Operator Training Simulator Handbook

Operator Training Simulator Handbook

by Joseph Philip
Released April 2022
Publisher(s): Packt Publishing
ISBN: 9781803242958

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Book description

Make the most of OTS systems in operator training and engineering

Key Features

  • 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

Book 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.

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

Who this book is 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.

Table of contents

  1. Operator Training Simulator Handbook
  2. Foreword
  3. Contributors
  4. About the author
  5. About the reviewers
  6. Preface
    1. Who this book is for
    2. What this book covers
    3. To get the most out of this book
    4. Download the color images
    5. Get in touch
    6. Share Your Thoughts
  7. Section 1: Introduction, Definitions, and Classifications
  8. Chapter 1: OTS Introduction
    1. Technical requirements
    2. Introduction to OTS
    3. What is an OTS?
    4. Who is this book directed toward?
    5. OTS – MPDS or digital twin
    6. OTS jargon and definitions
    7. The instructor station
      1. Run/freeze
      2. Initial conditions
      3. Snapshots
      4. Backtracks
      5. Malfunctions
      6. Instructor scenarios
      7. Record and playback
      8. Simulator speed (real time)
      9. FODs
    8. OTS types
      1. Representation
      2. Fidelity
      3. ICSS representation
    9. Third-party representation
    10. What is good for me?
    11. Some use cases
      1. Case study 1
      2. Case study 2
      3. Case study 3
      4. Case study 4
      5. Case study 5
    12. Summary
    13. Questions
  9. Section 2: Best Practices for the Development of OTS Systems
  10. Chapter 2: OTS Benefits and Best Use
    1. Technical requirements
    2. Generic simulators
    3. Replica simulators
    4. Low-fidelity simulators
    5. Medium-fidelity simulators
    6. Emulated ICSS representation
    7. High-fidelity replica simulators – digital twins
    8. Operations
    9. Control engineering
    10. Process engineering
    11. Examples of OTS projects
    12. Project 1
    13. Project 2
    14. Project 3
    15. Project 4
    16. Best use of an OTS
    17. Examples of best use
      1. Project build
      2. Procedure checkouts
      3. Control tuning
      4. Training
      5. Emergency response training
      6. Engineering studies
      7. Updating the OTS system
    18. Examples of OTS issue findings
      1. Potential safety incident
      2. Water injection pumps
      3. Water injection pump not starting
      4. Control valve mechanical stop
      5. Cooling high-temperature water
      6. Simple HMI mistake
      7. Sand sequence issues
      8. Trip and alarm schedule
      9. Turning gear engage
      10. Compressor train 2
      11. Well alignment
    19. Summary
    20. Questions
  11. Chapter 3: OTS Project Execution and Best Practices
    1. V-model
    2. Making the decision to acquire an OTS
    3. The SOR
    4. Project decision and award
    5. Kick-off meeting
    6. Typical agenda for the KOM
      1. Introductions and project contacts
      2. KOM objectives
      3. Project overview
      4. Project organization
      5. End user
      6. Project manager
      7. OTS consultant
      8. Training instructor
      9. Document controller
      10. ICSS control engineer
      11. Process engineer
      12. Other third-party controls
      13. Operations
      14. Engineering procurement c
      15. Scope-of-work review
      16. Schedule review
      17. Specification and design
      18. Test and acceptance
      19. Data collection
      20. Action list
      21. Meeting close
    7. Detailed design specification
    8. Functional design specification
    9. Documentation
    10. Model topology
    11. Model thermodynamics
    12. Instructor station
    13. ICSS controls
    14. Non-ICSS controls
    15. Model build
    16. MAT
    17. Integration with the ICSS
    18. FAT readiness
    19. FAT
    20. Shipping and installation
    21. SAT
    22. Warranty
    23. Training
    24. System maintenance
    25. Engineering maintenance
    26. Train the trainer
    27. Summary
    28. Questions
  12. Section 3: OTS' Future, Training Model, and Reference Documents
  13. Chapter 4: OTS Going Forward Toward Digital Twins
    1. Technical requirements
    2. Reaching the promised land
      1. Model build
      2. ICSS build
      3. Integration with the DT
      4. Benefits of the model
      5. Challenges
    3. The cloud is the way forward
    4. 3D virtualization
    5. Summary
    6. Questions
  14. Chapter 5: OTS Training and Delivery
    1. Technical requirements
    2. Planning OTS training
    3. Training and competency philosophy
    4. Criteria of success
    5. OTS standards
    6. Training and assessment matrix
    7. OTS training plan
      1. Prerequisite training course
      2. Introductory training course
      3. Introductory lite training course
      4. Intermediate training course
      5. Advanced training course
      6. First gas/oil training course
    8. Sample training plan
      1. Scheduling
      2. OTS location – during the initial training phase
      3. OTS location – beyond the training phase
      4. Cloud OTS is the solution
      5. OTS usage schedule
    9. Learning management systems
    10. Summary
    11. Questions
  15. Chapter 6: OTS Sample Documentation
    1. V-model document structure
    2. SOR document template
      1. Introduction
      2. OTS overview
      3. Model overview
      4. Trainee environment
      5. Instructor environment
      6. Engineering environment
      7. Process models
      8. System requirements
      9. Training requirements
      10. Documentation
      11. Acceptance testing
      12. Project management and project delivery schedule
      13. Maintenance aspects
      14. Quality assurance
      15. Appendices
    3. DDS document template
      1. Introduction
      2. Objectives
      3. Overview
      4. Process model and modeling standards
      5. Non-ICSS controls
      6. Instructor station
      7. Appendices
    4. FDS document template
      1. Introduction
      2. Objectives
      3. Overview
      4. Software and hardware design
      5. Process model and modeling standards
      6. Non-ICSS controls
      7. Instructor station
      8. System integration
      9. ICSS
      10. OTS communication
      11. General
      12. Appendices
    5. MAT document template
      1. Introduction
      2. Test methodology
      3. MAT procedures
      4. Appendices
    6. FAT document template
      1. Introduction
      2. Test methodology
      3. FAT procedures
      4. Appendices
    7. SAT document template
      1. Introduction
      2. General
      3. Document practices
      4. Prerequisites
      5. SAT equipment tests
      6. Site acceptance testing functionality test
      7. List of incident log sheets
      8. Test log appendices
    8. Instructor manual document template
      1. Introduction
      2. ICSS process control system overview
      3. OTS power up and power down
      4. Instructor interface overview
      5. Instructor training features
    9. Maintenance manual document template
      1. Introduction
      2. System architecture
      3. System description
      4. Base software
      5. System maintenance and diagnostics
      6. System features and notes
      7. System backup
      8. System restore
      9. System update
    10. Model manual document template
      1. Introduction
      2. OTS overview
      3. Process model
      4. Other process model packages
      5. Appendices
    11. Project execution plan document template
      1. Introduction
      2. Scope definition
      3. Execution plans
      4. Execution
    12. Training and competency philosophy document template
      1. Introduction
      2. Objective
      3. Scope
      4. OTS training model
      5. OTS standards
      6. Definitions and details of OTS standards
      7. Training and assessment matrix
      8. Training model next steps
    13. Training plan document template
      1. Introduction
      2. Competency and assessment
      3. OTS training program
      4. Training plan
      5. Prerequisite training
      6. Introductory training
      7. Introductory training (lite)
      8. Intermediate training
      9. Advanced training
      10. Initial startup training
    14. Data collection document template list
    15. Summary
    16. Questions
    17. Why subscribe?
  16. Other Books You May Enjoy
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Product information

  • Title: Operator Training Simulator Handbook
  • Author(s): Joseph Philip
  • Release date: April 2022
  • Publisher(s): Packt Publishing
  • ISBN: 9781803242958