Operator Training
Operator training models consist of an underlying model of the process, integrated to a graphical interface that replicates the actual control system used by the process operators.

At PlantLife we supply four main types of operator training system. These include simulated, emulated, virtual stimulated and stimulated. All four operator-training systems consist of a model of the underlying process integrated to a graphical user interface.

Simulated systems use a range of graphical interfaces mimic the look and feel of the actual control system. However, although simulated systems may look like the actual control system, they will respond differently and require different controller tuning constants to the actual control system. This is because simulated systems make use of the generic controllers available from within the simulation software and have different ‘Ziegler Nichols’ controller algorithms to the actual control system.

Emulated systems use an emulation of the control system that has been developed by the control system vendor or by some third party. Although the look feel and response of an emulated system should be better than a simulated system, it will still not use exactly the same controller algorithms, it will respond differently to the real control system and require slightly different controller tuning constants.

Virtual Stimulated systems use a software copy of the actual control system and can only be supplied by the control vendor. Unlike the emulated system, this uses exactly the same control system algorithms as the actual control system. Virtual stimulated systems respond exactly like the real system and controller tuning constants can be transferred directly between the training simulator and the actual control system. In addition control system software can be developed and transferred between the virtual stimulated system and the actual control system.

Stimulated systems are integrated to the actual control system hardware. Stimulated systems have all the advantages of virtual stimulated systems with the addition of training on system hardware such as swapping control cards and system wiring. Stimulated systems require a complete copy of the actual control system hardware and are therefore the most expensive.

All operator-training systems improve operator understanding and lead to improved operation and productivity with less wear on equipment and reduced down time.

By developing operator-training systems early at the design phase of a project considerable additional benefits can be achieved. These include:
Early commissioning of control systems leading to fewer or no surprises at start-up.

Development and commissioning of operating procedures and sequences ensuring start-up is not delayed and shutdowns and modifications are not required during production.

Operator feedback and buy-in ensures that operators have been part of the control system design and are much less likely to place control loops into manual or bypass the control strategies due to poor understanding or belief that their way of operating is better.

Operator training and readiness in parallel to construction leading to faster start-up times and higher production rates from day one.

At PlantLife we have a long history of providing operator training systems and ensuring that they are robust enough to withstand mal operation, start-ups, shutdowns and normal production. In addition we have developed a comprehensive suite of operator training applications, ProspecTS, to rapidly develop operator-training systems cost effectively, that are tailored to the operator training requirements of our clients.

A Typical Operator Training System