HF Design for Operability and Maintenability

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HF Design for Operability and Maintenability
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What is covered

• Background, why the need for HF in design.
• HF Models for design, inspection and maintenance.
• Examples where design ignored HF.

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Technische Universität Berlin
Why Human Factor?
Safety Improvement
Time
Industrial Revolution
2003
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The Design Team
Management
Design Output
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Technische Universität Berlin
The Principle

• Participatory design that involves operator (as
  the user) participation and task modelling at
  early stages.
• To make all departments feel that they own the
  design process.
• Human Factors are included from early stages and
  not to only for cosmetic purposes.

• To train Engineers to be HF experts
• To involve cognitive and physical ergonomists
  permanently actively in design projects

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Technische Universität Berlin
HF BARRIER
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Technische Universität Berlin
HF Iterative design Model
Commissioning Installation
Review
Evaluate
Conceptual Design
Basic Design
Detailed Design
Check
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Technische Universität Berlin
HF Iterative design Model
Commissioning Installation

• Abstract of design
• HF reviews
• Overview of tasks

Review
Evaluate
Conceptual Design
Basic Design
Detailed Design
Check
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Technische Universität Berlin
HF Iterative design Model
Commissioning Installation

• Abstract of design
• HF reviews
• Overview of tasks

Review
Evaluate
Conceptual Design
Basic Design
Detailed Design
Check

• User profile Biometrics
• Task analysis
• Critical tasks, Task scenarios
• Subtasks formulation
• Function analysis
• Link analysis

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Technische Universität Berlin
HF Iterative design Model

• HF training for contractors
• Feedback for an improvement

Commissioning Installation

• Abstract of design
• HF reviews
• Overview of tasks

Review
Evaluate
Conceptual Design
Basic Design
Detailed Design
Check

• User profile Biometrics
• Task analysis
• Critical tasks, Task scenarios
• Subtasks formulation
• Function analysis
• Link analysis

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Technische Universität Berlin
HF Iterative design Model

• HF training for contractors
• Feedback for an improvement

Commissioning Installation

• Abstract of design
• HF reviews
• Overview of tasks

Review
Evaluate
Conceptual Design
Basic Design
Detailed Design
Check

• User profile Biometrics
• Task analysis
• Critical tasks, Task scenarios
• Subtasks formulation
• Function analysis
• Link analysis

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• Detailed presentation of design
• Application of HF guidelines
• Task analysis review

Detailed design
Review
Check
Evaluate
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Technische Universität Berlin

• Detailed presentation of design
• Application of HF guidelines
• Task analysis review

Detailed design
Review

• Simulation
• Prototyping
• Operator testing training
• Cognitive walkthroughs

Check
Evaluate
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• Detailed presentation of design
• Application of HF guidelines
• Task analysis review

Detailed design
Review

• Simulation
• Prototyping
• Operator testing training
• Cognitive walkthroughs

• Specifications
• Error causes precursor Analysis and mitigation
• Evaluate results
• New concepts needed?

Check
Evaluate
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Technische Universität Berlin

• Detailed presentation of design
• Application of HF guidelines
• Task analysis review

• Are the error causes precursors designed
  out?
• Are they guarded against?
• Warn against?
• Training to avoid error occurrence?

Detailed design
Review

• Simulation
• Prototyping
• Operator testing training
• Cognitive walkthroughs

• Specifications
• Error causes precursor Analysis and mitigation
• Evaluate results
• New concepts needed?

Check
Evaluate
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HF Main Areas
Designing to reduce Human Error Precursors HF
Guidelines
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Inspection Model
Decision Response
Steps
Initiate
Access
Search
Action Example
HF Design Requirement
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Technische Universität Berlin
Inspection Model
Decision Response
Initiate
Access
Search
Steps

• Read understand work card
• Select inspection tools.
• Calibrate if necessary (NDI equipment)

Action Example

• Work card design
• Permit to-work procedures

HF Design Requirement
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Technische Universität Berlin
Inspection Model
Decision Response
Access
Initiate
Search
Steps

• Read understand work card
• Select inspection tools.
• Calibrate if necessary (NDI equipment)

• Locate area on the plant
• Move to work site

Action Example

• Work card design
• Permit to-work procedures

HF Design Requirement

• Proper clear labelling.
• Avoid difficult-to-reach areas.
• Easy safe isolation.
• Purging

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Technische Universität Berlin
Inspection Model
Decision Response
Access
Search
Initiate
Steps

• Read understand work card
• Select inspection tools.
• Calibrate if necessary (NDI equipment)

• Move eyes or probe on search areas

• Locate area on the plant
• Move to work site

Action Example

• Work card design
• Permit to-work procedures

HF Design Requirement

• Clear access
• routes.
• Good lighting
• Reachable locations

• Proper clear labelling.
• Avoid difficult-to-reach areas.
• Easy safe isolation.
• Purging

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Technische Universität Berlin
Inspection Model
Decision Response
Initiate
Access
Search
Steps

• Re-examine area of indication and mark as a
  defect if necessary.
• Write a Non routine repair (NRR)

• Read understand work card
• Select inspection tools.
• Calibrate if necessary (NDI equipment)

• Move eyes or probe on search areas

• Locate area on the plant
• Move to work site

Action Example

• Training of maintenance personnel.

• Work card design
• Permit to-work procedures

HF Design Requirement

• Clear access
• routes.
• Good lighting
• Reachable locations

• Proper clear labelling.
• Avoid difficult-to-reach areas.
• Easy safe isolation.
• Purging

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Repair/Maintenance Model
Site Access
Part Access
Steps
Initiate
Buy-back
Reset
Action Example
HF Design Requirement
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Technische Universität Berlin
Repair/Maintenance Model
Site Access
Part Access
Initiate
Buy-back
Steps
Reset

• Make tools ready, collect parts, inspect parts

Action Example

• Well design parts stores with parts clearly,
  logically labelled numbered

HF Design Requirement
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Repair/Maintenance Model
Site Access
Part Access
Initiate
Buy-back
Steps
Reset

• Make tools ready, collect parts, inspect parts

• With tools, parts, equipment
• Isolate equipment/ plant

Action Example

• Well design parts stores with parts clearly,
  logically labelled numbered

• Sufficient pathways to worksite with all required
  tools equipment included
• Easy Safe Isolation

HF Design Requirement
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Technische Universität Berlin
Repair/Maintenance Model
Part Access
Site Access
Initiate
Buy-back
Steps
Reset

• Isolate equipment.
• Open the parts that need repair

• Make tools ready, collect parts, inspect parts

• With tools, parts, equipment
• Isolate equipment/plant

Action Example

• Well design parts stores with parts clearly,
  logically labelled numbered

• Sufficient pathways to worksite with all required
  tools equipment included
• Easy Safe Isolation

HF Design Requirement

• Accessibility of part. to avoid working at
  awkward positions
• Easy safe isolation
• Purging

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Technische Universität Berlin
Repair/Maintenance Model
Site Access
Part Access
Reset
Initiate
Buy-back
Steps

• Isolate equipment.
• Open the parts that need repair

• Adjust systems to specs and inspect adjustment.

• Make tools ready, collect parts, inspect parts

• With tools, parts, equipment
• Isolate equipment/plant

Action Example

• Gauges and other indicators easily readable and
  shall be within eye reach

• Well design parts stores with parts clearly,
  logically labelled numbered

• Sufficient pathways to worksite with all required
  tools equipment included
• Easy Safe Isolation

• Accessibility of part. to avoid working at
  awkward positions
• Easy safe isolation
• Purging

HF Design Requirement
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Technische Universität Berlin
Repair/Maintenance Model
Site Access
Part Access
Buy-back
Initiate
Steps
Reset

• Isolate equipment.
• Open the parts that need repair

• Adjust systems to specs and inspect adjustment.

• Make tools ready, collect parts, inspect parts

• With tools, parts, equipment
• Isolate equipment/plant

• Examine if repair meets standards.
• Close document

Action Example

• Training of maintenance personnel.
• Good communication

• Gauges and other indicators easily readable and
  shall be within eye reach

• Well design parts stores with parts clearly,
  logically labelled numbered

• Accessibility of part. to avoid working at
  awkward positions
• Easy safe isolation
• Purging

• Sufficient pathways to worksite with all required
  tools equipment included
• Easy Safe Isolation

HF Design Requirement
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Repair/Maintenance Example
Pasadena Incident, October 23rd 1989

• Settling legs clogged by plastic material.
• Frequent cleaning was needed.
• The clogged leg is isolated but reactor keep on
  operating.

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Repair/Maintenance Example
Pasadena Incident, October 23rd 1989

• Valve operated by air.
• Connectors for open and close were identical.

DEMCOR Valve
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Repair/Maintenance Example
Pasadena Incident, October 23rd 1989
Consequences

• Explosion with the force of 2.4 tons of TNT
• 23 fatalities
• More than 130 injuries
• Nearly a billion dollars in asset damaged

HF design questions

• Was the isolation easy and safe?
• Was the alarm system detectable, could it be
  discriminated?
• Were the access/escape routes designed to contain
  an emergency situation, were they clearly marked?

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• Task
• To fill tank 1
• Close Valves 2 3 and open valve 1.
• Possible error
• Either valve 1 or 2 or both valves are left open
• ? Product to the wrong tank

Operational example
Technische Universität Berlin
Product1
Tank 1
Valve 1
Product2
Tank 2
From loading rack
Valve 2
Product3
Tank 3
Valve 3
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Solution
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Conclusions
Technische Universität Berlin

• HF should be as old as the conceptual stage of a
  design process.
• Iterative design process helps to reduce error
  causes
• before the whole design process is concluded.

Most important is to eliminate the Myth
The Primary function of a design engineer is to
make things difficult for the fabricator and
impossible for the the serviceman.
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Technische Universität Berlin
Thank you for your kind attention