When Realism Meets ROI: The Art of Selecting the Correct Fidelity for an Operator Training System, TAPPICon26

In today’s world of rapidly changing technology, an aging workforce, and market uncertainty, Operator Training Systems (OTS) are becoming essential tools to effectively manage changes to control systems, workforce competency, and knowledge transfer all while ensuring process safety and operation efficiency. This presentation explores the relative benefits and trade-offs between high, medium, and low-fidelity OTS and process simulation solutions. The methodology in choosing the correct fidelity OTS entails aligning the training goals of a given unit or facility’s operations stakeholders with the budget and resources available to devote to the simulation’s development.

High-fidelity simulators, which can accurately model advanced dynamics such as heat transfer, fluid mechanics, residence times, and other physical properties, offer incredible realism and can be used for critical operations familiarization, scenario-based training and advanced control development. However, these solutions come with high price tags and long development times. Low-fidelity models that are essentially I/O tiebacks that, while cheap and quick to deliver, may not accurately represent the process enough to be useful in operator training for anything more than conceptual understanding or familiarization with the control strategies configured on the system. Medium-fidelity simulations are, in most cases, the most practical and cost-effective choice for organizations seeking strong training outcomes without prohibitive costs. By blending realistic process behavior that focuses on the most important components of the process, medium-fidelity OTS solutions deliver high value for day-to-day operations and system migrations. Case studies will demonstrate how these OTS implementations have achieved measurable improvements in safety, operator readiness, and startup success.

Through proven successes, this session will help system owners identify the most effective strategy for OTS implementation for their mills’ specific goals, workforce needs, and budget.

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