Towards Process Safety 4.0 in the Factory of the Future
Description
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.
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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.
Content
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
1
The Industrial Revolution 4.0
Process industries that transform matter into energy, implementing chemical or physical processes, manufacture essential and innovative products that can improve well-being and the quality of everyday life in society.
Despite their indisputable contribution to the advances in standard of living, from the very beginning, all these activities have included intrinsic hazards and potential risks that must be managed. However, the implementation of these risk management measures is a difficult and demanding task. Our vision of this risk must not only be understood and viewed from an industrial or technological point of view, but must also include the choices made by people, citizens and society as a whole.
However, the problem must first be situated within the current industrial context.
1.1. A history of industrial revolutions
The various industrial revolutions have always been preceded by scientific, technological and organizational advances and innovations (André 2019). We present a brief overview of these earlier revolutions before introducing Industry 4.0.
Figure 1.1 illustrates the chronology of these different revolutions. It must be pointed out that the exact dates of the transitions related to each can fluctuate a little across literature.
Figure 1.1. The chronology of industrial revolutions
The first Industrial Revolution, or Industry 1.0, which begins here around 1750, was based on coal mining, metallurgy, the emergence of the weaving industry and the steam engine.
The second Industrial Revolution, or Industry 2.0, which began around 1840, was founded on electricity, oil wells and the birth of the mechanical and chemical industries. The earliest means of communication appeared around this time, with the first operational telegraph line (1833) and the telephone (1876). The railways became a means of public transport. In 1911, F.W. Taylor pioneered the scientific management of organizations. Henry Ford launched the assembly line manufacturing of an automobile.
The third Industrial Revolution, or Industry 3.0, began around 1960, with the emergence of electronics (transistors and integrated circuits), computer science, telecommunications, audiovisual and the nuclear industry. Industrial production was especially impacted by automation and robotics.
The latest and current Industrial Revolution, Industry 4.0, began in 2010. A new cyberphysics system brought together software, sensors and means of communication to manage complexity, anticipate malfunctioning and steer performance in real time. For the first time, resources, information, machines, tools and workers were connected in a network to create an industrial Internet of Things (IoT).
Breque et al. (2021) have already initiated a new transition toward Industry 5.0. According to the authors, Industry 5.0 will recognize industry's capacity to achieve According to the authors, Industry 5.0 will recognize industry's capacity to achieve of prosperity. Production will respect the needs of the planet by placing the well being of stakeholders, including workers, at the heart of production and manufacturing processes.
In France, the new Pacte Law (2019) aims to establish Corporate Environmental and Social Responsibility by creating the status of "Entreprise à mission", a legal framework whereby companies set environmental and social goals that they must achieve. The benefit of this framework is that it allows companies to frame their statutes around a mission made up of a set of freely chosen objectives that work for the greater good. For example, the company Danone, the only one of France's CAC 40 companies to have chosen this status, committed to several goals, including the promotion of best food practices, supporting a better and more sustainable mode of regenerative agriculture, giving each salaried employee the chance to weigh in on company decisions, as well as providing support to the most vulnerable actors in the company's ecosystem. The recent leadership crisis (2021) at the head of this food group will probably allow us to judge the robustness of this sociolegal innovation.
1.2. Defining the factory of the future
The technological advances in the fourth Industrial Revolution resulted in a new generation of factories, which have been given various labels: the factories of the future, smart factories, digital factories, cyberfactories, integrated factories, innovative factories, Factory 4.0, and even Industry 4.0. The concept of "Industry 4.0" was born out of a strategic initiative announced by the German government at the Hanover Trade Fair in 2011(Kagermann et al. 2013).
Following a bibliographic analysis, Hermann et al. (2016) considered that factory 4.0 is a collective term denoting the technologies as well as the concept of the organization of the value chain. In the smart factories with a modular structure, in Industry 4.0, cybersystems monitor physical processes, creating a virtual copy of the physical world and taking decentralized decisions.
By using the IoT, cybersystems communicate and cooperate with each other and with humans in real time. Internal and inter-organizational systems have been offered via the Internet of Systems, and these systems are used by members of the value chain.
1.3. Technology used in Industry 4.0
To clarify the semantics of the terminology relating to technologies in Industry 4.0, Julien and Martin (2018) have suggested categorizing digital technologies into three categories:
- disruptive technologies;
- technologies for communication and interconnection;
- data management technologies.
1.3.1. Disruptive technology
A disruptive technology or innovation is an innovation (often technological) related to a product or a service that ultimately replaces an existing technology that had dominated the market thus far. It gives rise to a new category of products or services that had not previously existed.
1.3.1.1. Additive manufacturing: 3D and 4D
The NF-E-67-001 standard defines 3D additive manufacturing or 3D printing as the set of manufacturing processes that enable joining materials to create physical objects from 3D model data, layer by layer, as opposed to subtractive manufacturing methodologies.
4D additive manufacturing, or 4D printing, consists of adding a new dimension to 3D printing or 3D manufacturing. The fourth dimension aims to bring in scalable functionalities that evolve over time based on the input of external energy from various sources. This fourth dimension is most often obtained by using smart materials, which most often correspond to active, transformable or programmable hardware. This involves adding information to the material, or endowing it with specific properties so that it can respond to stimuli that are electrical, magnetic, chemical, thermal, vibratory, etc., and can transform itself and cause the product to change (properties, shape, color, conductivity, etc.).
1.3.1.2. Robotics
Robotics is made up of the scientific and industrial fields that are related to design, study and creation of robots and their applications. In the industrial domain, robotics results in automatons that carry out precise functions in assembly chains. Robotics also produces devices that can move around in different hazardous environments: polluted, radioactive, aerial, submarine, in outer space, etc. Apart from industries, robotics is also used for scientific research, space exploration, military defense, and maintaining law and order. It is also used in the medical sector for prostheses and assisting healthcare workers. Robotics is also now available to the general public through autonomous devices that carry out specific tasks (vacuum cleaners, lawn mowers) or through entertainment devices (robotic toys).
1.3.1.2.1. Cobot
"Cobot" is a neologism formed from the words "cooperation" and "robotics". The cobot is a small and light robot that works directly with the operators, helping them by carrying out the most thankless and cumbersome tasks. The main distinguishing feature of the cobot is that it interacts with a human, hence the name "collaborative robot". This technology, which is already all the rage within Factory 4.0, allows the operator to gain in productivity and presents absolutely no danger in the workplace. It is especially likely to open up avenues for robotic applications within small and medium enterprises (SMEs).
Blaise et al. (1993) published an interesting guide to better understand what consequences the use of a cobot has on the health and safety of its operators.
In the sixth chapter of their book, Julien and Martin (2018) offer a highly pedagogic introduction to the methodology for using a cobot, illustrated with an example of an end-of-line packaging workstation that has been automated.
1.3.1.2.2. Exoskeletons
Exoskeletons and other physical assistance devices, first developed for the medical sector, are used more and more frequently within companies. They were introduced as systems that made it possible to complement efforts to assist operators. Exoskeletons are defined as external structures worn by the operator, designed to provide physical assistance in carrying out a task. They may be powered (active exoskeletons) or non-powered (passive exoskeletons). These devices make it possible to enhance mobility...
