moving from simply training operators to ensuring operator competency

2015 Honeywell Users Group

Europe, Middle East and Africa

Moving from Simply Training Operators to Ensuring

Operator Competency

Martin Ross, Honeywell

2 © 2015 Honeywell International All Rights Reserved

Today’s Speaker

Martin Ross, Product Manager

UniSim Competency Suite,

Honeywell Process Solutions

‒ Chartered Engineer with BSc and PhD

degrees in Chemical Engineering.

‒ Over 20 years experience in dynamic

simulation for operator training simulator

production and aftermarket support.

‒ 3 years as product manager for UniSim

Competency Suite

‒ Six Sigma Green Belt certified


Sound Familiar?

Questions What’s the solution?

• Are you the one wakened at night when something goes

wrong?

• Is one shift’s performance different than another?

• Do individuals’ performance vary widely?

• 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?


Challenges

Challenges What’s the solution?

• 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.


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 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

moving from simply training operators to ensuring operator competency

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