Methodology for Risk-Oriented Selection of Serial Monitoring and Control Devices at Industrial Facilities

Effective prevention of emergencies at industrial facilities is impossible without a well-founded selection of monitoring and control equipment for production processes, which should account not only for compliance with regulations but also for its contribution to risk reduction. This study presents a risk-oriented methodology for selecting off-the-shelf monitoring and control devices, based on a quantitative relationship between potential damage and the root mean square error of measurements. A decision-making algorithm is proposed that aims to minimize damage resulting from control errors under budget constraints. The methodology includes ranking monitored parameters by risk level, assessing potential damage reduction through equipment modernization, and selecting the optimal combination of replacements considering associated costs. A key feature of the approach is the use of metrological characteristics as the main criterion for effectiveness. To demonstrate the applicability of the methodology, a case study is conducted for a metallurgical plant. The methodology can be applied during the design, audit, and modernization of industrial monitoring systems.