Boiler simulation for improved operator training

Continuous, efficient and safe operation of a sugar factory depends on having competent and confident operators who can prioritise sometimes conflicting requirements and choose the best option under pressure. Most operators in sugar factories have another role during the maintenance season, and there is anecdotal evidence from factories that issues arising from operator error are more common early in the crushing season when operators are getting back up to speed. Operator training in the sugar industry, like in a lot of other industries, has been based on trainee operators working under the guidance of more experienced operators who act as mentors. In many cases, this approach works reasonably well, but in some cases it does not because some experienced operators may not be the best role models and/or the best trainers. Simulators are an ideal complement to the traditional modes of training because they allow trainee operators to learn by doing rather than learning just by observing other operators and following instructions. Trainee operators can learn from mistakes made on simulators rather than mistakes during actual boiler operation that can have serious consequences. This paper summarises the development of a boiler-simulator with a generic interface and a training program that can be used for operator training. Some of the components of the boiler-simulator can be incorporated into the distributed control systems used by factories. Use of the simulator will improve the skill level of operators and increase the effectiveness of operator training and operator refresher training. There will be a reduced risk of damage to boilers and lost production. With improved operator performance the number of incidents should be reduced. This will improve the financial performance of the industry, the public perception of the industry and in the long term, reduce insurance costs.