Towards Process Safety 4.0 in the Factory of the Future

The rapid development of new technologies in the industry of the future implies a major evolution in the industrial safety measures needed to be met, such as societal requirements. Towards Process Safety 4.0 in the Factory of the Future presents the concept of Safety 4.0 from the point of view of process safety, occupational safety and health, as well as systems’ cyber security. Numerous examples illustrate the different approaches of the identified methods and techniques of Safety 4.0. Their concepts, paradigms, structural bases, couplings, complexities and flaws are systematically analyzed. This comprehensive approach to Safety 4.0 is aimed at the wide variety of actors working in the industry of the future.

Table of Contents:
Foreword ix Preface xi List of Notations xv Chapter 1 The Industrial Revolution 4.0 1 1.1. A history of industrial revolutions 1 1.2. Defining the factory of the future 3 1.3. Technology used in Industry 4.0 3 1.3.1. Disruptive technology 4 1.3.2. Technologies used for communication and interconnection 5 1.3.3. Data management technology 7 1.4. Attempts at structuring technologies 11 1.5. Conclusion 14 Chapter 2 The Concept of Safety 4.0 15 2.1. Context and definition 15 2.2. The history of the evolution of safety 16 2.3. Safety framework 18 Chapter 3 Occupational Safety and Health 21 3.1. Impact of Industry 4.0 work conditions 21 3.2. Definitions 23 3.3. OSH versus process safety 23 3.4. OSH assessment of occupational hazards 24 3.4.1. Regulations, norms and unique document 24 3.4.2. Inventory of risk analysis techniques and methods 30 3.4.3. Applicability of risk analysis methods to OSH 32 Chapter 4 Process Safety and Cybersecurity 39 4.1. Reviewing risk analysis methods in process safety: example of the bow-tie method 39 4.2. Risk-evaluation matrix in process safety 42 4.3. Risk analysis methods for industrial information systems: example of the EBIOS and attack tree method 45 4.4. Cybersecurity risk-assessment matrix 49 4.5. Coordinating risk analysis methods 51 4.6. Reconciling process safety and cybersecurity methods 53 4.6.1. Preliminary risk analysis and preliminary cyber-risk analysis 53 4.6.2. HAZOP, CHAZOP and Cyber HAZOP methods 54 4.6.3. Bow-tie graph and cyber bow-tie 58 4.6.4. LOPA and Cyber LOPA methods 58 4.6.5. The integrated, simultaneous ATBT method 62 4.7. Concatenation of matrices 64 4.8. Reasoned use of risk matrices 66 Chapter 5 Examples: Safety 4.0 and Processes 71 5.1. Distillation column control 71 5.2. Attempt to classify the applications of a digital twin in the field of Safety 4.0 72 5.2.1. Potential of a digital twin for Safety 4.0 73 5.2.2. Proposal for a classification framework 73 5.3. Modernization of a pilot installation of an ejector pump 75 5.4. Model for developing a digital twin to prevent OSH in the process industry 77 5.4.1. Description of the model 79 5.4.2. Implementing the model 80 5.4.3. Conclusion 81 5.5. Custom manufacture of food product by project development 81 5.6. Impact of the design of a cyberphysical system on an industrial process 83 5.6.1. Choosing the problem to be studied 84 5.6.2. Design principle for the cyberphysical system 85 5.7. Principle for redesigning a process in a cyberphysical production system 87 5.8. Systematic integrated approach to improve the processing of contaminated sediments 91 5.8.1. The Novosol® process 91 5.8.2. The sociotechnical Novosol® system 92 5.8.3. Conclusion 92 5.9. Digitalization to benefit safety management 92 5.9.1. Improvement in the quality of technical risk assessment and modeling the impact of cumulative risks 95 5.9.2. Providing a real-time view of the actual state of critical equipment and their impact on the risks 96 5.10. Detection of deviations in the functioning of a heat exchanger through an artificial neural network 97 5.11. RFID applied to the prevention of occupational hazards 99 5.11.1. Fields of application of RFID technology 100 5.11.2. RFID applied to occupational safety and health 100 5.12. How RFID contributes to industrial engineering safety 102 5.13. Exploring the idea of a socially safe and sustainable workplace for an Operator 4.0 102 5.14. Industry 4.0 challenges related to safety and the environment in the leather industry 105 5.15. Safety 4.0: metrics and performance indicators 107 5.15.1. Impact or lagging indicator 108 5.15.2. Activity or leading indicator 109 5.15.3. Some recommended examples of performance indicators for process safety 109 5.15.4. Examples of the application of safety performance indicators 112 Chapter 6. Intensification and Inherent Safety: Myth or Reality? 117 6.1. A review of essential elements in process intensification 117 6.2. Some examples of process intensification 119 6.2.1. The reduction principle in support of the risk management 119 6.2.2. Areas of interest for using microstructured reactors 122 6.2.3. Transposition of an exothermic reaction in an intensified, continuous heat exchanger 124 6.2.4. Pilot demonstration of IMPULSE for the production of sulfur trioxide through the oxidation of sulfur dioxide by air 126 6.2.5. Synthesis of ionic liquids by alkylation in a microstructured reactor 128 6.2.6. Developing an intensified process for the industrial synthesis of methanol from carbon dioxide 129 6.2.7. Feasibility of intensifying the production of vinyl acetate monomer 131 6.2.8. The microstructured reactor with catalytic walls: accelerator of the performance of a conventional tubular reactor 133 6.2.9. Generic example of direct gaseous fluorination of a liquid hydrocarbon 135 6.3. An attempt to rationalize intensification equipment 138 6.4. Concept and application of a general methodological framework for the synthesis and design of processes that integrate intensification 141 6.5. Reality or myth? Safety 4.0 in intensification processes 143 6.5.1. A few assessment tools 144 6.5.2. Examples of safety versus intensification conflicts 152 6.5.3. Vigilance when putting into practice the risk analysis methods based on the use of digital data 162 Conclusion 165 References 171 Index 185

About the Author :
André Laurent is Emeritus Professor at École Nationale Supérieure des Industries Chimiques at the University of Lorraine, Nancy, France. He is also a member of the Réactions et génie des procédés laboratory at UMR CNRS, Nancy, France.