Interactive plant simulation modeling for developing an operator training system in a natural gas pressure-regulating station.
This study proposes a method of interactive plant simulation modeling which delivers the online simulated results to the field operators and induces them to take proper actions in the case of pre-identified accident scenarios in a chemical plant. The developed model integrates the real-time process dynamic simulation with 3DCFD accident simulation in a designed interface using object linking and embedding technology so that it can convey to trainees the online information of the accident which is not available in existing operator training systems. The model encompasses the whole process of data transfer till the end of the training at which a trainee operates an emergency shutdown system in a programmed model. In this work, an overall scenario is simulated which is from an abnormal increase in the main valve discharge (second) pressure due to valve malfunction to accidental gas release through the crack of a pressure recorder, and the magnitude of the accident with respect to the lead time of each trainee's emergency response is analyzed. The model can improve the effectiveness of the operator training system through interactively linking the trainee actions with the simulation model resulting in different accident scenarios with respect to each trainee's competence when facing an accident. [ABSTRACT FROM AUTHOR]/nCopyright of Petroleum Science is the property of Springer Science & Business Media B.V. and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Modeling of an interactive plant simulation. The study suggests a real-time 3D Computational Fluid Dynamics (3D–CFD) data processing method to increase the training effectiveness of the model.
A rating system was designed to evaluate the performance of the trainee. No further metrics or KPIs reported apart from technical values for modelling pipes, valves, discharge models…
Through the planned simulation linking structure, the model leads trainees to actively analyze process variable trends based on the simulation results and take proper actions with their own decisions to stabilize the variables or minimize operational losses. No deviations were reported by the authors.
No data was collected apart from specific data to model the pressure-regulating station
This study aims to develop an interactive plant simulation model in which the dynamic process simulator and self-developing discharge model are directly linked, and especially for a gas dispersion scenario, pre-calculated offline 3D-CFD data are processed real time with respect to trainees’ emergency actions. Simulated results are delivered to trainees so that they can correctly understand the abnormal situation based on the information from the model and actively take proper actions in the programmed interface. Then, the actions affect the process and accident simulation simultaneously.
The model could be applied to a more complex process such as a petrochemical plant in the future, and higher effectiveness of training is expected as the operating procedure becomes more complex
The developed interactive simulation model in this study could provide a training interface between operators and a training instructor and guarantee the reality of the upset situation by process and accident simulations. The training results of each trainee can be compared and the associated analysis would affect the emergency response manual in detail and the controller design in an emergency shutdown logic.
This study proposes a method of interactive plant simulation modeling which delivers the online simulated results to the field operators (FOPs) and induces them to take proper actions in the case of pre-identified accident scenarios in a chemical plant. The model can improve the effectiveness of the operator training system through interactively linking the trainee actions with the simulation model resulting in different accident scenarios with respect to each trainee’s competence when facing an accident.
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