Abstract
This study proposes a method of interactive plant simulation modeling which delivers the online simulated results to the field operators and induces them to take proper actions in the case of pre-identified accident scenarios in a chemical plant. The developed model integrates the real-time process dynamic simulation with 3D-CFD accident simulation in a designed interface using object linking and embedding technology so that it can convey to trainees the online information of the accident which is not available in existing operator training systems. The model encompasses the whole process of data transfer till the end of the training at which a trainee operates an emergency shutdown system in a programmed model. In this work, an overall scenario is simulated which is from an abnormal increase in the main valve discharge (second) pressure due to valve malfunction to accidental gas release through the crack of a pressure recorder, and the magnitude of the accident with respect to the lead time of each trainee’s emergency response is analyzed. The model can improve the effectiveness of the operator training system through interactively linking the trainee actions with the simulation model resulting in different accident scenarios with respect to each trainee’s competence when facing an accident.
Highlights
In 2011, the total revenue of the whole chemical industry came to about 100 billion euros (CEFIC 2011)
This study proposes a method of interactive plant simulation modeling which delivers the online simulated results to the field operators and induces them to take proper actions in the case of pre-identified accident scenarios in a chemical plant
The model can improve the effectiveness of the operator training system through interactively linking the trainee actions with the simulation model resulting in different accident scenarios with respect to each trainee’s competence when facing an accident
Summary
In 2011, the total revenue of the whole chemical industry came to about 100 billion euros (CEFIC 2011). Established operator training systems based on dynamic process simulation like UniSimÒ OTS (operator training simulator) by Honeywell (2005) and AspenÒ OTS by AspenTech have played great roles in training of proficiency in operation procedures and control of risk factors in the chemical process for control room operators (CROPs) They have difficulty in enhancing training efficacy due to limited information delivery for field operators (FOPs). A case study deals with a natural gas pressure-regulating station in South Korea and evaluates the applicability of our model to practical operator training by generating process upsets and accident scenarios, constructing dynamic process and accident simulation models, and developing a demonstration program
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