The modularization of process plants addresses the need for flexible production options in the process industry. In order to maintain the advantages of the adaptability of modular plants, an adaptation of established engineering methods and procedures to their dynamic context of use is required. This paper describes the development and the features of a demonstrator, which makes it possible to investigate aspects of modular plant topology, the design of modular process units, and the functional safety of modules and plants. During the engineering of the modules, modular planning principles are applied and evaluated with respect to the requirements for functional safety and with a strong focus on the modification of safety systems through the exchange of PEAs and FEAs. For the design and modification of the safety systems, a safety life cycle, which meets the requirements of modular automation and takes the provisions of IEC 61508 and IEC 61511 into account, is applied. Practical insights into the construction and the implementation of the distributed Safety Instrumented System as well as the Basic Process Control System are described. In addition to the validation of safety concepts related to the interconnection of Safety Instrumented Functions, the demonstrator is used to study human working environments in modular plants.

To leverage the full potential of cyber-physical production systems (CPPS) in terms of flexibility and adaptability, the development of such systems must go beyond digitization and modularization. During the engineering and operation of CPPS, humans are essential enablers for the system’s changeability. In this paper, we propose a model of an iterative conducive design process that incorporates perspectives and competencies from several research disciplines such as process control, industrial engineering, computer science, and instructional and cognitive psychology. The goal of this approach is to enhance human-machine interaction and to realize efficient functioning of the system via a combination of the unique potentials provided by humans and the system. The proposed iterative approach is exemplified on a practical level in the engineering of a demonstration plant that tests safety systems for modular plants.

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Mit dem Notebook am Küchentisch oder an ähnlichen Örtlichkeiten im Privatbereich zu arbeiten, ist vielfach Realität geworden. Diese quasistationäre mobile Arbeit erfolgt nicht im rechtsfreien Raum. Geeignete Methoden zur Beurteilung auch dieser Arbeitsbedingungen sind verfügbar.