Operator Training System (OTS) provides a virtual plant on your computer, allowing plant operators to train in plant operations ahead of plant start-up and throughout plant lifecycle. OTS enables the plant operators to gain experience in an off-line, non-intrusive environment without any damage on the actual plant, for both inexperienced and experienced plant operators.
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Key areas for Operational Excellence Transformation
Operational Excellence Transformation is Yokogawa and KBC’s co-innovated portfolio of solutions and services.We provides comprehensive solutions for business automation in all four areas using consulting and digital technology.
Operational Risk Management
Yokogawa's Operational Risk Management deals with managing safety, health and environmental risks on both individual and process levels in a reliable and risk-free manner. It involves the end-to-end process of designing, visualizing and orchestrating plant production and business systems.
Key Operational Competencies in Operational Risk Management
- Process Safety Management: Maintain License to Operate, preserve Business Reputation, and create value by utilizing and adhering to operating integrity processes to prevent loss of containment or catastrophic loss
- Personal Safety Management: Protect human assets by providing safe practices to improve behaviour and culture
- Environmental Management: Provide processes to protect the environment through operating integrity, and ensure compliance with environmental, regulatory and/or internal requirements
- Community Relations: Define and establish processes and protocols to communicate and implement emergency response plans, and enhance interactions in the community
- HSSE Reporting and Compliance: Assure visibility and achievement of HSSE goals and compliance requirements, by monitoring, learning and improving continuously through processes, initiatives and KPIs
- Plant Protocols and Security: Provide processes and strategies to protect assets and infrastructure from threats, and control access to vulnerable processes and equipment
By combining Yokogawa’s product portfolio and KBC’s consulting services, we provide our customers best practices and domain knowledge that empower them to improve their operations, as well as a digital platform that supports such activities and initiatives. Our Operational Risk Management scope does not only cover partial improvements in the organization, but also optimizations in plant operations to achieve continuously improving safety, reliability and operability.
·Supply Chain Optimization
- Optimize management of supply, whether oil in the ground or feedstocks for a refinery or chemical asset, in light of product market demands. This provides operators with the agility to take full advantage of market conditions.
·Asset Operations and Optimization
- Optimize the potential of physical assets, by pushing throughput and maximizing the production of the highest value products, whilst minimizing variable costs such as energy.
- Deliver small and large capex projects, on time and on budget, to deliver growth and meet environmental requirements.
·Asset Management and Integrity
- Confidently ensure asset reliability and availability, whilst controlling maintenance costs. This assures the asset always meets expectations and is always available to capitalize on short term market opportunities.
Operator Training Simulator
Operator Training System (OTS) provides a virtual plant on your computer, allowing plant operators to train in plant operations ahead of plant start-up and throughout plant lifecycle. OTS enables the plant operators to gain experience in an off-line, non-intrusive environment without any damage on the actual plant, for both inexperienced and experienced plant operators.
Customer Challenge
When Process Knowledge is Lost or Forgotten, Potentials for Disaster Increase
About 90%-95% of plant accidents are due to human factors. Human performance and reliability can be affected by many things such as age, state of mind, physical health, attitude, emotions, propensity for common mistakes, errors, cognitive biases - and lack of experience.
Facing the challenge of many plant operators retiring - especially those who are familiar with efficient and safe operations - the early training of rookie operators and successful knowledge transfer, from more experienced operators, has become an important issue. We must ensure that inexperienced operators do not lead to inefficient operations, and potential disasters.
Safe and efficient operations must be continuous; refreshing the skills of experienced operators is also necessary - increasing process knowledge and confidence prevents to the occurrence of a disaster, improves productivity, and efficiency.
Our Solutions
OmegaLand OTS & MIRROR PLANT
With more than 200 systems in Oil and Gas, Refining, Petrochemical, Chemical and Power industries distributed worldwide, OmegaLand high fidelity OTS is one of the leading OTS solution in such industries.
The OmegaLand high fidelity OTS reproduces actual plant behaviors, accurately giving you the ability to provide realistic operations training. The identical DCS, SIS, and graphical user interface gives you the ability to provide realistic operation training environment. High fidelity plant models built for OTSs are able to be leveraged to other purposes throughout the plant lifecycle.
MIRROR PLANT is a solution based on OmegaLand technology and is able to leverage OTS models for the operation phase. As MIRROR PLANT constantly synchronizes with the plant control system, it is able to predict plant internal states and plant responses, contributing to optimized plant operations.
Customer Benefits
Benefits of OmegaLand OTS:
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Training on a virtual plant which has the identical look and feel, reproducing realistic plant behaviors with identical DCS and SIS operational environments
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Gaining plant start-up, shut-down and normal plant operations
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Acquiring how to respond against equipment malfunctions and other emergency situations (early recognition, avoidance, and corrective action)
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Capturing and transferring plant operation knowledge among plant operators
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Increasing process knowledge and confidence in operators (experienced and inexperienced) for better plant operations
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Ability to leverage OTS assets over the plant lifecycle, from the design phase to the operation phase. The OTS assets can contribute to reduce design time and cost, evaluate and improve control strategy, and improve productivity and efficiency
For more information: OmegaLand
Resources
- Operator training system for the critical LNG processes had been built to reduce human errors and achieve operational excellence.
- The high fidelity modeling of LNG liquefaction process closely matches the behavior and operational environment of the actual plant.
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