2013 Honeywell Users Group Americas. Martin Ross UniSim Product Manager Driving Operations Excellence through Better Operator Competency

Transcription

1 Honeywell Users Group Americas Martin Ross UniSim Product Manager Driving Operations Excellence through Better Operator Competency

2 Agenda Driving Operations Excellence through Better Operator Competency context (simplified) role of training simulators software form and function advanced features Shaping the future Summary Q&A 3

3 Overview Process of continuous improvement based on: KPI definition Scientific Measurement Operations Excellence Safety Asset People Controls Operator Competency Focus on People 4

4 The Pyramid of Excellence Operator Advanced Information System Control System Equipment Reliability Safety System Competent Useful Capable Reliable Safe Operational Excellence relies on Competent People 5

5 Economics of Excellence People Impact on incidents: Procedural error (49%) Incorrect actions (22%) Work practices (17%) Installation (6%) Recognize problem (6%) Equipment Impact on incidents: 76% operating outside of range Process 20% Equipment 40% People 40% People Performance drive operational excellence 6

6 Capacity Achieving Excellence Borealis OCP Achieved 58,8% Days from start up 2007 Achieved 92,4% 2002 Achieved 62,2% 1997 Achieved 58,8% On spec. 3 days 10hrs, target 5 days New production target exceeded in 21 days, target 4 months Flaring losses 2000 Tonnes less than before 6 M, 1 st year Competent People Increase Level of Attainment 7

7 Agenda Driving Operations Excellence through Better Operator Competency context (simplified) role of training simulators software form and function advanced features Shaping the future Summary Q&A 8

8 Virtual World What are simulators? The Plant The Plant DCS Networked Dynamic Plant Models Operator Stations Instructor and Engineer 9

9 Benefits What are the types? Customized direct connect High Fidelity OTS Specific Complex Instructor Single Advanced Process Training Simulator Customized Standalone OTS Generic OTS Price Multiple Foundation Simple Self General 10

10 What are the training basics? Basic Training for New Operators Process/Control Familiarization 1 week Initial Startup, Shutdown 1 week Incident Avoidance 1 week, 10 exercises Incident Recovery 1 week, 10 exercises Annual Refresher Training between Turn-Arounds Incident Avoidance 1 week, 10 exercises Incident Recovery 1 week, 10 exercises Capture a lifetime of experience in a 4 week program 11

11 How do training simulators help? Training is specific: Focus on start-up, recurring failures, practice difficult or critical procedures Training is practical: Use familiar console interface with realistic plant responses Training is motivating Goals can be achieved Confidence is built Experimental learning Procedural learning Simulator based training offers unique advantages 12

12 How to get started Plan Identify a Simulation Sponsor from Operations Study Business Drivers Identify Risks in Startup and Operation Propose Training Solutions to Mitigate Risks Execute Scope Simulation for the Training Solutions Create Schedule identifying all dependencies (Data & DCS) Implementation, Delivery, Training, Turnover & Support Careful Planning and Execution are key 13

13 How to keep going Sustain Follow Up - Recognize Earned Benefits Communicate Earned Benefits to Justify Re-Investment Maintenance cost Sustained benefits Share success and continue to improve 14

14 Agenda Driving Operations Excellence through Better Operator Competency context (simplified) role of training simulators software form and function advanced features Shaping the future Summary Q&A 15

15 Honeywell Simulation Architecture Simulation Framework DCS/OPC Interface(s) Soft Controllers Simulation Engines Instructor Station Engineer Station APC Physical Properties FOD Station Dedicated solution architecture is required. 16

16 UniSim Operations Suite User Interfaces UniSim Engineering Station UniSim Instructor Station UniSim / Experion Operator Station UniSim Session Designer UniSim Design UniSim Dynamic Design UniSim Process Dynamic Design Models Process Dynamic Models Process Models UniSim / Experion DCS Interface UniSim Design Dynamic UniSim Safety Manager Control Environment Experion SimC300 Experion Server 17

17 Agenda Driving Operations Excellence through Better Operator Competency context (simplified) role of training simulators software form and function advanced features Shaping the future Summary Q&A 18

18 Advanced Features Virtual Deployments Integration with APC Integration with LMS Integration with 3-D simulation Integration with Competency Management Continuous development and investment in simulation based training solutions 19

19 Virtual Operator Training Systems VM deployment offers new opportunities. 20

20 Integration with APC Interfaces with one or more Profit Controllers on a single Profit Suite R410 node Commands & events between USO and Profit Suite Data communication between Profit Suite and DCS Profit Suite DCS Data Communication Profit Controllers URT OPC Server Data Communication DCS Interface USO Profit Suite Adapter Step & Checkpoint Commands Operator Events 21

21 Integration with LMS Simulation Server Centralizes assets Supports Classroom Training Modes Benefits Engineers create & maintain broad solutions with better consistency Instructors with a better view of trainee performance Trainees supported by better instruction through Learning Management System courses 22

22 Integration with 3-D Simulation Precise modeling, inside and outside the equipment for engineering and training with integration to MindSafe. 23

23 Competency Management inside UniSim Coming in USO R430: ASMC Operator competency model integration Formalizes competency structure for assessments and libraries Comprehensive performance assessment Outcomes (Key Performance Variables) Tasks (Checklists) Competency (Subjective Ratings) Scenario libraries mapped to competencies Generic libraries that can be customized and save for reuse Operator performance dashboards For operator feedback and coaching As part of operator training record 24

24 Agenda Driving Operations Excellence through Better Operator Competency context (simplified) role of training simulators software form and function advanced features Shaping the future Summary Q&A 25

25 Honeywell Development Workflow Ideas Needs Assessment Concept Definition Development Validation Market Introduction Customer Requirements Design & Specification Build Offering Testing Feedback Customer Requirements drive offering development. 26

26 Agenda Driving Operations Excellence through Better Operator Competency context (simplified) role of training simulators software form and function advanced features Shaping the future Summary Q&A 27

27 Summary Operations Excellence System for improving performance People play a key role in attaining organization goals Training with simulators provide unique opportunities Plan, Execute, Sustain Communicate to shape the future We welcome you to the Demo Area 28

28 Agenda Driving Operations Excellence through Better Operator Competency context (simplified) role of training simulators software form and function advanced features Shaping the future Summary Q&A 29