The hydrocarbon industry has been experiencing dynamic changes in recent years. To maintain safety, stability and efficiency, the need for effective, systematic operator training programs is increasingly felt. The secret of making your plant work optimally and safely depends on harnessing the potential of your human resources. They are the assets who extend it to its limits and make sure that you get maximum return from your investment.

What is ProSimulator ?

Enter ProSimulator, a high-end simulation based training platform for plant operators. ProSimulator provides opportunities to manipulate systems to simulate all possible emergencies and abnormalities, including plant startup, and emergency shutdown that an operator will have to face, when placed in the actual process plant control room. It provides the ability to respond to micro-second variations in the parameters of a process plant and ensure optimal production and absolute safety. ProSimulator offers real-time solutions to real-time problems.

Combining years of operation and simulation experience, we have made possible a technologically advanced dynamic simulator - the ProSimulator is designed to meet your training needs for personnel ranging from fresh operators to experienced engineers, all at an affordable cost.

How can ProSimulator improve your performance?

ProSimulator Instructor Station Tool

ProSimulator has an operator-instructor architecture in which the instructor has a central station to control training sessions, and the trainee operator has the actual simulated process plant system.

Features

Login

• User login
• Change password
• Model status display
• Customer information

 Mode

• Startup mode 
• Snapshot/backtrack 
• Simulation speed 
• Run/hold

Malfunction

• Failures 
• Disturbances 
• Instrument faults

Field Devices

• Block valves
• Globe valves

Advanced Training

• Exercise 
• Monitor

Logging

• PV logging
• Event logging
• Alarm logging
• Summary report
• Message

Tools

• Model view for model developer
• Backup restore
• Training database

Help

• Instructor station user guide
• Operator station user guide
• Process model user guide

ProSimulator Operator Station Tool

The operator station is the heart of any simulation system. It is the window through which an operator or an engineer monitors, controls, and manages the process plant. ProSimulator provides emulation for several standard DCS interfaces including Yokgoawa's Centum XL, CS 3000, and Honeywell's TDC 3000 DCS.

All functions and features that are essential for training are included. With ProSimulator, operators learn dynamic process interactions with the same in-depth understanding of the process, as with fully functioning operator training stations.

ProSimulator contains many standard features of a real DCS console. Using either a PC keyboard, simulated keyboard (on-screen keyboard), or ProSimulator emulated keyboard and touch screen/mouse the trainee can operate the simulated plant.

The features of DCS that are available are :

• Group and detail displays 
• Overviews 
• Trends 
• Schematics 
• Alarms

We use a cross platform RAD tool for developing dynamic data driven graphics and visual components. The tool kit includes an interactive graphics builder for creating 2D and 3D dynamic graphic displays and a number of containers for deploying the graphics in different programming environments, cross platform, and cross browser: for Windows/C++. Any number of operator stations can be connected to the instructor station, thus offering multiple operator station facility.

The ProSimulator Mode Development Tool

Process modeling is done using the ProSimulator software development package. It has an open architecture and offers complete flexibility to simulate a dynamic process in real-time. It can be used for a wide spectrum of applications, ranging from process operator training to complex control system studies, process and optimization.

The ProSimulator Model Development Tool consists of :

• "ProSimulator- LIB" has the building blocks for developing the model.
• "ProSimulator-INIST" for the instructor station to define failures, disturbances, etc. 
• "ProSimulator-OPR" for the operator station to define tag details, grouping etc. 
• "Model View" to test and tune the model. 
• "ProSimulator-CAL" for performing offline process calculations.

The outstanding feature of the ProSimulator model development tool is its simplicity and flexibility in configuring the plant to produce a rigorous dynamic model. This easy-to-use package allows experienced process site engineers with engineering skills to build a model without specialized software skills giving you the ultimate in modeling technology.

ProSimulator Process Model

Rigorous, high fidelity, and dynamic simulation models offer several process plants:

• Basic equipment and instrumentation
• Unit operations
• Compressor and utilities
• Furnace operations
• Advanced distillation unit
• Superheated steam generator
• Ammonia refrigeration system
• Amine absorption and regeneration
• Gas turbine with HRSG
• Batch reactor station
• Fixed bed reactor
• Atmospheric distillation unit
• Vacuum distillation unit
• Fluid catalytic cracking unit
• Hydro-desulphurization unit
• Hydrocracker Unit
• Catalytic Reformer
• Sulphur Recovery Unit
• Steam system and power generation
• Ammonia plant
• Urea plant

Our engineers have extensive experience in developing custom simulation models for the most complex technologies and petrol chemical facilities. We will work with you to define the scope and cost for custom simulation models for your plants. We will need extensive data to develop such custom models; 

• PFD, P&IDs
• Operating procedures (including startup and shutdown procedures)
• Instrument specifications ( including ESD/trip logics)
• Equipment specifications (including pump/ compressor curves)
• Heat and material balance for the entire plant
• Tray data for distillation columns (typically steady state simulation run)
• Reaction kinetics
• Training objectives for defining failures and disturbances to be simulated

Key benefits

• Improved plant safety
• Increased troubleshooting skills
• Faster recovery from external/internal process disturbances
• Efficient plant operations and optimization skills
• Smoother startup and shutdown
• Evaluation of operator proficiency
• Increased familiarization of controls and interlock systems
• Verification of plant design and operation procedures

Technology Platform

Client Server Architecture

Operating System : Windows Environment / Unix
RDBMS : Oracle

When you wish to fully explore the potential of your plant operators and improve plant efficiency, ProSimulator is a dynamic tool that delivers tangible results. Whether its improved safety or better performance, ProSimulator keeps you ahead.