Because Safety is not found in a Box

Transcription

1 SUBTITLE, E.G. INTERNAL SEPTEMBER 18, 2018 Human Factors and their impact on Plant Safety Because Safety is not found in a Box Luis Duran Global Product Manager Safety Systems and Security

2 Agenda Paradigm Shift in Industrial World Industrial Demands on the Operator Technology and Humans Optimization potential or risk factors Corporate Vision Top Ten Human Factors issues Technologies to Improve Plant Operations Systematic Failures and Capabilities Application of Design Best Practices Summary October 18, 2018 Slide 2

3 Paradigm Shift in Industrial World 1 Industrial revolution 2 Industrial revolution 3 Industrial revolution 4 Industrial revolution follows introduction of water and steam powered mechanical facilities follows introduction of electrical-powered mass production uses electronics and IT to achieve further automation and manufacturing Everything real-time connected to internet time today October 18, 2018 Slide 3

4 Paradigm Shift in Industrial World Generation Shift Human Centred Design Technological Development Benefits educated multi-tasking generation collaborative Risks lose of knowledge lose of experience Benefits human centered solutions personalized ergonomic meaningful work place flexible and collaborative WE Risks fits not one for all! Benefits less operators remote access centralized in one place automation combined DCS Systems Risks cyber security automation error one operator, many processes far away from process October 18, 2018 Slide 4

5 Industrial Demands for the Operator October 18, 2018 Slide 5

6 Plant Operations: Optimization potential or risk factor US$ 20 billion (5%) annual loss in the process industry (1) People 22% 42% Equipment Process 36% US$ 20 billion (5%) annual loss in the process industry (1) October 18, 2018 Slide 6

7 Why control systems go wrong and how to prevent failure All Lifecycle Steps matter Specification 21 Design and Implementation Operations and Maintenance 6 43 Installation and Commisioning Changes after Operation October 18, 2018 Slide 7

8 Technology and Humans Technology is a tool for Plant Operations October 18, 2018 Slide 8

9 Human Factors Issues Technology as a tool for Plant Operations Purely Human Organizational change and transition management Safety culture and blame Staffing levels Fatigue from shiftwork and overtime Communications e.g. shift handover Impacted by Technology Ergonomics: (a) design of interfaces (b) health ergonomics Alarm handling Training, competence and supervision Maintenance error Compliance with safety critical procedures October 18, 2018 Slide 9

10 Corporate Vision and Culture Framework Safety Culture Explicit statement of company culture Framework to live the vision Communication of vision and values Verification of the effectiveness of the communication Clear Risk Management Strategy A vigorous Safety Culture helps to Avoid Accidents October 18, 2018 Slide 10

11 Graphics Design: fast reaction, elimination of disturbances October 18, 2018 Slide 11

12 Alarm Handling Avoid distractions and improves Operator response Allows for continuous analysis and optimization to avoid nuisance alarms Helps the operator to focus on the important events in the process Promotes rapid operator evaluation and speedy response October 18, 2018 Slide 12

13 Ergonomics Efficient and motivating Harmonization despite heterogeneity Integration of different information Integration of different groups of people Situational environment Organized Drives better Operator response to abnormalities October 18, 2018 Slide 13

14 IEC and IEC Requirements Competence requirements are not new IEC Those organisations or individuals that have overall responsibility for one or more phases of the overall E/E/PES safety lifecycle, shall specify all management and technical activities that are necessary to ensure that the E/E/PES SRS achieve and maintain the required functional safety In other words a Functional Safety Management System IEC Persons, departments or organisations involved in safety lifecycle activities shall be competent to carry out the activities for which they are accountable October 18, 2018 Slide 14

15 Systematic Failures and Capabilities Impact of Human Factors in System Engineering Systematic Capability Measure of the confidence that the systematic safety integrity of an element meets the requirements of the specified Safety Integrity Level (SIL) - Expressed on a scale of SC 1 to SC 4 Safety Function(s) are applied in accordance with the instructions specified in the element s Safety Manual Determined with reference to the requirements for the avoidance and control of Systematic Faults Systematic Safety Integrity Part of the safety integrity of a safety-related system relating to systematic failures in a dangerous mode of failure Systematic Failure Failure, related in a deterministic way to a certain cause, which can only be eliminated by modification of the Design Manufacturing process, Operational procedures, Documentation Other relevant factors October 18, 2018 Slide 15 3BSE en A

16 Generation Shift: Old vs. Young 40% will retire in less than 12 years Attracting the young generation into the Control Room October 18, 2018 Slide 16

17 From Control Room to Control Center = = October 18, 2018 Slide 17

18 Human Centered Design October 18, 2018 Slide 18

19 Human Centered Design: From traditional October 18, 2018 Slide 19

20 Human Centered Design: to meaningful October 18, 2018 Slide 20

21 Human Centered Design through Technology Development Services Information technologies NANO technologies BIO technologies cognitive science R&D and educative Institution USA Germany Norway Chile Canada = = = = = predictive health-care analytics cloud WE-data October 18, 2018 Slide 21

22 Vinnova Project ABB CR Alarm situation awareness Lighting system integration Sound shower CCTV integration Close large overview Operator activity cloud Multiple monitors Touchpad control panel Telecom integration Smart keyboard integration Motion recognition sensors Sound system integration & telecommunication Personalised ergonomics October 18, 2018 Slide 22

23 Conclusions Safety Culture don t look the other way Safety is an all-inclusive effort 1 Competence: Everybody has appropriate process safety knowledge and expertise Include Root cause analysis of incidents /lessons learned Set up procedures - avoid incident Update HAZOPs 2 3 Proactive asset management best practices Written operating procedures Update Layers of Protection Analysis (LOPA) and Alarm philosophy Perform comprehensive hazard assessment after every incident or accident Benefit from Technologies 4 Consider Systematic Capabilities to drive a better Engineering Practices Design the Operation Environment carefully If you think safety is expensive, try an accident October 18, 2018 Slide 23

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