An object-oriented architecture for combined simulation modeling with real-time capabilities for operator training

Recently, there has been an increasing demand in the process industries for training simulations that allow operators to learn and practice normal, abnormal, and emergency operating procedures in a realistic setting. The major requirement of simulations used for training is the need to ensure that the timing of the execution of a simulation run corresponds to the timing of the operation of the real system and flexibility. This is necessary in order to offer the trainer the capability to rapidly reconfigure the simulation model as conditions warrant. This research presents an object-oriented real-time simulation architecture for operator training. The simulation allows the operators to train on an interactive system that offers the authentic look and feel of the plant's control, as well as accurate, real-time feedback on the result of their actions. The simulation architecture is based on the concept of having a virtual plant that is operated on by a combined simulation model. A virtual plant is a computer based representation of the actual plant. The virtual plant and the associated simulation is codified in an object oriented environment to maintain reusability, extensibility, and flexibility. A real-time simulation is maintained by using fixed time increment updates generated by the computer clock. This update scheme gives the user the ability to interact dynamically by evoking system events. With each time increment the calendar is also checked for scheduled random events. The simulation is modeled independent of any particular hardware controller. This permits connection of the simulation model to a variety of controllers. The simulation architecture is validated by creating a specific interface module for a Honeywell TDC 3000 controller. A questionnaire was developed and distributed to fellow colleagues in order to determine the effectiveness of the architecture for operator training. An overwhelming number of respondents felt that the architecture was appropriate for operator training. In conclusion, the simulation allows the operator to learn and practice with a process system that might otherwise be costly and dangerous, if not impossible in a real plant.