News and Information

Development and use of OTP's and simulation for accredited training and assessment

TSC's 2nd international forum, titled Development and use of OTP's and simulation for accredited training and assessment was held in March in the UK. The 2 day forum was held at CATCH (Centre for the Assessment of Technical Competence in Humberside), the UK's premier vocational process training site facility.

This high profile event attracted attendees from all over the world including Saudi Arabia, USA, France, Algeria, Nigeria, Caspian Sea and Canada and companies such as BP, British Gas, and Centrica, together with attendees from major UK colleges such as Hull and Pembrokeshire.

The forum targeted the development and use of Operator Training Plants and Systems together with blended learning training software, including dynamic process simulation in the CATCH Virtual Control Room to provide accredited training and competence assessment.

The speakers covered a wide range of topics such as Dynamic Simulation for Training, Comp'Ex Training, Blended Learning, Financial Savings Attributed to Simulation, Training Plant Design, Accreditation of new training centres and Competence Assessment.

Presenters included Alistair Shaw of SQA, Scotland's national body responsible for the development, accreditation and certification of qualifications. Malcolm Dawes of Pembrokeshire College, demonstrating the importance of virtual control room in a training environment. Alan Hurren of INRS Training, Dave Dyble of Hull College and Paul Read of Centrica Storage to name but a few.

There is considerable investment in training facilities in many countries to cope with the increasing requirement for competent technical staff to replace the present experience.

The event forged some excellent partnerships between key organisations to enable a more joined up offering to large oil and gas companies around the world.

Pembrokeshire College- VCR

Pembrokeshire College in the south-west of Wales near to the huge LNG terminal and refineries at Milford Haven, is ideally situated to be a training centre of excellence for the process industries in the region. The college has made                significant investment in its facilities over the past few years, culminating in the provision of a TSC Virtual Control Room (VCR) which was installed in February. Designed for the location based on our experience at many other sites, the Pembrokeshire College VCR uses state-of-the- art PC systems, touch-screen keyboards, and multimedia communications systems in conjunction with some of our most powerful simulation models.

The VCR includes four trainee workstations laid out as a conventional control room. The room includes video and audio feeds, hardwired alarm and shutdown panels, and radio and telephone communications with the trainers. In a specially-built trainers’ room, one or two trainers can either run a single process across all of the  workstations, or they can run separate models on different workstations to     promote communication skills between the operators. Full event log and CCTV monitoring is used to provide evidence of competency for the trainees.

The Trainer facilities include being able to start the model in any previously saved condition, introducing faults and unusual situations on an individual or scenario basis, and “role playing” as field operators, emergency services, workshops, supervisors etc, using the telephone or radio communications with each trainee  workstation. The trainers are also able to play pre-recorded video of scenarios such as flare stacks, internal furnace flame monitors, entry gates etc/ on monitors within the control room, to provide realistic feedback during scenarios.

The system has been supplied with several TSC models, including fractionation columns, oil production systems and LNG receiving and export compressor facilities. Initially using emulations of Honeywell and Foxboro DCS, the TSC system may also be used to emulate Delta V, ABB and other industry standard DCS systems. The VCR will run any of the range of standard TSC models, and may also be used in the future to run site-specific dynamic simulations for other processes in the South Wales region.

30th Anniversary of the First TSC Simulator

1979 saw the start of the development of the first dynamic process simulator for BP - and TSC are proud that BP has remained our major client right up to the present time. The UK was in the early days of exploring its North Sea oil and gas reserves, and had decided on a land terminal to be based in Sullom Voe in the      Shetland Islands. Two 150 mile long pipelines from the new Brent and Ninian Fields were to deliver up to 1.5 million barrels of oil a day to the Terminal.

In 1979, BP Petroleum Development required a process control training aid to help train new local operators,particularly on the Gas Fractionation Train at the terminal. At that time, the TSC team were a part of a company that specialised in training equipment and were UK-approved microprocessor application consultants. Over a 6-month period, the first-ever process simulator based on a digital computer was developed, using chemical engineering expertise help from Aston University in Birmingham. The unit was designed to look just like the actual control room panel, complete with the Kent Flexel controllers. An Intel 8085 single board computer with 32k EPROM memory used a Fortran program to run a mathematical model of the process. At the rear of the simulator cabinet, a fold-open panel allowed the instructor to enter up to 14 predefined faults into the model using a simple keypad and fault list. After a couple of years of successful operation, the unit was upgraded to enable alternative sets of EPROM memory to run simulated models of the de-ethaniser, or the overhead refrigerant compressor. It was to be another 5 years before the first graphics screens were to be used in the control room – and TSC were invited to use this medium for their simulators – and another 10 years before the first effective use of a simple 386 PC for dynamic process simulation.

30 years on, TSC remains at the forefront of technology for process simulation. Over the next months, we will be announcing our next generation of system software.  

TSC's 'Next Generation' upgrade for the basic generics range

TSC are proud to announce the 'Next Generation' upgrade for the basic generic range of simulations models. Widely used around the world for process, plant and control systems introduction, the TSC generic range of over 40 models has been given a complete facelift with many enhancements, including:

• Modern DCS style interface, with multiple graphic screens for the larger models.
• User Guide and Workbooks built into the models.
• DCS style controllers and faceplates based on the best elements of industry standard DCS systems.
• Speed-up and slow-down runtime function.
• Remote starting and monitoring over TCP/IP LAN for classroom use.

for further details please contact Lyndsey Done

TSC classroom simulation system supplied to Waha Oil

A complete classroom system for 10 Trainees and the Instructor has been supplied to the Waha Oil Company in Libya. Each Workstation is able to run either the complete TSC SIM675 Oil Production System model, or each may chose to run the TSC SIM676 Gas Production System model. The DCS based models include all the major components of typical full systems, including wellheads, separation, compression, water treatment, gas dehydration, tank storage, pipelines, and jetty loading of tankers.

The networked system is under the control of the Instructor PC, who may remotely monitor all of the trainees actions, and print or save any event log from any of the PC’s.

A team of engineers from Waha Oil spent a week at TSC recently to approve the system before shipping to the Waha Training facility in Tripoli. On arrival, the classroom was commissioned by TSC engineers with full Instructor Training.

The supply follows a successful visit by engineers from the Waha Oil Company to the TSC office suite in Tripoli, which was reported in the March 2007 Newsletter.

TSC develops a USB-connected shutdown panel

TSC has developed a cost-effective USB connected Shutdown Panel for use with its emulated training simulators.

The panel uses standard pushbutton, keyswitch and lighting components as normally found in the control room. The internal USB interface to a standard PC running under Windows allows the panel’s interactive use with the major TSC models. First supplied for the BP Shah Deniz simulator in Baku, Azerbaijan, the unit provides a cost-effective interface for shutdown, ESDV, Fire and Gas and Keyswitch activation procedures as a part of the training exercise. The panel is configured and built for each particular application on a site by site basis.

Mounted on a standard Flat Screen Monitor adjustable stand, the USB connected shutdown panel is a flexible addition to all our major DCS emulated models.

TSC updates the simulator suites at ASET

The simulator suites at the ASET Training Centre in Aberdeen have long been recognised as some of the finest in the UK. Originally built by Shell for their UK North Sea operational training, Aberdeen Skills & Enterprise Training Ltd assumed control of the Centre in 1999 as the commercial arm of Aberdeen College. TSC has now supplied a new generic Offshore Platform operator training simulator into the suite, together with a set of over 300 basic level training models into a classroom at ASET.

A third element, a special built-for-purpose Management of Major Emergencies simulator has now been designed for the simulator suite in conjunction with ASET staff.

Probably one of the most powerful and flexible offshore platform models of its type in the world today, the MME simulator allows the trainer to take full control (including failures) of over 800 gas/smoke/fire sensors and alarms, process conditions and outside communications systems. Scenarios from simple exercises to completely calamitous situations can be simulated, for training and assessment for operators and managers up to OIM level.

Further information on courses held at ASET is available on www.aset.co.uk

TSC features in the 'Chemical Engineer'

TSC’s Simulation Engineer Sam Jago featured in a double - page report in the Institute’s monthly publication ‘The Chemical Engineer’. It outlined the use of TSC simulators in the training and development of engineers and process operators.

With the declining number of engineering graduates and fewer people working in the process industry, personnel training and development is becoming increasingly important. In the report, Sam explains how simulations at all levels can be used in the training and assessment of process plant personnel.

Simple models of unit operations can be used to teach the basic principles of chemical engineering, whereas site specific DCS emulations can be used to teach the full complexity of a real process plant before it has even come on line. In virtual reality control rooms, TSC Simulations can be used to practise emergency procedures. This can help to prepare the operators to deal with the stress involved with the situation, whilst also helping to make communications with the emergency services more efficient

Read Sam Jago's article here 

GlaxoSmithKline

TSC have now produced eight computer based training units for GlaxoSmithKline, a leading research based pharmaceutical firm, to be used for their own operator training and assessment.

The training package builds from an introduction to the site specific Distributed Control System (DCS) through to Advanced Operator Training and includes fault finding and incident recovery and prevention. In addition to DCS training, the units refresh the trainee’s knowledge of basic Chemical Engineering Principles.

Each training unit starts and finishes with a series of questions.  The trainee’s results are logged to a file and a training certificate is automatically produced on completion.  The training process does not require supervision or marking so the trainee can complete the training courses whenever convenient and progress through at their own pace.  The implications of this are that training resources go further and administration and supervision requirements are dramatically reduced.

TSC have also supplied GSK with a simulation of a generic pharmaceutical batch process.  The process is sequence controlled and the interface is an emulation of the DCS System used on site.

Trainees can practice controlling a sequence controlled batch process.  An instructor / trainer can introduce faults, such as failure of an instrument, pump or valve, to test the trainee response.  This type of training is extremely beneficial in improving safety and loss prevention.

A 'CATCH' for TSC on Humberside

The Centre for the Assessment of Technical Competence – Humber (CATCH) has been created to satisfy the practical requirements of training and assessment for the 14 or more large chemical establishments on Humberside in the UK. TSC has supplied the computers and simulation software for a Virtual Control Room, which is being operated by TTE under their ProSimm™ banner. 
 
Costing £8 million and taking six years to complete, CATCH is a ground-breaking facility which uses full scale plant and simulators to provide realistic equipment in safety, and was built in direct response to industry needs.   
  
The ProSimm unit at CATCH includes four trainee workstations laid out as a conventional Control Room. The workstations include fully programmable touch screen keyboards,where emulations of alternative DCS keyboards are automatically displayed depending on the simulation model started. 
 
The facility includes simulations of a Fractionation Train, an Olefins Continuous Reactor system, and several single plant systems including compressors, various control loops, and a reflux drum condenser system. 

 
An associated Trainer room allows full monitoring, control and fault injection on any of the models. In addition, the system is equipped with radio and telephone links that the trainer may use to role-play,to develop and assess the communication skills between the trainee operators and field 
operatives/emergency services etc. 
 

Laptop based classroom trainer package

TSC Simulation have developed a low cost Classroom package based on a laptop computer and 10 of our most widely used Basic Process Models. 
 
The system has been created to form a cost effective tool for Universities, Colleges and Training Centres, to enable them to use the same techniques as the major process companies. The simulations may be used by the Instructor one-on-one with Trainees, or may link to a digital projector for whole class teaching. 
 
Utilisation of simulation based training offers benefits such as increased training effectiveness, improved recall and understanding and an increase in the understanding of complex processes.  Research has shown that virtual reality training is more realistic, lasting and memorable for the trainee than any other form. 
 
Generic models are available in the following five categories and examples of each are included in the above.  If you have specific requirements, please contact us to discuss: 
 
1. Basic Control Principles, including basic PID control, flow and pressure control and valve characteristics. 
2. Complex Control Principles, including direct and cascade control and split range level control models. 
3. Basic Plant Sub-systems, including Centrifugal compressor and three phase separation models. 
4. Basic Plant Systems, including separation trains and advanced two stage compressor models. 
5. Advanced Generic Systems including networked batch reactor and benfield process models. 

New Gas Turbine simulations Launched

TSC have developed two new generic Gas Turbine simulations to add to their increasing portfolio.  The new simulations covering a Basic Gas Turbine and a Gas Turbine Control System are now available for purchase.  These models are excellent training packages both for students of chemical engineering and plant operators.

The simulations provide a cost effective introduction to the controls and concepts of a Turboshaft Gas Turbine unit and a Boosted Turboshaft Gas Turbine unit.  This equipment, used widely in the Oil and Gas industry, also allows for the introduction of concepts such as the relationships between temperature, pressure, power and speed in a gas turbine and start-up and shut down procedures. 

The simulations allow for specific conditions to be set and trends monitored and analysed.  They are a useful tool for engineers to understand the implications of temperature and speed on pressure and power and how to manage these factors in a realistic environment.

All of our simulations are available both as stand alone software which can be installed from CD on any windows PC or ready installed on custom laptops. 

New FPSO simulation launched

TSC have developed a new generic FPSO simulation to add to their increasing portfolio.  The new simulation emulates a Floating Production, Storage and Offloading (FPSO) Vessel and is now available for purchase.  This model is excellent as a training package both for students of chemical engineering and those working closely with FPSO’s.

The FPSO vessel model can be used to train operators on correct facility use, safety and emergency shutdown procedures as well as the control of components such as compressors and the processes of cleaning and re-injection of gas and water.  As a basic simulation, once set up with the correct conditions, it allows for trend analysis, cause and effect reporting and scenario planning.

All of our simulations are available both as stand alone software which can be installed from CD on any windows PC or ready installed on custom laptops. 

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