Simulation for a new standard of process plant performance
Simulators are a proven, effective tool for training operators and engineers in the process industry — improving performance, safety, reliability, and cost effectiveness across chemical, gasification, and industrial process plants.
3KEYMASTER™ Extended to Process Applications
WSC's process plant simulation utilizes the 3KEYMASTER™ real-time simulation environment — extended beyond power applications to simulate various chemical processes. Plant-specific custom models can be ported into the platform and interfaced with traditional WSC models, retaining their proprietary nature while being embedded seamlessly in the 3KEYMASTER™ environment.
Relay logic and electrical systems modeling tools shared across both power and process industry applications.
WSC's fluid systems modeling tools for multi-phase flow, chemical kinetics, and process piping networks.
Full DCS and PLC integration covering stimulation, hybrid, virtual, and emulation approaches for process control systems.
Ergonomically designed GUI with instantaneous dynamic visualization of the process as the system is being configured.
Examples of Simulations Delivered
WSC's component modeling library and custom model porting capability have been applied across a wide range of process unit simulations — from chemical processes and gas treatment to industrial utilities and emissions control.
IGCC — World-Scale Simulation
Completed in parallel with the plant's own design and commissioning process, the simulator was made available for design and control validation as well as operator training ahead of plant start-up — a critical capability for a first-of-a-kind facility featuring new low-emissions gasification processes. Rather than burning coal directly, gasification first breaks coal into chemical components; the resulting gases fuel the combined cycle power plant.
Full-Featured Simulation Control
The 3KEYMASTER™ Instructor Station provides a flexible environment with embedded features for monitoring, validation, scenario management, and trainee assessment — including thousands of malfunctions for building realistic training exercises.
Real-time monitoring of key process variables with historical trending for analysis and scenario review.
Built-in tools to verify simulator fidelity against reference plant data and acceptance criteria.
Structured scenario creation with event triggers and automated testing for consistent training quality.
Thousands of generic and specific malfunctions — instructors replicate plant behaviors and demonstrate abnormal conditions to operations staff.
Objective assessment and performance recording for each training session and operator evaluation.
Ready to serve your process plant simulation needs
For a complete overview of WSC's process plant and pipeline simulation capabilities — including chemical kinetics, DCS integration, and custom model porting — refer to the 3KEYMASTER™ Process Plants and Pipeline Solutions brochure.
3KEYMASTER™ Process Plants & Pipeline Solutions →