What We Do - OTS
We specialize in three main areas
OTS
High-Fidelity Operator Training Simulator
Apogee OTS is a high-fidelity simulation platform that replicates real-world industrial processes and control systems to provide a realistic and risk-free training environment.
It allows operators to practice startup, shutdown, and emergency handling procedures using a virtual plant that behaves exactly like the real system.
By combining OmniSim® dynamic simulation with emulated DCS and field devices, OTS bridges the gap between theory and real operation — ensuring operators gain confidence and experience before stepping into live production.
- Simulates full process behavior from steady-state to dynamic
- Emulates DCS, SIS, and field instruments from major brands (Honeywell, Yokogawa, Foxboro, Emerson, SUPCON, Hollysys)
- Provides integrated instructor, operator, and field operator environments
- Supports both local and cloud-based deployments
High-fidelity modeling using OmniSim®Dynamics and OmniSim®Plus for process, control, and ESD simulation.
Simulates steady-state and dynamic operation with >100 process modules and 30+ thermodynamic models.
Full training ecosystem including Operator Station, Field Operator Station (2D/3D VR), and Instructor Station.
Supports startup, shutdown, load change, and abnormal condition management.
- Scalable deployment on-premise or cloud.
Supports multi-model, multi-user sessions with built-in evaluation, reporting, and malfunction management.
Key Advantages
- High realism — identical interface to real plant DCS graphics
- Real-time responsiveness — refresh rate < 1 second with robust data link
- Safety & risk reduction — practice abnormal and emergency conditions safely
- Instructor-led or self-guided — supports exam management and scenario playback
- Multi-discipline coverage — integrates process, control, and safety system training
- Cloud-enabled — supports remote training, group sessions, and enterprise scalability
- Proven performance — deployed in large-scale refineries and petrochemical complexes (e.g., Sinopec Qilu Branch)
Sinopec Qilu Branch (China)
Scope: Full refinery and petrochemical complex (20 million t/a)
Coverage: From crude distillation to petrochemical processing
Scale: 1.4 million t/a hydrocracking, 8 million t/a distillation, 140,000 t/a polyethylene
Integration: Multi-brand DCS and SIS systems integrated under a unified OTS platform
Highlights:
- Large-scale, cloud-enabled OTS system for enterprise training
- Competes directly with Honeywell and Yokogawa solutions
- Enables standardized training across multiple process units
Additional Deployments:
Petrochemical and polymer plants (ethylene, polyethylene, polypropylene)
Refinery and FCC unit operator training centers
Power and utility OTS systems for startup/shutdown safety drills
Key Takeaways
- OTS is essential for plant safety and operational readiness.
- Immersive simulation builds confidence and skill before operators face real production scenarios.
- Digital Twin technology bridges process design, commissioning, and operation training.
- Standardized procedures and evaluations enhance workforce competency.
- Cloud-enabled OTS ensures flexibility for enterprise-wide training — anytime, anywhere.