Impact of alarm management and automation on abnormal operations: A human-in-the-loop simulation study

Process control consists of complex states of performance that require a significant amount of operator attention and skill to manage. Automation and smart alarms can enhance these processes. This study investigated the effects of alarm management and automation on process control operator workload (NASA-TLX) and performance via material lost through flaring outcomes. Eleven console qualified operators participated in a human-in-the-loop, high-fidelity simulation-based training exercise. Three levels of alarm management (no rationalization, rationalization, and state-based smart alarm) and two levels of automation (no automation and automation) conditions were implemented using six scenarios. A repeated measures two-way MANOVA indicated that both alarm management schema and automation significantly affected operator workload and performance. These results indicate that state-based smart alarm management and automation schemas may assist operators in reducing workload and material lost through flare release during abnormal operating conditions. The simulation specialist administered the simulated scenarios and acted as a role-player when necessary (e.g., responding as the “cracking panel” and “outside panel operator” during the simulated scenarios). •The effects of alarming and automation on workload and performance were investigated via simulated tasks for ethylene manufacturing.•Alarm rationalization and automation strategies reduce operator workload and improve operator performance.•Automation strategies resulted in lower operator workload and increased operator performance.•Smart-alarming strategies resulted in lower operator workload.