Process Control Training—Simulators Are Only Half the Story

By: PERFORMANCE ASSOCIATES INTERNATIONAL Views: 3856 Downloads: 21
Author: Performance Associates International, Inc. Whitepaper/Case Study
simulator mining training process control loops alarms

Download



With reference to greenfield plant projects, using process simulators similar to the designed plant Human-Machine Interface (HMI) or Distributed Control System (DCS) has become common practice. These simulators represent a “virtual plant” based on process modeling of the circuit chemistry and thermodynamics, and on the physical nature of the plant, including equipment, valves, piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process variables, react to alarms, etc., all based on the process simulation model.

 

Performance Associates’ experience is that this complex simulator training is valuable, but only after more in-depth training on the process and control logic. To truly optimize a process plant, prior to simulator training, the control room operators must have detailed knowledge of the following:


  1. Process objective of each process system, comprising a group of unit operations.
  2. Process objective of each unit operation.
  3. Process chemistry and the variables affecting it.
  4. Important characteristics of each unit operation, the variables affecting it, and the impact on downstream unit operations.
  5. Plant control loops, interlocks, and alarms.
  6. Safety issues related to the process and control schemes.
  7. Operating procedures for start-up and shutdown under various scenarios, as well as important operator tasks.

Additionally, trainees must be intimately familiar with the applicable fundamental scientific concepts, such as pressure, temperature, heat exchangers, electricity, PID control logic, combustion, etc. With this fundamental and plant-specific foundation, the process simulator can be fully exploited for training. 




RELATED RESOURCES



Air-Swept Vertical Roller Mill Training
PERFORMANCE ASSOCIATES INTERNATIONAL

Three dimensional animations integrated into a process plant computer-based training program can greatly enhance trainee understanding of process equipment. This is an example ... Read more


Gold Mill Grinding—Example of a Detailed eLe ...
PERFORMANCE ASSOCIATES INTERNATIONAL

This video provides an example of the content and structure of a Performance Associates International computer-based operator training program. In this video, we focus on th ... Read more


Maintenance Cost Control—Is Your System Acti ...
PERFORMANCE ASSOCIATES INTERNATIONAL

Although many mines and processing plants have sophisticated maintenance cost information systems, cost control relies ultimately on management actions based on the informatio ... Read more


Gold and Silver Recovery—Carbon Adsorption T ...
PERFORMANCE ASSOCIATES INTERNATIONAL

Founded in 1983, Performance Associates International (PAI) is the worldwide leader in mine and plant industrial training. Our custom interactive modules have improved start-u ... Read more


Preparation of Effective Computer-Based Operator T ...
PERFORMANCE ASSOCIATES INTERNATIONAL

Effective plant-specific computer-based training (CBT) used in a formal training program can make the difference between a successful start-up and a failure. Or, in the case o ... Read more


Primary Crushing Training Module
PERFORMANCE ASSOCIATES INTERNATIONAL

In this training module, Performance Associates International (PAI) covers the characteristics of a gyratory crusher that’s designed to be the first stage in the size reduct ... Read more