Methodology for applying HF analysis or A Human Factors Toolkit

1. Methodology for applying HF analysisorA Human Factors Toolkit Debby Hallett, Ciba Specialty Chemicals

2. 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)

3. Ciba Specialty Chemicals & it’s requirements

4. 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

5. 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

6. 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

7. Overview of Methodology

8. 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

9. Examples of applying the method

10. 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

11. 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

12. 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

13. Problems encountered (& overcome)

14. 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’)

15. 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

16. 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

17. 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