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ABADI MASELA FLNG FEED

Human Factors Awareness Hand-out

H-000-1245-005

Abbott Risk Consulting Ltd


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Human Factors
Human Factors refer to job, organisational and
human and individual characteristics, which
influence behaviour at work in a way which can
affect health and safety
Design around human capabilities and limitations
Physical (size, shape, strength)
Mental (knowledge, skills, attitudes, situation appreciation)

Maximise Human Performance


Minimise Human Error
Preserve Human Health & Safety
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Human Factors why bother?

Humans are fallible but good design can reduce


and sometimes eliminate human error.
Human error can be expensive
It can cost $$$ in terms of production stoppages,
damage to equipment, environmental damage,
injury/loss of life (litigation), and loss of company
reputation & stock market value.

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Plant, Process & People

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Human Factors and the barrier model

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People - Size
Stature = 1874mm
Breadth = 616mm

Design access volumes for the 95th%ile Male


Design reach distanced for the 5th%ile Female

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Stature = 1479mm
Breadth = 369mm

People - Strength & physiology


Design to minimise dependence on strength
Max 66N* to crack small hand-wheel or operate lever
Max 445N* to crack larger hand-wheel or operate lever
Avoid need for portable torque extensions
Max 147N of sustained force to continue operation once cracked
Minimise number of rotations from open to close (max 100)
* Only applicable if in the preferred or acceptable zones (lower max. if outside)
Consider location of equipment and access to it if manual handling is required.
Maximum 23kg for 1 person lift & 45.5kg for 2 person lift

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People Cognition / Information Processing

Our brain is constantly making sense of the work around us


as experienced by our senses
We interpret information we are presented with in our
environment based on rules we have learnt, and our
expectations
We act on our interpretation of this
information - our mental model

Cognitive error is main source


of human error

Slips
Lapses
Mistakes
Violations
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SLIP

A simple frequently performed physical action


goes wrong.

Example solutions

You reach for button A (which is the raise


control for a hoist) but push button B (the lower
control) instead. On the control pad, Button B is
below Button A. Your error lowers the
object being moved onto electrical cables that
carry a critical power supply to the plant.

Another type of slip is reading the wrong


instrument. Again, if gauges are too
close to each other, there is a risk of reading the
wrong one.

better layout of controls (and


displays) functional grouping
design of controls to make it difficult
to operate them accidentally;
strict control so you never lift loads
above vulnerable equipment (or
physical barriers above if you cant
avoid this)

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9

LAPSE

A lapse of attention or memory.

Example solutions

At Step 9 in your 25-step start-up procedure the


phone rings and you answer.

Afterwards you go back to the task, forgetting


where you were in the sequence. You miss out
steps 10 and 11 and go straight to step
12. However, steps 10 and 11 are important safety
precautions.

provide written procedures that have


place markers or spaces to tick off
each step.
Supervise key tasks.
Strictly enforce rules about
interrupting staff on critical tasks.

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10

MISTAKE

Not understanding properly how something works or an


error of diagnosis or planning.

Example solutions

Your plant starts to behave oddly - you notice fluid flowing


in a waste pipe through a valve that you believed was
closed. You try to work out why its doing this and how to
get the plant back to normal.

You dont have the right data or experience, therefore,


your diagnosis and recovery plan are wrong. You think the
valve has been opened in error so you close it. This diverts
fluid via an overflow to a tank. The maintenance crew in
the tank had actually opened the valve manually to drain
hazardous waste to a treatment vessel while they work. It
was their error that they did not tell you, but your
solution sends the hazardous waste into their work area.

increase the knowledge and


experience applied to such problems
(by improving operator competence
or by ensuring that operators discuss
complex situations in a group and
later share knowledge around the
plant).
use special procedures (decision aids)
that guide you to a safe solution.

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11

VIOLATION

A deliberate breach of rules and procedures.

Example solutions

you are fitting a new pump and stores have given


you the wrong type of seal.

Its almost the same specification as the one you


want. It would take too long to get the right one
so you fit the one you have and leak test it.

It works OK.

After a few weeks of operation, the seal fails


because it is not designed for that pump.

Improve culture and attitudes


towards safety
Make procedures clearer and easier
to follow
Identify where supervision & cross
check is required
Think about applicability of
behavioural safety
Review whether labelling of
equipment items in stores could be
improved

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12

Performance Shaping Factors

Job factors

Person factors

Organisation factors

Clarity of signs, signals &


instructions
System / equipment
interface
Difficulty / complexity of
task
Divided attention
Procedures
PTW or risk assessment
Tools
Communication
Working environment

Physical capability
Fatigue
Stress / morale
Workload
Competence
Motivation

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Work pressure / priorities


Supervision
Communication
Staffing levels
Peer pressure
Role clarity
Consequences of failure
Organisational learning
Safety culture
Change management

Human Factors in recent energy industry disaster

1988 Piper Alpha oil rig

1989 Exxon Valdez

1986 Chernobyl power station

2005 BP Texas City refinery

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2005 Buncefield Oil Storage Depot

2010 Deepwater horizon, Gulf of Mexico

Human Factors Regulation

Human failures are responsible for


around 80% of all types of
accident and feature in almost
every major accident.
Increasingly regulators around the
world are demanding that oil and
gas companies pay far more
attention to human factors in both
design projects and existing
operations and policy.

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ISO Standards (e.g. ISO11064 CCR Design)


OGP Guidance HF in Projects
Operator standards (e.g. Shell DEPs, Chevron
SID, TOTAL GS
Assessment Principles for Offshore Safety Cases
(UK)
COMAH Human Factors requirements (UK)

Benefits of Human Factors

Benefits of applying HF
Increased

Ease of use
Ease of maintenance
Ease of learning
System reliability
Personnel safety & health
Satisfaction, trust, & loyalty
Productivity

Decreased
(Major) accidents, injuries &
illnesses
Need for re-design & recall
(CAPEX)
Near misses
Lost workdays
Error rates
Absenteeism & turnover
Equipment damage / downtime

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What can I do about it !?

Accept that humans can and will fail

Look for where human failure will


have a serious consequence

You can do a lot to fix the problems


when you find them during design

Get help from HF specialists if a


problem seems impossible to solve!

You cant
change the
human
condition, but
you can
change the
conditions
humans work
under
Reason & Hobbs 2003

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Human Factors scope on Masela


FLNG FEED

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18

FLNG

Large vessel, big modules & big


equipment, big pipework
Cryogenic contact risk to personnel and
equipment
Consolidation of liquefaction process
onto vessel (novel application)
High volume hydrocarbon storage, and
specialist LNG containment (antisloshing)
Offload of LNG & NGL products
More people on board
+ dont forget the usual FPSO gas and
condensate processing risks

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Overview of HFE Programme of Work


Human Factors Analysis & Design

Human Factors Management

HFE Screening
Identification of Valves Analysis
FEEEM / Task Analysis
SHERPA Human Error Analysis
HFE Cost Benefit Analysis
HFE 3D model reviews
HFE in HAZOP
Human Error Probabilities
Input to Safety Case
Control Room Ergonomics

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HFE Schedule & HFIP


HFE Specification
HFE Awareness Briefings
Project Ergonomics Team
HFIP for EPC phase

HFE Standards

SHELL DEPs

DEP 30.00.60.10 HFE in Projects


DEP 30.00.60.13 HFE - Valve Analysis
DEP 30.00.60.14 HFE in Construction
DEP 30.00.60.15 HFE in Control Room Design
DEP 30.00.60.16 Human Machine Interface Design for Situation Awareness
DEP 30.00.60.18 HFE in Skid Package Units
DEP 30.00.60.19 HFE - Safety Critical Tasks
DEP 30.00.60.20 Workplace Design Specification
DEP 30.00.60.21 Labeling and Signage

Project HFE Specification

The above standards, plus other requirements from ISO, EEMUA and
industry best practice
AF09B-450-HE-SPC-0001 / S-450-1245-001 (when published)

H-000-1245-005

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HFE Screening

Identify the most critical, complex & frequently used equipment


in order to focus HFE effort in the right areas.

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FEEEM / Task Analysis

Determine design requirements for important human tasks


Identify which human tasks require further review of human error potential

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SHERPA Human Error Analysis

What potential for human error exists for the HIGH priority tasks from FEEEM?
What are the consequences of these errors and what controls are in place?
Has the risk been reduced to sufficiently? More / different BARRIERS required?

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HFE 3D model reviews

Review topsides modules against HFE Shell DEP requirements


Captured comments in J-MRMS
Close-out comments in liaison with disciplines ahead of 30% model review

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Identification of Valves Analysis (IVA)

Determine access requirements to valves based on their process /


safety criticality and frequency of use.
Show VC rating on P&IDs
Colour code C-1 valves in 3D model

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Control Room Ergonomics Study


1

Role ref#

Functional Adjacency
Task Analysis
Control Room 3D modelling

Role Ref# Role / Role


Subsea, Inlet & Hot

HH

1 section Op
2

Cold section &


fractionation Op

HH

Marine Op

PTW
Controller

6
Production
Supervisor
(SP)

L
L
L
L

L
H

H
M

L
M
L

Production Supervisor

Production

ICSS System controller

Systems Maintenance

L
M
L
L

L
M
L
L

L
M
L
L

L
M
L
L

M
M
L
L

L
M
L
L

L
H
H
L

L
M
L
L

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Radio
HSE manager Operator

OIM

9 technician
10 Field Operator
11 OIM
12 HSE manager
13 Radio Operator

13

8 (CER)

12

7 Superintendant (SIP)

11

6 (SP)

10

4 Marine Op

Production ICSS System Systems


Superintend controller
Maintenanc Field
ant (SIP)
(CER)
e technician Operator

3 Utilities Op

5 PTW Controller

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Subsea,
Inlet & Hot
section Op

Cold section
&
fractionatio
Utilities Op
n Op

L
L
L
L

Project Ergonomics Team (PET)

Oversee implementation
of the project HFE
Strategy
Provide a forum to
resolve crossdisciplinary issues

Role
Project PET Chair

Responsibilities

Project HFE
Coordinator

Coordination of HFE activities and


delivery of the HFE work scope.

Chair the PET meetings and


highlight critical issues with other
members of the project management
team to ensure necessary follow-up.

Name
Takashi Nozato

Yuda Hartanto

Update the HFIL.


Update list of HFE Deviations from DEP.

HFE Technical
Authority
HFE Contractor

Quality Assurance and Quality


Control of the HFE CTR deliverables.

Takashi Nozato

Undertaking the agreed programme of HFE work, and producing


associated deliverables.

Matt Barron

Minute the PET meeting.

Facilitate integration of
HFE across the project

H-000-1245-005

Project Safety
Representative

To ensure that there is a high level of coordination between key


HFE issues and the overall HSE work activities on the project.

Takashi Nozato

Project O&M
Representative

To provide an O&M perspective on key HFE issues raised and


discussed at PET.

Paul McConnell

Topsides
Interface

Ensure that HFE issues identified relating to Topsides scope of


work are correctly shared and actioned within JGC. Report to
PET with any HFE issues and concerns to be addressed.

Yuda Haritanto

Hull Interface

Ensure that HFE issues identified relating to Hull scope of work


are correctly shared and actioned within SHI. Report to PET with
any HFE issues and concerns to be addressed.

Yuda Haritanto

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Ensure that HFE issues identified relating to Turret scope of work Yuda Haritanto
Turret Interface
are correctly shared and actioned within MODEC / SOFEC.
Report to PET with any HFE issues and concerns to be addressed.

HFE Shell DEP Deviations Management

DEP NUMBER
DEP 30.00.60.13
DEP 30.00.60.15
DEP 30.00.60.16

DEP TITLE
HFE Valve Analysis - Appendix B only
HFE Control Room Design - Section 4 & Appendix A only
HFE Human Machine Interface Design for Situational Awareness Section 4 only

DEP 30.00.60.18
DEP 30.00.60.20

HFE Design & Procurement of Skid Packaged Units - Appendix D only


HFE Workspace Design - Section 3 to section 5 only

1.
2.
3.
4.
5.
6.
7.

Engineering Discipline provides written case for HFE DEP deviation (using the DEP Deviation Request form to the
HFE Coordinator;
HFE Coordinator circulates requested DEP deviations to PET members 1 week prior to PET meeting;
PET members review the DEP deviation form(s) ahead of PET meeting;
For Deviation requests flagged as High Priority, which require an urgent response in the interests of schedule,
these shall be discussed by PET members outside of the monthly PET meetings, and a decision reached.
PET members discuss the DEP deviation form(s) during the PET meeting and agree (by consensus) how to treat the
deviation request. The decision of the PET Chair is final.
HFE Coordinator updates the HFE Deviations register (See Appendix B) with status of deviation as either a)
ENDORSED, b) FURTHER STUDY, or c) REJECTED.
HFE DEP Deviations which are ENDORSED shall then be forwarded to COMPANY via a Technical Query to seek
official COMPANY approval for the deviation. HFE Coordinator shall compile and submit the Technical Query.

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HFE Shell DEP Deviations Management

H-000-1245-005

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Some key HFE requirements


impacting LAYOUT

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31

Working space
DEP 30.00.60.20
As a minimum, adequate
standing workspace shall
be provided wherever an
operator or maintainer is
required to work

Parameter
A
B
C

Width
Depth
Height

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Minimum
Dimensions
1000mm
1000mm
2100mm

Where operators are


required to undertake
manual tasks from a
squatting or kneeling
position

Parameter
A
B
C

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Width
Depth
Height

Minimum
Dimensions
1300mm
1300mm
1300mm

Walkways
DEP 30.00.60.20
Minimum
Dimension
One person walking sideways in restricted area (e.g. machinery 600mm
space, skid packages, etc.) without bulky clothing
One person travelling forward in area with limited access
750mm
Walkways (or thoroughfares) usually subject to passage or 900mm
crossing of several persons simultaneously, OR
Corridor or passageway which serves as a required exit in 1000mm
temporary accommodation
Application

Operating aisles within process areas


OR
1200mm
External walkways designated as escape routes on offshore
facilities
OR
Route inside the permanent accommodations module, 1500mm
buildings, or other areas where 50 or more persons could
congregate, that serves as an emergency exit from manned
spaces

A clear unobstructed (clash free) escape volume


of 1200mm
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wide by 2300mm high shall be maintained along the full length
of the escape route.

Provide escape and access


routes in the 3D model and
ensure they are clash free in 3D
and joined-up

If you need to model piping or


structure which clashes with
access, raise an action to fix it,
dont leave for clash detection
or model review to find.

Distance to escape points

In elevated decks or platforms,


the maximum distance an
operator should have to run to
reach a point of escape from
that module (a stair tower or
ladder) is 15m.
Length of a dead-end shall be
maximum 5m. This is CLIENT
requirement (Shell DEP states max 7m)
DEP 30.00.60.20

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Number of escape points

The following shall have a secondary


means of escape:
all elevated work platforms
serving fired equipment or three
or more vessels;
all elevated work platforms
serving two or more pieces of
equipment that are concurrently
maintained and operated;
elevated work areas that have an
area of 20 m2 or more.
DEP 30.00.60.20
H-000-1245-005

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Ladders

Maximum unbroken ladder length


shall be 9m.
Side step ladders are preferred.
PET approval for step through.
Ensure 2300mm minimum head
clearance at top of ladders.
Clear route to exit from bottom of
ladder model access volumes
Avoid ladder volume clash with
escape / access routes
DEP 30.00.60.20
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APPLY max 1755mm (reduced by


75mm for SE Asian population)

Valve position
DEP 30.00.60.13

APPLY max 1195mm (reduced by


100mm for SE Asian population)

All C-1
Valves
All C-1
Valves

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Allow 1300mm behind hand-wheel if located


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in the lower Acceptable zone, to
accommodate squatting or kneeling posture.

Valve Location
Derived best practice

Locate the hand wheels / levers of


valves considering the optimal location
for human operation.
Valve handwheels orientated in-line with
pipe are harder to operate
biomechanically (require more force).
Avoid Operator having to access or use
handwheel / lever under structure.
Consider access for maintenance to
valve flanges.

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Displays - standing
DEP 30.00.60.20

Parameter

Dimensions

Maximum height

1730mm

Preferred maximum height

1590mm

Maximum height for vision over


the top

1460mm

Preferred minimum height

1390mm

Minimum height

1120mm

Minimum depth or clearance in


front of panel/console/cabinet
faade

910mm

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Displays - Squatting
DEP 30.00.60.20

Parameter

Dimensions

Maximum height

1190mm

Preferred maximum height

940mm

Preferred Minimum height

670mm

Minimum height

530mm

Minimum depth or clearance in


front of panel/console/cabinet
faade

910mm

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Controls - standing
DEP 30.00.60.20

H-000-1245-005

Parameter

Dimensions

Maximum reach height (Overhead


pinch grip of 5th percentile female)

1770mm

Preferred maximum reach height


(Shoulder height of 5th percentile
female)

1160mm

Preferred minimum height (Hand


grip height of 95th percentile
male)

870mm

Minimum height (Knee height of


95th percentile male)

540mm

Minimum depth or clearance in


front of panel/console/cabinet
faade

910mm

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Controls - Squatting
DEP 30.00.60.20

Parameter

Dimensions

Maximum height

1190mm

Preferred maximum height

790mm

Maximum height for vision over


the top

430mm

Minimum height

380mm

Minimum depth or clearance in


front of panel/console/cabinet
faade

910mm

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Hose Stations / hydrants


Derived best practice

Consider the operation manual fire


fighting in emergency conditions.
The hose station and hydrants must be colocated such that each is clearly visible
from the other, within 3 meters of each
and with no equipment or structure
separating them.
Visible from the process areas (not hidden
behind columns or structure).
Hydrant connection points must be clear of
obstruction to allow connection of hose and
routing of pressurised hose.

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Key Contacts

For:

Submission of HFE Deviation Request form

Raising of any HFE issues / risks

For:

Any HFE technical query

Comment on any HFE standard or project


HFE document

Yuda Hartanto

Takashi Nozato

Human Factors Coordinator


JTM
Email
yuda.hartanto@jgc-indonesia.com
Phone
+62-21-2997 6500 Ext. 70837

HFE Technical Authority


JTM
Email
nozato.takashi@jgc.co.jp
Phone
+62-21-2997 6500 Ext. 70931

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