Abnormal situation management for smart chemical process operation

For the chemical process industry, the goal of Smart Manufacturing should not only maximize economic competitiveness, but also significantly reduce safety incidents. Therefore safety risk intelligence (SRI) should be an essential feature for smart chemical process operation. Abnormal situation management (ASM) of chemical processes has been studied for more than two decades with the aim to gain and utilize the operational intelligence for handling complex abnormal situations which are difficult for operators to detect and prevent. This paper provides an overview on the methods of ASM with SRI. Following a brief introduction of risk assessment methods, different approaches for controlling and mitigating risks of chemical processes, equipment and human operators are reviewed. Finally, future directions and challenges associated with each area of ASM are discussed before the conclusion.