How a plant simulator can improve industrial safety

Abstract

Keeping the systems and processes safe is of paramount importance for all industries around the world. Process industry is a socio-complex system constituted of dynamic chemical processes, sophisticated computer algorithms, modern human machine interfaces, and teams of operators working at different locations. The decisions of the operators directly or indirectly influence the safety and production of chemical processes. The article presents and discusses a solution for immersive training of industrial operators that allows experiencing the multifaceted scenarios of (real) plant operations. This tool, called Plant Simulator (PS), combines a process simulator and an accident simulator to simulate dynamically both normal and abnormal/accident scenarios. These simulators are the engines that work behind the curtains of an Immersive Virtual Environment and make possible the realism of the simulated operations in the plant. The article explains the features of PS and discusses two case studies that show the potential improvements achievable in processes safety. 9 fatalities and 122 casualties; demolished life in 100-km Marcal river. Neptune Technologies and Bioresources. Sherbrooke, Quebec, Canada (2012); a huge blast followed by smaller ones.2 fatalities and 17 casualties.

Rethinking Maritime Education, Training, and Operations in the Digital Era: Applications for Emerging Immersive Technologies

“…Three-dimensional (3D) visualization can reduce the gap between simulation and real life [10], and well-designed simulation enhances learning, improves performance, and reduces errors [11]. Furthermore, simulation training improves trainees' perception and assessment of dangerous situations [12], improves training outcomes in comparison to conventional classroom-based exercises [13], and creates more collaborative, critical thinking and case-based learning [14,15].…”

Operator Training Simulator for an Industrial Bioethanol Plant

“…where S Rec defines the rotation speed [rpm] for adjusting the recovery factor (y Rec (υ P )) Equation (19). The ∑-factor [m 2 ] for disk centrifuges is used as performance parameter for comparing the cell recovery for different centrifuge sizes:…”

“…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]). …”

“…Also of interest is the handling of accidents at chemical plants [10]. Training in the actual working environment with psychological factors in focus and with interaction in teams, either in the control room or by field operators, are mirrored by several authors [17][18][19][20].…”

“…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.…”