Boiler simulation tool development

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 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. This switching between different roles is more difficult for inexperienced operators and a suitable mentor may not be available when needed. In some other industries simulation packages are an integral part of operator training, maintenance of skill levels and assessment of competence. Most of the training for sugar factory operators is on the job under the direction of a mentor and with assistance from peers. A simulation package that allows a trainee to test how changes in settings affect operations and for trainers to test how trainees respond to specific events without any risk is an ideal way to augment the usual on the job training. This paper summarises the progress towards the development of a boiler simulator for the sugar industry.