Abstract This paper presents a case study on design, development and implementation of a custom operation training system (OTS). The challenge in the studied floating production storage and offloading (FPSO) process was to find an appropriate design between a simple simulation model and a sophisticated virtual process for the operator training and automation design validation. The adopted solution ensured a high fidelity modeling of the real process and a low development time for the simulator by using a commercial software framework with custom developed modeling objects. Such custom models include the separation process, the gas compression process, and production water treatment among others. For the separator module the model was derived from theoretical perspectives and integrated in the process simulator. The simulator ensured a successful training of the process system engineers before the process start up, including special scenario testing, tuning, and optimization of the production.
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