Ask Ron Besuijen

Ron's Response:

Depending on the complexity of your process it can be impossible to write a procedure of every upset. If this was accomplished, could you find the right one in time. Another approach is to train the panel operators to gather information and think through problems. 

Going through situations that are not proceduralized develop information gathering and problem-solving skills. Start with basic malfunctions and evolve to the more complex. Even beginning with determining the difference between a valve failing closed compared to the failure of a flow transmitter is beneficial. They may initially look the same from the graphics unless you have feedback from the valve to the control room. 

Ask them to verify their initial assumptions. Are there indications upstream or downstream of the problem that can validate theories? As the simulator trainer, you will also be acting as the Field Operator and must respond to their requests for a field check. I typically deliver the answers from a recently qualified Operator's perspective and require that I be asked to check everything and not volunteer any information. 

The expectation is that these are growing experiences, and they may not be successful on all of them initially. It is important to distinguish between when they are training versus when they are being tested. If they know it is a training exercise, they will ask more questions and be more open about their thought process. Be clear on what the expectations are. 

They should be able to start the process and manage all the emergency procedures, including shutting the process down. Also, they can handle normal malfunctions, although I like to include some challenging scenarios that are intended to get them to think a little deeper where they may not be successful initially. 

I used to wonder if I was being too devious until I realized the real process sometimes delivered some very challenging problems to our Operators. The sign of a challenging scenario is when it will cause the first alarm to come in at a different system than the system with the problem. 

Also, include at least one process leak scenario that requires them to isolate a part of the process and requires them shut down the plant. There is typically a lot of hesitation to do this. Most of the training is focused on keeping the process online.  Having to make this decision at least once in training will help the trainee work through this if a large leak ever happens. 

Training for upsets on a simulator develops a problem-solving mindset that can be applied to many different failures that have similarities.