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Major process safety incidents are still frequently occurring despite many process safety and risk management improvement initiatives. Although digital systems have a long history of application throughout the life cycle of process plants, Industry 4.0 has the transformative potential to reduce process safety incidents and optimize the management of risk. A core technology of Industry 4.0 is the digital twin, a term used for various forms of models connected to plant data that can be utilized for improved analysis, predictions, and decision-making.To realize the transformative potential of Industry 4.0 in the process industries, a fundamental systems thinking approach needs to be applied to the implementation of the digital twin and should be applied for each intended use case. In addition, having a standardized language and ontology, such as ISO15926, is important as it enables the use of reasoning engines and the ability to interconnect models and systems across the process and product lifecycle. At present, components of Industry 4.0 are currently being applied to improve process safety, which should extend in the future to more use cases and forms of the digital twin to improve safety and optimize the management of operational risks within the process industries.Successful applications of Industry 4.0 initiatives require an overall strategy aligned with business priorities to deliver transformation in business processes and the management of process safety. Although there are immense opportunities available through the implementation of Industry 4.0, poor implementation can also create threats to managing process safety that need to be considered and mitigated. |
