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Last updated on 2024年9月6日

What are some innovative equipment designs that can improve plant safety?

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Plant safety is a crucial aspect of mechanical engineering, especially in industries that deal with hazardous materials, high temperatures, or complex machinery. In this article, we will explore some of the innovative equipment designs that can improve plant safety by reducing the risks of accidents, injuries, or malfunctions.

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Saravanan Lakshmanan

Senior Electrical Engineer | FEED | Detailed Engineering | Field Engineering | Oil & Gas | Onshore | Offshore | CCSU |…
Wayne Mohan

Process Safety Discipline Manager at Heritage Petroleum Company FIChemE (Process Safety), Professional Process Safety…
Vinod Erat

Technical Safety

1 Smart sensors

One of the ways to enhance plant safety is to use smart sensors that can monitor the conditions and performance of various equipment and systems. Smart sensors can detect and report any anomalies, such as leaks, cracks, overheating, or vibration, that may indicate a potential failure or hazard. By using smart sensors, engineers can prevent or mitigate the consequences of equipment breakdowns, fires, explosions, or spills, and also optimize the maintenance and operation of the plant.

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Saravanan Lakshmanan

Senior Electrical Engineer | FEED | Detailed Engineering | Field Engineering | Oil & Gas | Onshore | Offshore | CCSU | FPSO
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Implement ergonomic design principles to reduce worker fatigue and improve safety. Utilize immersive VR training to prepare workers for emergency scenarios and improve response times.

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Wayne Mohan

Process Safety Discipline Manager at Heritage Petroleum Company FIChemE (Process Safety), Professional Process Safety Engineer (PPSE)
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-Inherently Safer Design: This entails selecting materials and processes that are naturally safer- e.g. utilization of materials such as piping and vessels that can handle higher pressure than the operating pressure.

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Saravanan Lakshmanan

Senior Electrical Engineer | FEED | Detailed Engineering | Field Engineering | Oil & Gas | Onshore | Offshore | CCSU | FPSO
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Smart PPE: Develop advanced personal protective equipment with integrated sensors to monitor worker vital signs and detect potential hazards.

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Parthiban Rethinachalam

PIPING | LAYOUT | MECHANICAL HANDLING | PACKAGE ENGINEERING | PROJECT ENGINEERING
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Replace human operators with fully sensible auto bots in safety critical operations which are programmed to operate inline with plant layout

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2 Wearable devices

Another way to improve plant safety is to equip the workers with wearable devices that can protect them from various hazards and provide them with useful information. Wearable devices can include helmets, goggles, gloves, vests, or badges that have features such as cameras, microphones, speakers, GPS, or biometric sensors. These devices can help the workers communicate with each other and the control room, access instructions or manuals, navigate the plant, or alert them of any dangers. Wearable devices can also track the workers' health and location, and send signals in case of emergencies.

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Wayne Mohan

Process Safety Discipline Manager at Heritage Petroleum Company FIChemE (Process Safety), Professional Process Safety Engineer (PPSE)
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-Safety Instrumented Systems (SIS): SIS are designed to automatically initiate safety actions such as emergency shutdowns or venting when specific process conditions deviate from safe parameters, thus bringing the system to a safe position where there is no injury to persons or damage to the environments of assets.

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3 Robotic assistants

A third way to improve plant safety is to use robotic assistants that can perform tasks that are too dangerous, difficult, or tedious for humans. Robotic assistants can include drones, crawlers, or manipulators that can inspect, repair, or clean equipment and systems that are hard to reach, exposed to high temperatures or pressures, or contaminated with toxic substances. By using robotic assistants, engineers can reduce the exposure of workers to harmful environments, improve the quality and efficiency of the work, and avoid human errors or fatigue.

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4 Adaptive controls

A fourth way to improve plant safety is to use adaptive controls that can adjust the operation of equipment and systems according to the changing conditions and demands. Adaptive controls can use artificial intelligence, machine learning, or fuzzy logic to analyze the data from smart sensors and other sources, and modify the parameters or settings of the equipment and systems accordingly. By using adaptive controls, engineers can optimize the performance and reliability of the equipment and systems, prevent or correct any deviations or faults, and respond to any disturbances or emergencies.

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Wayne Mohan

Process Safety Discipline Manager at Heritage Petroleum Company FIChemE (Process Safety), Professional Process Safety Engineer (PPSE)
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Gas and Leak Detection Systems: Advanced gas and leak detection systems use sensors to detect leaks or hazardous conditions early, reducing the risk of explosions or chemical exposure.

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5 Modular design

A fifth way to improve plant safety is to use modular design that can simplify the installation, modification, or replacement of equipment and systems. Modular design can use standardized components that can be easily assembled, disassembled, or reconfigured, and have compatible interfaces and connections. By using modular design, engineers can reduce the complexity and cost of the equipment and systems, increase the flexibility and scalability of the plant, and minimize the downtime and disruption caused by changes or repairs.

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6 Human factors engineering

A sixth way to improve plant safety is to use human factors engineering that can enhance the usability and ergonomics of equipment and systems. Human factors engineering can use principles of psychology, sociology, and design to improve the interaction between humans and machines, and to reduce the physical and mental workload of the workers. By using human factors engineering, engineers can improve the comfort and satisfaction of the workers, prevent or minimize human errors or accidents, and increase the productivity and quality of the work.

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Vinod Erat

Technical Safety
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Assessing human factor requirements and implementing at an early stage of the project is a principal element to be followed.Early implementation ensures cost effective solution and avoidance of major changes towards the end of the project.As an example, control room design and accessibility of panels needs to be very well ?pecified at an early stage.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are some innovative equipment designs that can improve plant safety?

1

2

3

4

5

6

7

1 Smart sensors

2 Wearable devices

3 Robotic assistants

4 Adaptive controls

5 Modular design

6 Human factors engineering

7 Here’s what else to consider

Mechanical Engineering

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What are some innovative equipment designs that can improve plant safety?

1

2

3

4

5

6

7

1 Smart sensors

2 Wearable devices

3 Robotic assistants

4 Adaptive controls

5 Modular design

6 Human factors engineering

7 Here’s what else to consider

Mechanical Engineering

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