KBC has over four decades of deep expertise in developing training programs and industry-leading training content. It is based on this experience that has enabled us to deliver a training program that integrates program design with our high-fidelity operator training platform - Yokogawa OmegaLand.
An operator training simulator is an accurate replica of plant behaviors and operational environments giving plant operators realistic and effective training. Yokogawa OmegaLand powered by Petro-SIM® process simulation is a virtual environment that facilitates training and knowledge sharing among plant operators focusing on plant start-up, shut-down, and normal plant operations. As well as preparing operators for emergency situations and how to respond when equipment malfunctions.
The combination of KBC and Yokogawa means we can provide the industry leading process simulation technology, with the decades of Yokogawa control and operator training simulator experience. Packaged together it supports the largest global companies in developing their training programs, SOP design, and overall competency assurance.
Changes in staff performance put your operations plan and safety performance at risk. This variation in competency and performance levels is typically caused by substandard learning materials, inconsistent training practices, poor learner engagement, and a lack of performance management.
The challenge is to unlock the ambition of the younger generation joining your shift teams, accelerate capability transfer through structured pre-learning and blended learning techniques and shorten the time required off shift for classroom training. Improve reliability, capture margin, and reduce costs by developing shift team practices, operators who take ownership of equipment care in the field, and optimize your operations at the console.
KBC experience has shown that early access to an operator training simulator before facility completion has enabled:
This has resulted in:
The core simulation platform under-pinning our Operator Training Simulator system can be shared between multiple users enabling lower licensing and maintenance costs, and accelerated implementation.
Our platform covers:
Enabling optimization of your investment, reduced training, and easier maintenance.
Existing Petro-SIM and Yokogawa DCS/SIS clients are able to leverage our accelerated implemented project implementation methods.
The two largest technical tasks implementing a new high-fidelity operator training simulator are the underlying simulation model and replicating the control strategy/UI.
A refinery and aromatics plant complex in Thailand had a legacy distributed control system (DCS) that had been in use for more than 10 years. They decided to replace the system with Yokogawa's CENTUM CS 3000. The challenge was to minimize the replacement period while ensuring that the refinery's operators could make the transition to the new system interface and operate the system safely. To facilitate this transition, the refinery decided to purchase the Yokogawa OmegaLand operator training simulator (OTS) and used it to confirm the functionality of the new DCS. In so doing the refinery project team was able to achieve a flawless start-up, with no losses or downtimes, and appreciated OTS's virtual test functions.
KBC's operator training simulator (OTS) with VR enables the field operators to gain a deep understanding of not just the procedure to follow; but how it would look and feel in the real-world giving them a deeper understanding of what to expect when they are encountering various situations. Additionally, it helps to nurture collaborative operations between multiple field and panel operators.
Regional Head
"In many facilities, the available workforce is shrinking, and teams are charged with managing ever more complex facilities, combined with increased levels of automation resulting in the high potential for a lack of knowledge, which is exasperated in times of difficulty. This has made the need for an operator training simulator (OTS) to be more critical than ever, to enable operations teams to explore and develop their knowledge in situations that they would only experience during a plant upset.
We are now seeing the next generation of OTS systems starting to come into reality, by combining leading-edge dynamic simulation with VR/AR; enabling integrated training of panel and field operations. KBC and Yokogawa are tackling this challenge, whilst also integrating decades of KBC experience building holistic competency development programs."
See more details about OTS on the Yokogawa website
