Human Factors Handbook for Process Plant Operations
eBook - ePub

Human Factors Handbook for Process Plant Operations

Improving Process Safety and System Performance

  1. English
  2. ePUB (mobile friendly)
  3. Available on iOS & Android
eBook - ePub

Human Factors Handbook for Process Plant Operations

Improving Process Safety and System Performance

About this book

Human Factors Handbook for Process Plant Operations

Provides clear and simple instructions for integrating Human Factors principles and practices in the design of processes and work tasks

Human Factors, the science of interaction between humans and other elements of a system, draws from disciplines such as psychology, ergonomics, anthropometrics, and physiology to understand how and why people behave and perform as they do—and how best to support them in performing tasks. The goals of the Human Factors approach are to improve human reliability, minimize the risk from human error, and optimize the working environment, human wellbeing, and overall system performance.

Human Factors Handbook for Process Plant Operations guides supervisors, managers, and engineers on incorporating Human Factors principles and practices into plant maintenance and operations. With thorough and accessible coverage of all Human Factors topics of relevance to process industries, this easy-to-use handbook uses real-world anecdotes and case studies to demonstrate effective training and learning, task planning, communications, emergency response, risk and error management, and more. Throughout the text, the authors offer valuable insights into why people make mistakes while providing advice on how to help workers perform their process operational tasks successfully.

  • Explains all essential Human Factors concepts and knowledge with clear descriptions and illustrative examples
  • Offers actionable advice and models of good practice that can be applied to design, process operations, start-ups and shut-downs, and maintenance
  • Addresses job aids, equipment design, competence, task support, non-technical skills, working with contractors, and managing change
  • Discusses how lack of Human Factors considerations during the engineering design phase can adversely affect safety and performance
  • Describes how to use indicators to both recognize and learn from human error and performance issues

Written by highly experienced operating and maintenance personnel, Human Factors Handbook for Process Plant Operations is an indispensable resource for everyone involved with defining, planning, training, and managing process operations, maintenance, and emergency response in the food, pharmaceutical, chemical, petroleum, and refining industries.

The missions of both the CCPS and EI include developing and disseminating knowledge, skills and good practices to protect people, the environment, and property by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS, an industrial technology alliance of the American Institute of Chemical Engineers (AIChE), has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 35 years and has published over 100 books in its process safety guidelines and process safety concept book series. The EI's Technical Work Program addresses the depth and breadth of the energy sector from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.

Information

Publisher
Wiley-AIChE
Year
2022
Print ISBN
9781119640493
eBook ISBN
9781119640479

Part 1: Concepts, principles, and foundational knowledge

1 Introduction

1.1 What is “Human Factors”?

Schematic illustration of the human factors.
As illustrated in Figure 1-1, like engineering, Human Factors is a combination of science, concepts, and principles. Human Factors draws on several scientific disciplines. These include psychology, ergonomics, anthropometrics, and physiology. The Human Factors approach uses these disciplines to help people understand how and why they behave and perform as they do, and how best to support them to perform tasks. The science adds to the knowledge gained from operational experience.
Schematic illustration of the human factors science, concepts and principles.
Figure 1-1 Human Factors science, concepts and principles
Human Factors also provides a set of principles and concepts that can be used to guide day‐to‐day decisions. The decisions focus on how best to support successful human performance. This approach helps people to understand tasks from the perspective of the person doing the work and provides ideas on how to support people to perform better. It advocates an orientation (a way of thinking) towards making improvements that support human performance and the prevention of error. It recognizes people's capabilities and commitment, and it aims to maximize people's roles in safe and productive operations, and to build their ability to cope mentally and emotionally with stressful and demanding tasks, i.e., psychological resilience.
A short video that presents a Human Factors view for successfully addressing human performance, titled Being Human, is available as a resource for “understanding and accepting why, as people, we do what we do, why we do it, and the way we do it.” [7]
Human Factors covers a very wide range of topics including, training, work planning, and fatigue. Many of these topics come under existing management systems, such as the operation of rotating shift schedule systems, and training systems. Human Factors provides knowledge, tools, and insights that can be integrated into an organization's existing systems of work and operational management, safety assessments, incident investigations, and day‐to‐day operational decision‐making. In this book, the terms ‘incident’ and ‘accident’ will be used interchangeably.

1.2 Purpose of this handbook

1.2.1 Purpose and scope

This handbook provides practical advice and examples of good practice that can be applied to design, process operations, start‐ups and shut‐downs, maintenance, and emergency response. It is a comprehensive but simple to understand handbook aimed at people responsible for the process operations.
Schematic illustration of the purpose of the handbook.
The handbook:
  • Provides examples of practical application, principles, and tools. It also provides an understanding of the fundamentals of Human Factors, so the reader can develop their own approach.
  • Provides an explanation of how people think and behave, why people make mistakes, and how to help people perform process operational tasks successfully. This includes how to support human performance through procedures and job aids, training and learning, effective task planning, high reliability communications, fatigue risk management, development of error management skills, and preparing people to perform emergency response tasks.
  • Briefly covers the Human Factors of change management and managing contractors. It also offers help on how to learn from errors, and how to use indicators of human performance to improve support to people.

1.2.2 Other guidance

How does this handbook fit with other guidance documents?
Safety culture, leadership, and process safety management are covered in other CCPS publications, as shown by the book front covers. Most chemical process businesses have a set of process safety management systems in place already. The advice in this handbook can be integrated into these process safety management systems.
Schematic illustration of the propose safety leadership from the boardroom to the frontline handbook.
Human Factors methods, such as error analysis and Human Reliability Assessment, typically applied during a “Hazard Identification and Risk Analysis”, are not covered in this handbook. CCPS books on “Bow Ties in Risk Management” and “Guidelines for Integrating Process Safety into Engineering Projects” are available if further information is needed. This handbook does outline forms of error assessment that can be used by everyone involved in task planning and task management.
This handbook can be read in conjunction with other CCPS guidance on safety culture and process safety management, including:
  • Es...

Table of contents

  1. Cover
  2. Table of Contents
  3. Title Page
  4. Copyright
  5. Dedication
  6. List of Figures
  7. List of Tables
  8. Glossary
  9. Acronyms
  10. Acknowledgements
  11. Foreword
  12. Part 1: Concepts, principles, and foundational knowledge
  13. Part 2: Procedures and job aids
  14. Part 3: Equipment
  15. Part 4: Operational competence
  16. Part 5: Task support
  17. Part 6: Non-technical skills
  18. Part 7: Working with contractors and managing change
  19. Part 8: Recognizing and learning from performance
  20. References
  21. A Human error concepts
  22. B Major accident case studies
  23. C Human Factors Competency Matrix
  24. D Competency performance standards
  25. E Learning methods and performance
  26. F Situation awareness and behavioral markers
  27. G Human Factors change checklist
  28. Index
  29. Wiley End User License Agreement

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