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Test Earlier. Train Better.
Operate Smarter.

Through our partnership with Onyx 360, Scallon Controls helps industrial facilities evaluate and implement simulation solutions that ensure startup readiness, operator development, and performance improvement.

Dynamic simulation creates a virtual representation of process systems, control strategies, and operating conditions, allowing teams to test, train, and evaluate operating scenarios before changes are implemented in production.

Test Earlier. Train Better. Operate Smarter.

Join Scallon Controls and Onyx 360 for a live webinar

Learn how dynamic simulation is being used in energy and chemical plants across the Gulf Region to improve startup readiness, operator training, commissioning activities, and operational performance.

Lifecycle Value of Simulation

Simulation supports a range of operational objectives, from startup readiness and operator development to long-term performance improvement.

Reduced Commissioning Errors and Risk

Identify and solve issues earlier.

Safer Execution of Critical Operating Scenarios

Rehearse startup procedures before the plant goes live.

Improved Operator Readiness and Competency

Provide hands-on practice before and build muscle memory.

Boost Operational Performance

Identify and test opportunities for improvements.

Knowledge Retention and Workforce Development

Transfer years of experiential operational knowledge.

Multi-Purpose Dynamic Simulation

Test

Validate control strategies, operating procedures, and system responses before commissioning and startup.

Validate before startup.

Train

Prepare operators for daily operations, abnormal conditions, and infrequently performed procedures in a risk-free environment.

Build operator readiness.

Optimize

Evaluate operating scenarios, identify opportunities for improvement, and make more informed decisions before implementing changes in production.

Improve operational performance.

A Right-Sized Simulation Approach

Align Simulation with Your Operational and Business Objectives

Whether your need is to validate control strategies before startup, ensure operator readiness, reduce errors and time spent during commissioning activities, or optimize ongoing performance, simulation models can be designed and scaled to fit your goals and your budget. Onyx 360’s right-sized approach focuses simulation efforts where they will have the greatest impact.

Project Readiness

Support testing, validation, and commissioning activities before startup.

Operator Readiness

Prepare personnel for daily operations, abnormal conditions, and critical procedures.

Operational Improvement

Evaluate opportunities to improve performance, reliability, and efficiency.

Long-Term Value

Expand simulation capabilities as operational needs evolve.

Simulation should fit the application, not the other way around. The most effective solution is the one that aligns your project requirements and helps you achieve your operational and performance goals.

Simulation Lifecycle Maintenance

Keeping Simulation Aligned with Your Operation

A simulation environment is only valuable if it accurately reflects current operating conditions. As processes change, equipment is modified, control strategies evolve, and operating procedures are updated, simulation models should evolve as well.

Lifecycle maintenance and model governance by Onyx 360 help ensure your simulation environment remains aligned with current operating conditions and business objectives. Eliminate obsolescence with scheduled model maintenance from Onyx 360 and ensure your simulation investment continues to provide value for testing, training, and performance improvement long after initial implementation.

✓ Maintain Accuracy Keep simulation models aligned with current process conditions and system configurations.
✓ Support Ongoing Training Ensure operators continue training against realistic operating scenarios.
✓ Validate Future Changes Evaluate proposed modifications before implementation.
✓ Protect Long-Term Value Maintain the usefulness and reliability of simulation investments over time.

Industry Proof

Energy

Challenge

Preparing operators for infrequently performed startup, shutdown, and fuel transition procedures while preserving operational knowledge as experienced personnel retire.

Application

Operator Training System (OTS) used to safely rehearse startup, shutdown, and fuel transition procedures while supporting long-term operator development.

RESULTS

Zero Unplanned Downtime Events Attributed to Operator Error

  • Reduced planned downtime
  • Improved operator consistency
  • Expanded to additional refinery units
Onyx360 Refinery CaseStudy
Chemical

Challenge

Maintaining steam header stability across a complex utilities network while improving reliability and efficiency without disrupting production.

Application

Dynamic simulation environment used to evaluate control improvements, support operator training, and improve steam system performance before implementation.

RESULTS

$500K+ Annual Savings

  • Improved steam header stability
  • Increased reliability
  • Training and engineering benefits from a single simulation environment
Onyx360 Chemical Plant CaseStudy

Put Simulation to Work

Join Scallon Controls and Onyx 360 for a live discussion on how simulation is being used to reduce project risk, improve operational readiness, ensure operator competency, and boost operational performance.

Explore real-world applications, implementation considerations, and industry results from refining, oil & gas, and chemical operations.
Register for webinar

Learn more about the Onyx 360 and Scallon Controls partnership.

Speak with an Expert
(409) 842-5950