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.

Table of Contents:
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

About the Author :
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.