Sleep Better at Night: How to Ensure Your Operators are Competent

Sleep Better at Night How to Ensure Your Operators are Competent

2 © 2015 Honeywell International All Rights Reserved

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


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?


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.


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


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


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


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


UniSim Operations

• Operator Training Simulator (OTS) supports field and console operators

• Scalable, high fidelity process and control model • Comprehensive training features


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


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


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


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


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


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


[email protected] www.hwll.co/UltimateOperator

mailto:[email protected]

http://www.hwll.co/UltimateOperator

Technology

Sleep Better at Night: How to Ensure Your Operators are Competent