Overall design principle
• Systemic principle
The integrated training simulation plant system should totally represent actual industrial processes by leveraging on physical models of industrial process devices, OTS simulation software, DCS virtual environment, and DCS system software to carry out simulated training for all processes. This would allow the trainees to experience what it is like to control actual plants and actual hands-on experience using the DCS without touching the actual system or the actual plant processes.
• Principle of authenticity
The integrated training simulation plant system equipment and devices simulate actual field equipment and also covers internal structures and working principles in-depth. By using mechanism modeling to establish a “virtual plant”, it is possible to dynamically simulate the plant processes and control logic with a top-down approach. The simulation software’s dynamic models faithfully reproduce actual industrial process states and behaviour, accurately representing industrial field processes in real-time and simulating actual failures.
• Principle of full-coverage
Through the system, the students are able to understand how to operate and maintain the equipment under normal conditions, and be trained in technical operations and process indicator control operations such as a cold start, hot start, normal operations, normal stop, emergency stop, and equipment maintenance. The system is also able to simulate failures through safe approaches to train students to handle different types of emergencies, and operate, analyse, and eliminate failures that may occur during industrial production.
• A better understanding of industrial equipment
China’s best process simulation technology is adopted for the simulation training, incorporating equipment work principles into algorithms, and constructing mathematical models based on process structure. The user’s commands at the front-end are transmitted to the mathematical model at the back-end. The real-time mathematical model will generate actual values of process data in real-time, which will be used to provide feedback on the relationship between operations and industrial processes, allowing students to have a grasp of the working principles behind the actual equipment and processes without visiting the site, thus training the students to develop operational and vocational skills pertaining to common processes and equipment.
• Training of instrument maintenance personnel
Since a program that incorporates both model and devices is adopted, it is not only possible to train students on general processes, but also train instrument operators. The training subjects include:
• Instrument dismantling
• Instrument maintenance
• Pump dismantling and maintenance
• Control parameter tuning
• Control system wiring
• Control system equipment configuration
• Training of equipment operators
Scaled-down field equipment and semi-transparent core equipment are used for all employees to observe and learn the equipment’s inner structure and work principle. The training subjects include:
• Understanding of the equipment’s internal structure
• Equipment dismantling
• Equipment operation and maintenance
• Equipment patrols and checks