A Systems Approach to Managing the Complexities of Process Industries

A Systems Approach to Managing the Complexities of Process Industries discusses the principles of system engineering, system thinking, complexity thinking and how these apply to the process industry, including benefits and implementation in process safety management systems. The book focuses on the ways system engineering skills, PLM, and IIoT can radically improve effectiveness of implementation of the process safety management system.

Covering lifecycle, megaproject system engineering, and project management issues, this book reviews available tools and software and presents the practical web-based approach of Analysis & Dynamic Evaluation of Project Processes (ADEPP) for system engineering of the process manufacturing development and operation phases. Key solutions proposed include adding complexity management steps in the risk assessment framework of ISO 31000 and utilization of Installation Lifecycle Management. This study of this end-to-end process will help users improve operational excellence and navigate the complexities of managing a chemical or processing plant.

• Presents a review of Operational Excellence and Process Safety Management Methods, along with solutions to complexity assessment and management
• Provides a comparison of the process manufacturing industry with discrete manufacturing, identifying similarities and areas of customization for process manufacturing
• Discusses key solutions for managing the complexities of process manufacturing development and operational phases

Process Engineers, Chemical Engineers, Process Safety Engineers, HSEQ Managers and Engineers, EPC Managers, Engineering Managers, Plant Designers, Site Managers, Plant/Unit Managers, and Directors of Operations, Engineering

1. Perspective

Understanding a question is half the answer!

PSM in context of operational excellence

Regulatory compliance management system

Cost of non-compliance

Process safety versus occupational safety

Process safety indicators

What do we manage, "process safety" or "safety processes"?

Process industry versus discrete manufacturing

Application of system engineering in process industry

Essential skills to cope with cyber-physical systems

Why does complexity matter?
2. Fundamentals of the Systemic Approach

Systemic vs systematic

What is a system?

What is system engineering?

System thinking

Systems engineering competencies framework
3. Fundamentals of Complexity

What is complexity?

Characteristics of complexitiy

Identifying the right level of complexity

Cynefin complexity framework

How complex systems fail

Resilience engineering

Specific methods to address environmental and system complexity

Complexity thinking: guiding principles
4. System Engineering of Complex Megaprojects

Megaprojects definition

Megaprojects in oil and gas industry

Examples of megaproject failures

Megaprojects problems and their causes

System engineering for the megaprojects

Definition of complexity for megaprojects

Megaproject management challenges
5. Modelling and Simulation; the essential tools to manage complexities

Background

Evolution of web technology

Evolution of Industrial Internet of Things

Open Platform Communications

Big data management

Cloud computing

Cyber security risk management

Model based system engineering (MBSE)

Application lifecycle management (ALM)

Product lifecycle management (PLM)

Multiphysics

Frontloading simulation results in optimized products

Virtual reality

MBSE for process manufacturing

Application of ILM to create the process safety management framework

Conclusion