In contrast to nuclear plants and aerospace systems, human error is largely ignored in quantitative risk assessment for petroleum and chemical plants. Because of this, current risk analysis methods are able to calculate and predict only about one-third of the accidents happening in practice. Human Error in Process Plant Design and Operations: A Practitioner’s Guide shows you how to develop a comprehensive risk assessment that includes human error. Based on the well-known SRK model of human error, this book represents a practical collection of examples and statistics from more than 30 years of study, with many examples of the practical application of methods. The book provides a complete overview of the various types of human error, including operator error, hindrances and inability to function, errors in observation, errors in performing standard procedures, errors in supervisory control, errors in decision making and planning, infractions and violations, design errors, and errors in procedures. It then goes on to identify human error potential and probabilities, and discusses techniques and methodologies that can be implemented to minimize human errors and prevent accidents. The result of the author's observations of human error over a lifetime of work as an operator, as a commissioning coordinator, and as an operations manager, the book demonstrates how to analyse, manage, and mitigate many types of error. By taking advantage of the author's experience and expert knowledge, and by applying the techniques and methodologies illustrated in this book, you will be able to make changes which will make work easier, error free, clearly understood, and more congenial.

Almost all the major accident investigations--Texas City, Piper Alpha, the Phillips 66 explosion, Feyzin, Mexico City--show human error as the principal cause, either in design, operations, maintenance, or the management of safety. This book provides practical advice that can substantially reduce human error at all levels. In eight chapters--packed with case studies and examples of simple and advanced techniques for new and existing systems--the book challenges the assumption that human error is "unavoidable." Instead, it suggests a systems perspective. This view sees error as a consequence of a mismatch between human capabilities and demands and inappropriate organizational culture. This makes error a manageable factor and, therefore, avoidable.

Human Factors Handbook for Process Plant Operations Provides clear and simple instructions for integrating Human Factors principles and practices in the design of processes and work tasks Human Factors, the science of interaction between humans and other elements of a system, draws from disciplines such as psychology, ergonomics, anthropometrics, and physiology to understand how and why people behave and perform as they do—and how best to support them in performing tasks. The goals of the Human Factors approach are to improve human reliability, minimize the risk from human error, and optimize the working environment, human wellbeing, and overall system performance. Human Factors Handbook for Process Plant Operations guides supervisors, managers, and engineers on incorporating Human Factors principles and practices into plant maintenance and operations. With thorough and accessible coverage of all Human Factors topics of relevance to process industries, this easy-to-use handbook uses real-world anecdotes and case studies to demonstrate effective training and learning, task planning, communications, emergency response, risk and error management, and more. Throughout the text, the authors offer valuable insights into why people make mistakes while providing advice on how to help workers perform their process operational tasks successfully. Explains all essential Human Factors concepts and knowledge with clear descriptions and illustrative examples Offers actionable advice and models of good practice that can be applied to design, process operations, start-ups and shut-downs, and maintenance Addresses job aids, equipment design, competence, task support, non-technical skills, working with contractors, and managing change Discusses how lack of Human Factors considerations during the engineering design phase can adversely affect safety and performance Describes how to use indicators to both recognize and learn from human error and performance issues Written by highly experienced operating and maintenance personnel, Human Factors Handbook for Process Plant Operations is an indispensable resource for everyone involved with defining, planning, training, and managing process operations, maintenance, and emergency response in the food, pharmaceutical, chemical, petroleum, and refining industries. The missions of both the CCPS and EI include developing and disseminating knowledge, skills and good practices to protect people, the environment, and property by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS, an industrial technology alliance of the American Institute of Chemical Engineers (AIChE), has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 35 years and has published over 100 books in its process safety guidelines and process safety concept book series. The EI’s Technical Work Program addresses the depth and breadth of the energy sector from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.

Call it the Human element in how a refining and chemical process operation is run....the other side of the machine and control system operation equation. Its value is in lives protected and money saved. This plain English guide to the principles of human factors will enable operations and control personnel—both the experienced and uninitiated— to understand how to successfully incorporate the concepts within their own plants. Through real-world examples, the author explains how human factors engineering concepts do, and must, dovetail with process plant design and operation. Offering practical insights, the book lays out the principles of human-system interactions and how they must be incorporated into any plant and control system from the get go—in order to ensure safe and efficient operations. Control engineers and operations managers will gain incomparable, inside-the-industry experience from: • Clear discussion of performance-shaping factors; • In-depth discussion of key variables in terms of workload and staffing; • A detailed analysis of the all-important human-machine interface, including content and format; • How-to planning for system demands and levels of automation; • Invaluable guidance on worker selection and training, along with sample procedures and job aids; and • Tools for investigation of incidents and near-misses from the human perspective.

Plant Design and Operations provides practical guidance on the design, operation, and maintenance of process facilities. The book is based on years of hands-on experience gathered during the design and operation of a wide range of facilities in many different types of industry including chemicals, refining, offshore oil and gas, and pipelines. The book helps managers, engineers, operators, and maintenance specialists with advice and guidance that can be used right away in working situations. Each chapter provides information and guidance that can be used immediately. For example, the chapter on Energy Control Procedures describes seven levels of positive isolation — ranging from a closed block valve all the way to double block and bleed with line break. The Safety in Design chapter describes topics such as area classification, fire protection, stairways and platforms, fixed ladders, emergency showers, lighting, and alarms. Other areas covered in detail by the book include security, equipment, and transportation. A logical, practical guide to maintenance task organization is provided, from conducting a Job Hazards Analysis to the issue of a work permit, and to the shutdown and isolation of equipment. Common hazards are covered in detail, including flow problems, high pressure, corrosion, power failure, and many more. Provides information to managers, engineers, operators and maintenance personnel which is immediately applicable to their operations Supported by useful, real-world examples and experience from a wide range of facilities and industries Includes guidance on occupational health and safety, industrial hygiene and personal protective equipment

This book shows how to identify potential design errors and modify procedures in the design process to mitigate design-induced error. Real life examples are used to demonstrate the points being made. Many of the concerns raised in the book have come from a worldwide study conducted with designers, managers, and end-users.