Human Factors Methods for Improving Performance in the Process Industries

Since 1985, the Center for Chemical Process Safety (CCPS) has been the world leader in providing information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over eighty books in its process safety guidelines and process safety concepts series. In this book, CCPS teams up with the AIChE Safety and Health Division. Members of the CCPS Human Factors Subcommittee contributed chapters or sections in their areas of expertise. For more information, visit www.ccpsonline.org.

• Preface xiAcknowledgments xiiiAbbreviations and Acronyms xv1 Introduction 11.1 Purpose of This Book 11.2 Human Factors 11.3 Human Error 31.4 Structure of This Book 51.5 Linkage to Other CCPS Publications 61.6 References 72 The Case for Human Factors 92.1 Why is Human Factors Needed? 92.2 Past Incidents 112.3 Business Value/Justification 112.4 Human Factors in the Life Cycle of a Chemical Plant 162.5 Needs Driven Program 172.6 References 193 Performance Measurement and Improvements 213.1 Building Improvements into Existing Systems 213.2 Measures of Performance 223.3 Roles and Responsibilities 243.4 Continuous Improvement 253.5 References 28HUMAN FACTORS TOOL KITFacilities and Equipment4 Process Equipment Design 314.1 Introduction 314.2 Tools 334.3 References 334.4 Additional References 345 Process Control Systems 375.1 Introduction 375.2 Issues/Example 375.3 Tools 395.4 Additional References 396 Control Center Design 416.1 Introduction 416.2 Tools 426.3 References 436.4 Additional References 437 Remote Operations 457.1 Introduction 457.2 Tools 477.3 Reference 488 Facilities and Workstation Design 498.1 Introduction 498.2 Tools 538.3 References 558.4 Additional References 559 Human/Computer Interface 579.1 Introduction 579.2 Human Interactions with Control System Software 589.3 Tools 599.4 References 639.5 Additional References 6410 Safe Havens 6710.1 Introduction 6710.2 Human Factors Issues 6810.3 Tools 7010.4 References 7011 Labeling 7111.1 Introduction 7111.2 Tools 7211.3 References 74People12 Training 7712.1 Introduction 7712.2 Guidelines for Training Programs 7712.3 Guidelines for Designing and Delivering Training 7812 4 Tools 8112.5 References 8113 Communications 8313.1 Introduction 8313.2 Issues/Examples 8313.3 Tools 8513.4 References 8514 Documentation Design and Use 8714.1 Introduction 8714.2 Converting to Electronic Documentation 8814.3 Use of Documents 9014.4 Tools 9214.5 References 9314.6 Additional References 9415 Environmental Factors 9515.1 Introduction 9515.2 Noise 9515.3 Vibration 9615.4 Temperature and Relative Humidity 9915.5 Air Quality 10115.6 Lighting 10215.7 References 10516 Workloads and Staffing Levels 10716.1 Introduction 10716.2 Issues/Examples 10716.3 Tools 10816.4 References 10917 Shiftwork Issues 11117.1 Introduction 11117.2 Tools 11217.3 References 11417.4 Additional References 11418 Manual Materials Handling 11718.1 Introduction 11718.2 Manual Materials Handling Guidelines 11818.3 References 12118.3 Additional References 122Management Systems19 Safety Culture 12519.1 Introduction 12519.2 What is Safety Culture? 12519.3 Tools 12719.4 Safety Culture: A Process Industry Case Study 13019.5 Benefits 13119.6 References 13119.7 Additional References 13220 Behavior Based Safety 13320.1 Introduction 13320.2 Tools 13420.3 Expected Results 13720.4 References 13720.5 Additional References 13821 Project Planning, Design, and Execution 13921.1 Introduction 13921.2 Human Factors Tools for Project Management 13921.3 References 14322 Procedures 14522.1 Introduction 14522.2 Tools 14622.3 References 15122.4 Additional References 15123 Maintenance 15323.1 Introduction 15323.2 Identifying Critical Maintenance Tasks 15323.3 Maintenance Protocol 15423.4 Tools 15523.5 References 15624 Safe Work Practices and Permit-to-Work Systems 15924.1 Introduction 15924.2 Issues 15924.3 Tools 16324.4 References 16424.5 Additional Reference 16425 Management of Change 16525.1 Introduction 16525.2 Tools 16725.3 References 17226 Qualitative Hazard Analysis 17526.1 Introduction 17526.2 Tools—Human Failures 17626.3 Tools—Human Factors 17726.4 References 17926.5 Additional References 18027 Quantitative Risk Assessment 18127.1 Introduction 18127.2 Tools 18327.3 References 18427.4 Additional References 18428 Safety Systems 18528.1 Introduction 18528.2 People and Safety Systems 18528.3 Bypassing and Disabling Safety Systems 18528.4 Shutdown Systems 18828.5 Selection of Safety Systems 18928.6 Common Cause Failures in Safety Systems 18928.7 Tools 19028.8 References 19029 Competence Management 19129.1 Introduction 19129.2 Elements of Competence Management 19329.3 Tools 19629.4 References 19729.5 Additional References 19730 Emergency Preparedness and Response 19930.1 Introduction 19930.2 Tools 19930.3 Reference 20230.4 Additional References 20231 Incident Investigation 20331.1 Introduction 20331.2 Issues/Examples 20331.3 Tools 20531.4 References 205Appendix. Human Factors Checklist 207Index 225