Tel: 01492 879813 Mob: 07984 [email protected]
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What works in the oil, gas and chemical industries?
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A bit about me
Chemical engineer – Loughborough UniversityPhD – Edinburgh University11+ years working as a human factors consultant – predominantly in oil, gas and chemical industriesSelf-employed for 3 yearsRegistered member of the Ergonomics Society.
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The industry
Dominated by large multi-nationalsDominated by engineersNew ideas – agility of a super-tanker
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Engineers are interested in human factors, but don’t speak the same language
Biomechanics
Physiology
Anatomy
Psychology
Ergonomics
Machines for making beer
The flow of beer through the body (achieving a mass balance)
How beer is processed by the body (unit operations)
Topic of conversation when you’ve had a few
Know something about that.
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Ergonomics – not very interesting
But these things are interesting
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Rightly or wrongly, ergonomics and human factors are seen to be different
ErgonomicsHuman capabilitiesHardware designWork stationsUser interfacesWorking environmentManual handlingPersonal safety, health and well being
Human factorsWhole systemOrganisationCultureTasksErrorsProceduresTraining and competenceMajor hazardProcess safety.
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An engineering approach to human factors
Risk based – process safetyStructured on process systemsFocus on critical activities and tasksBorrow from engineering methods (e.g. HAZOP)Task and error analysisHuman factors risk control measures
Eliminate and reduceProcedures, training and competence.
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Staffing Assessment MethodologyTried and tested method for assessing staffing arrangements, especially during changeGives some objectivity to human factorsSuccessful at focussing efforts
YES
YES NO
NO
Do/will staffing arrangements cover worst case scenarios?
Physical assessment Ladder assessment
Are arrangements sustainable?
Ref: HSE CRR 348/2001 Ref: Energy Institute user guide
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Typical findings
Problems with communicationPassive approaches to stress and fatigue
No control of shift swaps, overtime, breaks etc.
Poor management of organisational change (including staffing levels)Lack of systems for procedures Reliance on informal trainingSubjective evidence of competence
Remainder of the talk focuses on the bottom three issues
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Hypothetical Gas Terminal – St Barton
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A systematic approach
Define the systemDefine the system goalsIdentify the functions to achieve the goalsIdentify the ancillary functionsIdentify safety critical elements requiring maintenanceIdentify tasks
Ref: ISO 11064
Simple and very effective
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St Barton
System definitionThe plant and equipment between inlet and outlet isolation valves
System’s goalsSupply gas to customer at required specificationManage risks to safety, health and the environmentAchieve nominationOperate profitably.
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St Barton - Main Functions
Receive gas from pipelineRemove liquids and particles Heat gas to achieve specificationInject nitrogen to achieve WOBBEControl flow rate to achieve nominationMeter gas for contractual purposes.
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St Barton utilities/ancillaries
Fuel gasNitrogenInstrument airFire fighting capabilityFire/gas detectionEmergency shutdownEmergency depressurisationElectrical powerDrainage.
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1. Start-up/Shutdown tasks1.1 Whole terminal
1.1.1 Return terminal to service after maint.1.1.2 Prepare terminal for maintenance1.1.3 Return to service after blowdown
1.2 Processing trains1.2.1 Return train to service after maint.1.2.2 Prepare train for maintenance1.2.3 Increase number of trains online1.2.3 Reduce number of online trains
1.3 Heaters1.3.1 Start additional heater1.3.2 Stop a heater
St Barton Operations Task ListCriticality
HighHighHigh
HighHighMedMed
MedMed
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Assigning criticality
Can be very subjectiveEverything is critical
Hazardousness of systemIgnition sourcesChanging line-upImpact of task deviationOverriding safety devicesOverall criticality
Low Medium High
1 2 3 1 2 3 1 2 3 1 2 3 1 2 30-3 4-8 9-15
Ref: OTO 1999 092
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1. Start-up/Shutdown tasks1.1 Whole terminal
1.1.1 Return terminal to service after maint.1.1.2 Prepare terminal for maintenance1.1.3 Return to service after blowdown
1.2 Processing trains1.2.1 Return train to service after maint.1.2.2 Prepare train for maintenance1.2.3 Increase number of trains online1.2.3 Reduce number of online trains
1.3 Heaters1.3.1 Start additional heater1.3.2 Stop a heater
St Barton – Task Criticality
3+0+3+2+2 High3+0+3+3+0 High3+0+1+2+2 Med
3+0+2+2+2 High3+0+2+2+1 Med3+0+1+1+0 Med3+0+1+1+0 Med
1+1+1+0+0 Low1+0+1+0+0 Low
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What has this achieved?
A human factors risk assessmentOnly a means to an end, but what is the end?Human factors risk management
Engineer out – beware of risk transferralHardware controls – beware of ironies of automationSoftware controls – procedures, training and competence
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1. Start-up/Shutdown tasks1.1 Whole terminal
1.1.1 Return terminal to service after maint.1.1.2 Prepare terminal for maintenance1.1.3 Return to service after blowdown
1.2 Processing trains1.2.1 Return train to service after maint.1.2.2 Prepare train for maintenance1.2.3 Increase number of trains online1.2.3 Reduce number of online trains
1.3 Heaters1.3.1 Start additional heater1.3.2 Stop a heater
St Barton - Procedures Required
YesYesYes
YesYesNoNo
YesYes
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Better procedure systemsOne size does not fit allDifferent types of procedure
Full step-by-step Aide memoirFlow chart ChecklistSign or label on plantTraining procedureNone
Requirements depend on the task’s:CriticalityComplexityFrequency it is performed (by an individual).
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1. Start-up/Shutdown1.1.1 Return terminal to service after maint.
2. Routine operations2.1 Field operator routines
3 Materials handling3.1 Receive bulk materials
3.1.1 Receive diesel from tanker
St Barton – Type of Procedure
Full procedure+ Checklist
Checklist (training)Guide + shift log
Full procedure +signs on plant
2.1.1 Plant patrol2.1.2 Receive shift handover
5 Respond to operational events5.1 Respond to high pressures
5.1.1 Respond to high pressure at inlet Flow chart
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Training
Required for all tasksTiming is important
Order tasks are learnt when starting a new jobPrior to infrequent task being performed
Method of training is importantClass room - theoryWorkshop – practical skillsOn the job – most tasksSimulation – infrequent tasks.
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1. Start-up/Shutdown1.1.1 Return terminal to service after maint.
2. Routine operations2.1 Field operator routines
3 Materials handling3.1 Receive bulk materials
3.1.1 Receive diesel in tanker
St Barton – Training Method
Pre-task briefing
On the jobOn the job + class
On the job
2.1.1 Plant patrol2.1.2 Receive shift handover
5 Respond to operational events5.1 Respond to high pressures
5.1.1 Respond to high pressure at inlet Simulation
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Competency assessment
A lot of training fails to achieve its objectivesNeed to assess the skills, knowledge and understanding requiredLevel of assessment depends on nature of task
Peer ObservationLine manager DiscussionInternal assessor Question and answerExternal assessor Written test.
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2. Routine operations2.1 Field operator routines
3 Materials handling3.1 Receive bulk materials
3.1.1 Receive diesel in tanker
St Barton – Competence Assessment
PeerInternal
Line manager
2.1.1 Plant patrol2.1.2 Receive shift handover
5 Respond to operational events5.1 Respond to high pressures
5.1.1 Respond to high pressure at inlet Internal
6 Respond to emergencies6.3 Respond to major incidents
6.3.1 Respond to propane tank BLEVE External
St Barton Task List Procedures required
Training method
Assessor
1 Start-up/shutdown1.1 Whole terminal
1.1.1 Return terminal to service after maint. 3 0 3 2 2 High Full procedure + checklist
Pre-task briefing
Internal
1.2.3 Prepare terminal for maintenance 3 0 3 3 0 High Full procedure + checklist
Pre-task briefing
Internal
1.2.4 Return to service after blowdown 3 0 1 2 2 Med Full procedure + checklist
Pre-task briefing
Internal
1.2 Processessing trains1.2.1 Return train to service after maint. 3 0 2 2 2 High Checklist On the job Line mgr1.2.2 Prepare train for maintenance 3 0 2 2 1 Med Checklist On the job Line mgr1.2.3 Increase number of trains online 3 0 1 1 0 Med None On the job Line mgr1.2.4 Reduce number of trains on line 3 0 1 1 0 Med None On the job Line mgr
1.3 Heaters1.3.1 Start an additional heater 1 1 1 0 0 Low None On the job Peer1.3.2 Stop a heater 1 0 1 0 0 Low None On the job Peer
2 Routine operations2.1 Field routine operations
2.1.1 Plant patrol 3 0 0 2 0 Med Checklist for training On the job Peer
2.1.2 Shift handover 3 0 0 3 0 Med Guide + shift log On the job + classroom
Internal
3 Materials handling3.1 Receive bulk materials
3.1.1 Receive diesel from tanker 2 2 2 2 0 Med Full procedure + sign on plant
On the job Line mgr
5 Respond to opeational events5.1 Respond to high pressre
5.1.1 Respond to high pressure at inlet 3 0 2 3 1 High Flow chart Simulation Internal6 Respond to emergencies
6.3 Respond to major incidents6.3.1 Respond to propane tank BLEVE E E E E E High Flow chart + job aid Simulation +
classroomExternal
Criticality scores
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Benefits of this approach
Theme and terminology familiar to the end userQuick and simple Focuses effort according to process riskExplains why full blown procedures are not provided for every taskEmphasises the role of on the job trainingMakes competence assessment less threatening
Provides a good demonstration of human factors risk management
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