Improving process safety is a high priority in process and manufacturing industries to address unwanted accidents and process disruptions. Research into the applications of dynamic simulators for hazard analysis has been rapidly growing. However, there is scant discussion in literature regarding the benefits and limitations associated with the utilization of dynamic simulations for process hazard analysis. A fundamental systems conceptualization, underpinned by the P3 model of people, plant and procedures, provides a framework for the characteristics to be considered by subject matter expertise when identifying the affordances and limitations within a dynamic simulation used for process hazard analysis. This subject matter expertise includes people with operations, process engineering, process safety and process simulation experience. All dynamic simulations will have limitations and understanding the affordances and limitations is crucial for the correct use of a model and the interpretation of results. A case study is presented on the application of a systematic approach for interrogating the dynamic simulation from an industrial operator training simulator of an operating residue catalytic cracking complex with the aim of conducting failure mode and effects analysis by identifying the significant consequences and the associated independent protection layers. Issues with respect to how one could automate the analysis rather than use human observation to assess the outcomes are considered and how to present the outcomes to complement existing process hazard analysis techniques are discussed. Future research requirements and developments that may assist in practically and effectively applying the technique in industry are also discussed.

提高过程安全性是过程和制造行业的首要任务，以解决意外事故和过程中断。动态模拟器在危险分析中的应用研究一直在迅速增长。然而，文献中很少讨论与利用动态模拟进行过程危险分析相关的好处和局限性。以人员、工厂和程序的 P3 模型为基础的基本系统概念化，为主题专业知识在识别用于过程危险分析的动态模拟中的可供性和限制时要考虑的特征提供了一个框架。该主题专业知识包括具有运营、过程工程、过程安全和过程模拟经验的人员。所有动态模拟都会有局限性，理解可供性和局限性对于正确使用模型和解释结果至关重要。提出了一个案例研究，应用系统方法来询问正在运行的渣油催化裂化综合体的工业操作员培训模拟器的动态模拟，目的是通过识别重大后果和相关的独立保护来进行故障模式和影响分析层。讨论了如何自动化分析而不是使用人工观察来评估结果的问题，以及如何呈现结果以补充现有过程危害分析技术的问题。还讨论了可能有助于在工业中实际有效地应用该技术的未来研究要求和发展。