As production demands intensify and resources dwindle, it's more vital than ever to reduce the time it takes to grow effective operators. Simulators can pack years of operating experience into weeks, building skills without jeopardizing people, production or equipment.

  A process simulator is a combination of hardware and software that replicates all or part of a manufacturing process. The simulator reproduces some aspect of the process and the controls used to regulate it. By simulating real life job assignments, we can reduce the time it takes to become a proficient operator.

  For example, a simulator can replicate the operation of the pulping process at your mill, or the operation of a recovery boiler, a paper machine, etc.

  Normally, the simulator platform is either a PC computer or a DCS control console just like the one used to control your processes.

  To use a simulator, trainees access information about the simulated process through the computer or console, and enter information into the simulated control system to control the process.

  Usually, the simulator reproduces both the console displays (either on a pc or on an off-line console) and the manufacturing process being controlled. Trainees can then use the simulator to control simulated processes, make changes to the process and correct upset conditions-just as they will later with the mill's real processes and controls.

  A good simulator allows a person to practice operating a process area without risk to people or production. Flight simulators are a classic example: you use a computer and simulation software to practice taking off, landing and handling in-flight problems, gaining flying experience without risk to people or equipment.