Sleep Better at Night How to Ensure Your Operators are Competent
Aug 17, 2015
Sleep Better at Night How to Ensure Your Operators are Competent
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Today’s Speaker
John Roffel, Product Director Simulation and Competency, Honeywell Process Solutions ‒ Bachelors and Master degrees in Chemical
Engineering ‒ Over 25 years experience in dynamic simulation
and advanced process control, including 22 years APC and simulation project experience.
‒ Global business leader for simulation and competency product lines
‒ 1991: First Users group as a Honeywell customer ‒ Six Sigma Green Belt certified
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Sleep Better at Night?
Fully Competent Operators Sleep Better
• Are you the one wakened at night when something goes wrong?
• Is one shift’s performance different then another? • Do individuals’ performance vary widely? • Do you and your organization have full Confidence in
the operations team’s abilities? • Would you like to better understand your
team’s strengths and weaknesses? • Could you demonstrate to an investigator
that your team is fully qualified? • Is your training yielding the right results?
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Sleep Better at Night – Challenges
A Moving Target – Always Aiming….
• Culture and Expectation of Continuous Improvement ‒ Safety, Compliance and Operational Performance ‒ Last year’s performance is this year’s baseline. ‒ Constant expectation to be better
• Experience literally walking out of the door through retirements and attrition
• Operational assets in remote locations, needing to train a local workforce.
• Wide variation in people, abilities and capacity to learn.
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Sleep Better at Night – More Challenges?
Yesterday’s Techniques – Not Valid Today
• Increasing Complexity ‒ Training as in the past, isn’t going to cut it today
• Increasing Automation, Advanced Process Control ‒ Autopilot limits real world experiences
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Why Focus on Competency?
• Errors and inefficiency cost money
• U.S. process plants lose over $20 billion annually from abnormal situations
• Largest contributing factor is people; +$8 Billion
Competent Operators Improve Performance
People 42%
Equipment 36%
Process 22%
http://www.asmconsortium.com
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The Problem of Operator Competency
Operator Competency Management
• Complex process operations requires a fully competent operations teams
• Evolving training needs, solutions and scope. • What if:
‒ You could replicate the performance of your best operations team, every day, every shift?
‒ You could capture and propagate knowledge and experience ‒ You could do this with a confidence
• Significant Challenge • Significant Opportunity
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Creating and Managing Competency
Ensuring Well-Rounded Competency Training
• Industry leader with over 30 years Operator Training Simulator experience
• Continued focus on operator competency WITH required tools
Implementing proven training process:
Build Training Plan
Define Required Tools
Measure Skills Evolution
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UniSim Operations
• Operator Training Simulator (OTS) supports field and console operators
• Scalable, high fidelity process and control model • Comprehensive training features
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UniSim Curriculum
• Deploy and manage a structured competency program
• Fully customizable predefined field and console operator competency model and content library
• Competencies evaluated using UniSim Operations exercises, UniSim Tutor and/or other training methods
• Expandable to maintenance, process engineering and other key competencies
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UniSim Tutor
• Knowledge capture and propagation tool
• Great supplement for OTS, fully integrated with UniSim Curriculum’s Competency library
• Effective systematic approach to knowledge and skills development
• Augmentable knowledge base can be easily and fully supported by customer
• Improves Operators’ decision making abilities.
What If
Diagnose
Graphics
Training Evaluation
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UniSim Field View
• Train as a team; Extend OTS Training to the Field Operator
• High resolution photographs produce a 360 degree panoramic representation of the process plant
• Hotspots overlays enable interaction with equipment and dynamic field measurements via the simulator
• Minimize field operator mistakes via credible training experience
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UniSim 3D Connect
Field Operator Virtual Training Environment
Control Room Operator Operator Training Simulator
• 3D model act as “Field Operator Station” • Actions in 3D can be linked to the UniSim OTS • Evolving virtual reality deployment and navigation
options
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Example of Field Operator Training
Using a 2D or 3D environment connected to the UniSim OTS, field operator training can be incorporated at specific points in a complete end to end training process.
FIELD OPERATOR TRAINING PATH
Trainee Re-evaluation
On-the-job Training
End of training Field Operator
Failure
Final Exam Success
Process Overview HSE Fundamentals Technical
Training Start Detailed Process
Equipment Process Control Field Exercises Troubleshooting
Preventive Maintenance for Operators
Field Exercises
Field Operator Overview Field Exercises
Joint OTS Field Operator
Exercises
Field Exercises
On-the-job Training
Field Exercise
• Normal operation parameters • Instrumentation malfunctions • Troubleshooting skills
• Familiarisation with layout • Location of main pieces of
equipment • Identification of emergency
equipment
• Line tracing • Location of instrumentation,
control and relief valves • Start and stop motor equipment
• Lock-out and tag-out • Equipment isolation
• Rounds • Sampling procedures • Shift handover
• Start-up • Shutdown • Malfunctions
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UniSim Competency Suite
UniSim 3D Connect Field Operator Training
UniSim Curriculum ASM Operator Competency Model
Plan Tools Results
UniSim Tutor Knowledge Based Training
UniSim Operations Operator Training Simulator
UniSim Field View Field Operator Training
Competent Teams are Safe, Efficient, Productive and Reliable
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[email protected] www.hwll.co/UltimateOperator