Direct connection of simulator and DCS enhances testing and operator training

Dynamic simulators are considered as efficient tools for training of operations personnel in many fields of industry, also in the pulp and paper. A multifunctional simulator can be used for automation configuration checkout, as well. Such a simulator can be obtained by connecting a process simulator directly to a distributed control system (DCS). However, there has been no standard way to establish the connection. Each application has required its own drivers and tailor-made solutions. The new OPC (OLE for Process Control) specification offers welcomed means for communication between a DCS and a process simulator software. The use of the actual configuration and hardware as a part of the training simulator removes the large effort to emulate control displays and model the plant automation. Dynamic simulation becomes more attractive to be used in DCS testing and operator training also in smaller projects, because of shorter development time and significantly reduced costs. Further requirements on improvements for DCS's, from a training simulator's point of view, are discussed. The paper presents experiences in developing and using a bleach plant training simulator.