested in the industry for many years
  • Get to grips with writing well-planned documentation for your OTS project
  • Review new model suggestions to maximize benefits of the OTS systems and the actual ICSS control systems to maximize ROI for users
  • Understand Cloud OTS systems as a new way to address some of the common issues that developers and users face
  • Create digital twins of your OTS projects
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Publication date : Apr 14, 2022
Length: 238 pages
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Table of Contents

10 Chapters
Section 1: Introduction, Definitions, and Classifications Chevron down icon Chevron up icon
Chapter 1: OTS Introduction Chevron down icon Chevron up icon
Section 2: Best Practices for the Development of OTS Systems Chevron down icon Chevron up icon
Chapter 2: OTS Benefits and Best Use Chevron down icon Chevron up icon
Chapter 3: OTS Project Execution and Best Practices Chevron down icon Chevron up icon
Section 3: OTS' Future, Training Model, and Reference Documents Chevron down icon Chevron up icon
Chapter 4: OTS Going Forward Toward Digital Twins Chevron down icon Chevron up icon
Chapter 5: OTS Training and Delivery Chevron down icon Chevron up icon
Chapter 6: OTS Sample Documentation Chevron down icon Chevron up icon
Other Books You May Enjoy Chevron down icon Chevron up icon

Customer reviews

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Full star icon Full star icon Full star icon Full star icon Half star icon 4.8
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4 star 25%
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Kyle Apr 30, 2022
Full star icon Full star icon Full star icon Full star icon Full star icon 5
I've had the pleasure of working with Joseph on a major new build oil and gas project. He is an expert i his field and it shows in this book.Great reading for anyone with an interest in process simulation, or for those looking to improve efficiency utilising OTS/MPDS/Digital twin in a new industrial project.
Amazon Verified review Amazon
LaLaS May 26, 2022
Full star icon Full star icon Full star icon Full star icon Full star icon 5
I’m not an engineer and I’ve never worked in a plant, but interested in selling OTS’. This book was VERY easy to read and understand for a non technical person! Amazing balance of just enough technical but not too much and your real life examples were PERFECT. Your book will help me in the future. Great job and thank you!
Amazon Verified review Amazon
James Apr 15, 2022
Full star icon Full star icon Full star icon Full star icon Full star icon 5
I have been a simulator trainer for 17 years and have been involved in the development of a simulator facility and acted as project manager of the development of a new simulator model. It would have been very beneficial to have had a guide like this. This Handbook takes you step by step on the selection and setup of a process simulator. The benefits of simulators other than training are also covered with examples. Every aspect of an OTS is covered with flow charts, responsibilities and a list of the documents required. Training plans, maintenance, digital twins and acceptance testing are also covered.I highly recommend this Handbook to anyone interested or working with an Operator Training Simulator.
Amazon Verified review Amazon
steve turner Jun 05, 2022
Full star icon Full star icon Full star icon Full star icon Full star icon 5
This book is a great resource for anyone involved in the OTS field, whether that is considering the procurement of an OTS, specifying, developing or deploying this technology.Joseph walks the reader through the many different aspects of an OTS including Use Cases to illustrate how end-users requirements can (and should) drive the technical specification and scope of the solution.In particular the section on the delivery of training is very important - in my experience this aspect is frequently overlooked, despite this being central to the OTS delivering value.There is a huge amount of real world experience embodied in the book that will benefit anyone involved in an OTS project, enabling them to learn from that experience. All too often an excellent technical solution fails to deliver the expected benefits because of a mismatch between these expectations and reality. Reading this book is a great way to prevent this from happening and I highly recommend it,
Amazon Verified review Amazon
James Apr 15, 2022
Full star icon Full star icon Full star icon Full star icon Full star icon 5
I have been a simulator trainer for 17 years and have been involved in the development of a simulator facility and acted as project manager of the development of a new simulator model. It would have been very beneficial to have had a guide like this. This Handbook takes you step by step on the selection and setup of a process simulator. The benefits of simulators other than training are discussed with examples. Every aspect of an OTS is covered with flow charts, responsibilities and a list of the documents required. Training plans, maintenance, digital twins and acceptance testing are also covered.I highly recommend this Handbook to anyone interested in or working with an Operator Training Simulator.
Amazon Verified review Amazon
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