How do you train and support your DCS operators and engineers on using multiple systems and platforms?

Thanks for bring this up, it is important article for the OIL/GAS companies. Every company need to develop their Governances on how to design a new DCS systems and other systems. It is very important to have asset operator and engineers on board during FAT, and the commissioning of a new DCS system. Operators and engineers need to be familiar with the process they are working on and can clearly understand the legend, P&IDs, C&E, isolation plan etc. Before talking about training.

It is very important to enhancement operators and engineers in handling a variety of DCS systems and platforms through regular training and comprehensive documentation. We always have to improve ourselves and remain available to provide personalized support, answer questions and resolve specific challenges through accessible communication channels. I recognize that the in-depth study of the SDCD to replicate knowledge is a process that takes time, and we need to be committed to facilitating this journey, to have a more robust process.

The modern approach for industrial process control is integrated control , ESD and FGS systems in single platform like Yokogawa centum VP/Emerson Delta V. But the existing scenario in many plants are dedicated individual different OEM systems for process control, ESD, BMS and FGS which are interconnected through OPC. For an optimum system maintenance and operational reliability both the operation and instrumentation teams should be trained in different perspective. Operators should be trained to properly identify different alarm segregation philosophies, operating methodology and to handle overrides. Instrumentation team should be trained to assess system diagnostics , troubleshooting and daily maintenance activities.

Normally the best option to training and support of operation/ production teams is with hand-on training, because you can teach in practice how the system operates, in addition to explaining how the system was designed. This is also the best way to receive feedback on how the system was configured and whether improvements can be implemented.

The organization's training needs plan and Management of personnel change basically drives this requirement. A comprehensive multidisciplinary training plan needs to be developed that fully covers the maintenance and operational aspects of DCS. These can be divided as per following: 1) Class room Trainings for freshly inducted engineers. 2) Trainings manuals and area specific courses for DCS and HMI operations for the boardman/production unit 3) Comprehensive scenario based Hands on DCS training on test setup/training workbench for control system engineer. 4) Mock system restore/recovery sessions for DCS engineer.

I had the opportunity to support Delta V and yokogawa Dcs and was able to configure and commission both. The delta V also included field bus transmitter, valve controllers and micro motion. I had in-company training on both that included configuration from start to finish. I was able to trouble shoot and change configuration

Provide initial training to operators and engineers on all systems and platforms they will use, including hands-on practice and simulations. Develop user manuals, guides, and tutorials with step-by-step instructions that are easily accessible and regularly updated. Conduct periodic training sessions to review best practices, troubleshoot common problems, and introduce updates. Encourage collaboration among operators and engineers to share tips and lessons learned

Training can be prepared using DCS Screenshots if not videos! The Operators prefer interactive trainings on DCS HMI itself instead in classrooms which they find boring.

Creating demo systems that operators are able to click around in and use before they enter a production environment is usually the best way with getting them familiarized with any DCS system. After they use the demo system they can shadow an operator in the production environment before starting to use the system themselves.

Exploring other sites and conducting research into new technologies is a valuable approach to improving and innovating. By visiting different platforms and analyzing new technological solutions, we can: Identify Trends: Track emerging trends and compare technologies. Operational Efficiency and Reliability: Discover more efficient systems that can optimize processes, always evaluating reliability. Networking: Attend events and conferences to interact with professionals. Always be on the lookout for technologies that can easily adapt to your needs. Involve your team in this process of discovering and evaluating new technologies. Collaboration and knowledge sharing are fundamental to the successful implementation of innovations.

I read whitepapers, case-studies, webinars and also best practices used by my seniors in other reputed companies! If given chance to choose only one of them because of time shortage then I will go with the webinars. You can learn quickly from webinars having highlights, bulleted, precise information and I can easily watch them while traveling. My preference is webinars>best practices>whitepapers>case-studies.

I upgrade myself using below techniques: - reading relevant books and knowledge base articles - Built-in help - updated OEM Manuals - watching YouTube videos even it's not same brand DCS - assisting friends/colleagues in their projects' issues - asking company to arrange trainings (the most difficult)

Participating in webinars, workshops and conferences on Distributed Control Systems (DCS) benefits the development of the operational group. These events offer updates, practical learning, networking, exchange of experiences, connection with experts and promote motivation, contributing to efficiency and innovation in working with DCS. Videos and operational manuals and exchange of knowledge between members of work groups, assist in the development of the entire unit. Developing a streaming platform at the unit is of great value to all work groups.

In the era of such frequent technological advancements, staying updated for a DCS engineer is very important. Easiest way is through networking, attend webinars, most of them are free of cost and offer a good amount of knowledge on the latest industry trends. Another approach is to become member of important membership bodies like ISA (International Society for Automation). These serve as a good platform to have access to the latest Automation standards, technical forums and blogs. Reading and understanding latest automation standards and best practices to ensure that our knowledge and practices are current and standardised.

I was involved in both brownfield and greenfield projects and both projects have included in their budget personnel trainings. There is training designed for Operation/Production team, another training for Maintenance team and a higher level of training for Control System team which include engineering aspect. These mandatory trainings, whether in-house or vendor's location, are essential for a successful operation of DCS.

Customer feedback is important as it highlights important areas for improvement. For a DCS engineer at plant, customer is Production Department. Maintain close liason with them. Have a simple meeting with them periodically to gather feedback on the DCS implementation that may include sluggish loop response, transmitter variation, HMI linking, Alarm priority and many such topics. All observations requiring DCS modification need to be processed through a proper workflow, either through Management of Change, Change of setting request etc whatever is applicable.

This is mostly ignored because of expected criticism but believe you cannot deliver best of the training if you don't get feedback as well as suggestions! Multiple Questionnaire based feedback is the usually quite helpful.

Integration of other systems with DCS and further upgrading operations and engineering is a question which needs proper management and planning. First thing to evaluate is, if the system and the operators can handle the extra load, which is going to be a part of this process. Secondly how to handle the additional data & control features implemented by the integration process. Thirdly & most importantly, what impact it will have on the safety, security, environment and ergonomics related to the process. No matter what standards are followed or how well the system is integrated, if the professionals handling it, either operators or engineers are not able to embrace the challenges coming with the new system it will not work satisfactorily.

- Ask the operators for their feedback on the current DCS that could be used for optimization of the DCS and improve the training requirements. For example are the HMI reflect all process requirements, are the colors reflect the status of the plant equipment, is the navigation tool is reliable, are the alarm management fit for purpose or need improvement. Is the DCS clearly show that an equipment is under maintenance. How is the bypass of safety system (SIS) is executed...etc. These feedbacks will assist for system performance optimization and improve the training in general

One important aspect of Operator DCS training is the need for refresher training and updating the operator on various changes in the DCS. In a facility I served earlier in my career, we had defined modules for the operators to review and be tested on to ensure that they understood the area operations from the DCS interface. This approach also helped when new operators joined the company and was a great tool for operators to get recognition by their peers and managers as being competent in the respective areas of control.

1. Include OEM training, while purchasing new Control system or any other specialised equipment like GC or Analysers. 2. Involve O&M Engineers during pre commissioning, commissioning and start up phases of new projects or upgrades. 3. Solicit OEMs to conduct Lunch and Learn sessions at Company premises.

It is essential to ensure operators who use multiple DCS systems understand the differences between the systems and that one might not function the same way as the other. Periodic trainings can help reinforce their understanding.