An Integrated Approach to Industrial Training

Summary

Capturing knowledge from retiring workers and transferring that knowledge to less experienced workers is a top issue for companies in developed and emerging regions alike. This is particularly true in industries where safety is paramount. The shortfall of qualified engineers, operators, and technical workers in Asia and elsewhere adds to the skills shortage, driving demand for specialized training programs; especially when building new industrial plants where large numbers of operators often need to be trained quickly.

Operator training simulators (OTS), computer-led training, mentor-based training, and immersive training simulators (ITS), along with conventional classroom training, are all important methods and technologies being used to train the new tech-savvy generation of workers and update the skills of experienced workers. It's also important to have an approach that integrates, tracks, and customizes the training for each worker's role.

While ARC Advisory Group research indicates that modern OTS and ITS are some of the best technologies available for knowledge transfer and retention, an integrated training approach that combines simulator-based training with more traditional classroom and multimedia training is a best practice for training employees in critical industrial environments; one that can offer the most value for training and faster knowledge transfer and lead to a safer, more effective, and competent workforce.

Training the New Generation of Workers
Companies need to capture the knowledge from the experienced workforce and transfer that knowledge to the new, less-experienced generation.

Industrial training programs that use an integrated approach combining simulators with other types of training can prepare workers to react to problems or deviations, improve process performance, and help avoid or reduce the impact of abnormal situations. For example, the latest generation of immersive 3D simulators can be linked to an OTS to provide even more realistic and effective training. The simulators use inputs calculated in real time, which allows trainees to practice responding to abnormal conditions to help improve their performance. This new technology can be particularly beneficial for the new tech-savvy workers, who tend to excel at collaboration, multitasking, and digital networking, and look at software tools differently than many "old-school" workers.

SNC-Lavalin's Training Tools and Technologies
An approach that integrates theory with hand-on practice in OTS and 3D immersive simulators can reinforce knowledge transfer. SNC-Lavalin Global Training & Simulation Services (GTS) recently briefed ARC on its own integrated, or "blended" training offering and the benefits the company's industrial clients are realizing.

As we learned, SNC-Lavalin GTS's integrated approach integrates 3D immersive training with 2D high-fidelity OTS, plus traditional types of training, such as e-learning, formal classroom and on-the-job training, as part of a structured and competency-based training program. These training tools are used as an integral part of the learning structure designed for the industrial company's workers, culture, equipment, and plant, and are used at different stages of the training program.

SNC-Lavalin training programs are customized for the specific client, and the specific skills and requirements needed to help ensure a safe and competent workforce.

Comprehensive and Integrated Training Program
Integrated training programs include all critical aspects of plant operations and maintenance (safety, troubleshooting, process control, normal operation, etc.).

SNC-Lavalin GTS' training solutions typically encompass:

• Induction: Provides all new personnel with general plant and HSE knowledge
• Fundamentals: Provide plant personnel with fundamental technical, process, and control knowledge
• Technical Training: Provides the required knowledge to safely and efficiently operate and maintain the plant
• Practice in Immersive Environments: Provides a safe and immersive environment, such as OTS and ITS, to practice executing normal operations as well as developing the skills and confidence to manage process upsets and emergency functions
• On-the-Job Training: Provides structured hands-on practice activities to solidify and apply skills acquired in the previous parts of the program
• Training Certificate: Provides plant personnel formal acknowledgement of successful training completion in the form of a training certificate.

Typical Customized and Blended Training Program for Field and Control Room Operators

 

Multi-disciplinary Training Team
SNC-Lavalin GTS assigns a dedicated, multi-disciplinary project team to work hand in hand with the client through the different phases of the project. This helps ensure that the training solution deployed is closely aligned with the client's specific operational and business requirements. The multi-disciplinary team of experts includes project managers, controllers, and administrators; strategic training consultants; training managers and specialists; process and industrial engineers; technical writers; simulation specialists; and graphic artists. They help the client:

• Analyze training needs
• Design and develop training material and activities
• Deliver training activities, including train-the-trainer
• Evaluate the training processes and objectives achieved

 

Competency-Based Training Program
The complete training program is individualized to meet the needs of each worker role (field operator, console operator, maintenance worker, engineer or plant manager, etc.), as well as the needs of the process and company. It uses a competency-based approach that identifies the precise list of skills required to perform tasks in a job position. This list of skills is used as the basis to determine the training modules to be developed, as well as the modules required for each job profile.

  

 

 

 

 

 

 

High-Fidelity Simulators and Virtual Training
Companies have found that workers learning on 3D ITS retain the information longer. These provide operators and maintenance personnel with a safe learning tool that enables them to navigate through a replica of their facility. Operators and other plant workers can practice key tasks essential to their jobs. According to the company, SNC-Lavalin's 3D Immersive Simulator, FieldOp3D, enables field and maintenance personnel to become familiar with the facilities and layout of their plant, practice standard and abnormal operating procedures, as well as emergency procedures.

FieldOp3D replicates operations and process plants from technical drawings and computer-aided design (CAD) models. Facility layout, equipment, instrumentation, piping, walkways, sound, lighting, and more are recreated to look like the real plant. The technology can provide realistic representation of sites and process plants that can be animated to increase training effectiveness. Workers can familiarize themselves with the location of equipment, instrumentation and safety devices, and perform operator rounds that might include instrument readings, sampling, etc. They can learn and practice standard operating procedures in a virtual environment. These can include lockout/tag out, equipment startup/shutdown, plant startup, etc. They can also review equipment information and specs, visualize equipment's internal components, and perform equipment assembly/disassembly exercises.

This kind of advanced technology can also improve communication and teamwork skills. FieldOp3D is linked to Honeywell's UniSim OTS platform. It can be integrated to a SCORM (Shared Content Object Reference Model)-compliant e-learning environment and deployed with single or multiple screens, single or multiple projectors, with Oculus' head-mounted displays, or with Igloo Vision's 360-degree cylinder system.

Cost of Blended Learning
Most end users agree that training workers for hazardous environments is critical for worker safety and reduced risk. They also recognize that ITS can be advantageous for worker's retention rates, especially for field operators or maintenance personnel. In the past, the cost associated with 3D ITS was one of the top reasons given for not implementing this technology. However, according to SNC-Lavalin claims, its product is significantly less expensive than most others available today. The technology is built using a commercial gaming platform, enabling the company to reduce the cost of immersive training to a price point much lower than most OTS. In addition, the newer technology enables the company to develop functionality faster.

Stakeholder Benefits
A well-designed and well-implemented integrated training program can provide enormous benefits. These include increased safety, reduced liability, and better knowledge transfer.

An integrated learning approach that includes a combination of theory and practice in OTS and ITS environments can help reduce startup time and protect capital equipment. In greenfield projects, immersive training can typically help shorten startup time by four to eight days. In brownfield projects, it can be shortened by one to two days. Effective training can also reduce damage to capital equipment during startups and shutdowns.

An integrated training program can also help increase operator and worker confidence by providing them with the tools needed to respond to abnormal conditions to prevent catastrophe events.

Benefits such as these can represent huge value to industrial companies. Productivity can be improved from 1 to 2 percent by helping prevent unplanned shutdowns, providing a faster return to normal operations following a process upset, reducing energy consumption, and improving product quality and consistency.

 

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Keywords: Operator Training Simulator (OTS), 3D Immersive Training, Industrial Training, eLearning, Online Training, SNC-Lavalin, Global Training and Simulation (GTS), ARC Advisory Group.