14. The Instructor Kit¶
Running a class needs paper as well as software: a sheet the trainee reads before touching the panel, a sheet the instructor fills in during the session, and a card that answers "which button was that?" without stopping the exercise. This page holds those documents. Print them from the browser (each section prints on one or two pages), or copy them into your own templates.
What is here
- A plant sheet for the trainee, for each sample plant
- A briefing and debriefing sheet the instructor fills in per session
- A one-page reference card for the Instructor Station and the operator windows
- A checklist for the room, before the trainee arrives
Plant sheet: gas-liquid separator¶
Give this to the trainee for the first sessions. It says what normal looks like and what the alarms mean, and nothing about the faults.
Unit: gas-liquid separator SG-01, 1 m³, 2 m tall, fed from a 5 bar header through FV-001. Gas leaves through PV-001 to a 1 atm header, liquid through LV-001 to a 1 atm header.
| Loop | Controls | With | Normal set point | Action |
|---|---|---|---|---|
| PID-012 | Separator pressure | PV-001 | 2.0 bar | Pressure above set point: vent opens |
| PID-013 | Liquid level | LV-001 | 0.30 m | Level above set point: drain opens |
| Reading | Normal | LL | L | H | HH |
|---|---|---|---|---|---|
| PIT-001 pressure | 200 kPa | 100 | 150 | 400 | 450 |
| LIT-001 level | 0.30 m | 0.15 | 0.25 | 0.40 | 0.50 |
| FI-001 feed | about 290 kg/h |
Trips: High pressure trip (PIT-001 HH for 5 s): closes FV-001 and hands PID-012 back in manual with the vent open. Reset from the Interlocks window once the pressure is below HH.
Your job: keep the pressure between 150 and 400 kPa and the level between 0.25 and 0.40 m. Acknowledge every alarm. If a controller no longer does what you expect, take it to manual and drive the valve yourself.
Plant sheet: two-stage separation¶
Unit: HP separator V-100 (6 m³, 4 m tall, 30 bar) and LP separator V-200 (3 m³, 3 m tall, 8 bar). Rich gas at 45 bar enters through FV-100. HP gas leaves through PV-100 to the 25 bar header; HP condensate flows through LV-100 into V-200; LP gas through PV-200 to the 3 bar header; condensate through LV-200 to the 1.5 bar header.
| Loop | Controls | With | Normal set point | Action |
|---|---|---|---|---|
| PIC-100 | V-100 pressure | PV-100 | 30 bar | Pressure up: gas valve opens |
| LIC-100 | V-100 level (from LT-100) | LV-100 | 1.2 m | Level up: liquid valve opens |
| PIC-200 | V-200 pressure | PV-200 | 8 bar | Pressure up: gas valve opens |
| LIC-200 | V-200 level | LV-200 | 1.0 m | Level up: liquid valve opens |
| Reading | Normal | LL | L | H | HH |
|---|---|---|---|---|---|
| PIT-100 | 30 bar | 20 | 26 | 34 | 37 |
| LIT-100, LT-100 | 1.2 m | 0.4 | 0.7 | 1.8 | 2.2 |
| PIT-200 | 8 bar | 4 | 6 | 10.5 | 12 |
| LIT-200 | 1.0 m | 0.3 | 0.5 | 1.6 | 2.0 |
| FI-100 feed | 11 000 kg/h | ||||
| FI-101 HP gas | 1 150 kg/h | ||||
| FI-200 LP gas | 680 kg/h | ||||
| FI-201 condensate | 9 200 kg/h |
Trips: V-100 low level (LIT-100 LL for 3 s) closes LV-100 and puts LIC-100 in manual at 0 %, to stop gas blowing through to V-200. V-200 high pressure (PIT-200 HH for 3 s) closes LV-100 and opens PV-200 fully. V-100 high pressure (PIT-100 HH for 5 s) closes FV-100. All three latch: reset them from the Interlocks window once the cause is gone.
Your job: keep both pressures and both levels between their L and H limits. A falling HP level is the most dangerous thing on this unit: when it reaches LL, gas at 30 bar goes straight into a vessel rated for 12. Watch LIT-100 and LT-100 together; if they disagree, believe the gauge and take LIC-100 to manual.
Plant sheet: aftercooler and knock-out drum¶
Unit: compressed gas at 10 bar and 150 °C is cooled in E-101 to 45 °C and separated in the knock-out drum D-101 (8 m³, 4 m tall, 7 bar). Gas leaves through PV-101 to the 6 bar header, condensate through LV-101 to the 3 bar header. The cooling duty of E-101 is what TIC-101 sets; behind it is the cooling water.
| Loop | Controls | With | Normal set point | Action |
|---|---|---|---|---|
| FIC-101 | Gas flow | FV-101 | 5 400 kg/h | Flow below set point: valve opens |
| TIC-101 | Gas outlet temperature (from TT-101) | E-101 duty | 45 °C | Temperature up: more cooling |
| LIC-101 | D-101 level | LV-101 | 1.0 m | Level up: condensate valve opens |
| PIC-101 | D-101 pressure | PV-101 | 7 bar | Pressure up: gas valve opens |
| Reading | Normal | LL | L | H | HH |
|---|---|---|---|---|---|
| TI-101, TT-101 outlet temperature | 45 °C | 30 | 35 | 60 | 75 |
| FI-101 gas | 5 400 kg/h | 1 500 | 3 000 | 9 000 | 10 000 |
| LIT-101 level | 1.0 m | 0.3 | 0.5 | 1.25 | 1.4 |
| PIT-101 pressure | 7 bar | 5 | 6 | 8 | 9 |
Trips: Hot gas to drum (TI-101 HH for 10 s) closes FV-101. D-101 high pressure (PIT-101 HH for 5 s) closes FV-101 and opens PV-101. D-101 overfill (LIT-101 HH for 5 s) closes FV-101. All latch.
Your job: keep the outlet temperature between 35 and 60 °C, the drum level between 0.5 and 1.25 m and its pressure between 6 and 8 bar. TT-101 and TI-101 measure the same temperature; if they disagree, believe TI-101, take TIC-101 to manual and set the duty yourself.
Briefing and debriefing sheet¶
One per session. The instructor fills the top half before the trainee arrives and the bottom half during the debriefing. Copy the block below into a document, or print this page.
SESSION SHEET Date: ________ Instructor: ____________
Trainee: ______________________ Plant: ______________________ Scenario: _________________
Speed: ____x Schedule: ______________ Initial state: ____ Station PC: ____________
BRIEFING (10 min)
What the plant does, in two sentences: ____________________________________________________
Normal readings the trainee should expect: _________________________________________________
Alarms and trips explained: [ ] limits [ ] what each trip does [ ] how to reset
Told the trainee the objectives? [ ] yes (lesson) [ ] no (assessment)
The fault (instructor only): _______________________________ at ______ (simulated)
EXERCISE (25 min)
Start at (wall clock): ______ First alarm at (sim): ______ Trainee's first action at: ______
Freeze / backtrack used: ______________________________________________________________
Extra faults by hand: ______________________________________________________________
Trips: ______________________________________________________________
End exercise at (sim): ______ Score: ______ / ______
DEBRIEFING (15 min)
What the trainee saw first: _______________________________________________________________
Time between the first alarm and the first action: ______ s (simulated)
What went well: __________________________________________________________________________
What to do differently: ____________________________________________________________________
Objectives failed and why: _________________________________________________________________
Next session: ______________________________ Report saved as: _____________________________
The times come straight from the journal (page 2) and the report (page 4): export the journal as CSV if the course keeps records.
Reference card¶
Print this on one page and keep it next to the instructor PC.
Instructor Station toolbar
| Button | Does |
|---|---|
| Start | Fresh session from the initial state; after Freeze, resumes |
| Freeze | Stops at the end of the step, keeps everything |
| Step | One integration step |
| Stop | Ends the session |
| Speed (x) | Simulated seconds per real second, 0.1 to 20 |
| Schedule | Which schedule (integrator, initial state, events) runs |
| Flowsheet in control panel mode | Trainee may touch controllers on the drawing; editors stop opening on click |
| Operator panel..., Interlocks..., OPC UA..., Stations... | The other windows |
| P-F network | Junction pressure solver, on by default |
Status line: RUNNING or FROZEN, simulated time, step, ms per step, overruns (steps slower than the budget), failed steps (solver could not finish), active alarms, network state.
Tabs: Scenarios (New, Delete, Save all, Load), Exercise (End exercise and score, Report...), Malfunctions (Object, Malfunction, Severity, Ramp, Activate, Deactivate, Remove, Clear all), Snapshots (Save, Restore, Backtrack), Journal (Show filter, Export CSV, Clear).
Journal categories: Session, Instructor, Operator, Alarm, Trip, Malfunction, Solver.
Operator panel: controller tile (PV, SP, OUT, MAN OUT, Mode, Switch to MANUAL/AUTO), valve tile (opening, flow, Set % or "Driven by controller"), equipment tiles (values and Start/Stop, Target rpm, Set duty), gauge tiles (value, alarm level in red). Banner: newest unacknowledged alarm; Acknowledge; Summary...; Interlocks.
Operator screens: Home, Back, screen selector, Fit, clock, alarm line (click for the summary), Faceplates, Interlocks. Click a symbol for its faceplate, a flag to change screen, a button for its action.
Interlocks window: Status tab (Reset, Force reset, Bypass on/off, Trip now), Configuration tab (Name, Enabled, Latching, All/Any, for (s), Conditions, Actions, Save and apply).
Malfunction kinds: Valve stuck, fails closed, fails open, passing; Pump trip; Exchanger fouling; Utility loss (duty); Sensor frozen, drift, bias, full scale, zero; Power failure; Instrument air failure.
Objective kinds: Reach (condition true before the deadline, held for the hold time), Avoid (condition never true; penalty per occurrence), KeepInRange (property inside Min to Max for the required fraction of the time; penalty per second outside), OperatorAction (journal text contains the action text before the deadline).
Where things are saved: scenarios, screens and interlocks in the flowsheet file (save it); snapshots as stored flowsheet states; the report as a Markdown file you choose; the journal as CSV.
Room checklist¶
Before the trainee arrives:
- Flowsheet file open on the instructor PC; the same file on the trainee PC (or a station launched from Stations...)
- Instructor Station open, scenario loaded, status line shows time zero and the initial state
- Stations server started; trainee station connected; operator screens visible there
- Alarm sound off on the trainee PC if the room is shared; on otherwise
- Speed set for the scenario (page 13 gives one per scenario)
- Interlocks reset, no malfunction active, journal cleared
- Session sheet printed, top half filled in
- Report folder ready: one folder per trainee, one file per session
The next page shows what the exercise report looks like when a session is over.