Method for Incorporating Human Factors During Design Phase

1. Technische Universität Berlin Presented at: Loss Prevention Symposium Prague, 31st May - 3rd June, 2004 Dipl.-Ing. Simon G. Kariuki & Dr.-Ing. Katharina Löwe Technical University of Berlin Method for Incorporating Human Factors During Design Phase

2. Definition & Background of Human Factors in Design. • Obstacles in Implementation of HF. • State-of-the-Art in the Process Industry. • Systematic Method to integrate Human Factors into Design Process. • Conclusion What is covered:

3. Definition of “Human Factors in Design” A body of science that incorporates the physical and cognitive capabilities and limitations of populations of people into the design of a system, process, or equipment aimed at achieving improved manufacturability, operability and maintainability.

4. Plant Design Management Operator • Equipment Design • Workplace Layout • Workplace Environment • Displays & Controls • Selection & Training • Communication • Shift transfer • Management structure • Safety culture • Anthropometry • Cognition (Mental Ability) • Skills/ Qualifications • Culture & & Components of HF

5. Plant Design Operator (Human User) Management Systems Intersection between factors lying under the three areas determines the quality of HF in a process facility. Components of HF

6. Facts about “Human Factors” • HF is an old science dating back to world warII. • Open Secret => HUMAN FAILURE is the biggest contributor of incidents in process plants. But: Very few companies implement HF during the design phase. Why not? There is lack of knowledge on HF implementation in the Process industry.

7. Lack of specific laws/regulations, guidelines on HF. • Lack of expertise and when available is called in too late. • Additional pressure to financial and time resources. • Conflicts on where to link HF. Some firms link it to SHE. What are the Obstacles?

8. What are the Obstacles? • Presence of conservative attitudes e.g. • We got everything right from core safety analysis • Fix the people not process • “As long as its working we did a good job”

9. State-of-the-Art in the Process Industry Design-Project Procedure Commissioning & Start-up Operation & Maintenance Basic Design Detail Design Feasibility study -Process choice - Parameters for plant location. - Basic flow diagrams - Rough cost estimations. - More elaborate basic flow diagrams. - Production & ancillary buildings, approximate pipe and equipment dimensions - Investment & operating costs assessment. - Detailed design with process flow diagrams (mass, energy balances), P&ID, 3-D models for plant layout, Process Control - Structural construction and assembly of equipment & machinery - Plant safety analysis and reports - Start-up scheduling & training on operations. • Test for conformity with P& ID - Handing over to operations and maintenance departments (Training) - Reviews for possible design problems for post start-up modifications -Task analysis for operation modifications

10. Engineering disciplines are well represented Design has good engineering strength. • Process Hazards are analysed (Core Safety) using tools like HAZOP & Checklists. • BUT: HF issues are not covered in details during design Some designs have to be modified after detecting a mismatch between operator characteristics & design. State-of-the-Art in the Process Industry • AND: There is a new challenge: Most companies are outsourcing major projects.

11. The method has the following advantages: • Provides a systematic approach to implement of HF principles during the whole design process. • Shows the design phase at which each HF activity gives most benefits. • Shows that there is a need to maintain a HF database for future projects. Method to Address HF issues during Design BENEFITS: Reduction in cost of design modifications, incidents due to operator error, injuries at workplace and improved operation efficiency.

12. Mapping HF Activities onto the Design Process Databank for future projects Evaluate Review Check Detail Design Feasibility study Commissioning & Start-up Operation & Maintenance Basic Design HF Related Activities

13. Mapping HF Activities onto the Design Process Databank for future projects Evaluate Review Check Detail Design Feasibility study Commissioning & Start-up Operation & Maintenance Basic Design HF Planning & Analyses • Choice of Process, Functions Analysis, Task Analysis HF Design Implementation • Equipment, Procedure, Training Design HF Evaluation & Validation • Iterative verification HF Performance Monitoring • Post-commissioning task analysis

14. Mapping HF Activities onto the Design Process Databank for future projects Evaluate Review Check Detail Design Feasibility study Commissioning & Start-up Operation & Maintenance Basic Design HF Planning & Analyses HF Design Implementation HF Evaluation & Validation HF Performance Monitoring

15. Feasibility study At the very conceptual stage of design process some important HF have already emerged: • Choice of process - Either to use inherently safer design. • Skills of operators and maintainers required. Is it highly trained, moderate or low trained? • The plant geographical location - Anthropometrics, culture. HF Planning & Analyses

16. What will be the operating environment? • What is the overall consequences if operation went wrong? HF efforts should correspond to the complexity & sensitivity of the process plant. HF Planning & Analyses

17. Basic & Detailed Design • Details about the process are being defined • The type of equipment is being specified • Detailed drawings, P&ID HF deliverables are Functions Analysis and Task Analysis. HF Planning & Analyses

18. Plant Design Functions Analysis Identification of functions to be performed Analysis of function and allocation. (Tradeoffs) - Capability & limitations of human /machine - Existing technologies. -Cost OR Human Hardware/ Software Hybrid Functions Evaluation Task Analysis =For tasks that involves Human Operator

19. HUMANS EXCEL IN • Sensitivity to an extremely wide variety of stimuli. • Perceiving patterns and making generalisation about them. • Ability to store large amounts of information for long periods and recalling relevant facts at appropriate moments. • Applying originality in solving problems, i.e, alternative solutions. • Ability to profit from experience and alter course of action. MACHINES EXCEL IN • Monitoring (both people and machines). • Performing routine, repetitive, or very. precise operations. • Responding very quickly to control signals. • Storing and recalling large amount of information in short time-periods. • Performing complex and rapid computations with high accuracy. • Exerting large amounts of force smoothly and precisely. Functions Analysis

20. HF Design Implementation Task Analysis Plant Design Identification of function to be performed Task Analysis Performance Shaping Factors, PSFs AND Training development Equipment Design Procedures design Testing, Evaluation & Validation Human Performance Monitoring

21. Mapping HF Activities onto the Design Process Databank for future projects Evaluate Review Check Detail Design Feasibility study Commissioning & Start-up Operation & Maintenance Basic Design HF Planning & Analyses HF Design Implementation HF Evaluation & Validation HF Performance Monitoring

22. PRISM Guidelines addresses specific areas of HF and design. This includes: Maintainability and operability Accessibility of work stations, design of ladders and stairs, location of valves. Control Monitoring and instrumentation Field control panels, display design, alarms. HF Design Implementation The result of task analysis used in designing Equipment Design (Human Machine Interface), Procedures and Training.

23. Automation and Control Design Fault management and false alarms, control room Design/ Layout. Work Environment Lighting, noise, heat Stress. Plant Labelling and Signing Information transmission, visibility and legibility, label location. HF Design Implementation Other important tools to implement HF design include checklists, computer models and electronic mock-ups.

24. Mapping HF Activities onto the Design Process Databank for future projects Evaluate Review Check Detail Design Feasibility study Commissioning & Start-up Operation & Maintenance Basic Design HF Planning & Analyses HF Design Implementation HF Evaluation & Validation HF Performance Monitoring

25. Important to verify tasks and to ensure that the design accommodates capabilities and limitations of operator. • Should starts at the Basic Engineering phase and stretch to commissioning and start up. • Most benefits are achieved during Detail Engineering when all specs have been defined. HF Evaluation & Validation

26. Mapping HF Activities onto the Design Process Databank for future projects Evaluate Review Check Detail Design Feasibility study Commissioning & Start-up Operation & Maintenance Basic Design HF Planning & Analyses HF Design Implementation HF Evaluation & Validation HF Performance Monitoring

27. All problems related to HF cannot be eliminated during Design,Evaluation and Validation. Therefore needed: • HF Monitoring Strategy. • Supplementary task analysis to make further improvement. But: Any modifications should not introduce further degradations. Lessons learned into HF databank. HF Performance Monitoring

28. Conclusion • Process industry lags behind in HF aspects. • HF are rarely addressed during design and if so, it is done too late. • The method suggested provides a systematic integration of HF into the design process. • Introducing HF databanks creates a valuable resource for future projects.

29. Thank You For Your Attention !