Operator training environment for training an operator for a technical system

Abstract

The invention relates to a computer-implemented operator training environment for a technical system, which environment is designed to: - receive a system configuration of the technical system; - generate a basic operator training scenario including a system configuration of the technical system; - automatically acquire or receive a sequence of operating actions performed by one or more operators of the technical system in order to derive and generate a specific operator training scenario from the basic training scenario; - receive an updated system configuration; - newly generate the basic operator training scenario including the updated system configuration; and - generate the specific operator training scenario by applying the recorded sequence of operating actions to the newly generated basic operator training scenario.

Description

[0001] 202422039 Foreign version 20.11.2025

[0002] 1

[0003] Description

[0004] Operator training environment for training an operator for a technical system

[0005] The invention relates to a method for operating a technical plant, in particular a manufacturing plant or process plant, by means of a control system of the technical plant, which comprises an operator station server and an operator station client. The invention also relates to an associated control system.

[0006] Technical systems, particularly manufacturing and process plants, are typically monitored and controlled by complex control systems known as master control systems. These systems generally include a central operator station server that generates visualization information for a multitude of plant components, as well as one or more clients through which operators can control and monitor the plant. The visualization information can encompass various types of data, such as process measurements, alarm messages, trend indicators, and schematic diagrams of the plant components.

[0007] As the complexity of technical systems increases, so does the amount of visualization information made available to operators. This can lead to challenges in effectively monitoring and controlling the system. Operators often need to quickly switch between different views and levels of information to find relevant data and react to events. The sheer volume of information can make it difficult to recognize important relationships.

[0008] To specifically prepare operators for the challenging operation and monitoring of technical equipment, operator training environments are used. These provide a virtual environment for training operators. These operator training environments typically comprise several parts of a digital twin of the real plant and its automation system:

[0009] • A 1:1 replication of the automation or distributed control system (DCS), comprising an operator HMI and emulated controllers (DCS and SIS simulation / emulation, control room replica). In known operator training environments, both are derived and typically represent an actual copy of the real automation system.

[0010] • A simulation of the connected field devices that provide values ​​from the process. This layer abstracts the behavior of real field devices that link the process. 202422039 Foreign version 20.11.2025

[0011] 2. Represent the digital automation world and the physical process (simulators here are, for example, SIMIT).

[0012] • A process simulation of the plant (dynamic process model) that represents the physical behavior of a plant up to a defined level of accuracy.

[0013] The motivation for operator training is to teach new functions, altered behavior, and hazardous situations that cannot be practiced in the actual plant. Furthermore, standard procedures can be practiced to keep knowledge up-to-date and to prepare and familiarize operators with the plant and automation system.

[0014] For these training purposes, it is necessary to create and load scenarios that

[0015] • reflect a specific initial state of the plant (process and automation)

[0016] • (optional) include a simulated process event to which the trained operator should react.

[0017] These scenarios serve as a starting point for the training and fulfill a specific training objective that is comparable and repeatable.

[0018] In an operator training environment, many different scenarios for various training tasks can be stored. Typically, an operator training environment offers a function for managing these scenarios ("scenario management"). To make the training as realistic as possible, it is necessary to keep these scenarios synchronized with any changes made to the plant or plant automation. This can be very difficult for the following reasons:

[0019] • Setting up a scenario itself can be very time-consuming if the starting point of the scenario can only be reached by bringing the simulated plant to the desired state and then saving the plant and automation state as "scenario snapshots." Especially in complex plants with multiple units, which sometimes even need to be started up by different personnel, this effort can take a team of operators several days.

[0020] Maintaining delta download capability for emulated controllers can be very costly, as it means that all delta changes must be reapplied to all emulated controllers in the same order as on the real controllers. It is essential to avoid situations where downloading a 202422039 foreign version dated November 20, 2025 would cause problems.

[0021] 3 emulated controllers require a restart, as this would invalidate the saved scenario snapshot and therefore the entire scenario would have to be set up from scratch, as if the plant were being completely restarted.

[0022] • Changes may also cause some scenarios to become invalid by their very nature (e.g., a scenario “How do I start pump 3” is invalid if pump 3 no longer exists).

[0023] The previously discussed issue of synchronization / updateability was previously addressed by exporting / importing configuration changes from the real plant to the simulated plant, followed by manual adjustments or scenario restoration (where possible). However, this approach required a deep understanding of the process plant and automation system, as well as adjustments or incremental updates to the imported plant configuration. Often, this effort resulted in the operator training environment no longer being updated, ultimately creating an outdated version that may no longer be used for training purposes.

[0024] Other approaches to solving the update problems followed a dedicated selection process that required manual selection and updates. A major problem with this was the resulting discrepancy between the actual plant and the automation setup compared to the scenarios in the operator training environment, which in turn led to an outdated system.

[0025] US patent 2017 / 0090970 A1 discloses an exemplary operator training environment which serves to train operators in the operation and monitoring of a technical system.

[0026] EP 4 086 717 A1 discloses an operator training environment for a control system of a technical plant.

[0027] EP 3 121 667 B1 discloses an operator training environment for a process control system based on the use of snapshot management. In this environment, state information of the plant is stored in the form of static images in order to restore it for training purposes.

[0028] In the publication “Towards an integrated use of simulation within the life-cycle of a process plant” (M. Oppelt et al., 2015 IEEE 20th Conf, on Emerging Technologies & Factory 202422039 Foreign version November 20, 2025

[0029] 4

[0030] Automation (ETFA), IEEE, Sep. 8, 2015, pages 1-8.) reveals a concept for the continuous use of simulation throughout the entire life cycle of a process plant.

[0031] The invention is based on the objective of providing an operator training environment for a control system of a technical plant, which is characterized by higher efficiency and accuracy.

[0032] This problem is solved by a method for generating a specific operator training scenario for a computer-implemented operator training environment for a technical plant with the features of claim 1. Furthermore, the problem is solved by a computer-implemented operator training environment for a technical plant with the features of claim 7 and by a control system according to claim 11. Advantageous embodiments are set forth in the dependent claims.

[0033] A method according to the invention for generating a specific operator training scenario for a computer-implemented operator training environment for a technical plant comprises the following steps: a) generating a basic operator training scenario incorporating a plant configuration of the technical plant; b) automatically capturing a sequence of operating actions performed by one or more operators of the technical plant in order to derive and generate a specific operator training scenario from the basic training scenario; c) updating the plant configuration; d) regenerating the basic operator training scenario incorporating the updated plant configuration; and e) automatically regenerating the specific operator training scenario by applying the recorded sequence of operating actions to the newly generated basic operator training scenario.

[0034] The technical installation can be a plant from the process industry, such as a chemical, pharmaceutical, petrochemical, or food and beverage plant. This also includes any plant from the manufacturing industry, such as factories where cars or goods of all kinds are produced. Technical installations suitable for carrying out the process according to the invention can also originate from the energy generation sector. Wind turbines, solar power plants, or power plants for energy generation are likewise included in the term "technical installation." 202422039 Foreign version 20.11.2025

[0035] 5

[0036] A plant configuration refers to the structural setup of a technical plant and its associated automation system for automated operation. The plant configuration includes, for example, the sensors and actuators used in the plant, or the piping provided to ensure interoperability between individual components. A plant configuration may also include:

[0037] Hardware: Physical devices and machines, such as pumps, valves, and control units.

[0038] Software: Programs and algorithms used to control and monitor the plant, including a control system or safety instrumented systems (SIS).

[0039] Settings and parameters: Specific settings and operating parameters that determine how the system is operated, such as temperature, pressure and flow limits.

[0040] Network and communication systems infrastructure that enables communication between the various components of the plant.

[0041] A "training scenario" is defined here as a situation or training case to be simulated by the operator training environment, replicating specific conditions and events in a technical plant. These scenarios are used to prepare operators for various situations they might encounter in the actual plant. A training scenario may include the following elements:

[0042] - Initial state of the plant: The starting point of the training scenario, reflecting the current state of the plant and its automation.

[0043] Simulated events: Events or disturbances that occur during training and to which the operator must react.

[0044] Training objectives: Specific learning objectives to be achieved through the training scenario, such as learning new functions, responding to emergencies, or performing standard procedures.

[0045] After creating a basic operator training scenario, the operating actions of one or more operators are recorded. These actions can be performed on the actual system or on the simulated system within the operator training environment. The operating actions can include, for example, the following:

[0046] Starting and stopping machines: Switching pumps, motors, valves, and other devices on or off. 202422039 Foreign version 20.11.2025

[0047] 6

[0048] Setting operating parameters: Adjusting temperature, pressure, or flow settings to optimize the process.

[0049] Responding to alarms and malfunctions: Taking action in the event of problems or emergencies, such as shutting down equipment or initiating safety procedures.

[0050] When a change is made to the configuration of the technical system, the system configuration is updated, preferably automatically. This update can be performed by a computer-implemented system configuration service, which is implemented, for example, on an operator station server. In this context, an "operator station server" is understood to be a server that centrally collects data from an operator control and monitoring system, as well as typically alarm and measurement data archives from a control system of a technical system, and makes this data available to users. The operator station server usually establishes a communication link to the automation systems of the technical system and forwards data from the technical system to so-called operator station clients, which are used to operate and monitor the operation of the individual functional elements of the technical system.The Operator Station Server can have client functions to access the data (archives, messages, tags, variables) of other Operator Station Servers.

[0051] This allows images of the operation of the technical system on the Operator Station Server to be combined with variables from other Operator Station Servers (server-to-server communication). The Operator Station Server can be, but is not limited to, a SIMATIC PCS 7 Industrial Workstation Server from Siemens.

[0052] In this context, a control system is understood to be a computer-aided, technical system that includes functionalities for displaying, operating, and controlling the technical plant. The control system can also include sensors for acquiring measured values ​​and various actuators. Furthermore, the control system can include so-called process- or production-related components that serve to control the actuators or sensors. In addition, the control system can include, among other things, means for visualizing the process plant and for engineering purposes. Optionally, the control system can also include additional computing units for more complex control systems and systems for data storage and processing.

[0053] The control system generates visualization information in a known manner, which is provided to a control system operator via the Operator Station Client. This visualization information can include plant images with graphical representations of individual process objects such as boilers, motors, robots, valves, mixers, or packaging stations. The visualization information can also include lists of messages (202422039 Foreign Version 20.11.2025).

[0054] Section 7 of the control system includes so-called message sequence displays, or time-based trend diagrams of individual or multiple process measurements. It should be noted that the visualization information does not only relate to current information about the process being carried out, but can also extend to, for example, historical process measurements or messages.

[0055] If the plant configuration has changed, the operator training environment regenerates the basic operator training scenario, incorporating the updated plant configuration. It can preferably receive the updated plant configuration automatically from the computer-implemented plant configuration service.

[0056] The specific operator training scenario can now be easily updated by using the updated basic operator training scenario as a starting point in the computer-implemented operator training environment, and additionally taking into account the previously recorded sequence of operating actions in order to recreate the specific operator training scenario efficiently and accurately from the overall view.

[0057] Another significant advantage of the method according to the invention is that this approach not only allows for the particularly effective creation of a specific operator training scenario, but also of any number of specific operator training scenarios - since only the basic operator training scenario needs to be fundamentally recreated.

[0058] Preferably, the newly created specific operator training scenario will then be used to train an operator in the operation and monitoring of the technical system.

[0059] The basic operator training scenario can simulate a cold state of the technical system. A cold state of a technical system refers to a condition in which the system is not in operation and no operating parameters need to be met. In this state, all processes and functions of the system are shut down, and there is no active use. This state is particularly well-suited as a starting scenario because it exhibits the lowest possible complexity.

[0060] In an advantageous further development of the invention, the sequence of operating actions during the operation of the simulated technical system is recorded within the computer-implemented operator training environment. Alternatively, the recording can be [202422039 Foreign version 20.11.2025]

[0061] 8 of the sequence of operating actions during the (real) operation of the technical system by the operator(s).

[0062] It is particularly advantageous to automatically determine, prior to process step d, whether the specific operator training scenario is affected by the updated plant configuration. The specific operator training scenario is then only regenerated if it is determined that it is not affected by the updated plant configuration.

[0063] In addition to the operating actions, values ​​and states that occur in the technical system during the derivation of the specific operator training scenario from the basic training scenario can also be recorded. This allows the technical system to be used even more precisely for operator training purposes.

[0064] The previously formulated task is also solved by a computer-implemented operator training environment for a technical system that is trained to

[0065] - to receive a system configuration of the technical system,

[0066] - to create a basic operator training scenario including a plant configuration of the technical plant,

[0067] - automatically a sequence of operating actions performed by one or more operators of the technical system to derive, generate, capture, or receive a specific operator training scenario from the basic training scenario;

[0068] - to receive an updated system configuration;

[0069] - to recreate the basic operator training scenario, incorporating the updated plant configuration, and

[0070] - to create the specific operator training scenario by applying the recorded sequence of operating actions to the newly created basic operator training scenario.

[0071] The computer-implemented operator training environment can include emulation tools for emulating an automation system for the technical plant. This emulation typically includes both hardware emulation to replicate the automation hardware (such as a microprocessor or an ASIC) and software emulation to replicate the automation software environment. 202422039 Foreign version 20.11.2025

[0072] 9

[0073] Furthermore, the computer-implemented operator training environment can include device simulation tools for simulating field devices of the technical plant and / or process simulation tools for simulating plant processes that are carried out in the technical plant.

[0074] The previously formulated task is also solved by a control system for a technical plant with an operator station server for operating and monitoring the technical plant, whereby a computer-implemented operator training environment as previously explained is implemented on the operator station server.

[0075] The properties, features and advantages of this invention described above, as well as the manner in which they are achieved, will become clearer and more easily understood in connection with the following description of exemplary embodiments, which are explained in more detail in conjunction with the drawing.

[0076] The figure illustrates the sequence of a method according to the invention. Initially, it is assumed that a technical plant, such as a process plant or a production plant, has been set up and automated, resulting in a plant configuration. Based on this plant configuration, a computer-implemented operator training environment, implemented in a cloud-based computing environment, generates a basic operator training scenario with the base state A in a first step 1. The computer-implemented operator training environment comprises emulation means for emulating an automation system for the technical plant, device simulation means for simulating field devices of the technical plant, and process simulation means for simulating plant processes that are carried out in the technical plant.

[0077] In a subsequent step 2, one or more operators perform operating actions on the technical system simulated by the operator training environment. This sequence of operating actions is recorded by the computer-implemented operator training environment and stored in a suitable data storage system. In a parallel step 3, the computer-implemented operator training environment can also record values ​​and states of the technical system and store these in the data storage system as well. When a defined state B of the technical system has been reached through the corresponding operating actions, the current state of the technical system is recorded, and the (first) recording of the sequence of operating actions is completed. 202422039 Foreign version 20.11.2025

[0078] 10

[0079] In subsequent steps 4 and 5, one or more operators perform further operating actions on the technical system simulated by the operator training environment. This (second) sequence of operating actions is recorded by the computer-implemented operator training environment along with the values ​​and states of the technical system and also stored in the appropriate data storage, until the simulated technical system is in state C.

[0080] It is now assumed that the plant configuration will be changed at a later time. This changed plant configuration is transferred to the computer-implemented operator training environment, which, in a subsequent step 6, first recreates the basic operator training scenario with the new plant state A'. Then, in a further step 7, the computer-implemented operator training environment automatically applies the previously recorded sequence of operating actions to the simulated technical plant in order to easily achieve plant state B' and the associated specific operator training scenario.After reaching plant state B', the computer-implemented operator training environment automatically applies the previously recorded (second) sequence of operating actions to the simulated technical plant in a next step 8 in order to easily reach plant state C' and the associated specific operator training scenario.

[0081] The operator can be trained both in the new plant state B' for the associated specific operator training scenario and in the new plant state C' for the associated specific operator training scenario.

[0082] Although the invention has been illustrated and described in detail by the preferred embodiment, the invention is not limited by the disclosed examples and other variations can be derived by the person skilled in the art without leaving the scope of protection of the invention.

Claims

202422039 Foreign version 20.11.2025 11 Patent claims 1. A method for generating a specific operator training scenario for a computer-implemented operator training environment for a technical plant, comprising: a) generating a basic operator training scenario incorporating a plant configuration of the technical plant; b) automatically capturing a sequence of operating actions performed by one or more operators of the technical plant in order to derive and generate a specific operator training scenario from the basic training scenario; c) updating the plant configuration; d) regenerating the basic operator training scenario incorporating the updated plant configuration; and e) automatically regenerating the specific operator training scenario by applying the recorded sequence of operating actions to the newly generated basic operator training scenario.

2. Method according to claim 1, wherein the basic operator training scenario represents a cold state of the technical system.

3. Method according to claim 1 or 2, wherein the sequence of operating actions during the operation of the technical system by the operator(s) is recorded.

4. Method according to claim 1 or 2, wherein the recording of the sequence of operating actions during the operation of the simulated technical system takes place within the computer-implemented operator training environment.

5. Method according to one of the preceding claims, wherein, prior to method step d, it is automatically determined whether the specific operator training scenario is affected by the updated plant configuration, and wherein the regeneration of the specific operator training scenario only takes place if it is determined that the specific operator training scenario is not affected by the updated plant configuration.

6. Method according to one of the preceding claims, wherein, in addition to the operating actions, values ​​and states are recorded that occur in the technical system during the derivation of the specific operator training scenario from the basic training scenario. 202422039 Foreign version 20.11.2025 12 7. Computer-implemented operator training environment for a technical plant that is trained to - to receive a system configuration of the technical system, - to create a basic operator training scenario including a plant configuration of the technical plant, - automatically a sequence of operating actions performed by one or more operators of the technical system to derive, generate, capture, or receive a specific operator training scenario from the basic training scenario; - to receive an updated system configuration; - to recreate the basic operator training scenario, incorporating the updated plant configuration, and - to create the specific operator training scenario by applying the recorded sequence of operating actions to the newly created basic operator training scenario.

8. Computer-implemented operator training environment according to claim 7, comprising emulation means for emulating an automation system for the technical plant.

9. Computer-implemented operator training environment according to claim 7 or 8, comprising device simulation means for simulating field devices of the technical plant.

10. Computer-implemented operator training environment according to one of claims 7 to 9, comprising process simulation means for simulating plant processes carried out in the technical plant.

11. Control system for a technical plant with an operator station server for operating and monitoring the technical plant, wherein a computer-implemented operator training environment according to one of claims 7 to 10 is implemented on the operator station server.

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