Operations Fundamentals

Polaris Hands-on Training Unit 1 — Operations Fundamentals Trainer. 

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How can I provide hands-on process technology training without access to real industrial equipment? What’s the best way to teach pump operations, valve lineups, and heat exchanger maintenance in a controlled setting? How do I help students develop critical troubleshooting skills for real-world industrial applications? What training tools can improve process flow understanding and schematic interpretation? How can I ensure learners master lockout/tagout (LOTO) procedures safely before working on live systems? What’s the most effective way to prepare students for careers in process operations, refining, petrochemicals, and power generation?

About the Unit

The Polaris HOT Unit 1, also known as the Operations Fundamentals Trainer, is a hands-on training unit designed to teach the fundamentals of process operations in a safe and realistic manner. It provides learners with practical experience with industrial equipment and instrumentation, allowing them to develop real-world skills in a controlled environment. The unit includes a comprehensive training program with detailed operating manuals and is designed to meet industry engineering standards  and regulatory requirements (OSHA).

How can I improve hands-on learning for process technology students without access to live industrial systems? What’s the best way to teach troubleshooting skills for pumps, valves, and heat exchangers? How can I help students understand process flow and system schematics more effectively? What tools can I use to provide realistic process operations training in a classroom setting? How do I ensure students master lockout/tagout (LOTO) procedures before working in the field? What’s the most effective way to simulate real-world industrial equipment operation for training? How can I prepare learners for process control and system diagnostics jobs in manufacturing and energy sectors? What training solutions can bridge the gap between theory-based learning and practical application? How can I create a safe and controlled environment for teaching complex industrial processes? What’s the best way to introduce competency-based learning in process technology education?

Equipment

This unit is equipped with a comprehensive range of industrial-grade equipment, designed to simulate real-world process operations. The following components work together to provide a hands-on learning experience, allowing learners to explore and understand the intricacies of process systems. Key equipment includes:

  • Duplex pump suction strainers 
  • Orifice flow assemblies 
  • 1.5 HP centrifugal pumps 
  • Shell and tube heat exchanger 
  • Fan–type air–cooler 
  • Electric heater 
  • 300 gal feed tank 
  • 300 gal product tank 
  • 20 gal chemical injection tank 
  • Safety Shower 

Instrumentation

  • Industrial–quality gauges that measure the following:
    • Pressure
    • Level
    • Temperature
    • Flow
  • Gate, globe, swing–check, safety relief, and ball check valves
  • Diaphragm–type control valves and positioners
  • Flow and pressure control loops
  • Emerson Delta V DCS control system
What are the dimensions and weight of the HOT 1 model? What type of materials is the HOT 1 model made of? What is the power consumption of the HOT 1 model? What are the operating temperature and humidity ranges for the HOT 1 model? What type of controls and interfaces does the HOT 1 model have? What are the safety features of the HOT 1 model? What is the warranty and maintenance requirements for the HOT 1 model? Can the HOT 1 model be customized or modified to meet specific needs? What are the shipping and handling procedures for the HOT 1 model? What type of training or support is available for the HOT 1 model?

Specifications

The trainer is 24′ L x 10′ W  7′ 6″ H and built from welded, structural steel. It sits on an industrial grating work surface, and the process piping is welded and flanged. 

  • Concrete pad able to accommodate the unit
  • 480V 3 phase (100 Amp) and 240V single phase (50 Amp) power
  • Make-up water supply (intermittent only)
  • Dry instrument air
What are the dimensions and weight of the HOT 1 model?
The Hands-On Trainer (HOT 1) provides real-world process technology training through interactive, hands-on learning for technical schools, workforce development, and industrial training programs. Designed to enhance operator skills, equipment troubleshooting, and process safety, this functional trainer unit allows learners to practice pump operations, valve lineups, heat exchanger maintenance, and lockout/tagout (LOTO) procedures. With a focus on competency-based learning and skills development, the HOT 1 trainer helps students gain practical experience in process control, fluid handling, and system operations, preparing them for careers in refining, petrochemicals, manufacturing, and power generation.

Comprehensive Curriculum

Training curriculum accompanies the HOT Model 1 and is filled with over 100 exercises, scenarios, and procedures. This includes an operating manual which details all operating procedures of startup, shutdown, emergencies, and exercises.

Simulations are provided with the HOT Model 1, which encompass: 

  • CPM–300 Process Model
  • Training Workbook
  • Virtual Field Operator
  • Virtual Training Environment
  • E–Learning
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Training Aids

To further enhance the learning experience and provide a complete training solution, we offer a range of optional training aids that can be integrated with the HOT Unit 3. These interactive tools and simulations provide learners with a comprehensive and engaging learning experience that prepares them for real-world process operations. Available training aids include:

  • Process Equipment Microlearning: A library of interactive and immersive modules for learners to explore a wide range of process equipment
  • zSpace: A 3D augmented reality platform that enables interactive and immersive learning experiences
  • LOTO EXP: A lockout/tagout training simulation that teaches learners critical safety procedures in a safe and controlled environment
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