Human Factors Methods for Improving Performance in the Process Industries Book

Preface     xi
Acknowledgments     xiii
Abbreviations and Acronyms     xv
Introduction     1
Purpose of This Book     1
Human Factors     1
Human Error     3
Structure of This Book     5
Linkage to Other CCPS Publications     6
References     7
The Case for Human Factors     9
Why is Human Factors Needed?     9
Past Incidents     11
Business Value/Justification     11
Human Factors in the Life Cycle of a Chemical Plant     16
Needs Driven Program     17
References     19
Performance Measurement and Improvements     21
Building Improvements into Existing Systems     21
Measures of Performance     22
Roles and Responsibilities     24
Continuous Improvement     25
References     28
Human Factors Tool Kit
Facilities and Equipment
Process Equipment Design     31
Introduction     31
Tools     33
References     33
Additional References     34
Process Control Systems     37
Introduction     37
Issues/Example     37
Tools     39
Additional References     39
Control Center Design     41
Introduction     41
Tools     42
References     43
Additional References     43
Remote Operations     45
Introduction     45
Tools     47
Reference     48
Facilities and Workstation Design     49
Introduction     49
Tools     53
References     55
Additional References     55
Human/Computer Interface     57
Introduction     57
Human Interactions with Control System Software     58
Tools     59
References     63
Additional References     64
Safe Havens     67
Introduction     67
Human Factors Issues     68
Tools     70
References     70
Labeling     71
Introduction     71
Tools     72
References     74
People
Training     77
Introduction      77
Guidelines for Training Programs     77
Guidelines for Designing and Delivering Training     78
Tools     81
References     81
Communications     83
Introduction     83
Issues/Examples     83
Tools     85
References     85
Documentation Design and Use     87
Introduction     87
Converting to Electronic Documentation     88
Use of Documents     90
Tools     92
References     93
Additional References     94
Environmental Factors     95
Introduction     95
Noise     95
Vibration     96
Temperarure and Relative Humidity     99
Air Quality     101
Lighting     102
References     105
Workloads and Staffing Levels     107
Introduction     107
Issues/Examples     107
Tools     108
References     109
Shiftwork Issues     111
Introduction     111
Tools     112
References     114
Additional References     114
Manual Materials Handling     117
Introduction     117
Manual Materials Handling Guidelines     118
References     121
Additional References     122
Management Systems
Safety Culture     125
Introduction     125
What is Safety Culture?     125
Tools     127
Safety Culture: A Process Industry Case Study     130
Benefits     131
References     131
Additional References     132
Behavior Based Safety     133
Introduction     133
Tools     134
Expected Results     137
References     137
Additional References     138
Project Planning, Design, and Execution     139
Introduction     139
Human Factors Tools for Project Management     139
References     143
Procedures     145
Introduction     145
Tools     146
References     151
Additional References     151
Maintenance     153
Introduction     153
Identifying Critical Maintenance Tasks     153
Maintenance Protocol     154
Tools     155
References     156
Safe Work Practices and Permit-to-Work Systems     159
Introduction     159
Issues     159
Tools     163
References     164
Additional Reference     164
Management of Change     165
Introduction     165
Tools     167
References     172
Qualitative Hazard Analysis     175
Introduction     175
Tools-Human Failures     176
Tools-Human Factors     177
References     179
Additional References     180
Quantitative Risk Assessment     181
Introduction     181
Tools     183
References     184
Additional References     184
Safety Systems     185
Introduction     185
People and Safety Systems     185
Bypassing and Disabling Safety Systems     185
Shutdown Systems     188
Selection of Safety Systems     189
Common Cause Failures in Safety Systems      189
Tools     190
References     190
Competence Management     191
Introduction     191
Elements of Competence Management     193
Tools     196
References     197
Additional References     197
Emergency Preparedness and Response     199
Introduction     199
Tools     199
Reference     202
Additional References     202
Incident Investigation     203
Introduction     203
Issues/Examples     203
Tools     205
References     205
Human Factors Checklist     207
Index     225