PSM Simulator

OVERVIEW

What This Application Does

PSM Simulator is a Process Safety Management training game played on a live P&ID. Players first learn the unit in normal operation, then run production and recognise abnormal conditions from trends, DCS alarms, field warnings and team chat, reporting each deviation as a HAZOP entry with node, parameter, CCPS guideword, cause and consequence.

In the final two stages players install preventive and mitigation barriers within a limited budget and control each barrier's escalation factors through inspection, testing and maintenance. The game ends with the player's own bow-tie diagram and scores for every stage, barrier reliability and budget effectiveness. Twelve scenarios cover oil and gas, petrochemicals, power, renewable energy, manufacturing, and property and EPC construction.

Platform: Web browser and installable PWA for desktop, tablet and phone
Scenarios: 12 in 6 industry sectors
Stages: 4: normal operation, abnormality, prevention, mitigation
Methods referenced: HAZOP (CCPS 2008, IEC 61882), bow-tie, human error (Reason 1990, HSE HSG48)
Budget currency: Rupiah or USD
Progress data: Stored in the browser on the device
Interface language: Indonesian, with English technical terms
Layout testing: 19 screen sizes from 360 x 740 to 1366 x 1024

FUNCTIONS

Built Around Real Workflows

Each function below replaces a step that used to run on paper, spreadsheets, or chat groups.

01

Four-stage learning path

Normal operation, abnormal conditions, preventive barriers and mitigation barriers, each scored and graded.

02

Live P&ID and trends

Live readings, vessel levels and 60-minute trend cards with alarm bands, following high performance HMI principles (ANSI/ISA-101).

03

Normal operation and quiz

Players inspect every equipment item and instrument, change set points and complete a five-question comprehension quiz.

04

Abnormality detection

Five events per game from five rotating variations, with DCS alarms appearing before field warnings so attentive players can act early.

05

HAZOP reporting

Reports use node, parameter, the seven CCPS guidewords, cause and consequence, with a bonus for early detection and a penalty for late reports.

06

Human factor cases

Two events per game start from team chat containing a human error, classified as slip, lapse, mistake or violation (Reason, HSE HSG48).

07

Barrier design on a budget

Sector-specific devices such as PSV, SIF, trips, gas detectors, ESD and deluge placed at P&ID points within a budget in Rupiah or USD.

08

Escalation factor control

Each barrier and critical equipment item needs the right inspection, test or maintenance control before its reliability is credited.

09

Bow-tie result

The final screen draws the player's bow-tie with credited barriers, human factor labels and the controls applied.

10

Three difficulty levels

Easy, Normal and Hard change the barrier budget, hint costs and quiz explanations.

11

Twelve scenarios in six sectors

Separator, LPG storage, batch reactor, distillation, coal boiler, substation transformer, POME biogas, solar with BESS, feed mill, ammonia refrigeration, building fire protection, asphalt plant.

12