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Methodology for applying HF analysis or A Human Factors Toolkit. Debby Hallett, Ciba Specialty Chemicals. Introduction…. Purpose of presentation: Share experiences of developing and using the “Human Factors Toolkit” Contents: Ciba Specialty Chemicals & it’s requirements
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Methodology for applying HF analysisorA Human Factors Toolkit Debby Hallett, Ciba Specialty Chemicals
Introduction… • Purpose of presentation: • Share experiences of developing and using the “Human Factors Toolkit” • Contents: • Ciba Specialty Chemicals & it’s requirements • Overview of methodology • Examples of applying the method • Problems encountered (& overcome)
Ciba Specialty Chemicals… • Globally: • 20,000 employees • 64 production sites • 25 countries • Bradford, UK site: • 1,200 employees • Top tier COMAH site • Human Factors at Ciba Specialty Chemicals: • Wide range of projects involve HF • 3 year history of specific HF work
Ciba Human Factors “History”… • 2000: submitted COMAH Safety Report • Considered Technical control measures • Improvement plan on Human Factors agreed • 2000 – 2001: Various individual assessments on lone working, manloading and Human Factors DNV • 2001: Developed HF assessment technique: Ciba/DNV • 2002: Pilot assessment – Grimsby site Ciba/DNV • 2002: Assessment – Bead, Bradford site Ciba/DNV • 2003: Assessment – Maintenance Ciba • 2003: Assessment – R2000 Control room Ciba/DNV • 2003: Assessment – Project Diamond Ciba
Ciba’s objectives: • COMAH (Seveso) compliance…demonstration of: • Evaluation of potential human error • Effectiveness of human interventions required to maintain control • Establish awareness of human factors: • Line Management • Engineering design • Technology transfer: • Develop internal HF assessment methodology • Apply to all types of activities on site • Suitable for use by non-HF professionals • Complement other risk assessment techniques
Major Accident Hazard scenarios identified from COMAH Safety Report Task inventory & criticality assessment Identify critical tasks Observational data Assessment Qualitatively assess critical tasks and potential errors Error analysis Task analysis (HTA & concurrent) Alarm & Procedure checklists Evaluate the safeguards Staffing assessment After Assessment Identify risk control strategies Human Factors Method to Support COMAH Before Assessment Incorporate relevant results into Safety Report
1) Maintenance activities • Manual task: • Breaking and making gasketted joints • Toolkit worked well: • Easy to identify task steps, errors & consequences • Easy to generate recommendations • Example - handover incomplete job to next shift • Error: fail to communicate task status • Consequence: • Gaskets missing/untightened - leak of hazardous substance • Recommendations: • Maintenance operatives handover job personally • Use job sheet to record status
2) Automated continuous plant • General control room duties difficult to assess • Selected a manual task, and looked at links to control room activities • e.g., communications, data entry & decision making • Example – taking sample of reactor contents • Error: fail to circulation valve on sample cooler • Consequence: • Unrepresentative sample taken - status of reactor unknown • Potential runaway reaction • Recommendations: • Ensure all operators understand importance of sampling • Improve labelling of valves • Investigate linking valves to sample point
3) Design phase of new plant • Multi-disciplinary team established during design phase • Applied methodology to proposed design: • Identified how plant will operate • Identified design problems before too late • Identified manning levels • Most importantly…ensured employee involvement • Example – connect road tanker to off-load point • Error: driver connects to wrong point • Consequence: • Incompatible substance into storage tank - exothermic reaction • Recommendations: • Tanker drivers not allowed on site unaccompanied • 2 x paperwork checks • Off-load points locked
Key learning points… • Consultants requirements Ciba’s: • Unused data removed from process • Role of Task Inventory? • Training modified: less academic, more pragmatic • Select the right assessment team: • Key people = experienced operators • Manager/supervisor also required (reality check) • Must be available for whole assessment • Time intensive process: • Moved some steps outside assessment timetable • Ensure assessment scope is realistic • Facilitator observe task(s) before assessment • Smarter recording (reduce time to ‘write-up’)
Key learning points (cont)… • Costs involved: • Move to Ciba Specialty Chemicals led assessments • DNV provide support as required • Staffing assessment: • Diagrams told us what we suspected – not specific enough • Concurrent task analysis = more useful
Conclusions… 1) Methodology meets Ciba’s requirements: • COMAH Compliance: • “Reality check” on current practice • Identifies deficiencies/opportunities • Raised HF awareness within Ciba Specialty Chemicals • Technology Transfer: • Simple method (but time consuming) • Suitable for wide variety of activities • Compliments other RA techniques 2) Most important parts of process: • Team selection • Setting scope • Concurrent task analysis • Smart recording
Way forward… • Continue assessment programme: • Incorporate into design process • Roll-out to remaining production areas • Development of best practice document • Continue Technology Transfer to other Ciba Specialty Chemicals EHS professionals • Link to other business initiatives e.g. quality