Advanced Applications in Process Control and Training Needs of Field and Control Room Operators

Abstract

adjustments (Emigholz, 1996). By contrast, the operators of modern industrial plants face different challenges due to handling, analyzing, and interpreting large amounts of distributed information simultaneously.Although some advanced control techniques (e.g., dynamic matrix control, model algorithmic control) had their origins in the industry from some enlightened development groups (e.g., Shell, IDCOM), the formalization and systemization of these techniques was conceived, conducted, and finalized by academia through a rather long incubation period (see Morari & Lee [1999] for a detailed review). Eventually, starting from the 1990s, the availability of robust software environments and fast hardware, both reasonably priced, allowed the seminal model-based techniques (still too theoretical and simplified) to be transposed into stable and complex algorithms, such as model predictive control (MPC) and real-time optimization (RTO;De Souza et al., 2010).MPC and RTO enabled the industries to implement models and solutions into their systems by optimizing the process parameters to maximize the production according to minimum energy usage, and/or minimum raw materials consumption, and/or minimum environmental impact. The growth and implementation of these optimization techniques can be judged by a prediction made by the ARC advisory group, that the RTO market will reach more than US$1.5 billion in 2015 (Abel, 2011).

Cognitive Challenges of Changeability: Multi‐Level Flexibility for Operating a Modular Chemical Plant

“…This effect is mediated by self-regulation tactics, speaking to the fact that at least in some work settings success depends on the willingness to broaden your skills. Of course it is problematic to freely experiment during the actual production process, but simulation is a promising tool [61,62]. Moreover, due to a modular plant's continuous real-time connection with its digital twin, it can provide operators with the opportunity to generate forecasts or run what-if analyses.…”

The role of situation awareness in accidents of large-scale technological systems

“…Therefore, the use of quantitative knowledge and hardware failures has been relied on significantly. Most of them consider the identification of operation faults (Qian et al, 2008) or the prediction of process variables (Juricek et al, 2001) that will violate an emergency limit in the future; however, further research show that when faults occur, operators have to rely on their experience under working pressure to understand what is going on and to contribute a solution (Kluge et al, 2014). Therefore, designing and integrating appropriate approaches to develop cognitive support systems are highly recommended (Naderpour et al, 2014b;Niu et al, 2013).…”

Operator Training Simulator for an Industrial Bioethanol Plant

“…Possibilities to observe cause-and-effect relations are therefore more difficult compared to laboratory-scale studies with lesser units, shorter training periods and better control of the experimental situation (cf. [19][20][21][24][25][26]). …”

“…In the biotechnological process industry, however, very few OTS have been realised, and they are limited to demonstrations with biogas, bioethanol and biopharmaceutical production in small-scale applications [21][22][23][24][25][26][27]. These previous studies have predominately been performed at a smaller laboratory scale in non-industrial environments or with only a single unit at a larger scale.…”

“…These assessments all conclude that the transfer-of-training factor, i.e., how efficient the OTS is in developing understanding, skills and other capacities of the trainee as a result of the training [3,6], is high and supports the use of OTS in academic as well as industrial training. Several detailed assessment procedures have been applied as reported by these authors and others [19][20][21]. However, observations of effects are more complicated to perform when OTS are applied in industrial environments, such as in a whole complex plant with a large number of process units operated by comparatively small groups of operators.…”