Brock uses PICS I/O Simulation (by SST) to quickly create on a PC a dynamic model that duplicates the behavior of the actual process and provides the PLC with real-time feedback.
Simulation is used to stress test the system and to ensure that performance specifications are being satisfied. As part of the test plan, each component of the system is
forced to fail during simulation. This permits testing of the back-up and
recovery procedures to ensure that they are adequate and perform as designed.
The
role of simulation is also important in training. With simulation, it is
possible for operators to be trained in an environment that performs exactly
like the real system. Process rates can be accelerated and selected scenarios
recreated so that operators get the maximum benefit from the training
sessions. Experience shows that with simulation the learning time for operation
of a new system is dramatically reduced, as operators train without the
stress of training on live equipment. Operators are able to experiment and make mistakes without endangering production, equipment, or personnel.
