By: Kobus Vermeulen - Direct Sales Executive, Process Automation at Schneider Electric

How do you keep pace with the relentless growth of technology innovation in a world that has become so competitive, most of suffer us from perpetual, virtual whiplash.  The same can be said for industrial settings where operators need to respond so quickly to change, it often feels like an insurmountable task. 

Enter system-agnostic Operator Training Simulator (OTS) software, a somewhat unsung hero of industry that trains plant operators in virtual world that mirror real-world operations. The benefits are multiple; OTS is particularly valuable industries like power generation, refining and chemicals:

• Risk-free learning - operators can make mistakes and learn from them without real-world consequences.
• Accelerated start-up - procedures are validated before commissioning, reducing delays and surprises.
• Operational excellence - builds muscle memory for handling abnormal situations calmly and correctly.
• Cross-team alignment: Engineers, safety teams, and operators can collaborate on procedures and troubleshooting

With advancements in virtual reality (VR) and augmented reality (AR) technology the OTS marketexpected to see rapid growth in the next few years, estimated to reach $27.53 billion in 2029 at a compound annual growth rate (CAGR) of 13.8%. 

This growth can be attributed to increased emphasis on immersive learning experiences,  demand for remote training solutions, integration with data analytics for performance evaluation, and alignment with evolving industry standards and regulations. 

The importance of system-agnostic OTS

Whilst the viability and continued growth of OTS software are both clear, with a system-agnostic option, companies will see a myriad of additional benefits. For one, it offers the adaptability required to keep training aligned with the reality of plant operations.  

In most modern industrial settings, there is a smorgasbord of legacy, bespoke and new systems and controllers, from multiple vendors.  To that end, a system-agnostic OTS integrates, amongst others, seamlessly with distributed control systems (DCS), programmable logic controllers (PLC), and next-generation automation platforms.

This flexibility, in turn, ensures continuity in operator training, even as core technologies evolve or are replaced. Also, operators can train on scenarios that accurately reflect their real working environments which then strengthen their preparedness for both routine operations and emergency events. 

Importantly, training downtime is minimised, and new software, equipment, or workflows can be incorporated into the simulator without extensive retraining or system re-engineering.

With system-agnostic OTS, organisations gain:

• Seamless integration across diverse control architectures, enabling consistent training across multiple sites and technologies.
• Cost efficiency, by avoiding repeated engineering, licensing, and integration fees tied to vendor-specific upgrades.
• Futureproofing, ensuring simulators remain relevant across successive generations of control systems.
• Transferable operator skills, as trainees learn workflows applicable to different environments, not just a single vendor’s interface.

From a business perspective, this agility enhances safety, reduces training costs, and empowers organisations to respond more quickly to regulatory, market, or technological shifts.

In industry

The benefits of a flexible, system-agnostic OTS are particularly evident in high-stakes sectors such as power generation, oil & gas, chemicals, and manufacturing.

For example, in power generation, operators can simulate responses to fluctuating grid conditions while in oil and gas, complex pipeline, instrumentation and emergency shutdown procedures can be safely practiced before deployment.

Also, manufacturing training can be scaled across diverse machinery, production lines and sites, ensuring operator competency is implemented across entire organisations.

Schneider Electric’s Operator Training Simulators is an interoperable, cloud-ready platform that integrates digital twins, real-time data, and a wide range of control architectures.

Indeed, today Schneider Electric’s OTS enables enterprises to standardise training globally, deploy new scenarios rapidly, and align workforce development with the realities of modern, digitalised operations.

Ultimately, by combining interoperability with continuous training, Schneider Electric’s OTS takes organisations one step closer to achieving safer, efficient, and more resilient operations.