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UniSim OTS Platform Migration and

Maintenance Benefits

Executive Summary

The oil and gas production, gas processing, petroleum refining and chemicals

industries make widespread use of Operator Training Simulators (OTS) for training and

competency management of process operations staff. The training simulator provides

the tools and techniques for trainees to experience and practice routine normal, non-

routine normal (start-up and shutdown) and non-routine abnormal (emergency

operations) activities in a safe environment.

The training simulator plays a critical role in operational effectiveness and competency

management. To ensure credible and realistic trainee experiences and outcomes, the

OTS must be relevant, reliable and realistic, aligned with industry training trends while

reflecting, as much as practical, the current real world dynamic operating environment.

The face of the training simulator system is the set of instructor features, training tools,

man-machine interface and integration capabilities with learning management,

competency management systems and other training tools. The heart of the training

simulator system is the replication of real world systems by the process, control, and

logic modeling engines. Both aspects are important in the development of high

performing process operators. As the process and automation systems evolve, an OTS

without regular updates and maintenance will deviate from the real world experience,

leading to compromised training outcomes and related risks.

A well maintained OTS system, deploying the latest tools and capabilities can create

well trained, high performant operators via more effective training interventions and

improved trainee outcomes. Well trained operators improve process operations

performance, reliability and safety.

UniSim OTS Platform Migration and Maintenance Benefits 2

Table of Contents

Introduction ........................................................................................................................................................................ 3

History of Product Investment ........................................................................................................................................ 3

Operator Training Simulation ......................................................................................................................................... 3

Abnormal Situation Management Consortium ............................................................................................................... 4

UniSim Competency Suite ............................................................................................................................................... 4

Creating and Managing Competency .............................................................................................................................. 4

Maintain Market Leadership ........................................................................................................................................... 5

OTS Migration and Maintenance Justification ............................................................................................................. 5

Case Study ....................................................................................................................................................................... 6

Operator Training Trends ................................................................................................................................................ 8

Improve Training Effectiveness ..................................................................................................................................... 10

Alignment with Evolving Requirements ........................................................................................................................ 10

Improve Modeling Effectivness..................................................................................................................................... 12

Alignment with Emerging Technology Trends .............................................................................................................. 12

Conclusion ....................................................................................................................................................................... 13

About the Authors ........................................................................................................................................................... 14

References ...................................................................................................................................................................... 14


Introduction

Honeywell performs a regular annual review of its product portfolio. As part of the Operator Training Simulation (OTS) product line

review in 2011, Honeywell identified considerable overlap between the constituent engine capabilities of OTISS, Shadow Plant and

UniSim Design. Furthermore, since its introduction in 2005, UniSim Design has become the workhorse of process simulation, with

customers preferring the unique lifecycle benefits of UniSim Design technology. For the past five years, new OTS projects have

consistently been delivered using the UniSim Design process modeling engine linked to the Shadow Plant Control and PLC simulation

engine. Since the Honeywell acquisition of the OTISS training simulation technology and business, OTISS has not been used in new

OTS projects. In recognition of these trends and to focus future product investments that best serve market needs, Honeywell Process

Solutions announced the withdrawal from sale of the OTISS and Shadow Plant legacy UniSim® Operations products.

The OTISS simulation engine was withdrawn from sale on June 30

2015, with standard and extended product support available until

December 31 2016. The last commercial release of UniSim Operations

supporting the OTISS simulation engine was R410 (Q2 2012). OTISS

has been withdrawn in its entirety.

The Shadow Plant process simulation engine will be withdrawn from

sale on December 31 2016, with standard and extended product

support available until the June 30 2018. The last commercial release

of UniSim Operations supporting the Shadow Plant simulation engine

is R430 (Q4 2013). Shadow Plant process model simulation

components will be withdrawn, while the control and PLC emulations

(Control and Logic modeling engine) are retained and supported.

Honeywell has a strong track record of supporting our customers’ investments in our solutions. As technology improves, Honeywell

strives to provide practical migration paths to protect its customers’ investments with the flexibility to upgrade at a time of their own

choosing. The withdrawal of these two process simulation engines has created a compelling need to migrate current OTISS and

Shadow Plant process model OTS systems to those hosted on the UniSim Design process modelling platform using a current release

of the Honeywell UniSim Competency Suite product. This paper outlines the value and benefits for such OTS process model

migrations, focusing on the long history of our product evolution, the range of new product features and capabilities, and how these

features and capabilities also align with current industry and technology trends in the area of operator competency management and

assurance.

History of Product Investment

Operator Training Simulation

Honeywell’s investment in Operator Training Simulators began with the acquisition of SACDA in 1992. The TRAINER product was

introduced by SACDA in 1985 and became the market leading technology for OTS as Honeywell expanded the SACDA business

globally. In 2000, the power of PC-based computing provided the opportunity to migrate the VMS-based TRAINER into the MS

Windows based Shadow Plant software. Further investment followed in 2005 when Honeywell completed the acquisition of Petrocom

OTS in Russia and the Aspen Technology’s OTS business, which included the OTISS modeling technology and the intellectual property

of HYSYS simulation modelling platform. The HYSYS intellectual property was introduced to the market under the UniSim brand as

UniSim Design. Soon after, Honeywell integrated the standalone Shadow Plant and OTISS operator training simulator (OTS) products

with the UniSim Design process simulation engine to create the UniSim platform architecture and the UniSim Operations Suite of

products. Prior to integration both Shadow Plant and OTISS had a distinguished legacy of providing customer value.


Abnormal Situation Management Consortium

In November 1994, soon after the investment in SACDA, Honeywell founded

the Abnormal Situation Management® (ASM®) Consortium. The ASM

Consortium grew out of a grassroots effort begun in 1989 by Honeywell’s

Alarm Management Task Force to address Alarm Floods. The consortium

sought to address the challenging problem of abnormal situation

management in the process industries. The new consortium was launched

with funding from Honeywell and seven petrochemical partners totaling $8.5

million (MM). This figure was matched by the US National Institute of

Standards and Technology (NIST) ($8.1 MM) to sponsor research and

development over the time period of 1995–1997. Since 1998, the consortium

has been independently funded by its member companies, and more than

$37 MM has been spent in research activities, both by universities on human

factor fundamentals and by consortium members in plant studies to develop

working prototype solutions and verify improvements. The consortium identified seven practical areas of focus, one of which was

improving operator competencies and skills.

The research done by the ASM Consortium also impacted the Honeywell UniSim Operations product line influencing new features,

capabilities and companion operator competency products. The research pointed to the importance of training intervention and

outcomes as well as the underlying simulation technology. By 2014, the suite of products for operator training had expanded as

Honeywell integrated technology from the Petrocom acquisition, from ASM research and other research activities. As a result, the suite

was more appropriately rebranded under the UniSim platform as UniSim Competency Suite.

UniSim Competency Suite

UniSim Competency Suite continues with the legacy of over 30 years of experience developing and delivery Operator Training

Simulators in the process industry, combined with research from the ASM Consortium. The suite includes robust software solutions to

develop and deliver process operations competency management leading to safe, incident-free and efficient startup, shutdown and

daily operations.

Today, UniSim Competency Suite includes:

UniSim Operations - Operator training simulator technology

UniSim Curriculum - customizable operator competency model

UniSim Tutor - powerful knowledge capture and propagation tool

UniSim Field View - interactive, navigable and panoramic view of plant assets that extends the OTS to field operator training UniSim 3D

Connect - secure simulator integration and connectivity to 3D virtual reality environments.

Creating and Managing Competency

Creating and managing competency is not a change in focus for the Honeywell, nor is it in any way abandoning our roots as an industry

leader. The competency suite products complement our core UniSim Operations OTS product and will help users successfully develop

operator competency using tools and experience available today; while better managing changes they face now and in the future.

Just like a book does not in and of itself make you a competent reader, a training simulator does not in and of itself create competent

operators. We did not learn to read in one session, nor did we become fully competent at reading using a single tool. Learning to read,

or more specifically, becoming a competent reader started with a plan or curriculum. The curriculum included clearly identified goals,

using specific tools, to support each grade requirement. The curriculum helped define lesson plans for key competencies with regular

evaluation of progress as tests and exams.


Developing competent operators is no different. UniSim Competency Suite is a collection of products that help create and maintain

competent operators through a proven training process. From managing the loss of experienced resources, to ensuring operations

teams can do their job safely, reliably and consistently, our Competency Suite products provide the tools needed to help “replicate the

performance of their best operator every day, every shift.”

Maintain Market Leadership

There are currently over 1200 world-wide installations of UniSim Competency Suite products. Honeywell seeks to maintain this

leadership position through innovative product development and partnership with customers. We hold regular user customer advisory

board meetings and face to face events at which we encourage our customers to influence and shape the future direction of UniSim

Operations. We partner with process licensors to provide unique value to their end users via embedded intellectual property. We

continue to engage in ASM Consortium research activities to understand current areas of focus and end user needs. We adapt to

emerging technology trends to better serve our customers. We engage with domain experts in the area of user experience and

interface design as an important characteristic of our product evolution. In everything we do we focus on customer current and evolving

needs.

UniSim Design and UniSim Competency Suite use the same technology platform and are a key part of Honeywell’s Advanced Solutions

line of business with a significant ongoing investment in the Advanced Solutions portfolio dedicated toward the UniSim Platform.

Continued investment and product life cycle planning is managed through our 5-year strategic business planning process, approved,

governed, and monitored by Honeywell leadership. The strategic plan identifies the products and services that provide value to our

customers over the 5-year time horizon, while ensuring functional team tactical plans remain in place to continue to offer and maintain

those products and services that are in the best interest of customers and Honeywell. The UniSim platform with UniSim Design process

modelling engine provides a robust flexible deployment solution that will be the basis of the UniSim Operations OTS technology for

years to come. The flexible UniSim platform software architecture is expected to support the underlying computer architecture trends,

such as datacenter, mobile and cloud computing, as they evolve in the future.

Today, Honeywell is the world’s #1 training and simulation solutions provider for the process industry and will continue to invest and

innovate to support the operator competency market. Honeywell’s 30+ year track record in product development, software support and

maintenance demonstrates a historical and ongoing strategic commitment to deliver long term value for Operator Competency

customers.

OTS Migration and Maintenance Justification

One method of looking at OTS system maintenance and migration is the Value-Driven Maintenance® (VDM) approach (Haarman and

Delahey) in which maintenance is framed within a value rather than a cost context. The decision to invest in a maintenance activity is

based on a cost benefit analysis using four value drivers as the basis of the analysis.

Asset Utilization – the availability of the system to function adequately when needed.

Resource allocation – the smart allocation of resources such as spare parts, labor and knowledge to increase value.

Cost control – finding the maintenance investment that delivers the most value.

Safety, health and environment – good SH&E policy ensures continued license to operate.

Failure of an OTS does not have a direct impact on SH&E, but in a wider context we know that operator performance is directly linked

to SH&E outcomes. So, if a company is operating in a situation in which SH&E is critical, then making sure the OTS is delivering the

competencies required to protect the business against SH&E risks could be a leading value driver. Resource allocation when applied to

training system maintenance involves decisions about spares inventory, in-house or out-sourced technical support, and software and

hardware support contracts and warranties. There follows the perpetual balance between asset utilization (availability of the system)

and cost control (resources consumed keeping the system available). The case study below describes how this balance can shift during

the life of the OTS.


Case Study

In this example, a customer has invested in an Operator Training Simulator for a new plant. The primary objective of the simulator is to

provide critical start-up training for the operations staff. After the initial training, the OTS will be used for regular refresher training during

the life of the asset. Figure 1 below shows the leading maintenance value drivers over the lifecycle of the OTS as the scenario evolves

in the form of swim lanes.

Figure 1 – Value drivers for OTS maintenance change over time.

Phase 1: Initial training. The value is training of the operator for the new plant start-up. Asset availability is the leading driver.

Customers invest to ensure that expertise is on hand to resolve any problems that may arise. Typical investment would be software

support contract with vendors along with site-based or remote help desk support.

Phase 2: Post commissioning. The key driver is cost control. During this phase there is the possibility of post commissioning updates to

the plant, but the critical training phase is in the past. Customers invest to accommodate those updates that provide the best value for

ongoing training. Typical investments would be a software maintenance and support contract with vendors and a framework for

application maintenance to accommodate post commissioning changes. Value is maximized by selecting the scope of the updates to

execute based on value and allocate work in-house, with the vendor or with contractors that minimizes cost.

Phase 3: Ongoing training. The key driver is cost control, Maintenance spend is minimized to maintain adequate performance. This

phase may last for many years. With a good maintenance planning policy this phase can keep OTS delivering value through the life of

the asset. The risk at this phase is that if the frame of maintenance is too narrow, for example “keep the system going”, the real value in

the context of the wider frame of plant wide performance can erode over time. Focus on cost tends to lead to a “run to failure” approach

in which the system is repaired only when broken while ignoring the fact that the true value add is diminishing, leading to increased risk

of non-optimal out come on the plant.

Phase 4: Compelling event. At some point in the OTS lifecycle a compelling event occurs. This is an event of significant scale that it

compels action to move from the cost control value driver to asset utilization value driver. Examples of a compelling event are 1)

Hardware or software failures reducing availability that cannot be economically remedied. 2) Accumulation of changes not managed in

phase 3 that have gradually reduced the value of the OTS beyond acceptable threshold i.e. the time spent on the OTS is not adding

value compared to the cost of delivering the training. 3) Cost of reactive maintenance is very high due to resource or skills shortage. 4)

Support from vendor or 3rd party contractor no longer offered or extremely limited. 5) Training requirements change that reduce the


value of assets and there is incremental cost of gap filling solutions. 6) New training opportunities present through product innovation

that increase the asset utility and hence deliver increased value to the customer.

Figure 2 below shows that at some point the cost to maintain the OTS and the value of the OTS cross over and there is no value

added. At this point a corrective intervention is required to either restore the value or further reduce the ongoing costs. It is at this point

that systems are either abandoned, upgraded or replaced.

Figure 2 – Corrective intervention is required.

Currently, many OTS systems continue to operate past expected lifespans due to extraordinary efforts to keep aging technology

functioning, combined with accepting compromised training experience as the simulator and the real process plant drift apart. Ironically,

because of such efforts, management frequently does not understand why the hardware must be replaced, the software updated and

the model updated to match current process conditions. Since the system is still "doing the job" (more or less), management will ask,

"What's the justification for upgrading?"

Such efforts maintaining a legacy system come at a price. As time passes, the compromises lead to less effective outcomes, with

resulting acceptable risks increasing more rapidly each year. It is important, therefore, to look at OTS system migration and updates

using a risk and reward approach that is broadened to include plant wide value drivers. Risks are reduced via more credible, realistic

and relevant training using current up-to-date process models.

Figure 3 below shows that at some point value can be enhanced by increasing utility through access to new functionality. New software

brings new capabilities and benefits that cannot be achieved using legacy technology. Understanding the benefits along with the

reduction in risk can provide the necessary incentive to invest in the migration and update of legacy OTS technology to current

technology platform and to maintain the platform in the future.


Figure 3 – Opportunity exists to increase utility.

Operator Training Trends

Process operator performance is important during the commissioning, operations and extension phases of a plant's lifecycle. As the

role of the process console operator has evolved, he or she now controls more pieces of equipment (assets) and more control loops.

The incentive for organizations to invest in training for process operators is simply that the automation system cannot do everything.

The interventions of a well-trained operator will reduce losses and sustain peak performance through appropriate prevention, detection

and mitigation activities. When staff are well trained, they make fewer mistakes and opportunities are available to capture the benefits

of better plant productivity, reliability and safety.

In the airline industry, pilots are responsible for complex and expensive equipment, and the lives of many people. Pilots also interact

with and engage with sophisticated automation systems in a similar manner as console operators in the process industries. Flight

simulators are used to train pilots in routine normal, non-routine normal, and non-routine abnormal events such as engine failures and

water landing. It is not too difficult to draw the analogy between the process console operator role responsibility and that of a pilot.

They both deal with complex automated systems with similar potential levels of consequences when a mistake or equipment failure

occurs.


As a result, many progressive processing

companies are using high fidelity operator training

simulators (OTS) to train operators for both non-

routine normal operations (startup and shutdown)

and non-routine abnormal situations (emergency

operations). OTS have been used in the oil and

gas production, gas processing, petroleum refining

and chemicals industries for decades and currently

represents a mature performant technology.

However, because of global trends and

competitive pressures, the need to improve the

skills, knowledge and behavior of operations staff

has never been greater. Trends leading to the

continued evolution in the proper deployment and use of a credible and realistic OTS and competency management system include:

Retirement of veteran operators: Many manufacturers worldwide expect most of their experienced operators to retire before 2020.

These companies risk losing a lot of knowledge and know-how. Mentoring is one alternative, but poses a risk of passing on bad, as

well as good, habits and does not necessarily reflect best practices. Using a training simulator program and other software tools to

capture the skills of veteran operators before they retire solves some of the problem of building knowledge and expertise of new and

less-seasoned operators.

The impact of human error: Research from the ASM Consortium indicates U.S. chemical plants lose more than $20 billion annually

from abnormal situations, with $8 billion due to human error and insufficient knowledge. Engineering measures, such as control and

safety systems, are necessary to reduce risk but are not in and of themselves, sufficient protection. Simulator-based training can help

manage that risk.

The quest for faster startups: For decades, the primary driver for investing in an OTS was to prepare operators for safe and

effective unit startup. The economics remain compelling with a faster safe start-up delivering massive potential benefits. Plant startup

is usually an infrequent activity. Simulators enable practicing and perfecting non-routine normal activities, such as startup and other

infrequent procedures that deliver immediate benefits.

Improved OTS effectiveness: The process industry has used OTS systems for decades. Companies that have installed simulators

have identified key areas for improving OTS effectiveness including the need to engage in timely direct performance feedback

relative to competencies when learning a complex skill. Thaler and Sunstein (2008) use the example of a golfer learning how hard to

hit the ball to sink the putt through hours of practice giving instant feedback. While golfers have ample opportunities to practice and

get performance feedback, plant operators’ daily environment is not optimized for learning. It is not easy to practice with a real plant

when the consequences of a wrong move are so significant. Doing so requires incorporating the OTS within a structured framework

with the right tools and competency model. Sustaining OTS benefits is best achieved by understanding operators required core

competencies and how these can map to training activities and performance feedback mechanisms.

A refocus on the training objectives: Applying dynamic process simulation to the problem of operator training has been a

significant achievement in modelling technology. The increasing power of computers enable accurate simulation of large process

models and practically any complex unit operation. However, all this technology is only a means to an end. As technology evolves, as

new tools are introduced to the market, it is prudent for the end user to consider how the OTS system needs to evolve with a focus

on the training objectives, training need against different and less stringent constraints than those of 20,10 or even 5 years ago.

Credible and Realistic Experience: The effectiveness of an OTS is strongly dependent on the need for trainees involved to

perceive the underlying system as credible and relevant. Organizations must keep the simulator as a close match to the actual

process unit. Once the actual plant deviates from the simulator, trainees challenge the OTS's relevance and the training value and

outcomes quickly erode. While experienced operators may be able to cope with significant differences, new trainees may not be able

to put even small ones into context, significantly decreasing training value.

Training for the Field Operator: Field operator training is also important. Mistakes in the field are not any different from those made

in the control room. Extending the OTS to include the field operator in a credible and realistic manner can improve individual

An OTS should satisfy both the operators' and company's needs. The evolving workforce, the next generation of process operators and

the need for more effective competency focused training all support the motivation and value of focused maintenance and evolution of


the OTS system. The requisite evolution delivers the benefits from the continuous evolution of the product suite, including improvement

in the training interventions and the outcome as it relates to overall effectiveness of the training program.

Improve Training Effectiveness

The productivity of an industrial facility starts with its personnel and their ability to perform critical jobs in a skilled and knowledgeable

manner. Today, industrial firms require new tools to meet a host of new challenges in effectively developing the skills and experiences

of key employees such as plant operators.

Experience has shown “millennial” age workers learn differently than their predecessors when entering the industrial workforce, and

prefer new, interactive types of instruction. At the same time, existing training programs must evolve to address the needs of field

operators, who extend the control room operator’s reach and view, to help ensure secure and efficient plant processes.

From an early age, Millennials learned they should use computers and

mobile devices to get things done as efficiently as possible. They are

technology-savvy, play video and computer games, and most

importantly, approach learning with a different mindset. For example,

the gamification of operator training through virtual reality was the

subject of a recent study by Abel (2014) who reported in many

industries, training designers are seeking to make operator training

more engaging through immersive technologies, such as 3D and 2D

virtual reality simulation.

Over the years, many operator training programs have focused

exclusively on control room personnel — leaving field operators (who

often work in hazardous, remote or mission-critical locations) to learn

on their own. This approach exposes personnel to practical limitations and risks. It is important to recognize training is no less important

for field operators than it is for Distributed Control System (DCS) console operators. The field operator is an integral part of the

operations team, and their training is crucial to ensuring secure and efficient plant processes. The challenges encountered in delivery

of field operator training include:

New Construction: Process facilities are not available for a worthwhile training experience.

Hazardous Environments: Potential for exposure to hazards must be minimized.

Remote Locations: Duration and number of employees in remote locations must be reduced, along with associated high costs.

Isolation: Field operator training is often detached and executed without participation by the console operator.

Informality: Field operator training objectives can be difficult to quantify and standardize, often resulting in informal training and

evaluation methods.

Companies now seek credible, realistic and immersive training solutions to prepare operations staff of all ages to run plants safely and

efficiently. New technologies can deliver content, such as standard operating procedures, in an enjoyable and effective way. They also

open the door to unique benefits, compared to traditional training techniques, by preparing field and panel operators to work as a team.

Alignment with Evolving Requirements

As the UniSim Operator competency suite product line evolves, it is more important for companies to ensure their training systems,

tools and infrastructure are aligned with evolving needs. Those needs are changing at an ever increasing pace. The current release of

UniSim Competency Suite provides capabilities to support evolving training needs as follows:


UniSim® Operations: Honeywell’s industry leading Operator Training Simulator (OTS) technology based on

rigorous dynamic process simulation model(s). UniSim Operations effectively and realistically trains process

operators by experiencing and interacting with a full range of process plant behaviors under normal and abnormal

situations. The solution accelerates knowledge transfer by consolidating a potential lifetime of experiences into a

concise operator training program. Features realistic process, control and safety systems modeling combined with

a Distributed Control System console interfaces and/or emulation capabilities to ensure a realistic console operator

training experience.

UniSim Curriculum: An operator competency model that helps our customers deploy a structured competency

management program. Based on Abnormal Situation Management Consortium (ASMC) research, including

extensive participation of ASM Consortium members in both development and validation, UniSim Curriculum’s

Competency Library includes a customizable predefined Competency Model for Console and Field Operators.

Each responsibility maps to competencies and behaviors that can be measured and assessed through various

training exercises and activities. UniSim Curriculum includes a trainee database to record progress and results of

individuals and teams through “aware” to “master” levels of proficiency. Training and evaluation activities can be

integrated with UniSim Operations training simulator, UniSim Tutor or other sources such as classroom based

training, workbooks, etc.

UniSim Tutor: A knowledge-based system to capture general and specific knowledge and experience for operator

training. Based on research by Dozortsev (2013), UniSim Tutor helps capture and propagate knowledge using an

accessible, game-style question and answer format. The knowledge of senior operators is captured as a matrix of

questions and answers about the process and its controls. During the game, feedback is presented in the form of a

score. UniSim Tutor’s mental simulations challenge the trainee and evaluate the ability to think, apply knowledge

and demonstrate a level of understanding against process and plant specific operating conditions, faults or

scenarios. These games mimic the activity of operators in the real plant: Abnormal situations must be diagnosed

using alarm summaries and analysis of process trends to validate root-cause hypothesis that immediately spring to

mind. This enables operators to determine the appropriate corrective action. As in the plant, feedback in the games

is rapid and relevant.

UniSim 3D Connect: UniSim 3D Connect leverages advances in the computer gaming industries to bring photo-

realistic training to the process industries. 3D computer-aided design packages are already used during new plant

construction, and these models can be repurposed as the basis for a virtual-world training environment. The 3D

model is “dressed” with realistic objects, textures and background images that represent the actual plant location.

Connecting a 3D plant model to UniSim Operations provides an integrated tool for team-based training. The

operator can experience the virtual world using 3D glasses, special headsets, an immersive environment or a

standard screen and game controller.

UniSim Field View: Field View is integrated with the UniSim OTS to provide a 2D immersive training environment

for field operators. It is one of several HMIs for the field operator orientation and procedural training. Field View

has as its basis a collection of panoramic photos with dynamic links and overlays representing navigation hot

spots, field measurements or field equipment. With UniSim Field View, the Field Operator can: navigate through a

plant to locate specific equipment, including finding locations of fire extinguishers, safety showers, and field

operated devices and indicators; follow the navigation hot spots to move from one area to the next; observe and

report on operating conditions in the field; interact with local indicators, panels and equipment. Field View can

support a console operator trainee as a team in a coordinated procedure operation.


These UniSim Competency Suite products provide capability and tools aligned with evolving requirements. Improvements in the

performance feedback, new diagnoses and decision making training tools, field operator training capabilities and the foundation for a

competency management system all provide incremental value and benefits to the organization in terms of training effectiveness and

operational performance.

Improve Modeling Effectivness

The OTTIS and Shadow Plant process modeling platforms were characterized as difficult to use, with a significantly compromised user

experience for process model configuration and maintenance. The UniSim modelling platform improves on this experience and in the

area of model value via product capabilities in the areas of dynamic fidelity, customization, configuration, maintenance, use and scope.

Specifically, the UniSim modelling platform and engine provide the following key characteristics to support incremental value:

Best in Class: UniSim Design is based on the HYSYS intellectual property acquired from Aspen technology in 2005 combined with

over 10 years of incremental product developments to create a best in class dynamic process modelling engine for high fidelity process

modeling. First principles engineering and thermodynamic relationships are used to represent plant behavior accurately. These

capabilities have been applied extensively and proven repeatedly in live plant applications.

Graphical Model Configuration: Unlike the OTISS and Shadow Plant legacy

modelling platforms, UniSim Design modeling platform provides an intuitive and

interactive graphical process modeling building solution that enables engineers

to create or modify steady-state and dynamic models for plant and control

design, performance monitoring, troubleshooting, operational improvement,

business planning and asset management.

Lifecycle Simulator: Unlike the OTISS and Shadow Plant legacy modeling

platforms, the UniSim Design modeling platform helps process industries

improve productivity and profitability throughout the plant lifecycle. The powerful

simulation and analysis tools, real-time applications and the integrated approach

to engineering solutions provided by UniSim enable companies to improve designs, optimize production and enhance decision-making.

Large Experienced User Base: The UniSim Design products are used across multiple industries including academia, process design,

multi-purpose dynamic simulation, process automation dynamic simulation, operator training simulators, and process performance

decision support. As a result, there is a large growing user base providing services and influencing continued product evolution.

Evolving Product: As a product with a large installed base and growing user base, UniSim Design modeling engine continues to

evolve with investments in new features and capabilities. By focusing on a single and common modelling platform, Honeywell is able to

progress and leverage significant improvements in the capabilities of dynamic modeling systems, thermodynamics, control systems,

computing capabilities, user interfaces and mathematical algorithms.

Fully Customizable: When appropriate, customized modeling capabilities can also be incorporated within the UniSim Design model to

derive maximum benefit for customers. From simple spreadsheet calculations to detailed modeling extensions, UniSim design provides

customization capabilities to support a wide range of operations including specialized industries.

Complexity and Scale: The UniSim platform permits the ability to develop large complex models by taking advantage of the multi-core

architecture to distribute model segments across multiple CPUs.

Alignment with Emerging Technology Trends

Technology continues to evolve at ever increasing rates, enabling new and effective ways to deploy software, hardware and

applications. Consistent with Honeywell’s strategy in product investment, new software releases not only provide new functionality and

capabilities but they also consider current and evolving technology trends to provide valuable capabilities to better serve our customers’

needs. Trends that are currently supported or are influencing future product investment include:


Virtualization: Minimizes the hardware foot print and related infrastructure requirements, providing both benefits in upfront costs but

also in subsequent maintenance and support.

Cloud Computing: The next step in application platform deployment migration to

cloud based computing environments providing scalability, high uptime

performance and access not limited by location and geography. Opens up new

way to deliver value for our customers, site wide and enterprise wide.

Cyber Security: An important and necessary trend to consider as connectivity

increases. From using the latest supported operating systems, latest anti-virus

detection means, to proactive detection and defense. An evolving field that is

becoming more and more important.

Industrial Internet of Things (IIoT): a network of networks that uses the internet to

connect people, processes and assets enabling a new way to optimize business

results. It leverages smart connected assets, enterprise integrated automation,

secured cloud-based data, and advanced analytics.

Virtual Reality: Technology that replicates an environment, real or imagined, and simulates a user's physical presence and

environment in a way that allows the user to interact with it. Virtual realities can artificially create sensory experience, which such as

sight, touch, hearing, and smell. Delivers safe yet credible, realistic experiences, well suited for training.

Augmented reality: A technology that enhances one’s perception of reality by supplementing sensory input, such as sound, video,

graphics, etc., live and directly on a view of the real-world physical environment.

Social Media: Trend and platform that enables people, companies or organization to create, share, or exchange information, via

virtual communities and networks.

Intelligent Automation: The combination of artificial intelligence and automation. Intelligent automation systems sense and synthesize

vast amounts of information and can automate entire processes or workflows, learning and adapting as they go.

Technology trends enable new ways to solve problems and provide better experiences and outcomes. These benefits can only be

achieved by maintaining and moving with the evolving base software tools.

Conclusion

Process operator training simulators systems have been widely adopted in the oil and gas production, gas processing, petroleum,

refining, and chemicals industries for both training and competency management. The training simulator provides the tools and

techniques for trainees to experience and practice routine normal, non-routine normal (start-up and shutdown) and non-routine

abnormal (emergency operations) activities in a safe environment. The key to successful training simulator maintenance is to consider

the real value drivers for maintenance within the wider frame of real plant performance. The cost benefit equation needs to consider the

risk that gradual erosion of value by continued focus on cost control once the critical training need has been satisfied exposes the

organization to the real risk of plant performance impact and SH&E license to operate issues through erosion of competence or lack of

opportunity for new hires to train effectively.

The effectiveness of an OTS is strongly dependent on the need for trainees involved to perceive the underlying system as credible and

relevant. Organizations must keep the simulator as a close match to the actual process unit. Once the actual plant deviates from the

simulator, trainees challenge the OTS's relevance and the training value and outcomes quickly erode. While experienced operators

may be able to cope with significant differences, new trainees may not be able to put even small ones into context significantly

decreasing training value and increasing risks.

The capabilities and tools available to help companies extract the most value from the OTS continue to evolve. Companies continue to

seek credible, realistic and immersive training solutions to prepare operations staff of all ages to run plants safely and efficiently. New

technologies can meet these challenges, extending simulator training to the field operator and/or delivering content and training

outcomes in an enjoyable and effective way.

Operator competency will continue to be an important contributor to a company’s performance. Competent operators improve process

operations performance, reliability and safety.


About the Authors

Martin Ross is product manager of Honeywell’s UniSim Competency Suite product lines, focusing on solving

customer problems and adding value through product innovation. Martin has over 20 years prior experience in

Honeywell’s simulation projects and after-market services where he was responsible for leading the delivery of

operator training simulation projects and service activities for customers in Europe, Middle-East and Africa.

Educated at Imperial College in London with BSc and PhD degrees in Chemical Engineering Martin is a

member of the UK Institution of Chemical Engineers and is Six Sigma Green Belt certified.

John Roffel is the director of Honeywell’s Operator Competency and Simulation product lines. John leads the

product line business teams, focusing on our product investments to address customer needs, and overall

business strategy for each product line. John has over 25 years’ experience in dynamic simulation and

advanced process control, with over 20 years Honeywell project operations experience delivering and leading

advanced process control and simulation projects and operations teams globally. John has a Bachelor’s and

Master’s Degree in Chemical Engineering.

References

1) Mark Haarman and Guy Delahay, “Value Driven Maintenance, New Faith in Maintenance” Mainnovation, Dordrecht, the

Netherlands, 2004.

2) Thaler, R. H and Sunstein, C. R. 2008. Nudge: Improving Decisions about Health, Wealth, and Happiness. Yale University Press.

3) Dozortsev V. M. 2013. Methods for Computer-based Operator Training as a Key Element of Training Systems (Present-Day Trends). Automation and Remote Control 74 (7) 1102 - 1200.

WP-16-04-ENG

May 2016

© 2016 Honeywell International Inc.

For More Information

Learn more about how Honeywell is delivering

performance, reliability, safety and security, visit our

website www.honeywellprocess.com or contact your

Honeywell account manager.

Honeywell Process Solutions

Honeywell

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Houston, TX 77042

Honeywell House, Arlington Business Park

Bracknell, Berkshire, England RG12 1EB UK

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www.honeywellprocess.com

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