Aracruz Uses a Dynamic Simulator for Control System ... - Andritz

TRAINING OPERATORS USING THE PROCESS SIMULATOR
The Simulator training program was as comprehensive as we could make it in the time available. The primary
goal was to allow the operators to become totally competent in the start-up and shut-down procedures. In
addition, operating fault scenarios, some already used in staging, were installed on the system and Trainees
were instructed to react to them as they would a normal task in a working mill.
The advantage to Aracruz of this training was that the operators experienced a close to real life workout, but
in a virtual setting. This setting eliminated any ill-effects on production, damage to process equipment, or
negative effects on the environment. The training was provided well before we had to start-up the real mill.
Training the Trainers
In order to accomplish training on the Simulator, we decided to implement a concept of lead operators acting
as Trainers for their peers. We nominated the best operators that we could find from the existing Aracruz
Mills “A” and “B”. The operators were released from their duties and put through a rigorous program of
schooling and work, to prepare them for their new role as Trainers in their assigned areas.
A number of the activities were part of the conventional training and commissioning designed by Aracruz and
the EPCs for Mill “C”. Our Simulator Trainers received this training alongside their colleagues in classrooms
or other settings. The remainder of the training was specific to the Simulator, or actually consisted of work
that we had to do to prepare the Simulator for training.
The seven stages of development of our Trainers are described below:
1) EPC training
Under the EPC suppliers’ contracts, they were required to deliver a comprehensive classroom program to
Aracruz operating and maintenance personnel. For each EPC area, the lectures were delivered over a period
of about fifteen days, based upon eight-hour days, and were supplemented by the EPC-prepared Operating
Manuals.
2) Training Scenarios development
The first involvement of the operators with the Simulator was prior to staging, immediately after EPC model
checkout in Atlanta, Georgia. It involved the elaboration of training scenarios. In a general way, the scenarios
were based on two causes; operational and equipment failures.
3) DCS Staging and FAT
The Trainers were involved also in the DCS contractor’s Factory Acceptance Test (FAT). That activity built a
practical understanding of the control philosophy.
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