human factor

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ABADI MASELA FLNG FEED

Human Factors Awareness Hand-out

Abbott Risk Consulting Ltd H-000-1245-005

www.consultarc.com H-000-1245-005

Human Factors

Human Factors refer to job, organisational and human and individual characteristics, which influence behaviour at work in a way which can affect health and safety

Design around human capabilities and limitations Physical (size, shape, strength) Mental (knowledge, skills, attitudes, situation appreciation)

Maximise Human Performance Minimise Human Error Preserve Human Health & Safety


Human Factors why bother?

Humans are fallible but good design can reduce and sometimes eliminate human error.

Human error can be expensive It can cost $$$ in terms of production stoppages,

damage to equipment, environmental damage, injury/loss of life (litigation), and loss of company reputation & stock market value.


Plant, Process & People


Human Factors and the barrier model

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People - Size

Stature = 1874mm Breadth = 616mm

Stature = 1479mm Breadth = 369mm

Design access volumes for the 95th%ile Male Design reach distanced for the 5th%ile Female

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People - Strength & physiology

Design to minimise dependence on strength Max 66N* to crack small hand-wheel or operate lever Max 445N* to crack larger hand-wheel or operate lever Avoid need for portable torque extensions Max 147N of sustained force to continue operation once cracked Minimise number of rotations from open to close (max 100) * Only applicable if in the preferred or acceptable zones (lower max. if outside)

Consider location of equipment and access to it if manual handling is required. Maximum 23kg for 1 person lift & 45.5kg for 2 person lift

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People Cognition / Information Processing

Our brain is constantly making sense of the work around us as experienced by our senses

We interpret information we are presented with in our environment based on rules we have learnt, and our expectations

We act on our interpretation of this information - our mental model

Cognitive error is main source of human error

Slips Lapses Mistakes Violations


A simple frequently performed physical action goes wrong. You reach for button A (which is the raise control for a hoist) but push button B (the lower control) instead. On the control pad, Button B is below Button A. Your error lowers the object being moved onto electrical cables that carry a critical power supply to the plant. Another type of slip is reading the wrong instrument. Again, if gauges are too close to each other, there is a risk of reading the wrong one.

Example solutions better layout of controls (and

displays) functional grouping design of controls to make it difficult

to operate them accidentally; strict control so you never lift loads

above vulnerable equipment (or physical barriers above if you cant avoid this)

SLIP


A lapse of attention or memory. At Step 9 in your 25-step start-up procedure the phone rings and you answer. Afterwards you go back to the task, forgetting where you were in the sequence. You miss out steps 10 and 11 and go straight to step 12. However, steps 10 and 11 are important safety precautions.

Example solutions provide written procedures that have

place markers or spaces to tick off each step.

Supervise key tasks. Strictly enforce rules about

interrupting staff on critical tasks.

LAPSE


Not understanding properly how something works or an error of diagnosis or planning. Your plant starts to behave oddly - you notice fluid flowing in a waste pipe through a valve that you believed was closed. You try to work out why its doing this and how to get the plant back to normal. You dont have the right data or experience, therefore, your diagnosis and recovery plan are wrong. You think the valve has been opened in error so you close it. This diverts fluid via an overflow to a tank. The maintenance crew in the tank had actually opened the valve manually to drain hazardous waste to a treatment vessel while they work. It was their error that they did not tell you, but your solution sends the hazardous waste into their work area.

Example solutions increase the knowledge and

experience applied to such problems (by improving operator competence or by ensuring that operators discuss complex situations in a group and later share knowledge around the plant).

use special procedures (decision aids) that guide you to a safe solution.

MISTAKE


A deliberate breach of rules and procedures. you are fitting a new pump and stores have given you the wrong type of seal. Its almost the same specification as the one you want. It would take too long to get the right one so you fit the one you have and leak test it. It works OK. After a few weeks of operation, the seal fails because it is not designed for that pump.

Example solutions Improve culture and attitudes

towards safety Make procedures clearer and easier

to follow Identify where supervision & cross

check is required Think about applicability of

behavioural safety Review whether labelling of

equipment items in stores could be improved

VIOLATION

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Performance Shaping Factors

Job factors Clarity of signs, signals &

instructions System / equipment

interface Difficulty / complexity of

task Divided attention Procedures PTW or risk assessment Tools Communication Working environment

Person factors Physical capability Fatigue Stress / morale Workload Competence Motivation

Organisation factors Work pressure / priorities Supervision Communication Staffing levels Peer pressure Role clarity Consequences of failure Organisational learning Safety culture Change management

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Human Factors in recent energy industry disaster

1986 Chernobyl power station

1989 Exxon Valdez 1988 Piper Alpha oil rig

2005 BP Texas City refinery 2005 Buncefield Oil Storage Depot

2010 Deepwater horizon, Gulf of Mexico

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Human Factors Regulation

Human failures are responsible for around 80% of all types of accident and feature in almost every major accident. Increasingly regulators around the world are demanding that oil and gas companies pay far more attention to human factors in both design projects and existing operations and policy.

ISO Standards (e.g. ISO11064 CCR Design) OGP Guidance HF in Projects Operator standards (e.g. Shell DEPs, Chevron

SID, TOTAL GS Assessment Principles for Offshore Safety Cases

(UK) COMAH Human Factors requirements (UK)

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Benefits of applying HF

Increased Decreased

Benefits of Human Factors

Ease of use Ease of maintenance Ease of learning System reliability Personnel safety & health Satisfaction, trust, & loyalty Productivity

(Major) accidents, injuries & illnesses

Need for re-design & recall (CAPEX)

Near misses Lost workdays Error rates Absenteeism & turnover Equipment damage / downtime

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What can I do about it !?

Accept that humans can and will fail Look for where human failure will

have a serious consequence You can do a lot to fix the problems

when you find them during design Get help from HF specialists if a

problem seems impossible to solve!

You cant change the human condition, but you can change the conditions humans work under Reason & Hobbs 2003


Human Factors scope on Masela FLNG FEED


FLNG

Large vessel, big modules & big equipment, big pipework

Cryogenic contact risk to personnel and equipment

Consolidation of liquefaction process onto vessel (novel application)

High volume hydrocarbon storage, and specialist LNG containment (anti-sloshing)

Offload of LNG & NGL products More people on board + dont forget the usual FPSO gas and

condensate processing risks


Overview of HFE Programme of Work

Human Factors Analysis & Design HFE Screening Identification of Valves Analysis FEEEM / Task Analysis SHERPA Human Error Analysis HFE Cost Benefit Analysis HFE 3D model reviews HFE in HAZOP Human Error Probabilities Input to Safety Case Control Room Ergonomics

Human Factors Management HFE Schedule & HFIP HFE Specification HFE Awareness Briefings Project Ergonomics Team HFIP for EPC phase


HFE Standards

SHELL DEPs

DEP 30.00.60.10 HFE in Projects DEP 30.00.60.13 HFE - Valve Analysis DEP 30.00.60.14 HFE in Construction DEP 30.00.60.15 HFE in Control Room Design DEP 30.00.60.16 Human Machine Interface Design for Situation Awareness DEP 30.00.60.18 HFE in Skid Package Units DEP 30.00.60.19 HFE - Safety Critical Tasks DEP 30.00.60.20 Workplace Design Specification DEP 30.00.60.21 Labeling and Signage

Project HFE Specification

The above standards, plus other requirements from ISO, EEMUA and industry best practice

AF09B-450-HE-SPC-0001 / S-450-1245-001 (when published)


HFE Screening

Identify the most critical, complex & frequently used equipment in order to focus HFE effort in the right areas.


FEEEM / Task Analysis

Determine design requirements for important human tasks Identify which human tasks require further review of human error potential


SHERPA Human Error Analysis

What potential for human error exists for the HIGH priority tasks from FEEEM? What are the consequences of these errors and what controls are in place? Has the risk been reduced to sufficiently? More / different BARRIERS required?


HFE 3D model reviews

Review topsides modules against HFE Shell DEP requirements Captured comments in J-MRMS Close-out comments in liaison with disciplines ahead of 30% model review


Identification of Valves Analysis (IVA)

Determine access requirements to valves based on their process / safety criticality and frequency of use.

Show VC rating on P&IDs Colour code C-1 valves in 3D model


Control Room Ergonomics Study

Functional Adjacency Task Analysis Control Room 3D modelling

Role ref# 1 2 3 4 5 6 7 8 9 10 11 12 13

Role Ref# Role / Role

Subsea, Inlet & Hot section Op

Cold section & fractionation Op Utilities Op Marine Op

PTW Controller

Production Supervisor (SP)

Production Superintendant (SIP)

ICSS System controller (CER)

Systems Maintenance technician

Field Operator OIM HSE manager

Radio Operator

1Subsea, Inlet & Hot section Op

HH H H H H M M M L M L L

2Cold section & fractionation Op

HH H H H H M M M L M L L

3 Utilities OpH H H H H M M M L M L L

4 Marine OpH H H H H M M M L M L L

5 PTW ControllerH H H H H M M M M M L L

6Production Supervisor (SP)

H H H H H M L L L M L L

7Production Superintendant (SIP)

M M M M M M L L L H H L

8ICSS System controller (CER)

M M M M M L L M L M L L

9Systems Maintenance technician

M M M M M L L M L L L L

10 Field Operator L L L L M L L L L L L L11 OIM M M M M M M H M L L H M12 HSE manager L L L L L L H L L L H L13 Radio Operator L L L L L L L L L L M L


Project Ergonomics Team (PET)

Oversee implementation of the project HFE Strategy

Provide a forum to

resolve cross-disciplinary issues

Facilitate integration of

HFE across the project

Role Responsibilities Name Project PET Chair Chair the PET meetings and

highlight critical issues with other members of the project management team to ensure necessary follow-up.

Takashi Nozato

Project HFE Coordinator

Coordination of HFE activities and delivery of the HFE work scope. Update the HFIL. Update list of HFE Deviations from DEP.

Yuda Hartanto

HFE Technical Authority

Quality Assurance and Quality Control of the HFE CTR deliverables.

Takashi Nozato

HFE Contractor Undertaking the agreed programme of HFE work, and producing associated deliverables. Minute the PET meeting.

Matt Barron

Project Safety Representative

To ensure that there is a high level of coordination between key HFE issues and the overall HSE work activities on the project.

Takashi Nozato

Project O&M Representative

To provide an O&M perspective on key HFE issues raised and discussed at PET.

Paul McConnell

Topsides Interface

Ensure that HFE issues identified relating to Topsides scope of work are correctly shared and actioned within JGC. Report to PET with any HFE issues and concerns to be addressed.

Yuda Haritanto

Hull Interface Ensure that HFE issues identified relating to Hull scope of work are correctly shared and actioned within SHI. Report to PET with any HFE issues and concerns to be addressed.

Yuda Haritanto

Turret Interface Ensure that HFE issues identified relating to Turret scope of work are correctly shared and actioned within MODEC / SOFEC. Report to PET with any HFE issues and concerns to be addressed.

Yuda Haritanto


HFE Shell DEP Deviations Management

1. Engineering Discipline provides written case for HFE DEP deviation (using the DEP Deviation Request form to the HFE Coordinator;

2. HFE Coordinator circulates requested DEP deviations to PET members 1 week prior to PET meeting; 3. PET members review the DEP deviation form(s) ahead of PET meeting; 4. For Deviation requests flagged as High Priority, which require an urgent response in the interests of schedule,

these shall be discussed by PET members outside of the monthly PET meetings, and a decision reached. 5. PET members discuss the DEP deviation form(s) during the PET meeting and agree (by consensus) how to treat the

deviation request. The decision of the PET Chair is final. 6. HFE Coordinator updates the HFE Deviations register (See Appendix B) with status of deviation as either a)

ENDORSED, b) FURTHER STUDY, or c) REJECTED. 7. HFE DEP Deviations which are ENDORSED shall then be forwarded to COMPANY via a Technical Query to seek

official COMPANY approval for the deviation. HFE Coordinator shall compile and submit the Technical Query.

DEP NUMBER DEP TITLE DEP 30.00.60.13 HFE Valve Analysis - Appendix B only DEP 30.00.60.15 HFE Control Room Design - Section 4 & Appendix A only DEP 30.00.60.16 HFE Human Machine Interface Design for Situational Awareness -

Section 4 only

DEP 30.00.60.18 HFE Design & Procurement of Skid Packaged Units - Appendix D only DEP 30.00.60.20 HFE Workspace Design - Section 3 to section 5 only


HFE Shell DEP Deviations Management


Some key HFE requirements impacting LAYOUT


Working space

Parameter Minimum Dimensions

A Width 1000mm B Depth 1000mm C Height 2100mm

Parameter Minimum Dimensions

A Width 1300mm B Depth 1300mm C Height 1300mm

As a minimum, adequate standing workspace shall be provided wherever an operator or maintainer is

required to work

Where operators are required to undertake manual tasks from a squatting or kneeling

position

DEP 30.00.60.20


Walkways

Application Minimum Dimension

One person walking sideways in restricted area (e.g. machinery space, skid packages, etc.) without bulky clothing

600mm

One person travelling forward in area with limited access 750mm Walkways (or thoroughfares) usually subject to passage or crossing of several persons simultaneously, OR Corridor or passageway which serves as a required exit in temporary accommodation

900mm 1000mm

Operating aisles within process areas OR External walkways designated as escape routes on offshore facilities OR Route inside the permanent accommodations module, buildings, or other areas where 50 or more persons could congregate, that serves as an emergency exit from manned spaces

1200mm 1500mm

Provide escape and access routes in the 3D model and

ensure they are clash free in 3D and joined-up

If you need to model piping or structure which clashes with

access, raise an action to fix it, dont leave for clash detection

or model review to find.

A clear unobstructed (clash free) escape volume of 1200mm wide by 2300mm high shall be maintained along the full length

of the escape route.

DEP 30.00.60.20


Distance to escape points

In elevated decks or platforms, the maximum distance an operator should have to run to reach a point of escape from that module (a stair tower or ladder) is 15m. Length of a dead-end shall be maximum 5m. This is CLIENT requirement (Shell DEP states max 7m) DEP 30.00.60.20


Number of escape points

The following shall have a secondary means of escape: all elevated work platforms

serving fired equipment or three or more vessels;

all elevated work platforms

serving two or more pieces of equipment that are concurrently maintained and operated;

elevated work areas that have an

area of 20 m2 or more. DEP 30.00.60.20


Ladders

Maximum unbroken ladder length shall be 9m.

Side step ladders are preferred. PET approval for step through.

Ensure 2300mm minimum head clearance at top of ladders.

Clear route to exit from bottom of ladder model access volumes

Avoid ladder volume clash with escape / access routes

DEP 30.00.60.20


Valve position

All C-1 Valves

All C-1 Valves

APPLY max 1195mm (reduced by 100mm for SE Asian population)

APPLY max 1755mm (reduced by 75mm for SE Asian population)

DEP 30.00.60.13

Allow 1300mm behind hand-wheel if located in the lower Acceptable zone, to accommodate squatting or kneeling posture.


Valve Location Derived best practice

Locate the hand wheels / levers of valves considering the optimal location for human operation. Valve handwheels orientated in-line with pipe are harder to operate biomechanically (require more force). Avoid Operator having to access or use handwheel / lever under structure. Consider access for maintenance to valve flanges.


Displays - standing DEP 30.00.60.20

Parameter Dimensions

A Maximum height 1730mm

B Preferred maximum height 1590mm

C Maximum height for vision over the top

1460mm

D Preferred minimum height 1390mm

E Minimum height 1120mm

F Minimum depth or clearance in front of panel/console/cabinet faade

910mm


Displays - Squatting DEP 30.00.60.20




C Preferred Minimum height 670mm

D Minimum height 530mm

E Minimum depth or clearance in front of panel/console/cabinet faade

910mm


Controls - standing DEP 30.00.60.20


A Maximum reach height (Overhead pinch grip of 5th percentile female)

1770mm

B Preferred maximum reach height (Shoulder height of 5th percentile female)

1160mm

C Preferred minimum height (Hand grip height of 95th percentile male)

870mm

D Minimum height (Knee height of 95th percentile male)

540mm


910mm


Controls - Squatting DEP 30.00.60.20




C Maximum height for vision over the top

430mm

D Minimum height 380mm


910mm


Hose Stations / hydrants Derived best practice

Consider the operation manual fire fighting in emergency conditions. The hose station and hydrants must be co-located such that each is clearly visible from the other, within 3 meters of each and with no equipment or structure separating them. Visible from the process areas (not hidden behind columns or structure). Hydrant connection points must be clear of obstruction to allow connection of hose and routing of pressurised hose.

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Key Contacts

Takashi Nozato HFE Technical Authority JTM Email [email protected] Phone +62-21-2997 6500 Ext. 70931

Yuda Hartanto Human Factors Coordinator JTM Email [email protected] Phone +62-21-2997 6500 Ext. 70837

For: Any HFE technical query Comment on any HFE standard or project

HFE document

For: Submission of HFE Deviation Request form Raising of any HFE issues / risks

Slide Number 1Human FactorsHuman Factors why bother?Plant, Process & PeopleHuman Factors and the barrier modelPeople - SizePeople - Strength & physiologyPeople Cognition / Information ProcessingSLIPLAPSEMISTAKEVIOLATIONPerformance Shaping FactorsHuman Factors in recent energy industry disasterHuman Factors RegulationBenefits of applying HFWhat can I do about it !?Human Factors scope on Masela FLNG FEEDFLNGOverview of HFE Programme of WorkHFE StandardsHFE ScreeningFEEEM / Task AnalysisSHERPA Human Error AnalysisHFE 3D model reviewsIdentification of Valves Analysis (IVA)Control Room Ergonomics StudyProject Ergonomics Team (PET)HFE Shell DEP Deviations ManagementHFE Shell DEP Deviations ManagementSome key HFE requirementsimpacting LAYOUTWorking spaceWalkwaysDistance to escape pointsNumber of escape pointsLaddersValve positionValve LocationDisplays - standingDisplays - SquattingControls - standingControls - SquattingHose Stations / hydrantsKey Contacts

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