Accidents ruin profit and image of process plants and accidents are caused mainly due to mechanical failures or operational errors.
Most of today’s process plants like refineries, gas plants, power plants, fertilizer units and petrochemical plants are large, complex and integrated. The quantum of instrumentation, control logics and interlocks involved in these operations is quite enormous and varies from plant to plant. The various advanced control and optimization techniques that are implemented in many plants automate the critical plant operations and greatly remove routine operator actions. Also the existing plants are being upgraded both technology-wise and capacity-wise to give a boost in their performance
Hence the operators tend to loose the integrated plant view, troubleshooting, operating capabilities and exposure. These drastic changes in technology & control systems in the existing plants, if not provided with adequate training to the operating personnel, affect safety, plant performance and hence profitability.
A good training is what is required to tackle and eradicate these problems. Classroom training is inadequate and on the job training is costly and risky. These are overcome with the introduction of a good training tool called the Dynamic Process Simulator.
The mathematical model of a process plant is the core of the Dynamic Process Simulator, which also incorporates the control systems, emergency shutdown logics and interlocks, and startup and shutdown procedures. The simulator presents the emulated view of the Distributed Control System (DCS) of the plant and hence provides very realistic environment for the trainee. The simulator training is controlled and monitored by an Instructor for imparting effective training.
The ProSimulator model is based on the first principles (Laws of Physics), Design and Experimental data from the plant. It consists of algebraic / differential equations representing mass balance, heat balance, momentum balance, reaction kinetics and equilibrium phase equations. These equations are solved numerically on every cycle giving all plant parameters. The Simulator model runs in real time with plant parameters getting updated once every 100 milliseconds. The scope of the model includes all equipments (battery limit – battery limit), discrete events (like safety valves), extreme conditions (cold start to design condition), and unlimited number of streams and components. The scope of the simulated model spans right from a simple centrifugal pump operation to complex process plants like a FCC/Hydro cracker/Ammonia/Ethylene Plant.
