api human factors in new facility design tool

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yright American Petroleum Instituteded by IHS under license with API Licensee=YPF/5915794100

Not for Resale, 09/02/2009 05:42:47 MDTeproduction or networking permitted without license from I HS

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Human Factors in New FacilityDesign Tool

API Human Factors Task Force

Regulatory Analysis & Scientific Affairs Department

SECOND EDITION, OCTOBER 2005



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FOREWORD

Nothing contained in any API publication is to be construed as granting any right, by implicationor otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered byletters patent. Neither should anything contained in the publication be construed as insuring

anyone against liability for infringement of letters patent.

Suggested revisions are invited and should be submitted to the Director of Regulatory Analysisand Scientific Affairs, API, 1220 L Street, NW, Washington, DC 20005.



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TABLE OF CONTENTS

Purpose................................................................................................................................................... 1

Scope...................................................................................................................................................... 1

Applicability ............................................................................................................................................. 1Structure of Tool ..................................................................................................................................... 1

How to Use the Tool ............................................................................................................................... 1

Economic Discussion.............................................................................................................................. 3

Application of Tool in Existing Facilities .................................................................................................. 4

1. Alarm Management ......................................................................................................................... 5

2. Blinds and Blanks............................................................................................................................ 9

3. Control House Ergonomics............................................................................................................ 11

4. Electrical Substations and Field Housing for Instruments ............................................................. 19

5. Emergency Equipment .................................................................................................................. 23

6. Field Analyzer Buildings ................................................................................................................ 25

7. Field Display Panels...................................................................................................................... 27

8. Filters............................................................................................................................................. 29

9. Furnaces and Fired Heaters.......................................................................................................... 31

10. Instrumentation Systems............................................................................................................... 33

11. Labeling / Signage of Process Equipment..................................................................................... 34

12. Loading / Unloading Facilities........................................................................................................ 36

13. Pumps and Compressors .............................................................................................................. 38

14. Reactors / Dryers........................................................................................................................... 40

15. Sample Points ............................................................................................................................... 41

16. Structural: Ladders, Stairs, Guards, and Handrails ....................................................................... 42

17. Tanks............................................................................................................................................. 44

18. Valves............................................................................................................................................ 46

19. Vessels (including Heat Exchangers)............................................................................................ 48

20. Work Environment: Lighting, Noise, Heating/Cooling.................................................................... 49

Glossary................................................................................................................................................ 67

References............................................................................................................................................ 70

Figures

1 Location of Controls and Displays on Local Control Panels.......................................................... 52

2 Recommended Layout of Equipment and Piping at Pumps .......................................................... 53



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3 Location of Valve Handwheels ...................................................................................................... 54

4 Force as Function of Valve Wheel Height & Stem Orientation...................................................... 55

5 Stair Design................................................................................................................................... 56

6 Extended Safety Gage Bars .......................................................................................................... 57

7 DCS Monitor Glare from Control Room Lighting ........................................................................... 58

8 Indirect Lighting Applications Can Control Reflected Glare........................................................... 59

9 Operators View of Wall Displays is Obstructed by DCS Console................................................. 60

10 Console Orientation....................................................................................................................... 61

11 Use of Sit/Stand Consoles to Reduce Operator Fatigue ............................................................... 62

12 Security Monitors Mounted Above & Behind the Control Room Operators Position .................... 63

13 Avoid Head Knockers Adjacent to Analyzer Building Work Area .................................................. 64

14 Locks on an Instrument Cabinet are Difficult to Reach by a Short Technician.............................. 65

15 Gas Bottle Access is Obstructed by Bottle Arrangement .............................................................. 66



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HUMAN FACTORS IN NEW FACILITY DESIGN TOOL

1

Purpose

This document describes a Human Factors Tool (or Tool, as it will be describedthroughout the rest of this document) that may be used by operating plants as an aid toincorporate human factors principles in the design of equipment that will be operated andmaintained by people.

Scope

This document focuses only on equipment design. Items such as human error, behavior-based safety, and operating procedure issues are not in the scope.

The Tool covers equipment that is common to both upstream producing and downstreammanufacturing operations. Equipment associated with specific activities, such as drillingrigs is not specifically addressed. The human factors principles described in thisdocument are intended for new equipment designs; however, many ideas provided in thisTool may be used to improve the operation of existing plants, where feasible.

Applicability

This Tool is applicable to equipment that is operated and maintained by people working inmanufacturing plants. It is for use whenever one is trying to assess hazards associatedwith the equipment design process.

The human factors principles described here are intended to complement properequipment designs, effective operating procedures and appropriate plant managementsystems to help eliminate unwanted incidents. This Tool is not a complete designstandard for applying human factors in plant equipment designs. Companies areexpected to use this Tool as a starting point in developing their own specific humanfactors design standards.

Structure of Tool

The Tool consists of three columns: Human Factor Issue, Example Situation, andPotential Solution. The topics addressed in each column are intended to be arepresentative sample of key issues and are by no means all-inclusive.

The Human Factors Issue column addresses key human factors issues, orproblems, related to various types of equipment.

The Example Situation column provides examples of situations where thehuman factors issue in the first column may manifest itself. The purpose of thiscolumn is only to provide clarification of the specific human factors issuedescribed in the first column and to aid the user in understanding that issue.

The Potential Solution column provides ideas for actions that may be taken toaddress the human factors issue mentioned in the first column. Operating plants

are encouraged to identify their own best solution(s) for their individual situations.

How to Use the Tool

The way this Tool will be applied in operating plants will depend on the specific projectmanagement systems used by each company. The expectation is that operating plantswill use the Tool as the basis for creating their own human factors design standards forplant equipment and/or for incorporating the Tool contents into their existing designstandards. Operating plants are encouraged to enhance their specific standards with



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additional site-specific and/or different human factors issues and/or potential solutionsthat are not presently included in the Tool.

The Tool is best applied during the early design phases of projects where early hazardidentification and risk assessments are utilized in the overall risk management support ofthe project. Depending on a specific company's project management system, this couldinclude the planning phase, the equipment design phase, and possibly through the

construction and startup phases, since safety personnel are always trying to identifypotential hazards during all stages of a project. Different parts of the Tool will be moreapplicable during one phase than another. Companies are encouraged to apply thedifferent parts of the Tool to their specific project management systems. Following aresome examples of how the Tool may be applied during the various phases of a project:

1. Planning / Design Considerations / Front End Loading Phase:

In the initial phases of a project the human factors design standards and requirementsfor equipment are agreed upon and a plan is prepared on how the human factorsconsiderations will be incorporated into the project equipment designs. During thisphase the Tool may be used to help determine spacing requirements, especiallyaround the larger equipment.

For example, paragraph 14B (p. 40) of the Tool points out that for reactors containingtoxic catalyst enough space should be provided to allow for proper catalyst removal.Similar spacing/accessing requirements are provided throughout the Tool as inparagraph 13E (p. 39) for machinery and 18E (p. 47) for exchanger valves. All theseconsiderations need to be made in the early phases of the project to ensure thatadequate plot plan spacing is provided.

2. Detailed Design Phase:

Application of human factors principles is most prevalent during the detailed designphase of projects, usually during preliminary hazard identification and riskassessment studies.

Essentially all equipment addressed in the Tool has at least one paragraph withrequirements that need to be specified during the detailed design phase of theproject. For example, Tool paragraph 9A (p. 31) may be used to appropriately locatethe furnace pilot fuel valve and the igniter. Similarly, paragraph 17A (p. 44) addressesthe human needs for accessing tank instrumentation. Paragraphs 1A (p. 5) on alarmmanagement and 4A (p. 19) on emergency egress from substations are two moreexamples of how the Tool may be used to apply human factors in plant designs.

During the model review phase of the project the design specifications made duringthe detailed design phase can be confirmed and/or altered/corrected.

Technological advances are making it increasingly possible and financially acceptableto use 3-Dimensional (3-D) computer models in projects of all sizes. 3-D visualization

of plant layouts during model reviews is making it easier to apply human factorsprinciples during plant designs, particularly in the area of equipment access for bothoperations and maintenance. 3-D models may be used to confirm or correct thedesigns specified during the detailed design phase and may also be used to applymany of the human factors potential solutions provided in the Tool.

For example, a 3-D model review may be the most appropriate way to determinewhether a fire monitor has a clear line of sight to a fire-prone piece of equipment, asdescribed in the Tool paragraph 5A (p. 23). Similarly, paragraph 9E (p. 31) may bemore appropriately applied during the model review phase to identify access tospecific equipment for both operations and maintenance personnel. Other examples



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where the Tool may be best applied during model reviews is paragraph 15A (p. 41),where access to safety showers is discussed; paragraph 4H (p. 20), where access toelectrical equipment is mentioned; and paragraph 16F (p. 43), where the extensionbars to ladder safety gauges on elevated platforms are discussed.

3. Construction/Startup Phase:

The Tool may also be utilized during the construction and/or startup phases ofprojects. At this stage, most of the human factors principles covered in the planningand design phases will be confirmed and evaluated against the completed designparameters, detailed equipment locations, and general operating/maintenanceenvironment.

For example, as described in paragraph 5F (p. 24), on field alarms, the actual noiselevel surrounding a certain piece of equipment or unit during startup may make itnecessary to increase the alarm sound level to ensure that personnel working nearbycan hear it and evacuate the unit in an emergency. Similarly, paragraph 7C (p. 28)that addresses glare on field control panels and consoles may be applicable duringthe final project phases. Other examples include the application of Tool paragraph10F (p. 33) on proper labeling of pipes and paragraph, and 4M (p. 22) on labeling and

signage of electrical controls and displays. Other examples may be found in the ToolSection 11 (p. 34), on labeling / signage of process equipment, and in Section 20 (p.49), on work environment.

Economic Discussion

A key component for the successful application of human factors principles in plantequipment designs depends on support and understanding from management on theneed for, and benefits of, human factors application in plant equipment designs. The earlyapplication of human factors principles during a project design actually costs less than ifhuman factors principles are not applied at all, or are applied after the equipment hasbeen constructed and started-up.

One API member company recently estimated that the net cost of applying human factorsto the design of an entire chemical plant unit was only 0.025 percent of the total projectcost. This is considerably less than the project savings resulting from the absence ofconstruction rework that is often necessary in many projects. In the particular chemicalplant unit studied, most of the human factors principles were applied without any cost atall by arranging the equipment correctly as it was being built.

Another API member company performed a study in the mid-1990s and found thataround 6-6.5 percent of the construction cost was saved in eliminating rework. Thisparticular company implemented a process in the design phase to address human factorsissues and then followed-up by working with the contractors for training, auditing, etc.

In cases where human factors principles are applied to an existing plant there is a cost

associated with the retrofit. If human factors principles are applied early in a project,however, then the overall project cost is actually reduced because everything is donecorrectly the first time and there is no need for any rework.

In addition to reduced project cost, application of human factors can result in moreefficient operations and reduced accidents. Understanding these cost/benefit issues iskey to successful implementation of this Tool and application of human factors principlesin general.



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Human Factors Issue Example Situation Comment /

1. Alarm Management

1A.Alarm limits do not provideearly warning to the operatorto enable a response before

unit failure or shutdown.

1. A high-high alarm on a storage tanktripped the pump supplying product tothe tank and sent the product to flare.

a. Design alarm system t(1) Detect the process(2) Clearly indicate the

operator

(3) Guide the operator(4)Allow sufficient tim

problem

1B. High priority alarms areganged or grouped.

1. The operator assumed that the groupalarm was referring to a problem fin fan,when in fact it was telling him that theuninterrupted power supply for thecontrol system computer hadmalfunctioned. Several hours later, thecontrol system failed and fires started.

a. Do NOT design the ala(1)Annoys the operato(2) Repetitively tells th(3) Confuses the opera(4) Distracts the opera(5) Misdirects the oper

1C. There is no formal process todefine alarms and to maintainalarm design andconfiguration.

1. Definitions varied for the same alarmson different Distributed Control Systems(DCS) in the same plant.

a. Develop formal alarm pestablish:

(1) Common definition(2) Common design m

establish alarm prio

(3) Design requiremen

1D. There are many Priority 1(High) alarms.

1. 30% of the unit alarms were classifiedas Priority 1 high alarms. As a result,the operator spent much of his timehandling and clearing alarms.

a. Define the two major fa(1) Consequence of fa

and

(2)Amount of time thaproblem

b. Rule of thumb:(1) Priority 1 (high) ala

the total number of(2) Priority 2 (Medium)

70 80%, and(3) Priority 3 (Low) sho

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1J. Alarms in computer cannot belisted according to priority.

1. The operator coming on shift did notsee that a priority alarm had not clearedbecause the alarms were sorted by timeof occurrence rather than priority.

a. Design the system so alarms by priority, time

b. One keystroke sorting examine Priority 1 (Higidentify the other alarmdiagnosis and resolutio

1K. Inadequate informationprovided on alarms.

1. Alarm message did not contain thecontrol valve number, so, the operatorsent the outside technician to the wronglocation.

a. Design alarm messageinformation for the opebe consistent across th

b. The alarm message shthat the operator needswhen it happened, wheapproach to solve the

1L. High-priority alarms are notvisible in a panel on the bottom

or side of every DCS display.

1. During an upset, the operator had toreplace the alarm screen with a plantscreen. As a result, he did not haveinformation on a high priority alarm anddid not know that it had cleared.

a. Design a unique auditoalarms and ensure thavisible to the operator.

1M. There is no clear indicationthat a certain alarm clears.

1. The operator was not advised that analarm had cleared and was still workingon a solution.

a. Design alarm system tcondition that initiated

b. Design alarm systems operator when alarms

1N. A suppression system for low-priority alarms does not exist.

1. During an upset, the operator receivedmany alarms that masked the realprocess condition and delayedresponse to it.

a. Use alarm suppressionupset conditions. Opersuppress critical (high-

b. Logic in the alarm manalarms such as low preequipment has shut do


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1O. Low priority alarms cannot betemporarily disabled when asignificantly large activity ofalarms is taking place.

1. An operator temporarily disabled alower priority alarm to concentrate onhigher priority alarms. The operatorforgot to manually reset the auditorydisplay following the disabling of a lowerpriority alarm. Thus, the operator wasnot reminded again later.

a. Allow for temporary dislow priority alarms for asignificant rate of alarm

b. It is important that any dspecifications be tempocontinually reminded of expected to remember tthe operating systems.

1P. Initial alarms are not capturedwhen a series of alarms arereceived and acknowledged.

1. Owing to an alarm flood, the operatorwas unable to recall what the first alarmwas that he received.

a. Capture first-in alarms examination.

b. When operators are dialarm flood, they are uterm memory. Capturinalarms will help the op

1Q. The Piping & Instrumentation

Diagrams (P&IDs)do notshow alarm information.

1. The Hazard & Operability (HAZOP)review process is not equipped with atechnique that would permit alarminformation to be captured during thereview of the process andinstrumentation drawings (P&IDs).

a. Integrate the alarm spe

process.b. Alarm screening quest

information as the P&Iwont be forgotten whe


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3. Control House Ergonomics

3A. The control room is not largeenough to support the people,

equipment and tasks.

1. There is no space for the peopleattending the morning meetings. As a

result, people lean or sit on the consolecreating the potential for control errors.

2. The printer, the FAX andcommunication equipment took up allavailable workstation space provided forthe operator.

3. Addition of new PC equipment crowdsoperator workspace and no floor spaceis available to add additionalworkstations.

a. Conduct a conceptual task and functional ana

following:(1) Number of console(2) Number of personn

both normal and ab

(3) Number, type and installed based on

(4) Storage needs(5) Work surface need

operations

(6) Traffic patterns as (7)Adjacent areas

b. Estimate the type, amowill be installed in the c

c. Prior to laying out the eaccess points of each determined.

d. Provide sufficient worknotebook use, and PC

e. The rule-of-thumb in anot out. PCs, printers, mounted on shelves abthus leaving the work s

3B. Control room illumination isinadequate. 1.

Control room operators complain aboutthe lack of illumination on the worksurfaces at the ends of the consoles.

a.Often the overhead lightsproduced on the screensillumination for paper andinstalled for the areas thamay be ceiling mounted

b. Indirect lighting would the level of ambient illuand pencil tasks do no


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3C. Glare from the control roomlighting is excessive.

1. The location of the ceiling luminaires isa glare source on the DCS displays(Figure 7).

2. An image of the ceiling-mountedluminaire was reflected in the DCSmonitor causing distraction andmasking the information on the screen.

a. Avoid precisely locatinin the ceiling until afterfinalized and sitting po

b. The incorrect location oin the project if a Reflereviewed prior to locatinceiling plan locates the same plan view.

c. Install uniform and diffuand flicker. As a generachieve the following r

(1) Illumination levels sLux at the console

(2)A color rendering in(3) Indirect (up-) lightin(4) High-frequency, ele

(5) Ceiling-mounted poreading tasks are p

d. Up- or indirect lightingto reduce screen reflecindirect light source is

e. Parabolic lenses work the effective cut-off ran

f. DCS screens should band not be angled upw

3D. Visual access to the majorcontrol room displays are

inadequate.

1. Operators vision of a wall display thattracked the critical condition of a unit

was blocked by the top of the console(Figure 9).

a. Consider visual clearaneed to see each othe

side of the console.b. All wall-mounted or pa

located so the shortestthem over the console

c. The console height shoheight of the 5thpercen


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3E. The console operators areunable to relocate or re-orientequipment to reduce visualproblems.

1. The operator is unable to eliminate thereflection of an overhead glare sourceon the DCS monitor.

a. Design consoles so ascomputer monitor and

b. The operator could redc. Rotating the monitor d

d. Inserting a glare shield(recommended as a lae. Inserting a glare screef. Turning off the single gg. Changing the source to

3F. The control room equipment isnot laid out to support thevisual access of the operator.

1. Operator vision to a set of instrumentswas blocked by a large pack of cablesfrom the ceiling plenum to the console.

a. Avoid placing obstructin such a way that theycommunications.

b. Raised floors should bcontrol console from th

3G. The control room feels darkand lifeless.

1. Much of the equipment is in shadow. a. The amount of light thanot only on how much whether it is reflected oon. If the high walls anreflective colors (e.g. winto the room.

3H. Noise is excessive in thecontrol room space.

1. In a multi-console control space, thenoise from the radios in one consoledisturbs those in an adjacent console.

2. Operators in a round control roomcomplain about the level of noise from

other areas of the control room.3. Noise from the radio speakers in the

adjacent control console interferes withcommunication and annoys theoperators.

a. Identify potential sourcexternally and reduce tdbA or less.

b. Noise in the room can (1) Installing noise abs

(2) High plenums (spa(3) Reducing ceiling fix(4) Installing noise abs

45 cm (18 in.) and

(5) Orienting consoles10).

(6) Using directional m


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3O. The equipment is notdesigned to accommodate thewide range of operator bodysizes that work in the controlroom.

1. Small operators had difficulty reachingthe touch screen display.

2. Operator was unable to access shelf-mounted materials when theworkstation was in the standing mode.

a. Design consoles to meextremes of the user pgiven in Reference 28.

b. Consider the use of sitonset of fatigue and bo

c. Reach envelopes are preference books (Refedesigned for the NorthThe extremes of the usin every design.

d. All of the materials thastorage and shelving) sworkstation when it is d

3P. Control room seating is

inadequate.

1. Seating in the control space was old

and shabby and the height adjusters onmany of the chairs were broken.

a. Provide good quality se

user population.b. The control room opera

are used excessively. Twide range of body sizeoperator. Chairs shouldof Institutional Furniture

3Q. Control room storage space isinadequate.

1. Storage space is overcrowded anditems hard to find.

2. Critical operating procedures are notclose by when needed during anemergency.

a. Provide sufficient shelfoperations and maintethose documents requavailable.

b. Required documents shshelf and storage spaceassigned elsewhere.

c. Storage space for criticthe control room layou


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3R. Equipment layout does notallow easy access formaintenance.

1. Insufficient clearance is provided behindthe equipment console to swing openthe panel covers and pull out theequipment racks.

a. Design and locate equof maintenance and clewith process operation

b. The equipment accessBoth must be considerretrofit and the specific

3S. The control room is difficult tokeep clean.

1. Oil tracked in from the plant haspermanently stained chair coveringsand countertops.

a. Use building and constcleaning.

b. Building materials that include:

(1) Coverings for tiles (2) Seat coverings(3) Console and writin

3T. Operator support areas are

not located close enough tothe control space.

1. An operator who was in the toilet

missed the onset of a critical alarm.

2. Lack of outside access to permitcounter requires contractors to walk intothe control space and disturb theconsole activities.

a. Locate operator suppo

rest areas as close as b. Operators should notifyc. Equipment should be d

incoming alarms in aresuch as toilets and lun

a. Locate permit counterscontrol room.

b. Access to permit countepublic entrance. At no console area. In additioprovided with seating fo

and telephone should b

3U. Control room windows are notproperly located or designed.

1. Operators complained of the glare frombright sunlight in the afternoon througha window.

a. Avoid installing outsideoperator must monitor

b. Windows should be inspossible, each windowtreatments such as ver


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3V. The control room does notcontain sufficient equipmentfor the tasks that areconducted.

1. The applications engineer must testnew versions of software online with thecontrol system operating. To do so, hehas to displace the control roomoperator from his console.

a. Provide additional DCSmaintenance staff. If thconsole, testing could control room operator.

3W. Operators are continuallybeing distracted by unwantedand unnecessary demands.

1. Operators are frequently disturbed fromtheir duties by managers who wantthem to display the operationsperformance overview screen.

a. Provide overview displ(1) Supervisors remote(2) Operators when se

information

b. The overview display cthe input from one of thscreens keypad).

c. Consider also the use plasma displays.

3X. The location of major visualdisplays are inadequate. 1. The control room operator isresponsible for monitoring anunmanned loading rack with a closed-circuit television monitor. He did notobserve a truck driver at a loading rackwho was not wearing correct PPE. Themonitor was mounted above and behindthe operator making it difficult to monitorthe rack. (Figure 12).

a. When operators are sedisplays:(1) Within a visual ang

forward line of site

(2)At a reading distan

3Y. The location and orientation ofcontrols and displays are

inadequate.

1. Owing to the width of the keypad andthe depth of the counter, a short

operator has to stand to reach the touchscreen display.

a. Locate critical controlswithin the functional ar

operator.b. All equipment should b

limitations of the extrem


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4M. Labeling and signage ofelectrical controls anddisplays is inadequate.

1. Switch was inadvertently closed by acontractor who thought the green lighton the panel meant that the equipmentwas operating.

a. Label and sign all contfunctions are understo

b. Confusion between procan lead to catastrophand displays in substatcolor, labels and signs

4N. Substation is inadequatelyidentified from the outside.

1. Contract maintenance worker enters thebuilding by accident.

a. Attach DANGER Hiall exterior doors.

b. Signs serve several puexperienced personnepersonnel and a WARN

4O. Lighting inside substation isinadequate.

1. The specified level of ambientillumination was provided by fluorescentdownlighting from the ceiling. Theshadow thrown inside the switchingcabinet made it difficult for the operatorto make out the individual terminals andincreased the risk of error.

a. Ensure that levels of aguidelines and that addprovided for those areaoperations are conduc

b. Ceiling-mounted ambieprovide enough light tomaintenance and operto detailed design to enrequirements are ident


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5. Emergency Equipment

5A. Operator of the "fire monitor"does not have a clear line of

sight to the target.

1. Potential fire area is blocked by astructure.

a. Raise monitor using a b. Develop a portable sys

areas.

5B. Operators access to firemonitor or hydrant isobstructed.

1. Operator is unable to access hydrant ormonitor.

a. Ensure alternate methomonitors based on fire

5C. Operator is unable to initiatedeluge as he or she is leavingthe area.

1. Local deluge activation box is notlocated in an escape route.

a. Ensure that emergencythe deluge activation bclearly labeled so oper

b. Ensure box is well signsearch for it.

c. Consider duplicate or s

inaccessible or multipled. Ensure that the operat

system is operating.

e. Ensure that the operatto the emergency cont

f. Consider "automatic" a

5D. Operator is unable to initiatedeluge from the battery limitstation (BLS).

1. Main deluge panels are not located atunit periphery (B/L).

a. Ensure that the delugeby the BLS is at that st

b. Ensure that the operatsystem is operating.

c. Ensure that the operatto the emergency cont

d. Consider "automatic" a


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5E. Operator in the unit/field doesnot see/hear flashinglights/alarms on automatedemergency systems duringemergency response.

1. Personnel unaware of toxic gas releasein area.

2. Person inside an enclosed, loudcompressor area and is unable to hearthe alarm.

a. Ensure indication is visof concern.

b. Include initial PPE andresponse plan.

c. Ensure that a visual alaproper location in all wmay be masked by noi

d. Ensure that highly impspecial identification (efuel isolation).

5F. Voice communicationsystems are chosen forreliable operations for thesettings in which they will beused.

1. System failure. a. Ensure that there are bcommunication system

5G. Personnel evacuation isrequired.

1. Numerous decisions are required.a. Ensure that procedure

actions with no more th

b. Use commonly known effectively describe a s

c. Ensure windsocks are

5H. Adequate and suitable spaceis provided for emergencyequipment and suppliesprovided so that they arereadily accessible.

1. Lack of maneuverability and criticalresources.

a. Provide for permanentand supplies.

b. Consider sufficient, paand staging areas.


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6. Field Analyzer Buildings

6A. Layout of the equipment inanalyzer buildings is

inadequate.

1. A large technician is unable to access atransmitter mounted behind a field gas

chromatograph.

a. Provide adequate spacin field analyzer buildin

access.b. Minimum access dimeaccommodate the 95th

dimensions should notthose operators that arthan the 95thpercentile

6B.Access and clearance aroundanalyzer buildings isinadequate.

1. A technician bumped his head on adrain valve located on a line that wasinstalled after the building wascompleted.

a. Provide adequate headequipment (Figure 13)

b. Clearance specificationbe reviewed during the

6C. Test points and otherinterfaces have not beenstandardized.

1. A new test probe recently purchased bythe plant is unable to access a test pointon a field instrument.

a. Ensure that test pointshave sufficient clearan

b. Test and evaluation eqdesign of the plant remneeds to be answered whether the new equipIf not, other manufacturetrofit of the existing pcost of the equipment.

6D.Access to equipment isinadequate.

1. A wall-mounted instrument cabinetcannot be unlocked and opened by a 5th

percentile operator (Figure 14).

a. Locate controls,latcheoperated and read by t

b. Before cabinets are momust consider the meacabinet latches are locoperator cannot reach


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Human Factors Issue Example Situation Comment /2. A storage tank that is mounted next to

the building, but below the test pointblocks access to an instrument testpoint.

a. Do not block maintenaequipment with other eexternally around the b

b. When designing for acbe considered as a pot

above it. The designerapproach to the test poand whether a 5thperc

6E. Connections to different testsources have not beenuniquely designed oradequately coded.

1. When routing the input line from asample stream to a gas chromatograph,the line was connected to the wronggas chromatograph.

a. Test the design and layclarity and understand

b. The interconnections smimic design that presprocess connections herror better than other

6F. The design of the regulators

and manifolds for gas bottlesis inadequate.

1. A technician blocked the regulator line

in preparation for the removal andrepair of the regulator. When the blockvalve was closed, gas was shut off tothe instruments and the process wentinto alarm.

2. In order to change a gas bottle, thetechnician has to remove three othersfrom in front of it, and then reinstallthem with the new bottle(Figure 15).

a. Design gas bottle regu

(1) Provide unobstruct(2) Ensure that the fail

of bottles does not

b. In a multiple regulator able to be bypassed andisabling the system.

c. Gas bottles are heavy immediately accessibleshould also be locatedto the exchange area (not require the technicthresholds.


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7. Field Display Panels

7A. Use of the panel requires aprocedure with more than

seven steps.

1. Compressor startup from a local controlpanel that requires more than seven

steps.

a. Ensure panel is designsame sequence as the

to right, top to bottom.b. Ensure that proceduresequential, logical, and

c. Provide checklists locaequipment) to remind t

d. Use consistent color-coused to prevent confusOn/Open).

7B. Consistent design and layoutprovided for multiple panelsthat operate similar

equipment on the unit.

1. Emergency Block Valve (EBV) panelson the same unit are not designed thesame way.

a. Ensure panels are conb. Ensure local equipmen

visual access from the

the necessary informatc. Ensure adequate lighti

maintenance access.

d. Use the same color-coequipment control panrooms.

e. Use ergonomic designthe likelihood of muscube at least 42 in. (1070allow operator adequa

f. Group together Contronecessary to support a

activities.g. Locate controls and dis

panels and auxiliary pa1.Avoid "mirror image

h. Locate Safety critical cthose used normally fo


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Human Factors Issue Example Situation Comment /i. Separate controls at le

accidental activation4:a. Push buttons by 1 b. Toggle switches byc. Controls operated wi

j. Space adjacent keyboaspaced at least 30 in. (

7C. Panels are used under all lightconditions [lighting sufficientand glare eliminated].

1. Boiler start up panel is not well lit.2. Panel instruments are unreadable due

to the glare from direct sunlight.

a. Ensure illumination of of reflected glare whenfollowing range of view(1) Between the 5th pe

56.3 in, 1430 mm fpopulation) and the(e.g. 5 ft-10 in., 177population) elevatio

(2) Between 1 and 4 ftdistance from pane

b. Ensure panel controls

7D. Panels are used underemergency conditions [clarityof layout sufficient].

1. ESD panel. a. Design panel so the opquickly. Example forma(1) Geographical (mim(2) Functional (mimic)

out in a process flob. Indicate safe state sec. Use of consistent color

be used to prevent conGreen = On/Open)

7E. Panels are used during normal

surveillance [located insurveillance path].

1. Furnace panels.

2. Pump operation panels.

a. Locate:

(1) Displays and local the surveillance paother equipment.

(2)Align displays durinthe surveillance pa

4From MIL STD 1472 "Human Engineering Requirements for Military Systems, equipment and practices" Amendment 2 published in


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8. Filters

8A. Filter must be frequentlycleaned, cleared, drained,

switched.

1. Operator is unable to easily access filterfor cleaning.

a. Ensure that filter accesb. Ensure that platform is

components to be staginstallation.

8B. Product being filtered ishazardous and/or operatormust wear PersonnelProtective Equipment (PPE).

1. Operators vision is blocked by the PPE.2. Operator is unable to manipulate filter

elements, tools or hardware in PPE.

a. Design the job of servidoes not interfere with

b. Conduct Task Analysisthat the operator can wfilters, cleaning and fluaccessible from gradeand lifting devices to famedia, using rodding ofor flushing. Utility stati

single hose length of thequipment and piping

c. Mockup the filter and cdetailed design.

d. Ensure that the specificoncerns above if filter

e. Application of inherenrather than dismantle/c

8C. Weight of filter or filterelement cover exceeds 51 lb(23 kg). (see Note 1 under

Blinds)

1. Operator services only the filter andshould not be manually handling theequipment.

2. Insufficient clearance has beenprovided for lifting equipment.

a. Conduct Task Analysisrequire handling by the

b. Use available biomech

the maximum lift for thc. Weigh components and. Ensure that lifting equi

components that are idoperator.

e. List potential hazards (


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8D. [Height of top of filter abovegrade or floor of platform] +[length of filter element]exceeds shoulder height ofthe 5th percentile of thefemale user population (e.g.,48.8 in. or 1240 mm for theNorth American femalepopulation).

1. Operator is unable to remove filterelement from the filter.

a. Ensure filter dimensionpopulation.

b. Consider lifting equipm

8E. Filter internal pressure to beverified locally at filter.

1. Operator or maintenance person notable to verify that pressure is off of filterhousing before opening to atmosphere.

a. Install local gauge androdded.

b. Install local interlock watmospheric vent.


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9. Furnaces and Fired Heaters

9A. Furnace is manually lightedoff.

1. Gas pilot valve, flame window andigniter are located too far apart for

operator to operate together.2. Access to valve, igniter and flamewindow is poor.

a. Locate valve and ignitewindow.

b. Locate the pilot gas vaallow the operator lightthrough an observation

9B. Furnace is automaticallylighted off from a remotelocation and no local panel isprovided.

1. No indication of valve position andburner operation is provided to theoperator.

a. Install display to show operation.

9C. Interior of the firebox requiresfrequent visual monitoring.

1. Firebox view window is located abovegrade and is not utilized by operator.

a. Improve flame detectiob. Review surveillance pa

firebox window.

c. Ease access to above ladders).

9D. Furnace must be frequentlydecoked, switched, visited.

1. Decoking valves are large multi-turnand located very close to the furnace.

a. Conduct energy expenfind areas producing e

b. Install MOVs,orc. Modify valve actuator f

turn valve.

d. Rotate valve-turning taone operator is not exc

e. Take into consideration

characteristics of the p

9E.Access to other supportingequipment required while unitis online.

1. Safe access and egress required formaintenance personnel (e.g., accessplatforms, furnace draft fans and sootblowers, furnace stack samplingsystems and analyzers, etc.).

a. Include heat barrier / inb. Ensure that equipment

areas.


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9F. Sufficient fired heater testingports required to allow forverification that heater box ispurged.

1. Heater box is purged to render it safe tolight. Access to the testing ports is notadequate.

a. Ensure presence of reqcombustion chamber epoints for large heaters

9G. Furnace refractory ispotentially toxic (arsenic) andmust be handled by personnelin PPE.

1. Limited room for storage and handling.2. Atmosphere may be contaminated.

a. Design enough room inrefractory in preparatiodepending on the task

b. Provide lifting equipmegrade.

c. Install air ventilation and. Ensure the design and

compatible.


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11. Labeling / Signage of Process Equipment

11A. Equipment is not labeled asto its function.

1. New lines are installed but are notlabeled.

a. Identify the equipmentthe facility that require

b. A revision must be madprocess to ensure thatthat require attention ware installed in the plan

11B. Equipment is labeled withunfamiliar signs.

1. Warning signs are designed in the USAto US standards, but are being used ina plant in Singapore that is regulated bya different signage standard withdifferent formats for Warning andCaution signage.

a. Ensure that the labelsrequirements.

b. Project process must iregulations in the jurisdoperated to ensure thaaccount in the design o

c. Symbology used in onthose in another culturthat the workers in the used on labels and sig

11C. Labels and signs in the fieldare not consistent with thosein the P&IDs.

1. Label on level controller readsdifferently from the designation on theP&ID.

2. Sign references procedure "xyz" andwas not changed when procedure wasrenamed.

a. Ensure that informationconsistent with the infoand P&IDs.

b. Work by different groulabeling, writing procedbe coordinated.

c. One person or group mresponsibility to ensureare designed consisten

11D. Labels fade or becomeeasily damaged.

1. Plastic labels are in service on a unitthat routinely emits hydrocarbon vapors.The labels deteriorate quickly in theenvironment.

a. Ensure that the labelmare compatible with thein which they are used

b. Process engineers neeensure that they can wenvironment in which t


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11E. It is not clear which piece ofequipment is described by acertain label.

1. Labels for overhead valves are placedon the wall and not on the valves.

a. Place and orient labelsb. Develop a checklist for

a walkthrough of the fasigns meet the design

11F. Labels are not replaced /corrected when oldequipment is reused in adifferent service.

1. A label on a replacement control valvewas not replaced with one that matchesthe P&ID for the service that the valve isin.

2. Label is missing a tag number that canbe referenced back to the P&ID.

a. Ensure that a process damaged labels and torequired.

b. Pre start-up checklist sthat ensure the labelsinformation as the proc

11G. Labels for all services andequipment have the sameformat and style.

1. Sign is designed as a procedure butdoes not meet the formattingrequirements of a procedure (pointform, active verbs, left justified).

a. Develop formatting stabased on the most up-processing.

b. A formatting standard wthe label refers to the P

c. Signs used as proceduguides that are used foguides must be insertelabels and signs.

11H. Labels on older equipmentare not replaced when theyget damaged, becomeunreadable, fall off, etc.

1. Labels purchased from an outsidevendor needed to be replaced, but thevendor is out of business.

a. Develop a means of adpurchased from outsid

b. Ask original vendors, alabel specification guidnecessary for the plantspecification that anoth


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12. Loading/ Unloading Facilities

12A. The product being loaded /unloaded is in a hazard class

where defined exposurecriteria must be observed.

1. Operator is in PPE and cannot operatethe controls,valves or see the displays

properly.

a. Conduct a Task Analysthe operator might mak

b. Mockup the operation c. Correct any deficiencie(observation) study be

12B. Weight of facilities(arm/hose/platforms etc.) tobe manipulated manuallyexceeds 51 lb (23 kg) (seeNote 1, under Blinds).

1. Operator weight manipulation limitsexceeded.

a. Conduct a Task Analysequipment that the opeexceeds the lifting limit

b. Determine the maximuequipment, given operbiomechanical tools.

c. Compare what is and wtask or provide lifting a

12C. Top-loading/unloading isrequired.

1. Operator is unable to see product levelin the tank.

2. Fumes escaping from the tankovercome operator.

a. Provide proper lightingb. Provide the operator wc. Ensure that the operat

stop and start product ensure that an emergetop of the vehicle.

a. Conduct operation remb. Provide operator with a

ensure that he/she canPPE.

c. Ensure direct, unobstrushower and eyewash swhich requires not mortravel distance of not msource(s) of exposure contaminant.


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Human Factors Issue Example Situation Comment /3. Operator is unable to properly line up

the vehicle with the loading facilities.

4. Operator is at risk of falling from thevehicle.

a. Ensure communicationvehicle operator is optisignals).

b. Ensure that system depracticability and usab

minimized).c. Mark the correct locati

a. Provide proper guardinb. Provide proper staging

12D. Loading/unloading requirescontinuous operatorattendance.

1. Unit operator needed elsewhere in theunit but is tied up unloading.

2. Safety and security monitoring systemis less than adequate.

a. Consider whether spacincluded in the unit des

b. Provide cross training loading/unloading activ

c. Consider each of the o

location of cameras an

12E. Loading / unloadingperformed with contractpersonnel.

1. Contractor vs. employee training /understanding of issues.

a. Design equipment withb. Post critical procedurec. Post facility rules.d. Ensure Labeling.

12F. Loading/unloading is a 24-hour activity.

1. Lighting is less than adequate for nightoperations.

a. Install portable task ligcan be positioned whe


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13. Pumps and Compressors

13A. Must be blown to a closedsystem before maintenance

and product/process ishazardous.

1. Pump is in hazardous service. a. Design equipment draimade to a closed blow

double valves.b. Ensure connection to clocated near equipmenwithout climbing over l

c. Ensure unobstructed aeyewash stations. Thean accessible location,seconds to reach, and 100 ft (30 m) from the be in an area that is fre

d. Ensure equipment is lo

13B. Local controls and displaysare associated with start-up,shutdown or surveillance.

1. Displays are not oriented to face theassociated controls, so operator cannotsee them during start-up.

2. Displays are not oriented for easymonitoring during operator rounds.

a. Ensure the layout of auand displays for paralleidentical in relation to t

b. Avoid mirror-image layc. Field-check installationd. Ensure local displays a

so operator can easily leaving his/her rounds recommended layout o


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13C. High noise levels areexpected.

1. Manufacturers data indicates that noiselevels in excess of 80 dBA5are to beexpected.

a. Consider remote operab. Mandate ear protectionc. Ensure noise mitigatio

are pursued.

d. Ensure equipment is henclosure.e. Install visible emergen

auditory displays will n

f. Conduct periodic noisnoise periods, e.g. starequipment is used.

13D. Auxiliary systems or packageunits are used.

1. Specialized design for which only alimited number of vendors makeequipment that meets performancespecifications (e.g., large diaphragm

pump).

a. Specify peripheral equthat can be modified fo

13E. Machinery needs to beremoved and carried away.

1. Removal of machinery to shop for repairis difficult. Lifting equipment is blockedby other facilities and equipment.

a. Ensure layout of machaccess to enable remoAlternatively, provide f

5dBA = Decibel. "A" is the filter that most represents the human ear. Reference Attwood, D.A. (1996) "The Office Relocation Source

75


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14. Reactors/Dryers

14A. Reactor must be entered forcleaning, repair, and catalyst

filling.

1. Manway is not located for conveniententry.

2. Introduction of air or water (humidity) isa dangerous reactant with catalyst.

a. Provide temporary intepermanent ladder to m

b. Ensure manways are laccommodate a healthenough to permit the eunconscious.

c. Ensure nitrogen (or eqcatalyst unloading and

d. Post caution signs for packed section, or stac

14B. Reactor catalyst is toxic,reactive, or pyrophoric andmust be handled by

personnel in PPE.


a. Ensure enough room staging catalyst in prepdepending on the task

b. Provide lifting equipmec. Install air ventilation and. Ensure design for oper

that is being used.

14C. Multiple reactors which mustbe switched frequently.

1. Confusion over status and potential forerror.

2. Switching operation is awkward andmay require operators to accessdifferent levels frequently and could betime consuming.

a. Ensure that the operatthrough the use of dispthe process (e.g., mim

b. Complete all reactor-rethe same general area


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15. Sample Points

15A. The product being sampledis in a hazard class where

defined exposure criteriamust be observed.

1. Caustic sample point.2. Sampling valve and sample outlet

are not located close together.

a. Ensure operator has ushowers and eyewash

should be in an accessmore than 10 secondsnot more than 100 ft (3and should be in an ar

15B. The sample point is locatedabove grade.

1. Hazardous sample must be carrieddown stairs or a ladder.

a. Ensure sample is acceb. Provide two means of

15C. The sample system is (isnot) using a closed purgesystem.

1. Sample bomb in closed purge system.2. Open system for caustic samples.

a. If closed purge, ensureallow operator to accesobstruction.

b. If not closed purge, theaccess to sampling sta

15D. Design of operator access tothe sample point has notconsidered the wearing ofPPE.

1. Hazardous sample without a closedpurge system.

a. Unobstructed access tis wearing PPE.

b. Ensure sample point ac. Consider modifying to

eliminate need for PPE

d. Minimize (or eliminate)


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16. Structural: Ladders, Stairs, Guards, Handrails

16A. Ladders are used to accessfrequently monitored

equipment.

1. Ladders are used to access a platformthat contains a field display panel that is

monitored during surveillance roundstwice per shift.2. A caged ladder is used to access a

battery limit valve platform.

a. Make ladders the defalevel to another. Use s

(1)As the primary met(2) Where personnel apieces of equipmenstructure

(3) Where equipment emergencies

(4) Where equipment (5) For access to critic

b. Critical tasks, includingidentified before detailedesigners will know the

c. Critical valves should b

engineering commenceaccess requirements.

16B. Structural components usedfor personnel access,likestairs and ladders, do notconform to the local facilitystandards.

1. The stairs and ladders were designedby an Italian Engineering firm toEuropean standards for use in aJapanese chemical plant.

a. Design stairs and laddlocal standards (e.g., O

b. The project execution equipment be designed

16C. Inadequate, or no platformsprovided for frequentlyaccessed equipment (e.g.,

filters, sample points).

1. Cartridge filters cannot be easilyremoved and replaced from the platformprovided.

a. Use platforms and walequipment when they c

Emergency block v

Sample points Vertical cartridge fi

Instrumentation anadjusted, serviced operations

Control valves

Service and inspec

Loading racks


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Human Factors Issue Example Situation Comment /b. Platform height should

height from the platformlength of the cartridge height of the 5thpercenplatform.

16D. Controls on a loadingplatform are too small forworkers wearing PPE anderrors are often made.

1. The access to the local display panelfailed to consider that personnel wouldbe in rubber suits, gloves and bootsbecause of the product beingtransferred. As a result the controlscould not be manipulated with thegloves worn and the gloves could notbe removed to set the controls.

a. Ensure that operationsprovided with the meanequipment when they apersonal protective eqthe proper tools.

b. If the task had been anpanel, the controls wouspaced further apart, swith rubber gloves.

16E. Stairs are not well designed

for the user population.

1. The stairs were designed according to

USA guidelines, but were installed in aplant in Singapore. Chinese andMalaysian workers, who make up 90%of the working population, find it tiring toclimb stairs that are spaced too farapart for their body characteristics.

a. Ensure that clearances

and the detailed designthe user population. Sedesign.

b. Provide handrails for a

16F. Ladders located near edge ofsmall elevated platforms donot have safety gaugeextensions to the platformhandrail.

1. Technician descending onto platformloses balance upon reaching theplatform and falls backward over theplatform handrail.

a. Provide extension barstop of the platform hanConsider all elevated pis greater than 20 ft (6centerline is within 2 ft

or 4 ft (1.2 m) from the


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17. Tanks

17A. Instruments, valves, gauging(stilling) wells, sampling

hatches, or other equipmentthat operators need accessto are located at the top offixed roof tank.

1. Manual gauging or sampling of tank. a. Provide circumferentiato the top of the tank.

b. Install guard railings alat least 15 ft (4.5 m) bec. Install a guard railing, 3

1200 mm) at the outsid(OSHA & ANSI have replatforms.)

17B. Floating roofs of tanks andother equipment located atthe top of the tank need tobe inspected.

1. Foam chambers.2. Various pieces of equipment on the

floating roof.

a. Provide a top platform stairway to the gauge w

b. Install guard railings onas walkways completefoam outlet stations ar

c. Provide slip resistant rfloating roofs to ensureof the stairs keeps chamovement.

d. Provide proper lightingtop of the tank.

17C. Above ground pipes locatedinside a tank dike hinderoperator's access to theentire dike area.

1. Foam laterals. a. Provide stairs and appover pipes.

17D. To save time, operator walksthrough the dike of the tankthat he/she just inspected inorder to get to the next tank.

1. Operator avoids walking back out to theroad and then around the entireperimeter of the first tank in order to getto the second tank.

a. Provide additional stairwhere operator exits thdike of the second wheinspection.


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18. Valves

18A. Valve is operated manually inan emergency, so the

operator must be able to getat it quickly and operate iteasily and without mistakes.

1. Battery Limit Valve.2. Pump suction.

3. Pump discharge.

a. Mount at grade or on ab. Orient so operator can

c. Mount larger valves to d. Ensure that location of

18B. Valve is operatedsequentially and its positionand operation must beconsidered in relation toother valves.

1. Manifold.2. Compressor startup.

a. Conduct Task Analysissequence of operation

b. Conduct Link Analysismovements affect loca

c. Ensure valve lies close

18C. The incorrect operation of thevalve will exceed safeoperating envelope and noapparent mitigation strategyhas been implemented intothe design.

1. Block Valve.

2. Switch valve on a coker.3. The valve manipulation is an integralpart of a task exceeding 7 steps6and/orrequires interaction with otheroperations.

a. Conduct Task Analysiscannot inadvertently op

b. Control valve position

18D. The valve is operatedremotely from a fieldlocation, so the design of thecontrol panel is important toconsider.

1. Large MOVs2. Small MOVs that control movement of

pyrophoric material (catalyst)

a. Ensure valve open/closlimit switch) is shown o

b. Ensure valve movemec. Ensure valve is shown

process flow.

6Based on generally acceptable industry research that has shown that humans should not be expected to memorize and accurately perf

See Sanders, M.S. and McCormick, E.J., 1993, Human Factors In Engineering and Design, Page 67, McGraw-Hill, Inc.


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18E. Several valves are located inclose proximity to each other

1. Around heat exchangers. a. Ensure minimum cleaadjacent valve handwhand 2 in. (50 mm) betwinsulation on the line in

b. Provide additional cleaof valve handwheels avalves. Valve wrencheplant.

c. Ensure valve handles aturn to restrict the acceof the valve.

18F. Large valve handwheels areoperated manually.

a. Ensure manual operatgear operators, levers,application of force excFigure 4,based on val

orientation.b. Operating valves that rthat require more than position, should be moof musculoskeletal and

18G. Drain valves must remainopen for long periods oftime.

1. Due to fatigue, the operator either tiesvalve open or walks away for a periodof time.

a. Install momentary cont


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19. Vessels (including Exchangers)

19A. Vessel must be entered forcleaning or maintenance.

1. Manway is not located for conveniententry.

a. Ensure manways are laccommodate a health

enough to permit the eunconscious.

b. EnsureAccess is sufficwearing encumbering equipment (e.g. SCBA

19B. Vessel contents arehazardous, reactive,pyrophoric, decomposingand require wearing of PPEand/or other precautions.


a. Ensure that enough ropermit staging vessel cor installation, dependi

b. Provide lifting equipmesupersacks if contents grade.

c. Install air ventilation and. Ensure design for oper

that is being worn.

19C. Exchanger bundles must beremoved for maintenance.

1. Limited space available for access tovalves, flanges, lines, etc.

a. Ensure layout of heat eclearance and access hoisting equipment. Altlifting facilities.

19D. Atmospheric vents forflammable and toxic vaporsare not routed to safe

locations, away frompersonnel and ignitionsources.

1. Vent at a location below or near aplatform where people are present.

a. Route vent to a safe lob. Route vent to a closed


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20. Work Environment: Lighting, Noise, Heating/Cooling

20A. Illumination levels aresufficient for walking through

the unit, but not for readinglabels and signs.

1. Operator turns the wrong valve becausehe cannot read the label at night.

a. Set levels of ambient ilperformed and the age

b. The levels of illuminatiorequired for the most dlighting should be emp

20B. Sunlight washes over thepanel creating glare on thedisplays making them difficultto read.

1. Operator misses the out-of-limitsreading because of glare on thedisplays.

a. Design lighting systemglare,maintain luminanoptimize the color of thsurfaces.

b. Field panels should fachemisphere) so bright

c. Field panels should besunlight.

20C. Inadequate emergencylighting.

1. During a blackout, employees found itdifficult to follow the escape route froma building.

a. Design emergency lighsafety, escape, and opfacilitate the restoration

b. Emergency lighting musafety.

c. In smoke-filled buildingemployees who are crathe smoke.

20D. Atmospheric conditionsinside buildings wherepeople work is notadequately regulated.

1. High temperatures combined with lowairflow caused control room staff to bedrowsy and less alert.

a. In occupied buildings, work, maintain:

(1)Temperatures betw

(2) The temperature ghead at 5 7F (3

(3) Relative humidity b(4)Air replacement at

person, with two-th

(5)Air velocity not to e(6)At least six comple


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Human Factors Issue Example Situation Comment /b. Temperature and airflo

extent that the numberincrease.

20E. No special protection

provided for workers in hot orcold environments.

1. Maintenance work on a skid unit is very

difficult in extreme cold conditions.

a. In outside areas, prote

extreme heat and coldb. Skids should be oriente

work is performed undsources of heat in cold

20F. Radio communication withthe control room is poor in afull body protection suit.

1. Outside operator cannot hear clearlythe control room instructions because ofhearing protection. Gloves make itdifficult to operate the portable radios.

a. Install specialized headb. Test communication sy

Index protocol.

c. Control noise levels so(1) Voice communicati

and over radios

(2) Background noise performance

(3) Speech privacy is m(4) Potential for hearin

20G. The sound pressure level ina compressor room is wellabove the safe exposurelevel for employees.

1. Employees cannot communicate clearlyand ears may hurt.

a. In areas where noise lethat personnel are notiprotective equipment.

b. Employees are fitted wexposure.

c. Each employee shouldsubsequent test to ass

20H. Heavy machinery andautomobile vibration levelsare excessive.

1. Whole body vibration levels in trucksare causing back pain complaints andabsenteeism among drivers.

a. Control vibration levels(1) Whole body vibrati

equipment is within

(2) Exposure of handspneumatic and impaccepted standard

(3) Whole body vibrati


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Human Factors Issue Example Situation Comment /injury is not distracperformance

b. Measure whole body vconditions and estimatminutes) for each drivi

c. Provide operators withlevels.

d. Reduce exposure to thlevels recommended bdone by re-scheduling among several drivers


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Figure 3Location of Valve Handwheels*

90

24

610

18

460

12

305

6

150

0 in.

0 mm

Acceptable

2nd

Choice

1st

Choice

8070

60

50

40

30

20

2nd

Choice

0

0

24

610

18

460

12

305

6

150

in.

mm

1st

Choice Acceptable

2nd

Choice

1st Choice

1st

Choice

2ndChoice

Acceptable

Small

Valves

Acceptable

Acceptab

but Prefer S

Valves O

2nd

Choice

2nd

Choice

Emergency

Operation

Normal

Operatio

mm

2135

1980

1830

1680

1520

1370

1220

1070

915

760

610

460

305

150

ft - in.

7 - 0

9

6

3

6 - 0

9

6

3

9

6

3

9

6

3

96

3

9

6

3

9

6

5 - 0

4 - 0

2 - 0

3 - 0

1 - 0

Notes:

(1) Valves operated more than four times per year should be located in the 1st Choice reach area

(2) Dimensions in this chart are for the male Caucasian population

* American Society For Testing And Materials (ASTM), Standard Practice For Human EngineeringDesign For Marine Systems, Equipment And Facilities, ASTM Designation: F-1166-95a, (reapproved2000); copyright American Society for Testing and Materials, 100 Barr Harbor Drive, WestConshohock, PA 19428-2959.



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Figure 4Force as Function of Valve Wheel Height & Stem Orienta


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Figure 5Stair Design

Maximum riser height (H):

+ USA: 24 cm (9.5 in)

[Asia: 20 cm (8 in)]

Tread depth (D):

+ 24 cm (9.5 in)-- min.+ 27 cm (10.5 in)-- prefer.

Tread overlap (O):

+ 3.8 cm (1.5 in) -- max.

D

O

Excessive overlap is

a tripping hazard

Example: ANSI A1264.1 - 1995 in the USA

Design stairs consistent with local population and sta


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Figure 6Extended Safety Cage Bars


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Figure 7DCS Monitor Glare from Control Room Lighting


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Figure 9Operators View of Wall Displays is Obstructed by DCS Co


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Figure 10Console Orientation


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