Human Factors in the Chemical and Process Industries Human Factors in the Chemical and Process Industries Making it work in practice Edited by Janette Edmonds AMSTERDAM • BOSTON • HEIDELBERG • LONDON • NEW YORK • OXFORD PARIS • SAN DIEGO • SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO Elsevier Radarweg 29, PO Box 211, 1000 AE Amsterdam, Netherlands The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom 50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States Copyright © 2016 Elsevier Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions. This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein). Notices Knowledge and best practice in this feld are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary. Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility. To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein. British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress ISBN: 978-0-12-803806-2 For Information on all Elsevier publications visit our website at https://www.elsevier.com/ Publisher: Joe Hayton Acquisition Editor: Fiona Geraghty Editorial Project Manager: Maria Covey Production Project Manager: Debbie Clark Designer: Mark Rogers Typeset by MPS Limited, Chennai, India This book is dedicated to the staff at The Keil Centre who were all involved in the writing and reviewing of the chapters. Author Profles Chiara Amati—Occupational Psychologist MA, MSc, DBA, C.Psychol Chiara is a Chartered Occupational Psychologist whose main area of expertise is the relationship between the indi- vidual and their work. She has experience of working with individuals, teams, and organizations to promote resil- ience, well-being, and engagement at work. Chiara also has a special interest in management and leadership devel- opment, having recently completed a doctorate study in this area. In her roles as a coach and an experienced facili- tator of leadership development, Chiara also promotes an understanding of how personality shapes individuals’ experience in work contexts. Janette Edmonds—Director/Principal Consultant Ergonomist Janette has a bachelor’s degree in psychology and a master’s degree in ergonomics. Janette is a Chartered Ergonomics and Human Factors Specialist (CErgHF), a Fellow of the Chartered Institute of Ergonomics and Human Factors (FIEHF), and a Chartered Member of the Institution of Occupational Safety and Health (CMIOSH). Janette has been a practitioner since 1994 working in a broad range of industries including oil and gas, petrochemical, chemicals and plastics, nuclear, manufacturing, food production, util- ities, energy, the emergency services, defense, rail, telecoms, medical products, and other applications. Janette has been a human factors manager for several engineering projects and has considerable experience of human factors applied to operational assets, incident investigation, and human reliability. Janette is the course director of the IChemE Human Factors in Health and Safety training program in the United Kingdom and Europe. xxiii xxiv Author Profles Jenny Foley—Clinical Service Manager/Counseling Psychologist Jenny has a bachelor’s degree in psychology, a master’s degree in counseling psychology, and a postmaster diploma in counseling psychology. Jenny is a chartered counseling psychologist and member of The British Psychological Society and registered with the Health and Care Professions Council. As well as assessing and treating a range of condi- tions, Jenny is also a qualifed Eye Movement Desensitisation and Reprocessing (EMDR) practitioner. EMDR is recog- nized as particularly effective in the treatment of trauma. Jenny has a special interest in absence management and the return to work, as well as working with promoting effective communication and healthy relationships. Ken Gray—Director/Occupational Psychologist Ken has an Honors Degree in Psychology and has been Chartered by the British Psychological Society as an Occupational Psychologist since 1995 (CPsychol). He is registered as a professional practitioner with the Health and Care Professions Council (HCPC), holds the Qualifcations in Test Use Register (RQTU), and is on the Occupational Safety and Health Consultants Register (OSCHR). Ken is an Associate Fellow of the British Psychological Society (AFBPS) and a member of the BPS Division of Occupational Psychology. Ken was shortlisted in 2010 for the BPS Practitioner of the Year. With his expertise in behavioral assess- ment, skills and competency advancement, team dynamics, and high impact lead- ership development, Ken works with both individuals and management teams to maximise individual potential and embed safe behaviors within organizations. He is particularly interested in psychological well-being and building resilience; both of which provide a solid basis for those leading organizational change or building future leadership capability. Author Profles xxv Kirsty McCulloch—Principal Human Factors Advisor Kirsty has a bachelor’s degree in psychology and a PhD in Applied Behavioral Science, specializing in fatigue risk management. Kirsty is an adjunct research fellow with Central Queensland University, and a member of the Human Factors and Engineering Society of Australia (HFESA). Kirsty is considered a world expert in fatigue risk management, and her methods have been adopted as regulatory models in several industries, across multiple countries. Kirsty also has extensive experience in under- standing human failure, human factors in incident investi- gation, task analysis, critical procedure reviews, and safety culture. She has worked in many safety-critical industries, including petroleum, mining, power generation, medicine, emergency services, transport, and manufacturing. Johnny Mitchell—Principal Occupational Psychologist Johnny is a Chartered Occupational Psychologist with con- siderable experience in human factors, safety culture, and psychological health. Over the last 10 years he has worked in every continent on global safety culture development projects and related topics. Johnny regularly presents at industry conferences and delivers the safety culture mod- ule on the IChemE Human Factors Course. He recently developed a model of Human Factors Maturity which fea- tured in SHP magazine and a set of tools (TEAVAM) that support the proactive detection and management of human error. Johnny provides training in The Keil Centre’s Human Factors Analysis Tools and he is also frequently involved in supporting organizations to investigate major incidents in the oil and gas, pharmaceutical, chemical, and construction industries. xxvi Author Profles Colin Munro—Consultant Ergonomist Colin is qualifed to master’s degree level with merit in ergonomics (human factors) and with a Bachelor of Science degree with honors in physiotherapy. Colin com- menced his professional career in 2002 and his experience includes 6 years within occupational health and safety for a safety critical organization. Colin has particular interests in ergonomics and human factors applied to design, con- trol room analysis and design, human error analysis, safety culture, and safer systems of work. He has worked in the oil and gas industry, nuclear, rail, biohazard, and medical sectors. Emily Novatsis—Organizational Psychologist/ Principal Human Factors Advisor Emily holds a Bachelor of Science (Honors) degree and a Doctor of Psychology (Organizational) degree, where her research focus was organizational culture. Emily is a Registered Organizational Psychologist and has been a practitioner since 2000, working in the felds of human fac- tors and organizational development. She has worked in both internal and external consulting roles and in a range of hazardous industries. Her experience includes 6 years leading Woodside’s human factors team, where she was instrumental in establishing the organization’s human factors programs and internal capability. Emily’s specifc human factors areas of expertise are organizational and safety culture, competency frameworks, incident investigation, learning and develop- ment, procedure design, and stress management and resilience. Author Profles xxvii Richard Scaife—Director/Occupational Psychologist Richard has a BSc(Tech) in Applied Psychology and a MSc in Occupational Psychology. He is a Chartered Ergonomics and Human Factors Specialist (CErgHF), Fellow of the Chartered Institute of Ergonomics and Human Factors (FIEHF), European Ergonomist (Eur.Erg), Chartered Psychologist (CPsychol), Registered Psychologist with the Health and Care Professionals Council, Chartered Scientist (CSci), and Associate Fellow of the British Psychological Society (AFBPsS). Richard has been a practitioner since 1989, beginning his career as a psychologist with the Royal Air Force. His early career included Human Factors specialist in the defense indus- try and air traffc control, latterly as the head of human safety of the NATS Human Factors Unit. Richard joined The Keil Centre 14 years ago, and has worked in a broad range of industry sectors including aviation, oil and gas, construction, petrochemicals, logistics and distribution, rail, nuclear, manufacturing, food production, defense, and energy. Richard specializes in all aspects of human factors, particularly human factors engineering, organizational safety, human safety analysis (including human error), and incident investigation. Richard has extensive experience of major project management in industry, and of managing teams of human factors and associated professionals. Elaine J. Skilling—Principal Consultant Ergonomist Elaine has a bachelor’s (Honors) degree in physiotherapy and a master’s degree in ergonomics. Elaine is a Chartered Ergonomics and Human Factors Specialist (CErgHF), a Chartered Physiotherapist, a Registered Member of the Health and Care Professions Council (HCPC), and Registered Member of the Association of Chartered Physiotherapists in Occupational Health and Ergonomics (ACPOHE). Elaine has provided ergonomic interventions within a variety of sectors since 2000, including oil and gas, chemical processing, manufacturing pharmaceuticals, and public sectors. Elaine is skilled in safety critical task analysis, human reliability analysis, procedure development, and control room design. She has also developed and implemented behavioral safety culture programs for several international clients. She is a qualifed trainer and has extensive experience in delivering training on mul- tiple human factors topics in many locations throughout the world. xxviii Author Profles Karen Smith—Interior Designer (guest author for Chapter 11) Karen has a Bachelor’s Degree in Interior Design and has focused her career on creating ergonomically compliant and aesthetically pleasing spaces for the 24-hour environ- ment. Karen cofounded BAW Architecture in 1992, with the vision of pioneering best practices in control build- ing design. Recognized globally as a notable speaker and roundtable chair, she is also an accomplished publisher of relevant articles addressing the challenges associated with designing state-of-the-art control buildings. BAW Architecture and The Keil Centre frst collaborated in 2012 to develop the ISO 11064 compliant design of one of the largest iconic centralized control buildings yet to be constructed in the world (2018). The two organizations have since collaborated on ® several control room and building projects. Karen served as the ASM Consortium’s designated representative as an associate member, bringing the unique interior per- spective to the development of Best Practices in Control Building design. Here she received the NIST Advanced Technology Program’s Certifcate of Appreciation for her 10-year contribution to R&D development and implementation. Recently a graduate of the Institute for Integrative Nutrition, Karen will continue to champion the voice of operations through ‘to Designwell’: translating seasoned expertise into skillfully designed control rooms that incorporate proper ergonomics with precision focus on mind, body, and space. John Wilkinson—Principal Human Factors Consultant John has a Psychology and Philosophy dual degree and a postgraduate diploma in health and safety. John is a Chartered Ergonomics and Human Factors Specialist (CErgHF), a Fellow of the Chartered Institute of Ergonomics and Human Factors (FIEHF), a Chartered Member of the Institution of Occupational Safety and Health (CMIOSH), and a Member of the British Psychological Society. John worked in the UK’s Health and Safety Executive (HSE) as a regulator for 22 years and as Human and Organizational Factors (HOF) Team Leader and Principal Specialist Inspector (Human Factors) from 2003. He helped develop the very successful “HSE Key Topics” approach to HOF including the HSE web page guidance, regulator training, safety report assessment, inspection, and investigation. He led the HOF strand of the HSE investigation at Buncefeld, and was an expert reviewer for the US CSB reports on Texas City and Macondo. He has worked with the EU Major Accident Hazards Bureau as a regulator and consultant. Since 2011 John has worked as a practitioner with the Keil Centre on a wide range of HOF projects in the United Kingdom, EU, and further afeld. He has presented widely at conferences and written many papers.