Exploiting Operator Training Systems in chemical plants: learnings from industrial practice at BASF

Demographic shifts and increased automation in chemical plants are reducing the experience and skill levels of plant operators. Therefore, BASF has implemented Operator Training Simulators (OTS) to allow operators to practice and improve their skills in this safe and controlled environment. The OTS consists of a dynamic model of the process, a control system and safety logics. This paper describes the learnings from using OTS at BASF, where they are used to train operators in process understanding, optimization, procedural training, and disturbance handling. Benefits include reduced training costs, minimized risks and improved efficiency. Also organizational guidelines are provided to ensure that the mentioned benefits are realized in industrial practice. Additionally, high-accuracy OTS models support HAZOP, debottlenecking, and optimization studies.