Ask Ron Besuijen

Ron's Response:

Process startups can be very challenging as there can be several systems coming online at the same time. This can be very challenging to cover in a step-by-step procedure when several activities can overlap on different pages of the procedure. Simulator training allows the operator to develop a mental model of the timing and interactions.

I believe starting up the equipment first is the most beneficial. It allows the trainee to work through all the controllers, and associated logic. It allows them to build some confidence. Hitting them with malfunctions right from the start can be overwhelming.

Having them review the start-up procedures with a qualified Operator before the training is helpful and then again just before going through them on the simulator. Highlighting the key steps and explaining the intent of each step can make this easier to manage. 

Understanding the reasons for each step and being able to think it through is preferred to only following each step of the procedure. This will prepare them to think through problems as there typically is some sort of failure during a start-up.

A simulator is also an excellent tool to improve startups which reduce flaring losses and allow the unit to reach full capacity faster. Different approaches can be tested and validated before being implemented in the unit. The procedures can be updated and then as importantly operations can be trained and allowed time to buy into the new approaches.

A simulator is a very powerful tool and can be used for a variety of purposes. Improving Process startups is just one of them. A simulator training program consists of preparatory work and hands-on experience, where board operators practice key routines such as startup, emergency procedures, and handling malfunctions or failures. These will be covered in future ProseraPods.