A good PC, 512 megs of RAM, 1 gigabyte of hard drive space, one or two monitors with a video card that can handle two if that is the choice (two monitors allows you to better replicate a control room situation). Most on-line processes have at least two monitors because that is what it takes to run the process. Sometimes it handicaps a trainee to only have one). Large monitors are desirable because so many items appear on the screen at one time.

What does PC hardware typically cost for a PC based training simulator? Can it be included in the total package price?

  Usually, you should budget between $3,000 and $5,000 for hardware, depending upon the processor you buy, monitor size, and peripherals (printers). Yes, we can provide the hardware as part of the package. In fact, we recommend it, since we often develop the simulation on the hardware that the mill will later use to run it.

What mill areas are candidates for training simulators? How many mill areas have you developed training simulators for previously?

  Any mill area is a candidate. Areas using DCS control schemes are prime candidates. Simulators have been for every mill area, and some have been fully operational since 1985.

How are mills using training simulation in their training efforts?

  Many mills use simulation as a final step in job position training for control room operators. After they have satisfied knowledge requirements, they have opportunity to practice running the operation from a simulator. Trainers and administrators can also set up individual trainees to handle specific upset or emergency conditions, and measure how well they respond.

  Another typical use is to refresh on critical tasks, for example a boiler ESP or a turbine shutdown or startup-tasks that are critical but rarely needed. Simulating these events keeps operators sharp. Long reliefs also benefit from periodic training to keep their skills sharp.

  You can also stage simulation activities so that operators dovetail simulation duties with structured OJT in the field. There are countless options for using a simulator to improve operating efficiency.

What does a training simulator for a process area cost?

  Simulators using a spare DCS console include the cost of the console and the labor to develop the training simulation. PC based simulators have a similar development cost, but the hardware is significantly cheaper.

Several factors influence development cost, including:

• The "size" of the process area-this means the number of pieces of equipment, the flow routes and complexity, bypass and recirculation options, support systems required, etc.
• The number of control "points" in the area-the actual count of all the indicators, controllers, etc. in the process to be simulated.
• The number of DCS control screens to be produced-as a rule of thumb, fewer screens usually costs less than more, though again, the number of points to simulate is more critical.
• The number of process areas you want to simulate and their similarity to one another. If development is for two paper machines, for example, which are similar in configuration, the second machine process would require less labor to simulate. There are also efficiencies in working in several mill areas at once or in series.

What about warranty and support?

  Warranty information is included in the scope of work, determined per project. Maintenance contracts are available. Support is also available through Delta, with specifics determined for each project. For more details, talk with the Delta Training.