Complexity

Can you do that? Is there? Surely both production managers and plant operators have already asked themselves these questions. To become more concrete: You, as a production manager, have experienced plant operators and you know that you have taken good care of your control and alarm strategy. Functional safety is also up to date. You won’t burn anything. Nevertheless, something is bothering you: No matter how stable and safe your system is, you don’t really know how efficiently it drives. Isn’t there the famous “grain” left in it?
Or let’s put ourselves in your place as a plant operator: you have been operating your plant for years and know it well. From time to time she does her “talking tricks” and you don’t know why. Although you keep to the allowed temperature step in the reactor, it is about to go through or it is going through. Such an “early warning system” would be very practical. This runs in real time and warns you in advance that something is going to go wrong. Then you still have enough time to react accordingly. Something like a “process crystal ball” would be good. But is there such a thing?