Transcript The Contract

Technische Universität Berl
Method for Incorporating Human Factors
During Design Phase
Presented at:
Loss Prevention Symposium
Prague, 31st May - 3rd June, 2004
Dipl.-Ing. Simon G. Kariuki
&
Dr.-Ing. Katharina Löwe
Technical University of Berlin
What is covered:
 Definition & Background of Human Factors in Design.
 Obstacles in Implementation of HF.
 State-of-the-Art in the Process Industry.
 Systematic Method to integrate Human Factors into
Design Process.
 Conclusion
Definition of “Human
Factors in Design”
A body of science that incorporates the physical and
cognitive capabilities and limitations of populations of
people into the design of a system, process, or
equipment aimed at achieving improved
manufacturability, operability and maintainability.
Components of HF
Plant
Design
Management
• Equipment
Design
• Workplace
Layout
• Workplace
Environment
• Displays &
Controls
Operator
• Selection &
Training
&
• Communication
• Shift transfer
• Management
structure
• Safety culture
• Anthropometry
&
• Cognition
(Mental Ability)
• Skills/
Qualifications
• Culture
Components of HF
Plant
Design
Management
Systems
Operator
(Human User)
Intersection between factors lying under the three areas
determines the quality of HF in a process facility.
Facts about “Human Factors”
 HF is an old science dating back to world war II.
 Open Secret => HUMAN FAILURE is the biggest
contributor of incidents in process plants.
But: Very few companies implement HF during
the design phase.
Why not? There is lack of knowledge on HF
implementation in the Process
industry.
What are the Obstacles?
 Lack of specific laws/regulations, guidelines on HF.
 Lack of expertise and when available is called in too late.
 Additional pressure to financial and time resources.
 Conflicts on where to link HF. Some firms link it to SHE.
What are the Obstacles?
 Presence of conservative attitudes e.g.
- We got everything right from core safety analysis
- Fix the people not process
- “As long as its working we did a good job”
State-of-the-Art in the Process Industry
Design-Project Procedure
Feasibility
study
- Process
choice
- Parameters
for plant
location.
- Basic flow
diagrams
- Rough cost
estimations.
Basic Design
- More elaborate
basic flow
diagrams.
- Production &
ancillary buildings,
approximate pipe
and equipment
dimensions
- Investment &
operating costs
assessment.
Detail Design
- Detailed design with
process flow diagrams
(mass, energy
balances), P&ID, 3-D
models for plant layout,
Process Control
- Structural
construction and
assembly of equipment
& machinery
- Plant safety analysis
and reports
- Start-up scheduling &
training on operations.
Commissioning
& Start-up
-Test for
conformity with
P& ID
- Handing over to
operations and
maintenance
departments
(Training)
Operation &
Maintenance
- Reviews for
possible design
problems for
post start-up
modifications
-Task analysis
for operation
modifications
State-of-the-Art in the Process Industry
 Engineering disciplines are well represented
Design has good engineering strength.
 Process Hazards are analysed (Core Safety) using tools
like HAZOP & Checklists.
 BUT: HF issues are not covered in details during design
Some designs have to be modified after detecting a
mismatch between operator characteristics & design.
 AND: There is a new challenge: Most companies are
outsourcing major projects.
Method to Address HF issues during Design
The method has the following advantages:
 Provides a systematic approach to implement of HF principles
during the whole design process.
 Shows the design phase at which each HF activity gives most
benefits.
 Shows that there is a need to maintain a HF database for future
projects.
BENEFITS: Reduction in cost of design modifications,
incidents due to operator error, injuries at workplace and
improved operation efficiency.
Mapping HF Activities onto the Design Process
Databank for
future projects
Evaluate
Review
Feasibility
study
Basic Design
Check
Detail Design
HF Related Activities
Commissioning
& Start-up
Operation &
Maintenance
Mapping HF Activities onto the Design Process
Databank for
future projects
Evaluate
Review
Feasibility
study
Basic Design
Check
Detail Design
Commissioning
& Start-up
Operation &
Maintenance
HF Planning & Analyses
 Choice of Process, Functions Analysis, Task Analysis
HF Design Implementation
 Equipment, Procedure, Training Design
HF Evaluation & Validation
 Iterative verification
HF Performance Monitoring
 Post-commissioning task analysis
Mapping HF Activities onto the Design Process
Databank for
future projects
Evaluate
Review
Feasibility
study
Check
Detail Design
Basic Design
Commissioning
& Start-up
Operation &
Maintenance
HF Planning & Analyses
HF Design Implementation
HF Evaluation & Validation
HF Performance Monitoring
HF Planning & Analyses
Feasibility study
At the very conceptual stage of design process some important HF
have already emerged:
 Choice of process
- Either to use inherently safer design.
 Skills of operators and maintainers required. Is it
highly trained, moderate or low trained?
 The plant geographical location
- Anthropometrics, culture.
HF Planning & Analyses
 What will be the operating environment?
 What is the overall consequences if operation went wrong?
HF efforts should correspond to the complexity & sensitivity
of the process plant.
HF Planning & Analyses
Basic & Detailed Design
 Details about the process are being defined
 The type of equipment is being specified
 Detailed drawings, P&ID
HF deliverables are Functions Analysis and
Task Analysis.
Functions Analysis
Plant Design
Identification of functions to be performed
Analysis of function and allocation. (Tradeoffs)
- Capability & limitations of human /machine
- Existing technologies.
-Cost
OR
Human
Hardware/
Software
Hybrid
Functions Evaluation
Task
Analysis
=For tasks that involves
Human Operator
Functions Analysis
HUMANS EXCEL IN
 Sensitivity to an extremely wide variety
of stimuli.
 Perceiving patterns and making
generalisation about them.
 Ability to store large amounts of
information for long periods and
recalling relevant facts at appropriate
moments.
 Applying originality in solving problems,
i.e, alternative solutions.
 Ability to profit from experience and
alter course of action.
MACHINES EXCEL IN
 Monitoring (both people and machines).
 Performing routine, repetitive, or very.
precise operations.
 Responding very quickly to control
signals.
 Storing and recalling large amount of
information in short time-periods.
 Performing complex and rapid
computations with high accuracy.
 Exerting large amounts of force
smoothly and precisely.
Task Analysis
Plant
Design
Identification of function to be performed
Performance Shaping
Factors, PSFs
Task
Analysis
AND
Equipment Design
HF Design Implementation
Procedures
design
Testing, Evaluation &
Validation
Human Performance
Monitoring
Training
development
Mapping HF Activities onto the Design Process
Databank for
future projects
Evaluate
Review
Feasibility
study
Check
Detail Design
Basic Design
Commissioning
& Start-up
Operation &
Maintenance
HF Planning & Analyses
HF Design Implementation
HF Evaluation & Validation
HF Performance Monitoring
HF Design Implementation
The result of task analysis used in designing Equipment
Design (Human Machine Interface), Procedures and Training.
PRISM Guidelines addresses specific areas of HF and design.
This includes:
Maintainability and operability
Accessibility of work stations, design of ladders and stairs,
location of valves.
Control Monitoring and instrumentation
Field control panels, display design, alarms.
HF Design Implementation
Automation and Control Design
Fault management and false alarms, control room Design/
Layout.
Work Environment
Lighting, noise, heat Stress.
Plant Labelling and Signing
Information transmission, visibility and legibility, label location.
Other important tools to implement HF design include checklists,
computer models and electronic mock-ups.
Mapping HF Activities onto the Design Process
Databank for
future projects
Evaluate
Review
Feasibility
study
Check
Detail Design
Basic Design
Commissioning
& Start-up
Operation &
Maintenance
HF Planning & Analyses
HF Design Implementation
HF Evaluation & Validation
HF Performance Monitoring
HF Evaluation & Validation
 Important to verify tasks and to ensure that the design
accommodates capabilities and limitations of operator.
 Should starts at the Basic Engineering phase and stretch
to commissioning and start up.
 Most benefits are achieved during Detail Engineering when
all specs have been defined.
Mapping HF Activities onto the Design Process
Databank for
future projects
Evaluate
Review
Feasibility
study
Check
Detail Design
Basic Design
Commissioning
& Start-up
Operation &
Maintenance
HF Planning & Analyses
HF Design Implementation
HF Evaluation & Validation
HF Performance Monitoring
HF Performance Monitoring
 All problems related to HF cannot be eliminated during
Design,Evaluation and Validation.
Therefore needed:
 HF Monitoring Strategy.
 Supplementary task analysis to make further improvement.
But:
Any modifications should not introduce further degradations.
Lessons learned into HF databank.
Conclusion
 Process industry lags behind in HF aspects.
 HF are rarely addressed during design and if so, it is done
too late.
 The method suggested provides a systematic integration of
HF into the design process.
 Introducing HF databanks creates a valuable resource for
future projects.
Thank You For Your
Attention !