Human factors methods for improving performance in the process industries

Human Factors Methods for Improving Performance in the Process Industries provides guidance for managers and plant engineering staff on specific, practical techniques and tools for addressing forty different human factors issues impacting process safety. Human factors incidents can result in injury and death, damage to the environment, fines, and business losses due to ruined batches, off-spec products, unplanned shutdowns, and other adverse effects. Prevention of these incidents increases productivity and profits.

Complete with examples, case histories, techniques, and implementation methodologies, Human Factors Methods for Improving Performance in the Process Industries helps managers and engineering staff design and execute an efficient program. Organized for topical reference, the book includes:

An overview on implementing a human factors program at the corporate level or the plant level, covering the business value, developing a program to meet specific needs, improving existing systems, roles and responsibilities, measures of performance, and more Summaries of forty different human factors relating to process safety, with a description of the tools, a practical example with graphics and visual aids, and additional resources Information on addressing the OSHA Process Safety Management (PSM) requirement for conducting human factors reviews in process hazard analyses (PHAs) A CD-ROM with a color version of the book

Note: CD-ROM/DVD and other supplementary materials are not included as part of eBook file.

Author Notes

Since 1985, the Center for Chemical Process Safety (CCPS) has been the world leader in providing information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over eighty books in its process safety guidelines and process safety concepts series. In this book, CCPS teams up with the AIChE Safety and Health Division. Members of the CCPS Human Factors Subcommittee contributed chapters or sections in their areas of expertise. For more information, visit www.ccpsonline.org.

Preface	p. xi
Acknowledgments	p. xiii
Abbreviations and Acronyms	p. xv
1 Introduction	p. 1
1.1 Purpose of This Book	p. 1
1.2 Human Factors	p. 1
1.3 Human Error	p. 3
1.4 Structure of This Book	p. 5
1.5 Linkage to Other CCPS Publications	p. 6
1.6 References	p. 7
2 The Case for Human Factors	p. 9
2.1 Why is Human Factors Needed?	p. 9
2.2 Past Incidents	p. 11
2.3 Business Value/Justification	p. 11
2.4 Human Factors in the Life Cycle of a Chemical Plant	p. 16
2.5 Needs Driven Program	p. 17
2.6 References	p. 19
3 Performance Measurement and Improvements	p. 21
3.1 Building Improvements into Existing Systems	p. 21
3.2 Measures of Performance	p. 22
3.3 Roles and Responsibilities	p. 24
3.4 Continuous Improvement	p. 25
3.5 References	p. 28
Human Factors Tool Kit
Facilities and Equipment
4 Process Equipment Design	p. 31
4.1 Introduction	p. 31
4.2 Tools	p. 33
4.3 References	p. 33
4.4 Additional References	p. 34
5 Process Control Systems	p. 37
5.1 Introduction	p. 37
5.2 Issues/Example	p. 37
5.3 Tools	p. 39
5.4 Additional References	p. 39
6 Control Center Design	p. 41
6.1 Introduction	p. 41
6.2 Tools	p. 42
6.3 References	p. 43
6.4 Additional References	p. 43
7 Remote Operations	p. 45
7.1 Introduction	p. 45
7.2 Tools	p. 47
7.3 Reference	p. 48
8 Facilities and Workstation Design	p. 49
8.1 Introduction	p. 49
8.2 Tools	p. 53
8.3 References	p. 55
8.4 Additional References	p. 55
9 Human/Computer Interface	p. 57
9.1 Introduction	p. 57
9.2 Human Interactions with Control System Software	p. 58
9.3 Tools	p. 59
9.4 References	p. 63
9.5 Additional References	p. 64
10 Safe Havens	p. 67
10.1 Introduction	p. 67
10.2 Human Factors Issues	p. 68
10.3 Tools	p. 70
10.4 References	p. 70
11 Labeling	p. 71
11.1 Introduction	p. 71
11.2 Tools	p. 72
11.3 References	p. 74
People
12 Training	p. 77
12.1 Introduction	p. 77
12.2 Guidelines for Training Programs	p. 77
12.3 Guidelines for Designing and Delivering Training	p. 78
12.4 Tools	p. 81
12.5 References	p. 81
13 Communications	p. 83
13.1 Introduction	p. 83
13.2 Issues/Examples	p. 83
13.3 Tools	p. 85
13.4 References	p. 85
14 Documentation Design and Use	p. 87
14.1 Introduction	p. 87
14.2 Converting to Electronic Documentation	p. 88
14.3 Use of Documents	p. 90
14.4 Tools	p. 92
14.5 References	p. 93
14.6 Additional References	p. 94
15 Environmental Factors	p. 95
15.1 Introduction	p. 95
15.2 Noise	p. 95
15.3 Vibration	p. 96
15.4 Temperarure and Relative Humidity	p. 99
15.5 Air Quality	p. 101
15.6 Lighting	p. 102
15.7 References	p. 105
16 Workloads and Staffing Levels	p. 107
16.1 Introduction	p. 107
16.2 Issues/Examples	p. 107
16.3 Tools	p. 108
16.4 References	p. 109
17 Shiftwork Issues	p. 111
17.1 Introduction	p. 111
17.2 Tools	p. 112
17.3 References	p. 114
17.4 Additional References	p. 114
18 Manual Materials Handling	p. 117
18.1 Introduction	p. 117
18.2 Manual Materials Handling Guidelines	p. 118
18.3 References	p. 121
18.3 Additional References	p. 122
Management Systems
19 Safety Culture	p. 125
19.1 Introduction	p. 125
19.2 What is Safety Culture?	p. 125
19.3 Tools	p. 127
19.4 Safety Culture: A Process Industry Case Study	p. 130
19.5 Benefits	p. 131
19.6 References	p. 131
19.7 Additional References	p. 132
20 Behavior Based Safety	p. 133
20.1 Introduction	p. 133
20.2 Tools	p. 134
20.3 Expected Results	p. 137
20.4 References	p. 137
20.5 Additional References	p. 138
21 Project Planning, Design, and Execution	p. 139
21.1 Introduction	p. 139
21.2 Human Factors Tools for Project Management	p. 139
21.3 References	p. 143
22 Procedures	p. 145
22.1 Introduction	p. 145
22.2 Tools	p. 146
22.3 References	p. 151
22.4 Additional References	p. 151
23 Maintenance	p. 153
23.1 Introduction	p. 153
23.2 Identifying Critical Maintenance Tasks	p. 153
23.3 Maintenance Protocol	p. 154
23.4 Tools	p. 155
23.5 References	p. 156
24 Safe Work Practices and Permit-to-Work Systems	p. 159
24.1 Introduction	p. 159
24.2 Issues	p. 159
24.3 Tools	p. 163
24.4 References	p. 164
24.5 Additional Reference	p. 164
25 Management of Change	p. 165
25.1 Introduction	p. 165
25.2 Tools	p. 167
25.3 References	p. 172
26 Qualitative Hazard Analysis	p. 175
26.1 Introduction	p. 175
26.2 Tools-Human Failures	p. 176
26.3 Tools-Human Factors	p. 177
26.4 References	p. 179
26.5 Additional References	p. 180
27 Quantitative Risk Assessment	p. 181
27.1 Introduction	p. 181
27.2 Tools	p. 183
27.3 References	p. 184
27.4 Additional References	p. 184
28 Safety Systems	p. 185
28.1 Introduction	p. 185
28.2 People and Safety Systems	p. 185
28.3 Bypassing and Disabling Safety Systems	p. 185
28.4 Shutdown Systems	p. 188
28.5 Selection of Safety Systems	p. 189
28.6 Common Cause Failures in Safety Systems	p. 189
28.7 Tools	p. 190
28.8 References	p. 190
29 Competence Management	p. 191
29.1 Introduction	p. 191
29.2 Elements of Competence Management	p. 193
29.3 Tools	p. 196
29.4 References	p. 197
29.5 Additional References	p. 197
30 Emergency Preparedness and Response	p. 199
30.1 Introduction	p. 199
30.2 Tools	p. 199
30.3 Reference	p. 202
30.4 Additional References	p. 202
31 Incident Investigation	p. 203
31.1 Introduction	p. 203
31.2 Issues/Examples	p. 203
31.3 Tools	p. 205
31.4 References	p. 205
Appendix Human Factors Checklist	p. 207
Index	p. 225

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Table of Contents