New Сhallenges to Industrial Safety — Will Computer Simulators Help?


Over the past 30 years, computer simulators became the powerful tool for training industrial process operators to work in normal, extraordinary, and emergency situations. Computer simulators use the most advanced information technologies of simulation, computer emulation and automated instruction. They allow to form and consolidate the reliable skills of safe and efficient industrial processes control for the operators. Computer simulators are wide-spread, including those at the plants of chemical-technological type (oil and gas production and processing, petrochemicals, chemistry, production of mineral fertilizers, pulp and paper, mining and metallurgical, pharmacological, food industries, etc.). Potentially hazardous plants are actively equipped with training systems, especially at the stage of new construction or modernization of the units, and their equipping with the modern control systems. According to the world statistics, over the past ten years the losses from industrial accidents decreased (to a great extent thanks to the use of computer simulators).

Domestic enterprises are experiencing the real training boom in the new millennium. At the same time, the requirements for computer simulators are defined only by Rostechnadzor in the General rules of explosion safety for explosion and fire hazardous chemical, petrochemical and oil refining plants, which cannot serve as a barrier against entering the low-functional solutions to the enterprises. The enterprises themselves are not always able to filter out such proposals. All this happens against the background of worsening emergency statistics and causes anxiety for the professional community.

The paper analyzes the objective and subjective reasons for practical declining in the quality of training. The world best practices are given concerning the development, implementation and support of computer simulators, the transfer of which to the domestic soil would help to reverse the negative trends. The need is shown in developing a standard for computer simulators, which will require to combine efforts of the suppliers, independent experts and regulatory bodies in the field of ensuring occupational safety in industry.

  1. Operator Training Simulation Global Market Research Study. Market Analysis and Forecast through 2017. ARC Advisory Group, 2012.
  2. Dozortsev V.M. Computer simulators for process operators training. Мoscow: Sinteg, 2009. 372 p. (In Russ.).
  3. Koteswara R.G., Kiran Y. Analysis of accidents in chemical process industries in the period 1998–2015. International Journal of ChemTech Research. 2016. Vol. 9 (4). pp. 177–191.
  4. The 100 Largest Losses 1974–2015. Large property damage losses in the hydrocarbon industry 24rd edition. Marsh&McLennan Co., March 2016. Available at: (accessed: August 16, 2019).
  5. Johnsen S.O., Kilskar S.S., Fossum K.R. Missing focus on Human Factors — Organizational and cognitive ergonomics — In the safety management for the petroleum industry. Journal of Risk and Reliability. 2017. Vol. 231 (4). pp. 400–410. DOI: 10.1177/1748006X17698066
  6. Process Safety Management. U.S. Department of Labor, Occupational Safety and Health Administration. Available at: (accessed: August 16, 2019).
  7. General rules of explosion safety for explosion and fire hazardous chemical, petrochemical and oil refining plants: Federal norms and regulations in the field of industrial safety. Ser. 09. Iss. 37. Moscow: ZAO NTTs PB, 2019. 130 p. (In Russ.).
  8. Bainbridge L. Ironies of Automation. Automatica. 1983. Vol. 19 (6). pp. 775–779. Available at: (accessed: August 16, 2019).
  9. Dozortsev V.M., Kreidlin E.Yu. State-of-the-art automated process simulation systems. Automation and remote control. 2010. Vol. 71 (9). pp. 1955–1963. DOI:10.1134/S0005117910090171
  10. Seleznev V.E., Skiteva I.A. Some Conceptual Aspects of Using High-Accuracy Computer Modeling in the Pipeline Transport. Bezopasnost truda v promyshlennosti = Occupational Safety in Industry. 2012. № 6. pp. 72–76. (In Russ.).
  11. Stefenson G., Khenderson P., Shindler G., Dozortsev V. Beyond operator training: other applications of process simulation. Promyshlennye ASU i kontrollery = Industrial Automatic Control Systems and Controllers. 2009. № 6. pp. 1–5. (In Russ.).
  12. Novichkov A.Yu., Frolov A.I., Pogorelov V.P., Dozortsev V.M. Field operator interface in the computer simulator: 3D view or 2D panorama?  Vtoraya mezhdunar. nauch.-prakt. konf. «Chelovecheskiy faktor v slozhnykh tekhnicheskikh sistemakh i sredakh» (The second inernational scientific-practical conference «Human factor in the complex technical systems and environment»). Saint Petersburg, 2016. pp. 66–74.  (In Russ.).
  13. Nazin V.A. Automated training systems for process plant personnel.  Avtomatizatsiya v promyshlennosti = Automation in Industry. 2006. № 6. pp. 10–14. Available at: (accessed: August 16, 2019). (In Russ.).
  14. Ishkildin R.R., Korotchenko A.Yu., Dikamov D.V., Murzagalin A.T., Chetin D.A., Voronova Yu.A. Methods of Information Technologies Application to Improve the Competence of the Employees as a Mechanism to Ensure Safe Operation of Oil and Gas Fields. Bezopasnost truda v promyshlennosti = Occupational Safety in Industry. 2019. № 2. pp. 76–83. (In Russ.). DOI: 10.24000/0409-2961-2019-2-76-83
  15. Dozortsev V.M., Itskovich E.L. Features of selecting computer simulator for process operators training. Avtomatizatsiya v promyshlennosti = Automation in Industry. 2010. № 4. pp. 3–9. (In Russ.).
DOI: 10.24000/0409-2961-2019-9-31-38
Year: 2019
Issue num: September
Keywords : industrial safety computer simulator computer-based training industrial process model operator interface console and field operators
  • Dozortsev V.M.
    Dozortsev V.M.
    Dr. Sci. (Eng.), Director on strategy and business development of high-tech solutions, JSC Honeywell, Moscow, Russia