Our generic simulation products are designed to reinforce the fundamental concepts, enhance the skill and competency of plant personnel, facilitate re-skilling, and speed up the induction of fresher’s into mainstream works. They facilitate a graded approach with fundamental modules for understanding basic unit operations, before graduating to plant specific larger processes. Importantly, these solutions are highly cost-effective, enabling organizations to achieve high-quality training outcomes with minimal investment in infrastructure and resources.
Fundamental process concepts; working principles of common process equipment
Equipment performance under different operating conditions
Hands-on practice on operations such as start-up, shutdown, troubleshooting etc.
Practice safe operation of the unit; prepare for handling emergencies
Effects of changes in operating conditions such as flow, pressure, temperature, etc.
Effects of changes in boundary conditions such as supply & discharge pressure, supply temperature, feed composition, etc.
Performance of control systems; functioning of different control schemes such as antisurge control, minimum flow control, overpressure control, etc.
Common problems and the recovery actions
Concepts of vapor-liquid separation; bubble and dew points
Principles of gas-liquid-liquid separation; gravity settling, interface level, residence time
Distillation concepts; conditions affecting separation quality and energy consumption
Absorption concepts; conditions affecting quality of gas-liquid absorption
Common problems such as transmitter drift, transmitter failure, valve failure, etc.
Reaction kinetics; rate of reaction, heat of reaction, conversion, etc.
Factors affecting reactions such as temperature, pressure, reactant concentration or partial pressure, residence time, etc.
Petroleum products blending: Achieve blended final product meeting specifications
Environmental compliance: Additives usage
Optimize operations: Minimize giveaways, maximize efficiency and profitability
Blending process: Batch blending and inline blending
Working principles; performance under different process conditions
Safety in operation; common problems such as supply failure, driver failure, loss of load, higher discharge or exhaust pressure, etc., and their recovery
Heat transfer concepts and equipment dynamics
Performance under different operating conditions such as flow, temperature & composition
Common problems such as fouling, tube plugging, tube leak, and their recovery
Performance under different operating conditions such as flow, pressure, temperature and fuel gas composition
Practice safe operation; prepare for emergencies
Common problems such as partial & incomplete combustion, coil fouling, coil leak, coil rupture, equipment failure and their recovery
Refrigeration concepts and chiller dynamics
Chiller performance under different operating conditions such as feed gas flow, temperature and chiller levels.
Safety in compressor operation; anti-surge control
Compressor performance under load changes
Common problems in the chiller such as fouling, tube leak and their recovery
Common problems in the compressor such as driver failure, loss of efficiency
Evaporator performance under different operating conditions such as steam load, steam pressure, cane juice load, etc.
Evaporator safeguard systems
Common problems such as scaling of evaporator tubes, loss of vacuum etc.
Fundamental concepts of industrial controls and their functioning
Merits / performance of a control scheme and comparisons with other schemes