Advanced Process Control (APC) technology is prevalent in most operating facilities, providing automation that results in optimal plant performance. The day-to-day operation of a process has been automated, reducing operator intervention significantly. Often, operators who do not have APC on their plant are envious of their colleagues who do have APC. This is because operators with APC are less stressed and can focus on other important activities rather than having to make adjustments regularly.
Does APC reduce vigilance of operators and their ability to react to process upsets and emergencies? Learn about the APC impact in this blog.
During the early implementation of APC in the 90’s, there was a widespread concern of operator jobs being made redundant and that APC would completely take over the operation of the plant. Many years of experience have shown that APC implementations reduce nuisance alarms and APC operator stress, but there is no threat to operator jobs. Many operators have commented that APC helps operators “put their feet up” and “relax” when it is in operation. Whilst it may be true that some operators literally put their feet up, the important point is that stress levels are reduced, and time is freed up to do other activities. Some plant managers and operations managers have raised concerns on whether there is erosion of operator knowledge, reduction in their vigilance and perhaps a risk of slower operator response in emergencies. Are their concerns valid?
Over the years it has become abundantly clear that APC is a tool to assist operators in optimising their plant. A well-designed and well-implemented APC along with good operator training results in operators obtaining the best outcomes for their plants, reducing their need to make frequent adjustments. The time freed up allows operators to focus on plant improvement, maintenance, training new operators and getting trained in new tools.
All these activities enhance and reinforce operator understanding of their plant. During emergencies, operators are still entirely in charge and responsible for taking appropriate actions to mitigate risks, since APC is operated only during normal, steady-state conditions. Operator Training Simulators (OTS) are often used to refresh operator knowledge of plant operations. Refresher APC courses are also recommended for operators to get the best out of the tool and hence a better-optimised plant.
APC implementation does not reduce operator vigilance or experience. On the contrary, the time saved from day-to-day operation and adjustments can be better utilised to learn new tools, enhance their understanding of APC and be a mentor to other operators. Operator stress induced by nuisance alarms is reduced, which improves the state of mind of operators and helps them focus easier on the many tasks they typically perform during the day. Overall, APC improves the well-being of operators, creating opportunities for them to enhance and upgrade their skill set.
Get more information on APC implementation, and contact IPCOS today.