Human Factors Methods for Improving Performance in the Process Industries

Preface xi

Acknowledgments xiii

Abbreviations and Acronyms xv

1 Introduction 1

1.1 Purpose of This Book 1

1.2 Human Factors 1

1.3 Human Error 3

1.4 Structure of This Book 5

1.5 Linkage to Other CCPS Publications 6

1.6 References 7

2 The Case for Human Factors 9

2.1 Why is Human Factors Needed? 9

2.2 Past Incidents 11

2.3 Business Value/Justification 11

2.4 Human Factors in the Life Cycle of a Chemical Plant 16

2.5 Needs Driven Program 17

2.6 References 19

3 Performance Measurement and Improvements 21

3.1 Building Improvements into Existing Systems 21

3.2 Measures of Performance 22

3.3 Roles and Responsibilities 24

3.4 Continuous Improvement 25

3.5 References 28

HUMAN FACTORS TOOL KIT

Facilities and Equipment

4 Process Equipment Design 31

4.1 Introduction 31

4.2 Tools 33

4.3 References 33

4.4 Additional References 34

5 Process Control Systems 37

5.1 Introduction 37

5.2 Issues/Example 37

5.3 Tools 39

5.4 Additional References 39

6 Control Center Design 41

6.1 Introduction 41

6.2 Tools 42

6.3 References 43

6.4 Additional References 43

7 Remote Operations 45

7.1 Introduction 45

7.2 Tools 47

7.3 Reference 48

8 Facilities and Workstation Design 49

8.1 Introduction 49

8.2 Tools 53

8.3 References 55

8.4 Additional References 55

9 Human/Computer Interface 57

9.1 Introduction 57

9.2 Human Interactions with Control System Software 58

9.3 Tools 59

9.4 References 63

9.5 Additional References 64

10 Safe Havens 67

10.1 Introduction 67

10.2 Human Factors Issues 68

10.3 Tools 70

10.4 References 70

11 Labeling 71

11.1 Introduction 71

11.2 Tools 72

11.3 References 74

People

12 Training 77

12.1 Introduction 77

12.2 Guidelines for Training Programs 77

12.3 Guidelines for Designing and Delivering Training 78

12 4 Tools 81

12.5 References 81

13 Communications 83

13.1 Introduction 83

13.2 Issues/Examples 83

13.3 Tools 85

13.4 References 85

14 Documentation Design and Use 87

14.1 Introduction 87

14.2 Converting to Electronic Documentation 88

14.3 Use of Documents 90

14.4 Tools 92

14.5 References 93

14.6 Additional References 94

15 Environmental Factors 95

15.1 Introduction 95

15.2 Noise 95

15.3 Vibration 96

15.4 Temperature and Relative Humidity 99

15.5 Air Quality 101

15.6 Lighting 102

15.7 References 105

16 Workloads and Staffing Levels 107

16.1 Introduction 107

16.2 Issues/Examples 107

16.3 Tools 108

16.4 References 109

17 Shiftwork Issues 111

17.1 Introduction 111

17.2 Tools 112

17.3 References 114

17.4 Additional References 114

18 Manual Materials Handling 117

18.1 Introduction 117

18.2 Manual Materials Handling Guidelines 118

18.3 References 121

18.3 Additional References 122

Management Systems

19 Safety Culture 125

19.1 Introduction 125

19.2 What is Safety Culture? 125

19.3 Tools 127

19.4 Safety Culture: A Process Industry Case Study 130

19.5 Benefits 131

19.6 References 131

19.7 Additional References 132

20 Behavior Based Safety 133

20.1 Introduction 133

20.2 Tools 134

20.3 Expected Results 137

20.4 References 137

20.5 Additional References 138

21 Project Planning, Design, and Execution 139

21.1 Introduction 139

21.2 Human Factors Tools for Project Management 139

21.3 References 143

22 Procedures 145

22.1 Introduction 145

22.2 Tools 146

22.3 References 151

22.4 Additional References 151

23 Maintenance 153

23.1 Introduction 153

23.2 Identifying Critical Maintenance Tasks 153

23.3 Maintenance Protocol 154

23.4 Tools 155

23.5 References 156

24 Safe Work Practices and Permit-to-Work Systems 159

24.1 Introduction 159

24.2 Issues 159

24.3 Tools 163

24.4 References 164

24.5 Additional Reference 164

25 Management of Change 165

25.1 Introduction 165

25.2 Tools 167

25.3 References 172

26 Qualitative Hazard Analysis 175

26.1 Introduction 175

26.2 Tools—Human Failures 176

26.3 Tools—Human Factors 177

26.4 References 179

26.5 Additional References 180

27 Quantitative Risk Assessment 181

27.1 Introduction 181

27.2 Tools 183

27.3 References 184

27.4 Additional References 184

28 Safety Systems 185

28.1 Introduction 185

28.2 People and Safety Systems 185

28.3 Bypassing and Disabling Safety Systems 185

28.4 Shutdown Systems 188

28.5 Selection of Safety Systems 189

28.6 Common Cause Failures in Safety Systems 189

28.7 Tools 190

28.8 References 190

29 Competence Management 191

29.1 Introduction 191

29.2 Elements of Competence Management 193

29.3 Tools 196

29.4 References 197

29.5 Additional References 197

30 Emergency Preparedness and Response 199

30.1 Introduction 199

30.2 Tools 199

30.3 Reference 202

30.4 Additional References 202

31 Incident Investigation 203

31.1 Introduction 203

31.2 Issues/Examples 203

31.3 Tools 205

31.4 References 205

Appendix. Human Factors Checklist 207

Index 225