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Operator Training Simulator

The document describes requirements for an Operator Training Simulator (OTS) for an ammonia and urea plant. The OTS will use dynamic modeling and realistic controls to simulate plant operations for training operators. It must mimic the actual Distributed Control System (DCS) configuration. The OTS will include an instructor station, operator stations, and customizable process models for the ammonia and urea units. It is intended to train operators for normal operations, start-ups, shutdowns, and emergencies to ensure safe and efficient plant operation.

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460 views

Operator Training Simulator

The document describes requirements for an Operator Training Simulator (OTS) for an ammonia and urea plant. The OTS will use dynamic modeling and realistic controls to simulate plant operations for training operators. It must mimic the actual Distributed Control System (DCS) configuration. The OTS will include an instructor station, operator stations, and customizable process models for the ammonia and urea units. It is intended to train operators for normal operations, start-ups, shutdowns, and emergencies to ensure safe and efficient plant operation.

Uploaded by

galant_pp
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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11.4.10.5.

OPERATOR TRAINING SIMULATOR

The Operator Training Simulator (as OTS) for Ammonia and Urea
shall be provided and used, primarily to insure safe working
conditions and efficient operation. Additionally, as the PROJECT
become more reliable, operator/ maintenance personnel/ process
training, is also required to maintain expertise on critical but
infrequent operations such
start-ups,
temporary
or total
shutdown, and for handling of emergencies. OTS satisfy all of
these objectives by providing a dynamic model, hand-on, realistic
environment, which represents closely to an actual plant of
Ammonia-Urea 2 project.
The OTS console shall be same manufacturer with DCS console.
The OTS Plant Dynamic Model shall accessible for Owner
modification for future plant development.
The simulator system shall consist of but not limited the
following major components:
Simulation software and hardware as required.
DCS hardware/software as required for database and controls
emulation.
DCS database and relevant operator displays consistent with
Amonia-Urea II project.
All required hardware and software for interfacing the simulation
computers to the DCS hardware/software (The OTS will be
standalone system with no connection to the actual DCS).
Two (2) Instructor Station (Simulation Computer) for each plant.
The simulation computer shall host the simulation, model
development, and debugging and system maintenance software
Operator/Trainee Station (DCS System)
The operator /trainee station shall be the same as the real
PROJECT DCS system and shall contain the following as a
minimum:
Four (4) Operator Stations with two (2) DCS consoles each with
dual stack monitors.
Panel/Field Operations Console
Field Operator Station. Field
Operator
Station
shall
have
capability
for
simulating
remote functions
such
as
starting/stopping pumps or opening/closing block valves as an
option.
Simulation Software. Simulation software consists of:
Instructor System
Operator/Trainee System
Engineering System
Process Model The OTS shall be provided, but not limited to,
customized simulation programs for the following process units
in collaboration with Process Licensor:
Ammonia Plants
Urea Plants
The simulator software shall have a high degree of modularity
to allow models to be easily modified as the process changes. It

shall be possible to create process models by connecting


modules of equipment and assigning physical properties and
other characteristics.
The training simulator needs to be based on the following basic
assumptions:
The simulator software shall have Rigorous, engineering
quality modeling (including any proprietary reaction kinetics and
thermodynamics).
Industry accepted high fidelity OTS platform
Complete model inclusive of Amonia-Urea II process model,
controls and logic
Direct/Emulation connection to DCS specific hardware and
software identical to plant DCS selected
A complete turnkey supply inclusive of all hardware/software,
engineering & development, User training, and packing &
shipping
The system shall be able to simulate the following operations
as results of utilizing the functions included.
Normal operation
Start-up operation (cold start and hot start)
Normal shutdown operation
Emergency (abnormal) operation
The hardware functions of the Trainee System shall be the same
as the DCS system to be used in the real PROJECT
requirements. The operation display shall use the real PROJECT
DCS system configuration, therefore providing the same
operation environment as the real PROJECT requirements. The
graphic display shall be the same as the real plant DCS
graphic display in terms of plant number, equipment numbers
and location, line colour, etc. The loop configuration shall be
the same as the real plant DCS loop configuration. The system
shall be also provided with standard display function of DCS
operator work station.
Overall, the OTS shall be used for the following purposes:
Training on process, normal and emergency procedures, and
abnormal situations prior to startup of the facilities and training
of new operators throughout the life of Ammonia plant facility
On-going training on emergency procedures, abnormal
situations and training for startup and shutdown
Development and maintenance of diagnostic skills pertaining to
trouble-shooting of facility problems.
Validating control systems implementation, safety system logic,
testing alarm management strategies
Conceptual Architecture of OTS
The OTS consists of several logical components that together provide the
overall functionality of the OTS. The below diagram provides a conceptual
architecture of these components.

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