RUWAIS LNG PROJECT
HUMAN FACTOR DESIGN SPECIFICATION
COMPANY DOCUMENT REF. RLNG-000-PM-PP-2501
CONTRACTOR DOC. REF.
215122C-000-PP-2501
REVISION: 1A
PAGE 1 OF 81
ADNOC GAS
HUMAN FACTOR DESIGN SPECIFICATION
COMPANY Contract No.
4700022871
JV TJN RUWAIS Contract No
215122C
Document Class
Class 2
Document Category (for Class 1)
OPERATING CENTER Contract No.
OPERATING CENTER Doc Ref.
1A
1
0
IFC – Issued for Construction
2-Aug-2024
X.Carcaud
A de Vandière
S Deilles
IFC – Issued for Construction
24-Apr-2024
X Carcaud
A de Vandière
S Deilles
ICR – Issued for Company Review
9-Apr-2024
X Carcaud
A de Vandière
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Rev.
Revision Purpose
Date
Prepared by Checked by Approved by
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
HUMAN FACTOR DESIGN SPECIFICATION
COMPANY DOCUMENT REF. RLNG-000-PM-PP-2501
CONTRACTOR DOC. REF.
215122C-000-PP-2501
REVISION: 1A
PAGE 2 OF 81
Table of Contents
Contents
Page
1.0
INTRODUCTION… 4 1.1 Project Objective and Location … 4 1.2 Scope of the Document … 4 1.3 Holds List … 4 1.4 References … 4 1.5 Definitions and Abbreviations … 4 2.0 Appendix … 5 2.1 AGES-SP-03-004 … 5
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
HUMAN FACTOR DESIGN SPECIFICATION
COMPANY DOCUMENT REF. RLNG-000-PM-PP-2501
CONTRACTOR DOC. REF.
215122C-000-PP-2501
REVISION: 1A
PAGE 3 OF 81
Table of Changes compared to previous revision (for Procedures and Job Specifications only)
Paragraph
Modification description
Remarks / Origin
Changes limited to template update
Page 32
Statement removed to avoid access obstruction
As per CPY comment on Rev 1
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
HUMAN FACTOR DESIGN SPECIFICATION
COMPANY DOCUMENT REF. RLNG-000-PM-PP-2501
CONTRACTOR DOC. REF.
215122C-000-PP-2501
REVISION: 1A
PAGE 4 OF 81
1.0
1.1
INTRODUCTION
Project Objective and Location
The ADNOC Ruwais LNG Project is a two train, near net-zero electrically driven LNG facility, targeting international markets. The feed gas for the project is supplied from the Habshan Gas Processing Plant via a new export gas pipeline. The plant will have two 4.8 MTPA (nominal capacity) electric driven LNG Trains with associated LNG storage/marine export facilities and utilities.
Figure 1 – Project Context
The ADNOC Ruwais LNG Project foresees the following main components at the facility:
• Onshore LNG Liquefaction facilities for 2 x 4.8 MTPA electrically driven LNG Trains (9.6MTPA
total)
• Common facilities including inlet receiving facilities, LNG storage, BOG handling, flare,
refrigerant storage and support buildings.
• Utilities to support the facilities including import power from the national grid.
• Marine facilities for LNG export and bunkering.
1.2
Scope of the Document
This specification endorses ADNOC General Engineering Specification AGES-SP-03-004 which is attached hereto in Appendix 1, without any change.
1.3
Holds List
Not Applicable
1.4
References
[1] AGES-SP-03-004
Human Factors Engineering
1.5
Definitions and Abbreviations
COMPANY
CONTRACTOR
LNTP EPC
ABU DHABI NATIONAL OIL COMPANY (ADNOC) P.J.S.C. TJN Ruwais, Joint Venture of Technip Energies France-Abu Dhabi, JGC Corporation and National Petroleum Construction Company (NPCC) Limited Notice To Proceed Engineering Procurement Construction
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
RUWAIS LNG PROJECT
HUMAN FACTOR DESIGN SPECIFICATION
COMPANY DOCUMENT REF. RLNG-000-PM-PP-2501
CONTRACTOR DOC. REF.
215122C-000-PP-2501
REVISION: 1A
PAGE 5 OF 81
ADOC POC YOC
Abu Dhabi Operating center - National Petroleum Construction Company Paris Operating Center - Technip Energies Yokohama Operating center - JGC Corporation
2.0
APPENDIX
2.1
AGES-SP-03-004 rev 1
The terms of Contract / Agreement No: CON22-146 shall apply for any disclosure of this document to any third party.
THE CONTENTS OF THIS DOCUMENT ARE PROPRIETARY AND CONFIDENTIAL.
ADNOC GROUP PROJECTS AND ENGINEERING
HUMAN FACTORS ENGINEERING
Specification
APPROVED BY:
NAME: Abdulmunim Al Kindy TITLE: Executive Director PT&CS EFFECTIVE DATE:
AGES-SP-03-004
All parties consent to this document being signed electronically -PT&CS/GP/INT/2021/20121Abdul Munim Al Kindy
GROUP PROJECTS & ENGINEERING / PT&CS DIRECTORATE
CUSTODIAN ADNOC
Group Projects & Engineering / PT&CS Specification applicable to ADNOC & ADNOC Group Companies
REVISION HISTORY
DATE
REV.
NO
PREPARED BY (Designation / Initial)
REVIEWED BY (Designation / Initial)
ENDORSED BY (Designation / Initial)
ENDORSED BY (Designation / Initial)
20-Dec-2021
1
Rajeevan K Maroli/ TL. HSE
Mahmoud Abdel Hakim/ HOD Pipeline Eng. - GPE
Najem Qambar/ VP Group Eng.- GPE
Ebraheem Al Romaithi / SVP- GPE
Reuben Yagambaram/ Manager Proj. Portfolio- GPE
Ali Al Breiki / VP Upstream Projects- GPE
Group Projects & Engineering is the owner of this Specification and responsible for its custody, maintenance and periodic update.
In addition, Group Projects & Engineering is responsible for communication and distribution of any changes to this Specification and its version control.
This specification will be reviewed and updated in case of any changes affecting the activities described in this document.
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INTER-RELATIONSHIPS AND STAKEHOLDERS
The following are inter-relationships for implementation of this Specification:
i. ADNOC Upstream and ADNOC Downstream Industry, Marketing & Trading Directorate.
ii. ADNOC Onshore, ADNOC Offshore, ADNOC Sour Gas, ADNOC Gas Processing. ADNOC LNG,
ADNOC Refining, Fertil, Borouge, Al Dhafra Petroleum, Al Yasat
The following are stakeholders for the purpose of this Specification:
iii. ADNOC PT&CS Directorate
This Specification has been approved by the ADNOC PT&CS is to be implemented by each ADNOC Group company included above subject to and in accordance with their Delegation of Authority and other governance-related processes in order to ensure compliance.
Each ADNOC Group company must establish/nominate a Technical Authority responsible for compliance
with this Specification.
DEFINITIONS
“ADNOC” means Abu Dhabi National Oil Company.
“ADNOC Group” means ADNOC together with each company in which ADNOC, directly or indirectly, controls fifty percent (50%) or more of the share capital.
“Approving Authority” means the decision-making body or employee with the required authority to approve Policies & Procedures or any changes to it.
“Business Line Directorates” or “BLD” means a directorate of ADNOC which is responsible for one or more Group Companies reporting to, or operating within the same line of business as, such directorate.
“Business Support Directorates and Functions” or “Non- BLD” means all the ADNOC functions and the remaining directorates, which are not ADNOC Business Line Directorates.
“CEO” means chief executive officer.
“Group Company” means any company within the ADNOC Group other than ADNOC.
“Specification” means this Human Factors Engineering Specification.
CONTROLLED INTRANET COPY The intranet copy of this document located in the section under Group Policies on One ADNOC is the only controlled document. Copies or extracts of this document, which have been downloaded from the intranet, are uncontrolled copies and cannot be guaranteed to be the latest version.
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TABLE OF CONTENTS
GENERAL … 6
INTRODUCTION … 6
DEFINITION OF HUMAN FACTORS ENGINEERING … 6
DEFINITIONS AND ABBREVIATIONS … 7
INTERNATIONAL CODES AND STANDARDS … 10
ADNOC SPECIFICATIONS … 12
DOCUMENT PRECEDENCE … 12
SPECIFICATION DEVIATION / CONCESSION CONTROL … 13
HUMAN FACTORS ENGINEERING PROCESS … 13
HUMAN FACTORS ENGINEERING CONSIDERATIONS IN THE PROJECT LIFE CYCLE … 13
HFE ISSUES REGISTER … 13
STAGE 1 - HFE SCREENING AND STRATEGY … 14
STAGE 2 - HFE DESIGN ANALYSIS (FEED) … 15
STAGE 3 – HFE VALIDATION (EPC) … 17
STAGE 4 – SUPPORT TO START UP … 18
STAGE 5 – OPERATIONAL FEEDBACK … 18
PLANT LAYOUT AND DESIGN … 19
EQUIPMENT AND INSTRUMENTATION … 19
VALVES … 26
STAIRWAYS, LADDERS, PLATFORMS, WALKWAYS AND RAILING … 32
ANTHROPOMETRIC RANGE … 35
SIGNAGE AND LABELLING … 36
HUMAN MACHINE INTERFACE & RELATED INSTRUMENTATION REQUIREMENTS … 37
ALARMS … 37
LOCAL CONTROL AND DISPLAY PANELS … 39
INSTRUMENTATION … 44
CONTROL PANEL SIGNAGE AND LABELLING … 44
HUMAN MACHINE INTERFACE (HMI) DESIGN … 45
CONTROL ROOM DESIGN AND LAYOUT … 47
REMOTE OPERATIONS … 48
MANUAL HANDLING AND LIFTING REQUIREMENTS … 49
WORKING ENVIRONMENT … 49
NOISE … 49
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LIGHTING… 50
VIBRATION … 53
TEMPERATURE … 54
VENTILATION … 55
WEATHER PROTECTION … 56
HUMAN RELIABILITY AND PERFORMANCE … 56
IMPACT OF PERSONAL FACTORS … 56
HUMAN FACTORS SCREENING … 63
GUIDANCE FOR HFE PLANS … 72
A2.1. FEED HFE PLAN … 72
A2.2. EPC HFE PLAN FOR CONSTRUCTION PHASE … 72
SAMPLE QA/QC HFE CHECKLIST … 74
LIST OF TABLES
TABLE 1-1 LIST OF ABBREVIATIONS … 9 TABLE 6-1 VERTICAL AND HORIZONTAL CLEARANCES AND DISTANCES … 24 TABLE 6-2 VALVE CRITICALITY … 31 TABLE 7-1CONTROL ACTUATOR MOVEMENT EXPECTATIONS … 44 TABLE 9-1 RECOMMENDED ILLUMINATION LEVELS FOR DIFFERENT TYPES OF ACTIVITIES … 51 TABLE 9-2 RECOMMENDED ILLUMINATION LEVELS FOR SELECTED TASKS IN PROCESS AREAS … 52 TABLE A1-1 TASK COMPLEXITY – HOW COMPLEX ARE THE MANUAL ACTIVITIES INVOLVED IN
OPERATING, MAINTAINING AND SUPPORTING THE ITEM … 64
TABLE A1-2 UNIT CRITICALITY – IS THE UNIT CRITICAL FOR OPERATIONS OR HAZARD CONTROL, OR
IS IT INVOLVED IN HAZARDOUS SERVICE. … 65
TABLE A1-3 – TASK FREQUENCY – HOW FREQUENTLY ARE PEOPLE LIKELY TO NEED TO INTERACT
WITH THE ITEM (OTHER THAN ROUTINE OPERATOR ROUNDS) … 66
TABLE A1-4 NOVELTY – WILL THE ITEM REQUIRE THE WORKFORCE TO GAIN NEW KNOWLEDGE, OR SKILL, OR WILL IT INTRODUCE NEW PRODUCES, WORK PRACTICES OR ORGANIZATIONAL STRUCTURES. … 67
TABLE A1-5 DESIGN SCOPE – TO WHAT EXTENT IS THERE SCOPE TO INFLUENCE CONTROL OVER
HFE ASPECTS OF DESIGN, PROCUREMENT OR LAYOUT OF THE ITEM … 68 TABLE A1-6 KNOWN PROBLEMS … 69
LIST OF FIGURES
FIGURE 6-1 VALVE OPERATOR POSITIONING… 30 FIGURE 6-2 THE GOING (G) AND RISE (H) … 34 FIGURE 7-1 POSITIONS OF DISPLAYS ON CONTROL PANELS … 41 FIGURE 7-2 POSITIONS OF CONTROLS ON CONTROL PANELS … 43
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GENERAL
Introduction
This specification describes the Human Factors Engineering (HFE) aspects that shall be considered during design and construction of new facilities in ADNOC Business units and projects. Good HFE design shall consider the operability, maintainability and accessibility for all the facility and equipment, including Human Machine Interface (HMI) and control panels etc. The design shall ensure areas of the facility and equipment can be accessed and personnel can be evacuated safely under normal and emergency conditions. All requirements for manual lifting, pushing, pulling and carrying shall be designed to be within the capabilities of the workforce. The working environment shall be designed to meet the requirements of noise, lighting, chemical agents, vibration, climatic conditions etc. to optimize human performance.
The overall aim should be to minimize risk to the health and safety, improving the human performance and the reduction of the risk of human error.
This specification does not include other aspects of Human Factors Engineering, such as Psychosocial Hazards such as stress, fatigue and factors such as shift patterns, (See HSE-OH-ST13) and General office ergonomics (see HSE-OH-ST11).
It also does not include Incident Notification, Reporting & Investigation and Root Cause Analysis (see HSE-GA- ST04), or the writing of operational or maintenance procedures or Task Analysis.
Definition of Human Factors Engineering
HFE is a “sociotechnical” approach to systems design. It recognizes that any complex technological system that involves people to critically depend on the organizational and social context in which it operates. The term “Ergonomics” is used by many organizations and can be considered synonymous with HFE, however HFE is broader than the traditional scope of Ergonomics. HFE aims to optimize human performance and minimize the potential for human failure.
HFE is a multidisciplinary approach to engineering that focuses on the integration of five elements:
a. People. The characteristics, capabilities, expectations, limitations, experiences and needs of the people
who will operate, maintain, support and use the facilities.
b. Work. The nature of the work involved on operating, maintaining and supporting the facility.
c. Work Organization. How the people are organized, in terms of, for example, team structures,
responsibilities, working hours and shift schedules
d. Equipment. The equipment and technology used, including the way equipment is laid out, and the elements
that people need to interact with, both physically and mentally.
e. Environment. The work environment in which people are expected to work, including the climate, lighting,
noise, vibration and exposure to other health hazards.
By incorporating HFE into design, the aim is to:
a. Reduce the risk of hazards to personnel health, safety and the environment.
b. Ensure ease and efficiency of operations and maintenance thereby reducing the likelihood and/or
consequences of human error and physical & mental overload.
c. Enhance usability and user-acceptance of facilities and equipment through ergonomically efficient design,
thereby enhancing operational performance.
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d. Facilitate a healthy workplace culture by optimizing personnel satisfaction, motivation, and team spirit by
incorporating end-user knowledge into ergonomic layout and design.
e. Contribute to the principles of Inherently Safer Design (ISD), including through reduced exposure to
hazardous environments.
f. Provide well designed and easily understandable instructions, job aids, operating manuals, and
procedures to optimize human reliability, and reduce maintenance and inspection times.
g. Reduction on CAPEX by developing a more efficient design and avoiding the need for expensive changes
or rework late in design.
h. Reducing the need for rework or change during construction.
i. Reduction in life cycle costs of operating and maintaining the facilities.
j. Enhanced user commitment (“buy in”) often resulting in faster approval cycles.
Definitions and Abbreviations
1.3.1
Definitions
The following defined terms are used throughout this standard:
‘Alarm’ means an audible and/or visible means of indicating an equipment malfunction, process deviation or abnormal condition requiring an operator response.
‘Commissioning’ means procedures prior to or related to handing over the system for placing into service. This often includes acceptance testing, handing over of drawings and documentation, delivering instructions for operations, maintenance etc., and providing training.
“COMPANY” means ADNOC, ADNOC Group or an ADNOC Group Company, and includes any agent or consultant authorized to act for, and on behalf of the COMPANY.
“CONTRACTOR” means the parties that carry out all or part of the design, engineering, procurement, construction, commissioning or management for ADNOC projects. CONTRACTOR includes its approved MANUFACTURER(s), SUPPLIER(s), SUB-SUPPLIER(s) and SUB-CONTRACTOR(s).
“Control Room” The place where a person monitors and controls plant and equipment. It is physically separated from the system and technology is used to monitor and control.
‘Control System’ is the system that responds to input signals from the equipment being controlled and/or from an operator and generates output signals that cause the equipment under control to operator in the desired manner.
‘Discipline Engineers’ Facilitate integration of HFE with relevant engineering disciplines.
“Graphic” A software-generated visual representative of the process forming part of the Human-Machine Interface, used by the operator for monitoring and control the process.
“Human Factors” At a high level “human factors” is the scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data and method to design in order to optimize human well-being and overall system performance.
“Human Factors Engineering” is concerned with human, anatomical, anthropometric, physiological, psychological, behavioral and biomechanical capabilities and limitations as they relate to human activity and the
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human-technology environment. Examples include but are not limited to, workplace layout and design, information and data displays, usability, working posture, materials handling, line of sight, repetitive movements, and safety. In the design context HFE is primarily to be understood as synonymous with “ergonomics”.
‘HFE Technical Authority (HFE individual discipline specialist)’ Quality Assurance and Quality control of the HFE deliverables. As a multidisciplinary document, related discipline engineers shall be coordinated for the assurance and compliance of this specification. Project management to ensure the compliance assurance, coordination with related disciplines (e.g. piping – plant design, Instrumentation – control room, Occupational Health – OH impact due to HFE issues).
‘HFE Working Group’ Complex projects should organise a Human Factors Engineering Working Group (HFEWG). The HFEWG provides a minuted forum – reporting to project management and with involvement from affected disciplines – to both oversee and manage the HFE work programme and to ensure effective integration and coordination of HFE with other project activities is a method of extracting a user’s requirements based on a review of tasks performed by the user. (refer to OCP 454).
‘Human Machine Interface’ the collection of hardware and software used by the operator and other users to monitor and interact with the control system and with the process via the control system.
‘may’ means a permitted option
‘Project HFE Chair (Engineering Manager) or equivalent’ – Chair of the Human Factors Engineering Working Group (HFEWG) meetings and highlight critical issues with other members of the project management team to ensure necessary support for follow up. Projects, use of the HFE Screening tool should be facilitated to determine the requirements of the HFE studies in the project.
‘shall’ indicates mandatory requirements
‘should’ means a recommendation
“SUB-CONTRACTOR” means any party engaged by the CONTRACTOR to undertake any assigned work on their behalf. COMPANY maintains the right to review all proposed SUB-CONTRACTORs; this right does not relieve the CONTRACTOR of their obligations under the Contract, nor does it create any contractual relationship between COMPANY and the SUB-CONTRACTOR.
“SUPPLIER” means the party entering into a Contract with COMPANY to provide the materials, equipment, supporting technical documents and/or drawings, guarantees, warranties and/or agreed services in accordance with the requirements of the purchase order and relevant specification(s). The term SUPPLIER includes any legally appointed successors and/or nominated representatives of the SUPPLIER.
“SUB-SUPPLIER” means the sub-contracted SUPPLIER of equipment sub-components software and/or support services relating to the equipment / package, or part thereof, to be provided by the SUPPLIER. COMPANY maintains the right to review all proposed SUB-SUPPLIERS, but this right does not relieve the SUPPLIER of their obligations under the Contract, nor does it create any contractual relationship between COMPANY and any individual SUB-SUPPLIER.
‘Task Analysis’ is a method of extracting a user’s requirements based on a review of tasks performed by the user.
1.3.2
Abbreviations
The abbreviations used throughout this specification are shown in Table 1-1
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Abbreviations
ADNOC
ALARP
CCTV
CRI
DCS
EEBA
EPC
FEED
HAZID
HAZOP
HFE
HFEWG
HMI
HSE
ICSS
IOGP
ISO
MSD
OHID
OHRA
PCS
PLC
PPE
PSSR
PSV
REBA
RULA
RVO
SCADA
VC
VCA
Table 1-1 List of Abbreviations
Abu Dhabi National Oil Company
As Low as Reasonably Practicable
Closed Circuit Television
Color Rendering Index
Distributed Control System
Emergency Escape Breathing Apparatus
Engineering Procurement and Construction
Front End Engineering Design
Hazard Identification
Hazard and Operability Study
Human Factors Engineering
Human Factors Engineering Working Group
Human Machine Interface
Health, Safety and Environment
Integrated Control and Safety System
International Oil and Gas Producers
International Standards Organization
Musculoskeletal Disorder
Occupational Health Identification OHID is a synonymous with Qualitative Occupational Health Risk Assessment (OHRA) and part of Occupational Health Risk Management Standard (OHRM)
Occupational Health Risk Assessment
Process Control System
Programmable Logic Controller
Personal Protective Equipment
Pre-Startup Safety Review
Pressure Safety Valve
Rapid Entire Body Assessment
Rapid Upper Limb Assessment
Remote Valve Operation
Supervisory Control and Data Acquisition
Valve Criticality
Valve Criticality Analysis
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REFERENCE DOCUMENTS
International Codes and Standards
The following Codes and Standards shall form a part of this standard. When an edition date is not indicated for a Code or Standard, the latest edition in force shall apply.
International Association of Oil and Gas Producers IOGP
OGP Report 454
Human Factors Engineering in Projects
OGP Report 384
A Roadmap to Health Risk Assessment in the Oil & Gas Industry
International Standards Organization (ISO)
ISO 6385
ISO 9241-4
ISO 9241-400
ISO 9241-410
ISO 11064-1
ISO 11064-2
ISO 11064-3
ISO 11064-4
ISO 11064-5
ISO 11064-6
Ergonomic Principles in the Design of Work Systems
Ergonomic Requirements for Office Work with Visual Display terminals (VDTs) – Part 4: Keyboard requirements
Ergonomics of Human-System Interaction – Part 400: Principles and Requirements for Physical Input Devices
Ergonomics of Human-System Interaction – Part 410: Design Criteria for Physical Input Devices
Ergonomic Design of Control Centers – Part 1: Principles for the Design of Control Centers
Ergonomic Design of Control Centers – Part 2: Principles for the Arrangement of Control Suites
Ergonomic Design of Control Centers – Part 3: Control Room Layout
Ergonomic Design of Control Centers – Part 4: Workstation Layout and Dimensions
Ergonomic design of control centers - Part 5: Displays and control panels
Ergonomic Design of Control Centers – Part 6: Environmental Requirements for Control Centers
ISO 15535
General Requirements for Setting up Anthropometric Databases
Safety of machinery. Permanent means of access to machinery. Part 1 - Choice of a fixed means of access between two levels
Safety of machinery. Permanent means of access to machinery. Part 2 - Working platforms and walkways
Safety of machinery. Permanent means of access to machinery. Part 3 - Stairways, stepladders and guard-rails
Safety of machinery. Permanent means of access to machinery. Part 4 - Fixed ladders
ISO 14122-1
ISO 14122-2
ISO 14122-3
ISO 14122-4
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ISO 17770
Petroleum and Natural Gas Industries – Offshore Production Installation – Guidelines on tools and techniques for Hazard Identification and Risk Assessment Guide words
ISO 26800
Ergonomics: General Approach, Principles and Concepts
Abu Dhabi Occupational Safety and Health System Framework (OSHAD-SF)
OSHAD-SF CoP 23.0
Working at Heights
Occupational Safety and Health Association (OHSA) USA
OSHA 1926.1053
Ladders
OSHA 1910.21
OSHA 1910.22
OSHA 1910.23
OSHA 1910.25
Scope and Definitions
General Requirements
Ladders
Platforms and Ladders
ASTM International
ASTM F 1166
Standard Practice for Human Engineering Design for Marine Systems, Equipment and Facilities
Engineering Equipment and Material Users Association (EEMUA)
EEMUA Pub No 191
EEMUA Pub No 201
EEMUA Publication 191 Alarm systems - a guide to design, management and procurement, Edition 3, 2013.
EEMUA Publication 201 Control Rooms: A Guide to their Specification, Design, Commissioning and Operation, Edition 3
International Electrotechnical Commission
IEC 62682
Management of Alarm Systems for the Process Industries
UK HSE
Research Report 001
Human Factors Integration: Implementation in the Onshore and Offshore Industries
COMAH Competent Authority
Inspecting Human Factors at COMAH Establishments (Operational Delivery Guide)
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ADNOC Specifications
HSE-GA-ST07
HSE- OH-ST01
HSE-OH-ST02
HSE-OH-ST03
HSE-OH-ST08
HSE-OH-ST09
HSE-OH-ST11
HSE-OH-ST13
HSE-OS-ST17
HSE-OS-ST21
HSE-OS-ST22
HSE-OS-ST27
HSE-RM-ST02
HSE-RM-ST03
HSE-RM-ST04
HSE-RM-ST07
HSE-RM-ST12
HSE Design Philosophy
Occupational Health Framework
Occupational Health Hazard
Occupational Health Risk management (OHRM
Physical Health Hazard Standards
Chemical Health Hazard
Ergonomics Hazards
Psychosocial Hazards
Manual Handling
Management of H2S
Working at Height
Hazard Communications Standard
HSE Impact Assessment
HAZID, ENVID & OHID
Hazard and Operability Study (HAZOP)
Escape Evacuation and Rescue Assessment
Pre-Startup Safety Review
AHQ/UPS/PRD/STD/004/R00/20 Alarm Management Standard
AGES-GL-02-001
AGES-GL-03-001
AGES-GL-08-005
AGES-PH-04-003
AGES-SP-06-002
AGES-SP-09-001
AGES-SP-09-003
AGES-SP-14-001
AGPM-MNL-001
Electrical Engineering Design Guide
Facility Layout & Separation Distances Guidelines
P&ID/PFD Development Guidelines
Alarm Rationalization Philosophy
Pressure Vessel Specification
Piping Basis of Design
Manual Piping & Pipeline Valves
Specification for HVAC Design
Technical Authority (TA) Systems Framework
DOCUMENT PRECEDENCE
The specifications and codes referred to in this standard shall, unless stated otherwise, be the latest approved issue at the time of contract award.
It shall be the CONTRACTOR’s responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.
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The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein.
Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design/manufacture.
In case of conflict, the order of document precedence shall be:
a. UAE Statutory requirements
b. ADNOC HSE Standards
c. Equipment datasheets and drawings
d. Project Specifications and standard drawings
e. Company Specifications
f. National / International Standards
SPECIFICATION DEVIATION / CONCESSION CONTROL
Deviations from this standard are only acceptable where the MANUFACTURER has listed in his quotation the requirements he cannot, or does not wish to comply with, and the COMPANY / CONTRACTOR has accepted in writing the deviations before the order is placed.
In the absence of a list of deviations, it will be assumed that the MANUFACTURER complies fully with this standard.
Any technical deviations to the Purchase Order and its attachments including, but not limited to, the Data Sheets and Narrative Specifications shall be sought by the MANUFACTURER only through Concession Request Format. Concession requests require CONTRACTOR’S and COMPANY’S review / approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.
HUMAN FACTORS ENGINEERING PROCESS
Guidance for HFE design recommends that HFE is considered during all stage of the project from design to execution and operations.
HUMAN FACTORS ENGINEERING CONSIDERATIONS IN THE PROJECT LIFE CYCLE
HFE is applicable to all stages of a Project and should be implemented as early as possible. At all stages of the project HFE awareness training should be given to ensure that project personnel have an understanding of HFE issues and the implementation of HFE requirements. HFE issues that are identified as part of HSEIA and Other engineering reviews and shall addressed as part of project Engineering Deliverables during the lifecycle of the project from FEED to Operations.
HFE Issues Register
A HFE register establishes a system whereby HFE issues that arise during the design process can be effectively managed. This may be integrated into the HSE Register. The register provides a means of tracking and managing actions associated with HFE. These issues may arise from:
a. HFE screening findings.
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b. Actions arising from HAZID studies (including OHID), HAZOP studies, 3D model reviews, constructability
reviews and other HFE review activities.
Each issue is assigned to an engineering discipline. As part of project HSE Action tracking register with input from related Engineering team, Individual Engineering discipline will be responsible to manage the HFE actions related to their study / document and its closeout tracking. Overall assurance to be managed by Project Engineering management. Each HFE issue on the register will include:
a. Source (e.g., review name) and date
b. Discipline assigned.
c. Description of the equipment (e.g., tag number), drawing number, system or area.
d. Description of the issue
e. Recommended action required.
f. Decision on whether the proposed action close out has been accepted, rejected (with rejection reason) or
transferred to another responsible party.
g. Close out statement.
This register should continue to be updated and maintained throughout all project stages.
A sample QA/QC for HFE checklist for different project stages has been provided in APPENDIX A3. This should be tailored to suit project requirements.
Stage 1 - HFE screening and Strategy
An HFE Screening should be conducted early in the project life cycle -preferably before the FEED stage. HFE screening can quickly identify whether there are significant issues or opportunities associated with the facilities being developed that would benefit from further HFE activities.
See APPENDIX A1 for an example of a HFE screening tool taken from IOGP 454.
This screening should be conducted as structured workshop using a guideword approach and a suitably experienced Chairperson (Refer to HSE-RM-ST02 for competency requirements). However, depending on the size and complexity of the project, this may be a desktop review. This will depend on several factors including:
a. The degree of change or novelty, including the use of automation.
b. The criticality of the facilities to be developed (to process or personnel safety, environment or production).
c. The Operational Context. Such as geographical location, climatic conditions and hazards inherent to the
process.
The decision between workshop review or desktop review shall be made by a competent HFE Technical Authority.
The output of the HFE screening study should be a minuted record or report. This report should include:
a. Summarize the key HFE risks identified during the screening review.
b.
Identify the key actions, reviews and activities required during the various project stages.
c.
Identify any additional relevant HFE specific standards or technical guidance.
d. Any organizational arrangements needed to manage risks should be identified.
e. The competency requirements, and the requirements for the HFE awareness training should be identified
as part of the project.
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The project manager shall ensure there are adequate project resources to support HFE activities, including HF screening. For large or complex projects, it may be appropriate to have a HFE working group with different disciplines and operations & maintenance as necessary.
The requirement for an HFE plan shall be included in the contract for the FEED Contractor (See guidance in APPENDIX A2 )
Stage 2 - HFE Design Analysis (FEED)
Identification of HFE related activities to be carried out in the FEED stage shall be defined in the HFE plan as part of the project document. The HFE Design analysis shall be based on the review of the following but not limited to:
HAZID reviews (refer to HSE-RM-ST03)
OHRA Reviews (Refer to HSE-OH-ST03 and Guidewords from ISO -17776)
HAZOP reviews (refer to HSE-RM-ST04, note that this includes Human Factors as a guideword)
SIL reviews (refer to HSE-RM-ST05)
Inherently Safer Design reviews (refer to HSE-RM-ST13)
Plant Layout/3D model Reviews (procedure to be developed on individual projects)
Vendor Package Reviews (procedure to be developed on individual projects)
Factory Acceptance tests (FAT) (procedure to be developed on individual projects)
Constructability reviews.
5.3.1
Review of standards
The standards specified for the project shall be reviewed to ensure they support the HFE strategy for the project. This includes regulatory, industry and company standards. This review shall ensure the applicable standards are appropriate for:
a. The scope of work identified
b. The anthropometric and cultural make-up of the expected workforce.
c. Any local legal requirements to include HFE content e.g., within HSEIA.
d. Project Stakeholder Interests.
Any conflicts between company and regulatory requirements must be identified, recorded and resolved.
5.3.2
HFE Design Analysis
Typical HFE Design activities conducted during FEED may typically include but not limited to:
a. OHID (Refer to HSE-RM-ST03) and HSE-OH-ST-03) (also called Working Environment Health Risk
Assessment)
b. Valve Criticality Analysis (VCA)
c. Task Requirement Analysis (TRA)
d. Human Machine Interface (HMI) Requirements Analysis
e. Control Room Analysis
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f. Alarm Management Analysis
g. HFE Functional Analysis for facilities, accommodation, buildings etc
h. Safety Critical Task Analysis
i. Critical Task Analysis
j. Human Error ALARP demonstration
k. Materials Handling Studies
(Refer to OGP 454.)
The activities required during FEED shall be defined in the HFE Plan with responsibility assignment matrix (RACI Chart). A report documenting the findings of reviews shall be produced. HFE requirements arising from HFE, and related design reviews shall be incorporated into all relevant documentation e.g., project specifications, procurement specifications etc.
5.3.3
HFE Validation
In addition to specific HFE activities/reviews, the HFE design requirements in other reviews and activities are important to achieving HFE is integrated into the design. HFE validation activities conducted during FEED include:
a. Any formal and informal Design Reviews that focus on specific HFE requirements.
b. Reviews and inspections of equipment and packages to be procured.
c. HFE support to Plant Layout reviews, plot plan reviews, control room and operator console design, building
design and 3D model reviews etc.
d. Ensuring HFE requirements are included in all relevant specifications, scopes of work and bid packages
etc.
Any HFE deviations required arising during Design validations shall formally be recorded and approved by relevant Technical authority (refer to AGPM-MNL-001).
5.3.4
Implementation Plan
During FEED, an EPC HFE Plan should be produced to specify the HFE activities to be conducted during EPC. This will outline the roles, responsibilities and lines of reporting including those of the EPC contractor, vendors etc.
The HFE Plan should define any additional HFE design analysis and/or validation activities that still need to be conducted during EPC. This shall be used as the guide to the overarching approach to HFE during EPC to ensure that requirement have been meet and that any non-compliances have been reviewed, managed and closed out.
5.3.5
HFE Design Close Out
At the end of FEED there shall be a HFE Close out meeting (Prior to PHSER). This is to verify that all the HFE actions have either been completed or closed or are included in the HFE Plan for completion in the EPC stage of the project. Any key HFE issues and risks should be reviewed, and plans put in place for mitigation. This shall be recorded in the HFE FEED Close Out Report.
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5.3.6
HFE Plan for EPC
The requirement for EPC Contractor to produce a HFE Plan for EPC shall be included the EPC tender documentation. This shall include the EPC Contractors scope of work, and the roles and responsibilities. This will also include any incomplete FEED activities. (Guidance for the HFE Plan is in APPENDIX A2)
Stage 3 – HFE Validation (EPC)
In the EPC stage, HFE deliverables described in the HFE Plan developed during FEED and deliverables produced during FEED shall be reviewed, updated as required and validated.
HFE activities in EPC may also require the completion of some of the activities from FEED if these have not yet been closed out.
5.4.1
HFE Design Analysis
The majority of the HFE Design analysis should have been completed during the FEED stages. Additional HFE design analysis may be needed to ensure critical tasks are adequately covered. This is likely to include analysis of operations or maintenance tasks that have not been covered in sufficient detailed during FEED. Further HFE design analysis may be needed for the control room or the HMI if they are particularly complex or novel.
5.4.2
HFE Design Validation
For most projects, there should be HFE representation at all relevant design reviews (e.g., HAZOP etc) and 3D model reviews during the EPC stages of the project.
The HF Issues Register should be consulted at the finalization of detailed engineering and actions addressed before progressing to construction activities (Accountability – Project & Responsibility -related discipline engineer). Prior to conducting a PHSER-3 (80% of detailed engineering) there shall be a HFE close out meeting to verify that the detailed engineering HFE plan has been fully implemented.
The design shall be reviewed to verify the design complies with the project HFE standards and requirements and that HFE requirements identified during FEED and EPC have been satisfied.
5.4.3
HFE Plan for Construction Phase
The HFE Plan for construction phase shall be developed at the end of the EPC stage, the purpose of which is to guide the construction contractor with respect to installing equipment not usually shown in 3D CAD models. This will mainly concern ‘field run’ installed equipment (e.g., small bore piping, instrument cabling etc.). The HFE design intent should not be compromised by the location of field run items.
Any relevant HFE requirements shall be inserted in the scope for the installation contractors, and the construction contractors shall ensure they have adequate HF competence/awareness. In addition, HFE awareness training for all relevant disciplines (e.g., inspectors, Mechanical, Piping, Process, Structural, Electrical, Instrumentation, HSE etc.) shall be provided as part of the project.
Once construction and commissioning has begun, HFE working group shall be involved in any investigation that may occur as a result of accidents, near misses and non-conformances that are related to Human Factors. Prior to conducting a PHSER-4 (50% of construction phase), there shall be a HFE plan interim review meeting to verify that the Construction HFE plan has been fully implemented and followed.
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Stage 4 – Support to Start Up
During commissioning and start-up, HFE work becomes focused on closing out outstanding HF issues and ensuring a smooth handover to the operators.
5.5.1
HFE Support for Prestart-up Audits
For projects where high risks associated with HFE have been identified, an HFE authorized person (working group discipline engineer or independent operation support discipline engineer) shall be included in prestart audits and inspections as part of the Pre-start Safety Review (PSSR) team.
5.5.2
HFE Close-Out Review
Prior to conducting PHSER-5 (90% of construction phase) there shall be a HFE Close out meeting to verify that the HFE issues have been fully resolved or actions has been identified for effective closure.
HFE (working group) and Operations teams shall produce a list of final HFE acceptance criteria for a final as-built inspection and audit as part of the Pre Start Safety Review (PSSR) (Refer to HSE-RM-ST12). This team will be multidisciplinary and typically comprise of HSE, piping, instruments, mechanical, structural and civil etc. and shall conduct this audit together with the operations team.
Stage 5 – Operational Feedback
By the time Operations starts, design and construction work is complete, and any HF requirements identified during the preceding stages should be addressed, including in the HFE Plan for Construction. The HSE management system shall be followed during operation.
Prior to conducting PHSER-6 (1 year after start-up), there shall be a final review to close out HFE issues and to identify any implications. The review should address safety critical tasks and control measures, ensuring a comprehensive demonstration. These will have important implications for the competence requirements of the operations and maintenance personnel and must therefore be communicated to Operations to ensure that the competency criteria shall be built into training.
A Job Hazard Analysis and Report should be prepared to identify and analyze work tasks where there is a credible risk of occupational injuries occurring. mitigation measures should be developed using a hierarchy of risk control.
The final review shall address the following:
a. The level of operability and maintainability.
b. HFE issues identified over the operational period, any changes made and any proposed modifications to
address HFE issues.
c. Any incidents, near misses and other operational difficulties considered to have an HFE aspects
d. Any lessons learnt to be fed back to the company and the contractor(s).
e.
Identification of HFE value and, if possible, in comparison with similar projects at a similar stage of operation.
Prior to commissioning and handover the Project HFE Risk Register shall be reviewed through action tracking. During operation if HFE issues identified shall be reviewed, risk ranked and added to the Asset risk register for mitigation action tracking.
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PLANT LAYOUT AND DESIGN
Equipment and Instrumentation
The facility shall be designed so that work areas where there may be exposure to hazards (e.g., noise, chemicals) such as the process areas, maintenance areas, workshops etc., shall be separate from offices, control rooms, living quarters and recreational areas.
6.1.1
Operability and Maintainability
The plant and layout design should allow for easy access for operation and maintenance under normal, abnormal, and emergency conditions, during all weather conditions by 90% of the full range of potential employees. This should be based on designing for the anthropometric variability, taking a size range of potential users from the 5th percentile females to 95th percentile males, and also reflect the multi-ethnic mix of the working population. (See section 6.4) The design also needs to consider the personal protective equipment (PPE) requirements and how wearing of PPE will impact accessibility (e.g., wearing safety footwear and hard hats increases the ‘height’ of personnel, wearing breathing apparatus can impact access requirements).
The minimum space requirements to be provided for operators and maintenance workers can be found in AGES- SP-09-001 Piping Basis of Design. In general clearances mentioned in the Piping Basis of Design shall be followed. In case of conflicts the more stringent shall apply.
The minimum space provided for a standing operator or maintenance worker should be 700mm wide x 700mm depth x 2100mm (this may need to be increased based on the workplace anthropometric data).
The minimum squatting or kneeling space to be provided should be 900mm wide x 900mm depth x 1300mm (this may need to be increased based on the workplace anthropometric data).
For workspaces that require the operator to be prone or crawling, the cross-sectional area should be a minimum of 700mm wide x 900mm high (this may need to be increased based on the workplace anthropometric data). If crawling is required, then the travel distance required shall be minimized and is subject to approval by the COMPANY HFE Technical Authority.
The operability of equipment also ensures the usability of display and control design including local control panels. This would mean that the placement and orientation of all controls and displays/instruments are appropriate to ensure safe and effective viewing, reach, and operation. Any screens, gauges, sight glasses etc., shall be easy to read from a standing position on the floor or from a platform. See section 10.1.1.5 on Visual Acuity.
Design should ensure the efficient and safe movement of equipment requiring maintenance without removal of other items such as piping, motors, etc. This includes the provision of adequate space and lay down areas for all anticipated activities. Consideration should also be given to the provision and configuration of doors and access hatches.
Hatches shall be capable of being secured in the open position. Access openings shall be side hinged with handgrips on both sides of the opening.
Design should ensure that all areas of the facility and equipment can be accessed and evacuated safely under normal and emergency conditions and whilst wearing PPE.
Body position
Work should be positioned where it causes the least stress on the limbs of the operator. The dimensions of the workplace shall consider not just the physical size of the workforce but the range and flexibility of their limbs and body.
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Placing materials and equipment controls in easy reach of operators and maintenance staff saves time and energy and may prevent an accident when time and accessibility are critical. In addition, it is also beneficial to ensure the locations of tools and materials is the same from one work area to another, to reduce errors among operators who transfer between locations.
Static postures require the muscles to work without movement, whereas muscle movement promotes blood flow. As a result, static muscular effort increases muscular fatigue, discomfort and ultimately muscle failure. It can also lead to higher energy consumption, increased heart rate and require longer rest periods to recover. In the long term. Longer term, static postures can lead to the deterioration of joints and soft tissue. Static postures can include standing for long periods of time, holding items in the arms with arms extended and pushing/pulling objects for extend periods. Static posture can also lead to fidgeting and moving weight from one leg to another. To minimize the effects of static posture work areas and task should be designed to promote frequent changes in body position and posture.
Tasks should also be designed to avoid causing the arms to work above the shoulder. The ideal location is in the range beginning below the elbow and ending at a position below the elbow and shoulder. The upper end of this limit is recommended for lighter loads requiring high levels of dexterity, heavier loads should be performed at the lower end of the range.
Work that causes the spine to be twisted should be avoided.
A Rapid Entire Body Assessment (REBA) is an assessment tool to evaluate whole body postural musculoskeletal disorders (MSD) and risks associated with tasks. In addition, a Rapid Upper Limb Assessment (RULA) can be used to evaluate risk the ergonomic risk factors associated with upper extremity MSD. (See HSE-OH-ST11 for further information and assessment worksheets for REBA and RULA.)
6.1.2
Layout
The layout should minimize the risk of human error by the adoption of a consistent approach to equipment location and identification, along with unambiguous relationships between related components (e.g., the equipment and its associated control panel).
Equipment layout and equipment numbering should consider how operators view the equipment and conform with cultural expectations, languages and local stereotypes. E.g., equipment should be laid out and labelled 1, 2, 3/A, B, C from left to right as the operator would normally look at them (unless the local stereotype is right to left) or top to bottom, valves are clockwise to close, red is stop etc.
The layout should allow a logical workflow and efficient access for routine operations. Layout should allow for operational and maintenance tasks to be conducted without operators and maintenance staff requiring to be repeatedly moving on and off or up and down units.
Equipment is to be laid out with full consideration of the immediate interfaces and connections such that adequate access is ensured to and around the machinery unit or skid. This is to include consideration and space for efficient product / materials top up and change out activities in addition to required access for monitoring, operation, inspection and maintenance of installed components. This is to also include consideration for completions activities and schedules.
Where multiple trains or similar equipment are installed, these shall be in a similar layout and orientation. Mirroring of layout shall not be used.
Equipment layout should be prioritized for accessibility in the following order:
a. Safety Critical Equipment.
b. Process Critical items from HAZOP studies.
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c.
Items that reduce the safety or efficiency of the process when removed due to maintenance and therefore need rapid maintenance.
Sufficient space must be ensured around compressors, turbines / drives, pumps, heat exchangers and other major equipment for the lay down of the heavy machine parts during maintenance. Lay down provision must be of adequate size and load rating for the largest and heaviest machine parts required and with full consideration of: withdrawal and maneuvering space, task sequence/order of work / lift schedule, maintenance equipment lay down / storage (e.g. tool container), and the number of people working in the area during major maintenance campaigns. The arrangement shall accommodate the expected number of personnel required to perform all operational or maintenance tasks associated with the equipment, including their requirements for tool use, test equipment and manual handling equipment. There shall be space to accommodate any transport devices required to move equipment to and from the area.
Sufficient clear headroom is to be provided under elevated platforms where personnel are required to gain access for operations and / or maintenance and / or where through access is permitted.
Adequate space is to be provided around pump and compressor seals, couplings, bearings and stuffing boxes for removal and replacement activities. Pumps and similar equipment requiring routine maintenance should be located toward the periphery of a skid for ease of maintenance access when practical.
Adequate space is to be provided around strainers and other in-line equipment for ease of maintenance and removal. Strainer selection is to consider ease of handling in addition to technical criteria. Withdrawal volumes should be sufficient to facilitate ease of handling. Associated local instrumentation is to be easily accessible.
Flushing, draining and venting facilities shall be located such that these activities can be operated in a logical sequence and can be accessed easily.
Equipment is to be laid out such that the work component during maintenance is minimized. In particular the extent of disconnection of piping and cabling and/or removal of other non-failed equipment required for the removal, replacement or repair of items should be strictly minimized.
Items that need regular replacement should be mounted in a manner that will make them easy to remove. Structural members and other equipment items should not impede access to equipment for maintenance or replacement.
Small or fragile components should be located and protected so that incidental damage during maintenance or removal of larger or heavier items is avoided.
Fill points should be easily accessible (e.g., lubrication points). Local level indication is to be provided at all fill points. Fill lines for high volume consumables should generally be hard piped to periphery of the supplied equipment interface for connection to fill line for bulk filling. Drainage and isolation requirements for extended fill lines should be considered. Additionally, local isolation at tanks is to be available for extended fill lines unless otherwise specified.
Check points, test points, adjustment points, cable connectors, should be accessible and visible to perform routine maintenance without hindrance or hazard.
Portable equipment shall be designed to be easily maneuvered around the facility, and minimize the manual handling required by the operator or maintenance team.
Operation Handling
Product loading or draining operations should not require any manual handling of drums on stairs. Special platforms and facilities should be required for elevated equipment that requires refilling where hard piped bulk delivery method or filling from floor level is not practicable. All drains, vents, bleeds and sampling ports etc., should be capable of operation without risk of exposing the operator to chemical, thermal or other hazards.
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Handling requirements for stored equipment or materials, including consumables, should be considered and adequate space, including maneuvering space, provided. On-skid storage of materials or equipment should generally be avoided but where required is to not interfere with work areas or access ways.
Where practical, auxiliary piping and electrical connections, junction boxes etc. for rotating equipment should be routed on one side of the machine leaving the other side relatively free for maintenance access.
Couplings and their guards should be accessible from both sides. Consideration should be given to using spacer couplings to provide sufficient access between machinery components.
General Safety Considerations
All machinery and equipment, including any attachments and connections, shall be designed, constructed, located, insulated, and/or guarded to prevent accidental or personnel contact with any part that could cause injury due to motion, temperature, pressure, sharpness or electrical charge. Removal of guards shall not be possible without special tools. Quick release fasteners shall not be used for guards.
Sharp edges should be avoided wherever these could pose an injury risk to personnel. This includes but is not limited to, equipment internals, sheet metal lagging, heat shielding, cable trays and cable ties etc.
Any atmospheric vents should be located and orientated away from access ways.
The operation of switches or controls that initiate hazardous operations (for example, equipment-moving devices) should require the prior operation of a related or locking control. When practical, the critical position of such a control is to activate a visual and auditory warning device in the affected work area.
Where stored energy devices are necessary, safety features such as removal tabs, lockouts, and warning placards shall be provided.
Both the presence of a hazard and the fact that an interlock exists should be noted on the equipment case or cover such that it remains visible when the access is open.
Manways, access hatches, hand holes, inspection ports, coupling guards, junction boxes and all covers requiring removal for operations or maintenance access to internals should be fully accessible and should not be obstructed or restricted by platform structures, ladders, railings, piping, equipment, cable trays, conduit etc.
Drain pans or drip trays should be installed where required and these should be hard piped wherever practicable. Drain pans and drip trays should be designed and installed such that they do not constitute a trip hazard.
6.1.3
Pipework
The routing of pipework shall not prevent safe and rapid egress from any structure, platform, stair way, building etc.
The minimum clearance between any pipe flange and equipment, walls, structural supports etc., shall be as defined AGES-SP-09-001 Piping Basis of Design Table 1. A minimum of 750mm shall be provided as clear access in the front of the valve.
Adequate space shall be allowed for the installation/removal of blinds and the swinging of spectacle plates.
In general clearances stated in AGES-SP-09-001 shall be followed as a minimum. In case of conflict the more stringent shall apply.
6.1.4
Manways/Access Openings
Manways and Access openings shall be designed to account for the operator wearing PPE, weather protective clothing and any required breathing apparatus. The design shall also consider the access for required tools,
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equipment (including ladders if required) and materials, and emergency rescue requirements. Manways/Access minimum size requirements are outlined in. However opening sizing shall consider the anthropometric data of the workforce and increased accordingly.
Manways and access ways on roofs of vertical storage tanks should be located along the perimeter of the tank with appropriate platforms, guard rails and stairs or ladders.
6.1.5
Access and Egress
Ensure that all areas of the facility and equipment can be accessed and evacuate safely under normal and emergency conditions and whilst wearing PPE.
Access shall be designed in the following order of preference:
a. Access direct from the grade or the floor.
b. Ramps.
c. Stairs.
d. Permanent inclined stepladders or spiral staircases
e. Permanent vertical ladders.
If access is required daily, then the access shall be by options a, b or c. Options d and e can be used when access is required less frequently.
Temporary access, such as mobile platforms or scaffolding, should only be used if access is required less than once a year.
Access ways where trolleys, carts or other wheeled mobile equipment may be used shall not have steps, thresholds or steep gradients (ramps should be between 7o and 15o).
Any outdoor handles, door switches etc., shall be operable while wearing gloves
6.1.6
Emergency Egress
Emergency Egress, Evacuation and Rescue requirements are covered by HSE-RM-ST07, HSE-GA-ST07 and AGES-GL-03-001.
6.1.7 Working Environment Area Limits.
The below gives guidelines for clearances and distances. Note that these figures should be adjusted where required to account for the anthropometric data of the local workforce. Clearances mentioned in the Piping Basis of Design (AGES-SP-09-001), Facility Layout & Separation Distances Guidelines (AGES-GL-03-001) and Pressure Vessel Specification (AGES-SP-06-002) shall be followed as a minimum. In case of conflict the more stringent conditions shall apply, or alternatively a resolution made in consultation and agreed with COMPANY. As far as practicable working at height and elevated platforms should be avoided in the H2S Zone (see HSE-OS-ST21 for more detail).
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Table 6-1 Vertical and Horizontal Clearances and Distances
Description
Vertical (mm)
Horizontal (mm)
Notes
Access Ways
Access Ways (including stairs)
2100
See Notes
2300mm height recommended.
Horizontal minimum width for access to workplaces as AGES-SP-09-001. This applies to clearance to vessels, towers, columns etc., from guardrails
Horizontal minimum for access ways within skids/packaged units or on vessel access platforms as AGES-SP-09-001.
If equipment is regularly carried, ensure access way width is a minimum of the width of the equipment plus 200mm
Stretcher accessible minimum width.
routes shall be 1200mm
Clear access to stairways and escape ladders shall be minimum of 1200mm
Width dimensions on stairs are inside handrails.
At least 600mm x 600mm for openings of cofferdams and tanks from decks and platforms
Doors Hatch Openings
2050 800
750 800
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Description
Vertical (mm)
Horizontal (mm)
Notes
Manholes (circular)
600 diameter
This is the inside diameter, not nominal flange size.
Manholes (rectangular) Top or bottom access
Manholes (rectangular/square) Side Access
Access to Manways
750 diameter if top entry (for ladder access)
360 x 560
size
Manway PPE requirements, Tools/equipment requirements and ability to rescue workers.
accommodate
should
810
410
660
460
610
660
Dependent on orientation of opening. Rectangular openings shall be minimum of 410x610 OR 810 x 460. Square openings shall be 660x660
As AGES-SP-09-001 Maximum vertical distance between standing surface and the center of the manway.
Handholes
200 diameter
This is the inside diameter, not nominal flange size.
At work position for access to permanent equipment during operations or maintenance
Distance between uninsulated pipes without flanges or between insulation
Distance between fixed cabinet and floor
Distance between drain points (vertical, pointing down) and the floor/deck
Distance between handwheel/wrench on valves and an obstruction
Clearances
The operator’s reach to equipment ⇐ 500mm Minimum maintenance space required between flanges of exchangers or around other bolted equipment connections which must be serviced and maintained shall be 1000mm as AGES-SP-09-001
75
75
Min 250
Min 300
75
75
Work Areas
Preferably attached to the floor without any spacing
If the distance is less than 300mm, the termination shall be turned to a horizontal position
Work Areas
2300
The center height of control devices above the floor level, (this includes valve handles, switches, push buttons, displays with keys
Visual displays above floor/deck level
2100mm may be acceptable in some work areas (e.g., under structures and pipes)
See Figure 7-1 Positions of Displays on Control Panels and Figure 7-2 Positions of Controls on Control Panels
See Figure 7-1 Positions of Displays on Control Panels and Figure 7-2 Positions of Controls on Control Panels
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Description
Vertical (mm)
Horizontal (mm)
Notes
Maximum unprotected openings in floor
Platforms
100x100
Larger openings shall be covered or secured by guardrails or similar
Maximum opening in gratings
25 diameter
A grating shall not allow an object of greater diameter to fall through
Maximum variation in platform level without an intermediate step
250
Vertical distance from deck or platform to sampling points
1100- 1400 preferred
Minimum Platform Size (other than those below)
Minimum Platform Size for standing
Minimum landing platforms for ladders
900 x 760 (or width of swing gate plus 460)
610 x 760
650 x 750 (or equal to the width of the ladder cage)
Sampling position will be dependent of orientation of the pipe and position of the sample point (e.g. bottom, top or side of pipe). Task Analysis is recommended for sampling points.
This applies to platforms solely used for standing, e.g., to access a valve.
6.1.8
Maintenance and Cleaning
All materials and surfaces, including structural members, installations, equipment, cameras, light fittings etc., shall be easy to clean and maintain. This is especially important in facilities where there is risk of dust explosion. For heavy equipment or areas difficult to access then a cleaning in place system shall be made available.
6.1.9
Storage and Laydown Areas.
Areas for storage and laydown shall be located in the vicinity and on the same level. Storage rooms shall be located so that transport to and from, and lifting operations are straightforward.
6.1.10 Communications and Labelling
All labelling and equipment identification/information should be clear, understandable, and concise. See Signage and labelling section 6.5.
Valves
6.2.1
General
The operability and maintainability of valves should be given prime consideration. As a minimum requirement, access to valves is to be in accordance with the assigned Valve Criticality (VC) analysis category (refer to Table 6-2).
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a. When weld-end valves are used, maintenance requirements shall be addressed, i.e., top-entry type valves
should permit the change out of internals such as valve seats, seals, ball etc.
b.
Irrespective of frequency of use, larger valves may require power operation (this may be pneumatic, hydraulic or motor driven) and the need for this shall be assessed. Refer to AGES-GL-08-005 P&ID/PFD Development Guidelines.
c. Valves should be located such that the operator does not have to stand on pipe work, cable trays, handrails, other equipment, or any object not specifically intended as a standing surface for the operation, maintenance, repair, or replacement of any valve (taking into account the height range mentioned).
d. Valves should be orientated and positioned such that spindles, hand wheels or handles do not protrude into designated access ways, including off-skid access ways. If valve spindles on rising stem valves will be close to the periphery of access ways in any position, they should be protected by highly visible caps.
e. Valve position, spindle lengths, and hand wheel/lever orientation (in both open and closed positions)
should be reviewed during the 3D model reviews and shown on the isometric drawings.
f. Sufficient space shall be preserved around valves and valve actuators to allow for the use of tools and the removal of parts, and/or entire valve, during maintenance. This applies equally to clearance from top of base plate / platform to bottom of flange for removal of flange bolts for valves at low elevation such as drain valves.
g. Manual operation of valves is to be by means of a circular hand wheel or lever. The use of chain operators is prohibited. However, preference is for valves with handwheels rather than levers where practicable to avoid accidental opening/closing.
h. Valves that are operated and maintained from elevated access platforms should be accessible within the confines of the platform (i.e., should not require personnel to reach outside the platform). Any exceptions should require specific review and approval.
i. Minimum 75mm hand clearance should be provided around all valve hand wheels and levers over the full
range of available travel.
j. Valve handwheels shall meet AGES-SP-09-003 Piping and Pipeline Specification. However for operational
ease, it is recommended that valve handwheels should not be larger than 460mm in diameter.
k. Valve levers shall meet AGES-SP-09-003 Piping and Pipeline Specification.
l. Handwheels should be designed with one or more of the following to aid the operator’s grip for applying
maximum torque.
i.
knurling
ii.
Indentation
iii. High Friction Covering
m. Hand wheels should turn counterclockwise to open and clockwise to close the valve.
n. Valve position indicators should be located and oriented such that the indicator is clearly visible from the
operator’s normal working position.
o. The cracking force required to turn manual valves shall be assessed to ensure that the maximum force that operators are capable is not exceeded. Unless a specific deviation is approved, the maximum cracking force required to operate any large valve (with a handwheel diameter > 125mm or lever length > 125mm), without hindrance, is not to exceed 360N. For smaller valves that are deemed one handed operation (handwheel between 50mm and 125mm), a maximum cracking force is not to exceed 66N.
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p. The force required to operate manual valves (once the valve has been cracked) is to be assessed to ensure that the maximum force that operators are capable is not exceeded. Unless a specific deviation is approved, the maximum force required to operate any large manual valve, without hindrance, is to not exceed 147N for valves with hand wheels above 125mm or levers above 125mm long.
q. Any valve that requires more than 80 turns to go from fully open to fully closed should be equipped with a
motorized actuator.
r. Remote Valve Operators (RVO) or mechanical extenders should be used to operate valves that cannot be located within the reach limit distances specified in below where direct operation would expose the operator to hazards (e.g., confined space or where noxious fugitive emissions may be present).
s. Valves should be self-lubricating or allow easy manual lubrication.
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.
450mm
300mm
m m 0 0 6 1 m m 0 5 2 1
m m 0 5 1 1
m m 0 0 7
m m 0 5 4
200mm
Optimal
Acceptable
Acceptable with COMPANY Approval
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450mm
300mm
m m 0 0 2
Optimal
Acceptable
m m 0 0 8 1 m m 0 5 7 1
m m 0 5 6 1
m m 0 0 7
Acceptable with COMPANY Approval
Dimensions to be adjusted dependent on anthropometric data of the workforce.
Figure 6-1 Valve Operator Positioning
6.2.2
Valve Criticality Analysis (VCA)
All manual operated critical valves shall be located so that they are accessible from floor level or platform. Locating critical valves, such as emergency isolation valves, at floor level is preferred where practical. It is preferred to
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mount critical valves on shared common platforms, such as the battery limits platform or a vessel platform, to the greatest extent possible.
Valves should be categorized as VC1 (critical), VC2 or VC3 according to their criticality to process, safety, frequency of access, redundancy and reliability factors. Table 6-2 below provides further information and examples.
Table 6-2 Valve Criticality
Category
Criteria for Selection
Accessibility Requirements
Category 1: VC-1
Category 2: VC-2
(One or more of the following applies) Valves that require rapid and/or frequent access during normal or upset conditions. Valves that require access during emergency conditions. Valves where consequences of failure to operate as intended would have serious operational or safety implications. Valves that are expected to be operated more than once every 6 months. Valves with high maintenance requirements. Examples include control valves, their bypasses and isolation valves; relief valves; trip/recycle valves; emergency shutdown valves. Valves that are accessed during start-up or shutdown operations.
Permanent unrestricted access shall be provided. (a)Preferably valves shall be at deck or ground level. Where this is not possible access shall be by stairs to a permanent standing elevated surface or platform
(b)Valve Height shall be between 500mm to 1500mm, with a maximum reach of 300mm (these dimensions should be adjusted to suit anthropometric data for the workplace population if required)
(One or more applies) Valves with low operating frequency and low maintenance requirements. Valves that are accessed during non-routine maintenance or during turnarounds only. Valves where consequences of failure to operate as intended would not have safety or operational implications. Examples include tie-in valves; valves used for initial start-up purposes only; valves for pressure testing etc.
The minimum accessibility criteria shall be a vertical fixed ladder leading to a standing surface. Valves should not normally be operated directly from a ladder.
Category 3: VC-3
Valves that do not come under VC1 or VC2.
The use of auxiliary equipment to gain access is permitted (e.g., mobile platforms or scaffolding). The layout design shall include space for such access equipment. No other specific layout requirements are imposed other than to provide sufficient space for infrequent maintenance activities
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Notes
a. Critical valves (VC1) should be located within the Preferred Range unless impracticable in which case
second choice locations may be acceptable subject to review.
b. VC1 valves with hand wheel diameters larger than 400 mm and/or those requiring a reasonable (>165 N) cracking force to operate shall be located between 900 mm (optimum) and 1000 mm above the standing surface for hand wheels in the horizontal plane; and between 1100 mm and 1300 mm above the standing surface for hand wheels in the vertical plane (these figures should be adjusted to suit anthropometric data for the workplace population if required).
c. Where a number of valves having the same VCA rating are located together, and the piping arrangement does not allow for all to be at the preferred position, then the following order of priority should be given to the valves:
i. The valve requiring the greatest physical force to operate.
ii. The valve or valves requiring two-handed operation.
iii. The valve or valves requiring single-handed operation.
d. With the exception of drain valves, VC1 valves located outside preferred and second choice ranges shall
e.
f.
require specific approval. In all cases there should be no object preventing the operator from standing right at the valve hand wheel or lever. Where a barrier (e.g., handrail) is allowed for smaller valves, reach distance shall not exceed 500 mm. If a PSV has the inlet and outlet valves are in close proximity (i.e., they can both be operated from the same physical location) then the operation of both valves is considered to be a ‘single action’. Where inlet and outlet valves are not in close proximity and the operator must move to a different location to operate the second valve then the operation of both valves is considered to be two independent actions.
Stairways, Ladders, Platforms, Walkways and Railing
Stairs, ladders, platforms, walkways etc., are fundamentally important in plant design. The workforce will be required to access, inspect, operate and maintain equipment above grade. Stairs, ladders, platforms and ramps etc., shall be provided to give access to equipment and avoid operators and maintenance staff needing to climb on equipment and pipework.
The selection of ramp, stairs or ladder depends on the angle of ascent/descent and the task (including rescue in the H2S Zone, see HSE-OS-ST21).
Ramps should be used for angles between 0o and 20o (preferred range is 7o to 15o, especially in the case of pushing/pulling carts/trollies etc).
Stairs should be used for angles between 30o and 50o (preferred range is 30o to 40o) including for rescue in the H2S Zone.
Ladders should be used for angles between 50o and 90o (preferred range is 0o to 80o for step ladders, preferred range for ladders is 75o to 85o).
Stairs should be installed if personnel are required to carry large tools or pieces of equipment, or if equipment must be accessed or personnel evacuated during emergencies (e.g., battery limit stations). Stairs are mandatory in locations where evacuation requirement is foreseen, especially in H2S Zones.
Bad stair/ladder design and excessive climbing of stairs and ladders can cause wear and tear to the body. Therefore, if any of the following apply:
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a. The height of the climb is more than 9m
b. The climb is performed by the same person more than four times a shift.
c. Equipment and tools are often carried up and down.
Then consideration should be given to providing an alternative (such as an elevator or use of manual handling equipment to move equipment/tools), redesigning access or redesigning the task.
All stairways, ladders, platforms and other walking/working surfaces shall be designed to OSHAD-SF CoP 23.0, OSHA 1926.1053, OSHA 1910.25 and OSHA 1910.23 as a minimum, but shall take into account to anthropometric data of the workforce. (This is defined in ADNOC standard HSE-GA-ST07 HSE Design Philosophy and AGES- GL-03-001).
6.3.1
Specific requirements Applicable to Stairs and Stairways
Stairs should be provided where the task analysis indicates these are essential for safe execution of operational or maintenance tasks. This includes any platforms where:
a. Manual sampling and handling is required.
b. Access to VC1 valves.
c. Battery limit platforms.
d. Work areas that are used once or more per shift.
Stair widths and head clearances shall meet the requirements for access ways. In general stairs shall meet the requirements and dimensions set out in the UAE Fire and Safety code (Buildings).
Stairs should be provided where access is required for routine operational checks or personnel are required to gain access on a regular basis.
Stairways should be provided whenever operators or maintenance workers must change elevation abruptly by more than 250mm (see also for access).
If steps are wider than 2400mm, they shall be separated into several parts by one or more handrails, so the width of each part does not exceed 2400mm and is not less than 800mm high.
Going, g, and rise, h, shall meet Formula :
600 ≤ g + 2h ≤ 660 (dimensions in millimetres) (N)
The going (distance t minus r, see Figure 6-2 below) shall be between 210 mm and 310 mm.
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Figure 6-2 The Going (g) and Rise (h)
The overlap, r, of the step shall be ≥10 mm and shall apply equally to landings and floors (t is thread depth).
On the same flight, h shall be constant. Where it is not possible, the rise of the first step in the flight, h1, may be reduced by maximum of 15 %.
The maximum riser height for an individual step shall be 300mm.
The leading edge of the stair tread shall be of a contrasting color for a minimum width of 38mm.
6.3.2
Fixed Ladders
Fixed ladders should not be the primary method of escape. They are acceptable for access to platforms that are used less than once a week.
The maximum height of a single run ladder shall be 9m. however if there are several runs of ladders, the height of each single ladder shall be a maximum of 6m.
Fixed ladders shall be attached to permanent structure and should not be attached to removable items or interfere with the removal of any other items or equipment.
Structures such as ladder cages shall not be fixed to the ladder in any way that causes interference with handgrip or foot placement.
Ladders shall be for access only. Personnel should not be conducting any task from the ladder. There shall be no manual handling or lifting of any load via ladders.
The exit/entrance access to the top of the ladder should be a side-step orientation.
A self-closing safety gate covering the full width of the ladder opening shall be installed at the top of each ladder. Chains shall not be used.
Ladders shall not interfere with the movement or removal of equipment items, covers and manways.
Ladder landings/platforms shall be independent of primary and secondary escape ways and other access ways.
6.3.3 Walkways and Platforms
Walkways and platforms provide access to equipment that is above grade.
Platforms should be provided wherever operators or maintenance staff are required to use two hands to perform a task.
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Platforms shall provide access requirements.
Effective fall protection is to be provided on stairs, ladders and platforms at or above 1800mm (as defined in HSE- OS-ST22). If the workforce is exposed to a potential fall of equal to or more than 1800mm, safety belts or harnesses shall be used.
Handrails for walkways and stairs should be continuous, including the transition between walkways, platforms and stairs.
The clearance dimensions for walkways, stairs, ladders should comply with.
There should be unobstructed access to all stairways, platforms and walkways. No equipment, piping, cabling, or any other object shall protrude into designated access routes, walkways and platforms.
Elevation changes in walkways and access routes shall be avoided. The greatest height difference between adjacent floorings shall be less than 4mm. Gaps between adjacent flooring shall be less than 20mm.
6.3.4
Handrails
Handrails should be provided on stair landings and at the edge of any floor where there is a drop of more than 500mm to grade or the adjacent level. Handrails should be provided on both sides of stairways with more than 3 steps.
The vertical height of the handrail shall be between 900mm and 1000mm above the step and a minimum of 1100mm above the walking level on the landing.
Handrails should be smooth, continuous, circular in cross section and be between 25mm and 50mm outside diameter. It should provide a good grip for the hand.
6.3.5
Landings
The width of landings should be at least as wide as the stairways but have a minimum width/length of 900mm. Landings on primary escape routes and routes where stretcher access is required should have a minimum width of 1200mm and 2200mm long. Where there are changes in direction it is recommended that landings should be a minimum of 1778mm in length and 2900mm wide to accommodate rotating the stretcher.
The maximum height between stairway landings shall be 3650mm. For tanks, a landing should be provided for every 6000mm of vertical rise.
Stair landings shall be independent of primary and secondary escape ways and other access ways.
6.3.6
Flooring/Surface materials
Slippery floor surfaces shall be avoided in work areas and access ways. All access ways shall be self-draining. Non-slip alternatives shall be installed in exposed stairways and ladders. They shall remain non-slip when wet, oily etc. The surface of every stair tread is to extend across the full width of the stair and also be slip resistant.
Grating should be used if rain is expected, wetting the floor during operations/maintenance tasks is anticipated or if for other reasons there can be accumulation of liquid or loose solids, unless a solid floor is a requirement for containment. Grating/openings in floorings shall be less than 35mm. If there is a risk from falling objects to people below, the grating/openings shall be 25mm or less.
Anthropometric Range
The design shall reflect the requirements of the local workforce, including anthropometric data. The design shall consider the range from the 5th percentile woman to the 95th percentile man, and account for the various different
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ethnicities of the workforce. This shall account for the height, size, range of movement, lifting and carrying, strength etc. Anthropometric data shall be taken from peer reviewed sources (agreed/approved by ADNOC technical Authority) or from data taken from the workplace, based on the general requirements set out in ISO 15535.
Signage and labelling
6.5.1
General
a. All units of equipment, including valves, instruments, control panels etc. should have identifying labels. These labels should be securely attached, permanent, non-fading, chemical and solvent resistant, corrosion resistant and abrasion resistant. Labels should preferably be engraved plastic.
b. Equipment labels should be located so that they are visible and readable with the equipment in its installed position (see 10.1.1.5 on Visual Acuity). Labels are not to be located so that they are covered by movable items such as doors, racks, access openings or other equipment.
c. Labels should be located (preferably above) so they are not obscured from the operator when operating the associated equipment (e.g., the operator’s hand should not obscure the label when the operator is carrying out a task).
d. Labels on similar units of equipment should be placed in approximately the same location on each.
e. Labels should be located so that they can be read from the operator’s normal work position or station, and
should read from left to right (unless the local stereotype is right to left) or top to bottom (allowed).
f. Labels shall be concise and unambiguous. The amount of information on the label is to be sufficient to convey a clear message to the intended user. Clear and complete words should be used. Acronyms and abbreviations should be avoided. Excessive detail, redundant words, phrases, and information should be avoided.
g. All characters should be of adequate size and with a choice of a simple block font suitable for ease of reading and understanding. Font size shall be large enough so that the label can be read from the operator’s normal work position. See Section 10.1.1.5 for further information on visual acuity.
h. Labels should be of high contrast, preferably black text on a white background.
i. All labels shall be in the appropriate language/languages for the workforce (typically English and Arabic).
For labels of more than three words, mixed upper/lower case text shall be used.
j. Trade names, logos, equipment model, contract numbers, or any other information not directly required by the user to accomplish operational or maintenance tasks should be avoided on the face of displays, control panels, and consoles. Where such information is provided it should be on the back or side of the panel.
k. Techniques including unique labelling, color coding or similar should be employed to distinguish between
process trains. However, if color coding is used it shall not the sole means for indication.
l. Descriptive text shall always be used to accompany any symbols.
6.5.2
Safety Signs
All safety signs shall also conform with the requirements of HSE-OS-ST27 Hazard Communications Standard.
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HUMAN MACHINE INTERFACE & RELATED INSTRUMENTATION REQUIREMENTS
Alarms
7.1.1
General Principles
Alarms should be designed in accordance with ADNOC Group Alarm Management Standard, AHQ/UPS/PRD/STD/004/R00/20, AGES Alarm Rationalization Philosophy: AGES-PH-04-003 taking into considerations international/ industry standards inclusive of IEC 62682 and EEMUA 191 Alarm Management Systems. The Alarm management system vendor shall develop an Alarm Management System that shall include all the required Alarm Management requirements. General HFE principles for alarms are as follows:
a. Alarm prioritization is to be accomplished using three priority levels and is to be based on a continuum of
importance, severity, or time-based need for operator action.
b. Each alarm should prompt a unique action or response (e.g., monitoring). If there is no action required, there should be no alarm. If multiple alarms all prompt the same action, there should only be one alarm with the visual alarms denoting each system sending the audible alarm signal.
c. A notification that has no associated panel operator action as stated above shall be considered as an alert or message (sometimes called “journal”) and logged in the system for any post-event analysis or to be used as historical data.
d. Cues for prompt recognition of out-of-service alarms should be designed into the system. The system should log the operator who initiated out-of-service alarm together with date/ time/ authorization details. Further, system should all reporting of all the out-of-service alarms on demand and at the end/ start of each operation shift.
e. The limits or set points for initiating the annunciator warning system should be established to meet the
following goals:
i. Alarms should not occur so frequently as to be considered a nuisance by the operators.
ii.
iii.
If applicable, the limits or set points that initiate an alarm or warning display should be set so that the alarm gives operators adequate time to respond to the condition before it becomes more serious.
If it is possible for an alarm to be “ON” or disabled for an extended period during normal operations (e.g., for equipment repair), the alarm is to be distinctively coded for positive recognition during this period.
f. For control panels, a control to test the auditory signal and flashing illumination of alarms is to be provided.
g. Repetitive groups of alarms should have the same arrangement and relative location at different workstations. Any alarm controls (e.g., acknowledge, reset, clear) should be consistent from panel to panel.
h. For the brown-field works and the facilities being added as the part of existing process area the existing
HMI and associated philosophy/ practice should be considered.
7.1.2
Visual Alarms
For Control workstations and local control panels visual alarms shall have:
a. Sufficient contrast between illuminated versus non-illuminated alarm banners and flashing versus steady-
on alarms is to be provided so that operators can easily and instantaneously discern each state.
b. Color coding is to be consistent across all alarm displays and shall reflect alarm priority.
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c. Conspicuousness of color coding of alarms should reflect alarm priority and state.
d. Due to the possibility of the operator having impaired color vision, color coding should not be used on its own but as a secondary indication. Other methods such as text, shape, shading or contrast shall be used as a primary means. Alarm priorities shall be displayed using at least using three distinct visual features inclusive of distinct color codes, distinct alarm prompt shapes, distinct text for each alarm priority.
e.
If the visual alarm is important then if shall be located to be in the operator’s middle visual field. See section 10.1.1.2.
7.1.3
Audible Alarms and Warnings
a. A signal-to-background noise ratio of at least 10 dB(A) is to be provided at the operating position of the
intended receiver
b. No audible alarms should exceed 110 dB(A) without specific written approval
c. Completion of a corrective action is to automatically terminate the audible signal
d. Acceptable priority coding methods for audible signals include a combination of pulse coding, duration,
frequency, intensity change and shape change may be used as designated by EEMUA 191.
e. Audible signals should have a frequency range between 200 and 5000 Hz.
f. For a quick response time, a “yeow” (descending frequency from 800 t0 100Hz every 1.4 seconds) or a
“beep” (415Hz, on for 0.7 seconds, off for 0.6 seconds) are ideal.
g. The best frequencies to travel through the facility are between 500-1000Hz.
h. The most effective alarm noises for penetrating and attracting attention are sirens and horns.
i. For existing sites, any new alarms shall be consistent with existing site alarms to avoid confusion.
7.1.4 Warning Devices
a. Hazard alerting devices should be provided to warn personnel of impending danger or existing hazards.
b. Multiple sensory warnings should be provided (e.g., flashing light and audible alarm) when conditions are
changing and hazardous (e.g., crane movement).
c. Visual alarms / warning beacons (rotating or flashing lights) should also be used in conjunction with audible alarms in spaces with high ambient noise levels and/or where conditions exist which may interfere with audible alarm detection.
d. Locations of warning devices (such as beacons and horns) should consider access for maintenance and
to ensure appropriate operational coverage should a warning device be out of service.
7.1.5
Control/Display/Alarm Integration
a. The relationship of a control to its associated display and alarm should be immediately apparent and unambiguous to the operator. The control / display relationships should be apparent through proximity, similarity of groupings, coding, framing, labelling, and similar techniques.
b. A control actuator and its associated display and alarm should be mounted in the same plane where practical. Controls should be located below the relevant display (preferred) or to the right (acceptable). Layout and clearance should be such that both the display and alarm remain clearly visible to the operator whilst operating the control actuator.
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c. Controls and displays / alarms used on identical systems located in different locations in the same compartment or in different compartments should be located in the same spatial relationship to the equipment in each compartment.
d. Functionally related controls and display / alarms should be located in proximity to one another and arranged in functional groups. Functional groups within a panel should be set apart by outlining with contrasting lines that completely encompass the groups. Functional groups of controls and displays / alarms should be located to provide for left-to-right (preferred) or top-to-bottom order of use, or both.
e. Providing the integrity of grouping by function and sequence is not compromised, the more frequently used groups and the most important groups should be located in areas of easiest visual and / or reach access. Control-display groups required solely for maintenance purposes should be located in positions providing a lesser degree of access relative to operating groups.
f. Location of recurring functional groups and individual items should be similar from panel to panel.
g. Mirror imaged arrangements shall not be used.
h. Whenever possible the controls associated with a horizontal row of displays should be placed in a horizontal row directly below the displays. Avoid a horizontal row of displays / alarms associated with a vertical column of controls or vice versa.
i. For control actuators that cannot be located beneath or to the right of their respective displays or alarms,
the actuators should be grouped in the same row arrangement as the displays or alarms.
j. An analogue display that must be monitored concurrently with manipulation of a related control should be
located so that the operator can observe the display directly to avoid parallax error.
k. When the manipulation of one control requires the reading of several displays, the control should be placed as near as possible to the related displays and below the middle of the displays, but not so as to obscure the displays when manipulating the control.
l. Emergency displays and controls - those associated with a hazardous or potentially hazardous condition that require immediate action to prevent injury to personnel and/or damage to equipment - should be located where they can be seen and reached with minimum delay.
m. Display indicators should clearly and unambiguously direct and guide the appropriate control response. The responses of a display to control setting movement should be consistent, predictable and compatible with the operator’s expectations.
7.1.6
Escape and Evacuation Alarms
Detection, communications, warnings and alarm systems in place for Emergency Escape and Evacuation shall adhere to the Escape, Evacuation and Rescue Assessment HSE-RM-ST07.
Local Control and Display Panels
Working clearance around Instrument panels etc. is to be in accordance with ISO 11064: Ergonomic Design of Control Centers.
The following minimum requirements should be incorporated into the design for all electrical and instrumentation cabinets to enable maintenance:
Clearance between cabinets and/or other equipment, to allow for door opening and any requirement for equipment withdrawal plus an additional minimum of 900mm of free space.
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The spacing requirement shall also take into consideration operation/ maintenance/ removal/ replacement of panel parts and EMC requirements together ensuring ergonomic design.
a. Door hinges should allow full opening and have ‘tiebacks’ or equivalent to prevent doors swinging closed.
b. Equipment arrangements should consider the weight and manual handling implications (e.g., place heavier
equipment lower down in cabinets, allow access for manual handling equipment if required).
c. Accessibility for instruments and local control panels shall be assessed during 3D model reviews.
Additional Instrumentation Requirements
General principles that should be considered for displays:
a. All information is to be presented in directly usable form; a user should not have to decode or interpret data. The operator should not be expected to perform mental calculations using the information provided.
b. All displays necessary to support an operator activity or sequence of activities should be grouped together. Displays should be arranged in relation to one another according to the sequence of their use or the functional relations of the components they represent.
c. Displays should be arranged in sequence within functional groups, whenever possible, to provide a viewing
flow from left to right (preferred, unless the local stereotype is for right to left) or top to bottom.
d. Primary displays, including those used frequently, that are used for obtaining precise readings or those used in emergencies, should be located within the immediately readable field-of-view. See 10.1.1.2 below.
e. Dual gauges providing an IN and OUT reading (e.g., suction and discharge, voltage in and out, etc.) should be arranged so the gauge with the IN reading is on the left (preferred, unless the local stereotype is for right to left) or top, and the gauge with the OUT reading is on the right (preferred) or bottom.
f. Methods should be provided to determine if a display circuit has failed.
g. The absences of a signal or visual indication should not be exclusively used to denote a malfunction or
out-of-tolerance condition; malfunction indicators are required.
h. Separate and distinct information required for operations versus maintenance should not be combined in
a single display unless the information content and format are suited to both users.
i. Trade names, logos, equipment model, contract numbers, or any other information not directly required
by the users should be avoided on the primary HMI face of display panels.
j. No display shall require the removal of a cover or other component to be visible, unless the display is only utilized for maintenance and it has a clearly marked quick access door that does not require the use of tools to open.
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Figure 7-1 Positions of Displays on Control Panels
Gross Displays **
1575mm – 1702mm
Precision Displays *
1194mm – 1575mm
Gross Displays **
965 mm – 1194mm
No Displays
Below 965mm
Precision
reading
required, frequently used
or emergency
** Status lights or low
accuracy displays
(Note – heights should be adjusted dependent on anthropometric data. These dimensions are taken from ASTM F1166 – 07 for the 5th percentile female to 95th percentile male South East Asia population)
General principles that should be considered for controls:
a. Where practical, controls for similar functions should be standardized in regard to size, shape, color, location and direction of movement. However, standardization of controls is to not be applied in cases where differentiation between distinct functions is critical. In cases where separate controls serve different critical functions (e.g., start vs. stop; release vs. move) such controls should be sufficiently differentiated and instantly recognizable.
b. Controls associated with a specific display shall be located directly below the display so the operator’s
hand does not obscure the view of the display.
c. Spacing between controls and/or adjacent obstructions should consider method of operation and ensure
required accessibility and clearances. For example, for:
i. Single-handed finger operated toggle switches and rocker switches; the minimum separation
requirement is 19 mm.
ii. Single-handed finger operated push buttons, rotary switches and knobs; the preferred separation
is 50 mm, and the minimum requirement is 25 mm.
iii. For Palm operated push buttons the preferred separation is 150 mm.
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iv. For Thumb operated push buttons the preferred separation is 100mm.
d. Positive indication of control activation (e.g., via feel, an audible clicking noise, or a display) should be
provided.
e. All controls that function in sequential operation necessary for a particular task or that operate together should be grouped together along with their associated displays. When several steps of a sequence are selected by one control, the steps should be arranged by order of occurrence. Cycling through the control’s ON / OFF position is not acceptable. Where sequential operations follow a fixed pattern, controls should be arranged to facilitate operation (such as in a fixed pattern left-to-right (unless local stereotype is right to left) and top-to-bottom).
f. Controls should be designed / located / protected so that they cannot be operated accidentally. This is critical for any control where inadvertent movement may result in injury to personnel, damage to equipment, or degradation of system functions. Transparent guards should be considered.
g. Any methods of protecting a control from inadvertent operation should not preclude operation within the time required. If a cover guard is used, it is to not interfere with the protected control, or adjacent controls, when in the open position.
h. All emergency stop buttons should be colored red. Emergency stops should be designed / located /
protected so that they cannot be operated accidentally.
i. Emergency stop buttons should be located such that they are easily visible and accessible from the normal operating positions and do not require the operator to enter a hazardous situation to activate. This may require additional emergency stop buttons for specific equipment.
j. Controls (excluding valve hand wheels) mounted on a vertical surface should be located between 1000 mm and 1650 mm above the operator’s standing surface. Push buttons should be located no higher than 1650 mm. Critical controls should be no lower than 945 mm and no higher than 1333 mm. (Consider the anthropometric data for the workforce and adjust these dimensions if required to suit, dimensions to be agreed with COMPANY) See Figure 7-2 below.
k. Control panels should be located and oriented so the operator can directly view the equipment being controlled and/or monitored. Local control panels should be oriented so the operator faces the equipment as their face the panel. The layout of the panel is to reflect the spatial arrangement and functional layout of the controlled equipment.
l. Where control panels are required to be remote from the equipment, the controls and displays should be mounted such that the relationship of the controls and displays matches the arrangement of the controlled equipment.
m. Controls should be selected, located, and oriented so that their motion is compatible with the movement of the associated display or equipment, and should match operator expectations. Table 7-1 provides general guidance only. Designers should consult an HFE specialist or their designated discipline engineer for further specific guidance as needed.
n. Note that optimal elevation (“Preferred”) is more important for digital displays than for equivalent analogue
gauges.
o. Critical controls such as emergency stops should always be located in the preferred range.
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Gross Controls **
1270mm – 1778mm
Precision Controls *
762mm – 1270mm
Gross Controls **
711 mm – 762mm
No Controls
Below 711mm
- Are
frequently used
controls
accurate
that
and
require
specific
settings such as
rotary
switches and thumbwheels
** are those controls that no
precision is required such
as push buttons, levers and
cranks
Figure 7-2 Positions of Controls on Control Panels
(Note – heights should be adjusted dependent on anthropometric data. These dimensions are taken from ASTM F1166 – 07 for the 5th percentile female to 95th percentile male South East Asia)
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Table 7-1Control Actuator Movement Expectations
(These shall be adjusted to match local stereotypes if required)
Direction of Movement
Down, right, forward, clockwise
Up, left, rearward, anticlockwise
Clockwise, right
Anticlockwise, left
Up
Down
Rearward
Forward
Forward, up, right, clockwise
Rearward, down, left, anticlockwise
Anticlockwise / counterclockwise (valve)
Clockwise (valve)
Instrumentation
Function
On
Off
Right / CW
Left / CCW
Raise
Lower
Retract
Extend
Increase
Decrease
Open valve
Close valve
The location of instrumentation, shall be designed so that:
a. Heavy instruments (greater than 23kg) shall be accessible by (preferably) mobile lifting equipment or
b.
permanent lifting facilities. Instruments, junction boxes, local control panels and impulse lines shall allow sufficient working area around them to allow cleaning, set up, calibration, maintenance, rodding out and removal/replacement. This includes any special requirements necessary for the safe handling due to very toxic substances.
c. Local instruments such as pressure and temperature gauges shall be mounted so they are upright. d. Gauges and displays requiring frequent monitoring that are fitted to equipment inside acoustic enclosures
shall be located outside the acoustic enclosure.
e. Gauges and other analog instruments shall have black text/numbers on a white background. Text shall be
sized according to the requirements for visual acuity (see Visual Acuity section 10.1.1.5).
f. The drain/vent of the Level gauges require regular draining / venting in operation and shall be routed to
closed process drain / flare as necessary.
g. For instruments having Fire Proofing, the hand wheel for on/off or control valve shall be accessible for operation and the accessories shall be accessible using access door arrangement. These shall not compromise the quality of the fire proofing enclosure.
Control Panel Signage and labelling
See section 6.5 for general guidelines on signage and labelling, which also apply to control panels.
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Human Machine Interface (HMI) Design
HMI shall be designed based on the requirements of AGES-PH-04-001, related AGES and ADNOC Group standards together with international/ industry standards inclusive of ISO 11064-5, ASM Consortium Guidelines on Effective Console Operator HMI Design, ISO 62682, EEMUA 201, etc.
The process control displays are the screens that the operator uses to monitor the process. The process is usually controlled by a Process Control System (PCS), although some facilities may use Programmable Logic Controllers (PLC) with some form of user interface such as a Supervisory Control and Data Acquisition (SCADA). There may also be hardwired emergency systems and annunciator panels. Refer to AGES-SP-04-001: Process control system specification for details. Usually, hardwired emergency systems and annunciator panels are also provided to maintain safe state of the process, refer AGES-SP-04-003: Fire & gas specification, AGES-SP-04-004: Emergency shutdown (SIS) system specification for details.
The HMI is the major tool used by the operator to determine what is happening with the plant and make adjustments.
The HMI shall be simple to learn and use. Operators have access to a large amount of plant information, but it is important they are not overloaded.
To be effective the HMI must be consistent and unambiguous. Displayed information should be reliable and valid, with indication if information may be unreliable (e.g., faulty instrument).
Information displayed in groups on graphics should be functionally related. Graphics shall be consistent with the actual process.
The HMI shall be designed to ensure that errors made by operators do not create a hazard. E.g., using data entry checking.
The operations team shall be actively involved in the development of the HMI design. This has the added benefit of user ‘buy in’.
The workstations/ HMIs system response times and other performance requirements shall be as per ISO 11064- 5:2008 Annex-A.
7.5.1
Display Design
Display Hierarchy
The hierarchy levels help the operator navigate through the process control displays. How the levels are configured will depend on the complexity of the process. The top level should provide key process information and emergency alarms, plus fire and gas alarms. The second level could be the process overviews of each area, the third level could contain more detail about subsections of the plant. Navigating between levels and from one section to another should be intuitive with minimal number of inputs from the operator. Multiple methods for navigating between different levels and screens shall be available to the operator, including menus, process overview screens, navigation targets on screens, using text input, search tools etc.
Guidelines given in AGES-PH-04-001 shall be applied for developing and organizing the hierarchical displays for workstations HMIs. Navigation among the displays shall be logical/ sequential and aid in managing the normal and abnormal situations.
Display Contents
The displays will consist of both static information (e.g., lines, titles, equipment symbols etc.) and dynamic information (e.g., pressure, temperature etc. and status of valves and equipment). Pop ups can be useful to provide
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the operator with extra information as required without cluttering up the display but should not obscure important information on the main display.
If operators will need to routinely compare information, then that information shall all be available on the same display rather than across screens, so they do not need to try and retain information. Information presented to the operator shall not require the operator to perform any mental calculations or conversions.
Trends shall indicate the normal range for the variables shown. Color shall be used to distinguish between several variables being trended, but should account for operators with impaired color vision when selecting colors. Each variable shall be labelled, including the units of measurement. There should be no more than 12 traces per trend, and the ability to distinguish between trends (other than color) by using symbols or different line types, and/or the ability to ‘hide/show’ specific traces (without deleting the data) should be used.
Display Layout
The components of each display, such as title, alarms list, navigation lists etc., shall be consistent on all displays.
Abbreviations and labels shall be standardized across the system.
Symbols shall be consistent across the system and be meaningful to the operator. The size of the symbol shall be determined by the viewing distance.
Graphical objects such as analog dials, digital counters etc. help present information in a useful way. These objects shall be consistent across the system.
Numeric Values shall only be displayed to the level of accuracy required, e.g., 75psi not 75.05psi. Numbers shall be presented horizontally and include units of measurement. For numeric values in tables, ensure that the decimal points are lined up.
Text
Text is used to identify items on screen, such as equipment names and tag numbers. A simple block font and font size shall be used. Font size shall be dependent on the viewing distance, the limit of legibility is considered to be 200x the letter height (see section 10.1.1.5). If the text forms a ‘clickable’ target e.g., a navigation target, then it needs to be large enough for the operator to be able to select it reliably.
Text shall be presented horizontally.
Text messages and labels longer than three words shall be in mixed upper and lower case for ease of reading.
AGES-PH-04-001 shall be applied for defining text information/messages used in displays. Text on displays is required to be brief and consider location and functional/contextual information.
Display Color
Choice of colors is important. Effective use of color can decrease the time required to search for information on the display. Therefore, use of color should be meaningful to the operator. Color coding of data shall be consistent across the system and shall adhere to any local stereotypes. The use of color should not be overused and should not be the primary means of coding due to possible color vision impairment. (See 10.1.1.4) Text, shape, shading etc. can all be used in addition to color. However, flashing/blinking/animation shall be restricted to items that need to attract the operator attention and shall not be used to indicate normal operations such as an agitator moving. Colors of routine statuses of equipment shall not detract from detection of parameters in alarm. For instance, consider using Red for an alarm, but use pink for valve closed or equipment stopped status to avoid confusion.
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For the background color, white and black shall both be avoided in normal circumstance due to eye strain (note that black may be useful when operators are in a dark working environment, so their eyes do not need to adapt to large changes in light intensity. See 10.1.1.3). Ideally an off-white color such as light or mid grey should be used.
Color can be used as a secondary means to differential between identical process trains.
The choice of colors shall aid in situational awareness of the process and identify normal and abnormal conditions within the process/ process equipment.
Data Entry
Methods for reducing likelihood of error when entering data shall be used e.g., programming in acceptable ranges, using drop down menus or allowing small incremental changes. Should any safety study (such as HAZOP) identify circumstances where incorrect data entry may result in a hazard then the design shall ensure these errors cannot be made.
Control Room design and Layout
In general, control room design should meet ISO 11064 series – Ergonomic Design of Control Centers, in particular the following parts.
Part 1: Principles for the Design of Control Centers.
Part 2: Principles for the Arrangement of Control Suites
Part 3: Control Room Layout.
Part:4: Layout and Dimensions of Workstations
Part 5: Displays and Controls
Part 6: Environmental Requirements for Control Rooms
ISO 11064 provides a clear framework for designing control system through five phases:
a. Phase A: Clarification of purpose, context, resources and constraints.
b. Phase B: Analysis and definition of function and performance requirements.
c. Phase C: Conceptual design of initial layout, furnishing, equipment and communications.
d. Phase D: Detailed Design
e. Phase E: Operational feedback.
EEMUA 201 – Control Rooms: A Guide to their Specification, Design, Commissioning and Operation provides additional guidance for Control Room Design, including visual displays, console and desk design etc. It also includes a Human Factors Integration Plan template.
The design of the whole control system, including the control room and its environment, console desk and HMI, needs to support the operator, both physically and psychologically, and provide the facilities needed to ensure that they are alert, comfortable, healthy, and physically and mentally capable of doing their job.
It is important to include existing control room operators in all stages of the development of the control system design. This gives current operational feedback and improves operator ‘buy in’.
Location of the control room is also an important design decision. The control building will be deemed ‘occupied’ and therefore it may be desirable to locate it outside of any hazardous area to reduce construction costs, but
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various factors, such as user requirements, proximity requirements to other buildings, future expansion plans etc. also need to be considered.
7.6.1
Visual Displays
Note that is important to recognize that control rooms and consoles will be used by a number of people. The body dimensions and eyesight (e.g., operators wearing varifocal glasses, needing to them raising or lowering their heads to read) of those people will vary but the adjustability of screens and consoles is likely to be limited and may not be sufficient to accommodate the full range and requirements of all individuals. However, the design should try to ensure there is as much adjustability as possible and/or that issues arising from lack of adjustability are addressed by alternative means (e.g., different set ups for different sized people, supply of single vision glasses etc.).
Video screens for flares and windsocks shall be easily viewed from all operator workstations and located within the visual field (see 10.1.1.2) of the operator in their normal working position.
7.6.2
Console Design
Input devices such as keyboards, mice, trackballs, touchscreens etc. form part of the workstation design. Therefore, the design and input devices need to meet the requirements of all users. This may require additional devices that can be swapped over. The design shall also consider that some users may operate mice/trackballs etc., with their left hand rather than their right hand, so an easy changeover of position should be possible. Proprietary keyboards can improve operability, but the availability of spares should be considered, along with the impact of any temporary changeover to standard keyboards may have.
With multiple users, it is also important that devices are easy to keep clean. Touchscreens in particular will need regular cleaning due to fingerprints.
Other devices may include CCTV controls etc.
7.6.3 Work area design
The console desk size needs to account for all the items the operator may need and their space requirements, The number of screens, input devices, phones, radios etc., need to be accommodated. There is also the need for space for files, manuals etc. and operators should have space to review open folders and complete paperwork. Standing desks may be used but factors such as their maintenance, cable requirements, adjustment for the full range of operator heights, sight lines to wall mounted displays etc. need to be considered. They need to be easy to adjust so that operators use them at the correct height.
The design will need to accommodate the range of sizes from the 5th percentile woman to 95th percentile man, and also account for different ethnicities. See section 6.4.
As chairs will need to accommodate operators of a wide range of heights, these will need to be adjusted frequently and therefore should to be more robust than a normal office chair. More than one style may be required to suit the full size range of operators. Operators should be actively involved in chair selection.
Remote Operations
There may be a requirement for operators to control plant remotely rather than from the control room. This may be to observe the current status of the plant (read only access) or may allow them various levels of control (read/write access). This may impact the network requirements of the control system, to ensure the capacity and speed of the network is suitable for remote access. Slow and/or unreliable networks will cause problems for remote access and negate any benefits gained.
Remote Operations could be from remote operator shelters or from handheld devices (e.g., tablets).
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Remote HMI may need to be ruggedized/weatherproof and therefore may be nonstandard, which may impact usability. Operators may need to use keyboards or handheld devices whilst wearing gloves. Screens may be smaller and more difficult to read, so different graphic displays to allow remote operations maybe necessary. Suitable task lighting shall be provided.
Audible alarms from remote HMI shall account for any increased local background noise.
Handheld devices may also be used to replace traditional paper checklists, avoiding the need to later enter data manually (and therefore reducing the potential for error). These shall be suitable for use in the applicable hazardous/non-hazardous areas.
If an operator is regularly required to collect data that is considered important enough to require a handheld device, then an assessment shall be made whether providing permanent instrumentation instead is a better option. This prevents operator error/omission and reduces their workload and is more robust from cyber-security aspect.
MANUAL HANDLING AND LIFTING REQUIREMENTS
When designing and constructing machinery, the design shall meet the essential requirements for safety and health. The hazards of the machine, installations, equipment and consider these hazards related to the life cycle of the machine. (refer to HSE-OS-ST17 Manual Handling)
During the design a three-stage approach shall be adopted:
a. Avoid manual handling activities wherever possible.
b. Utilize technical aids, such as lifting equipment where manual handling activities cannot be avoided.
c. Further reduce the inherent level of risk by optimizing handling activities.
The design shall ensure that the requirements for manual lifting, pulling, pushing, and carrying of equipment are met, with respect to the biomechanical and physiological capabilities and limitations of personnel are considered. Associated needs include the availability of mechanical lifting aids for assisted lifting and appropriate storage or placement of lifting aids for safe reach and effective operation. All manual handling tasks shall have a manual task risk assessment that will be a deliverable to operations.
Manual handling of loads can lead to a high risk of injury to the musculoskeletal system if the loads to be handled are too heavy, and/or handled at high frequencies for long durations and/or in awkward postures. Disorders of the musculoskeletal system are of a common occurrence. Risks exist if the design of the machinery/ installation is not in accordance with ergonomic design principles. The risk shall be assessed and shall consider the variation of physical size (based on anthropometric data), sex, age, strength and endurance of the workforce.
WORKING ENVIRONMENT
Designers shall ensure that working environment aspects including noise, lighting, vibration, air quality, movement, humidity and temperature; and proximity or exposure to thermal, physical, chemical or other hazards, have been adequately considered and addressed in equipment layout and design.
Noise
Maximum noise limits and safeguards shall conform to HSE-OH-ST08 Physical Health Standard. In general noise control (e.g., choosing low noise equipment) at source shall be the primary goal and noise mitigation (i.e., hearing protection) is to be adopted as the last line of defense.
Hearing and understanding audible communications may be masked (blocked) in a noisy environment. The closer in frequency the masking noise is to the sounds (e.g., speech, audible indications etc.) the listener needs to hear,
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the more masking impacts the ability to hear. The design shall ensure that essential operational audio information/communications are readily distinguishable and easily discernible with the context of the general noise environment for all credible scenarios.
This requirement includes but is not limited to:
a. Routine operational equipment checks.
b.
Inter-personnel voice / radio communications.
c. Critical information such as alarms and device movement warnings.
d. Alarms and warnings should be appropriate for the particular environment. All critical information, alarms and warnings should have multiple sensory indications that should at a minimum include clear visual indication in addition to audible warnings. (See section 7.1)
e. Acoustic insulation / noise enclosures create operability and maintainability issues. Where acoustic
insulation or noise enclosures are essential, they should meet the following HFE criteria:
i. Acoustic insulation should not impede access, including visual access, for routine operational checks
and activities.
ii. Acoustic insulation applied to equipment or components requiring infrequent visual inspection and /or access for maintenance / replacement should be able to be easily removed, identified, and reinstalled.
9.1.1
Nuisance Noise
HSE-OH-ST08 Physical Health Standard specifies the limit values for noise in the workplace. However lower noise levels can also cause annoyance during work, causing issues such as difficulty in concentrating etc. Noise is considered a nuisance when it interferes with a worker’s ability to carry out an activity. There is a subjective nature to nuisance noise, what one worker may consider annoying may not be annoying to another.
However, in general:
a. Loud and high frequency noises are considered a nuisance. They can affect performance by creating
distraction and affecting concentration and communication.
b. More familiar noises tend to be less annoying.
c.
Intermittent noise can reduce performance on mental tasks more than continuous noise.
It should also be noted that very quiet environments may also be distracting as even quiet conversations and noises are noticeable and can become intrusive. In areas such as control rooms, the operators may want to play music etc. to counteract this. If this is the case, then consideration should be given during design to installing a system that automatically cuts out the music when alarms and radio messages are received so that the alarms and messages are heard clearly without additional operator action.
Lighting
Adequate lighting is essential for safe and efficient access and egress, operations, inspection and maintenance of equipment. Designers should provide project compliant lighting to ensure adequate visibility in all conditions (daytime, night-time, various weather conditions, sea spray, sandstorms etc) for:
a. Access ways.
b. Level and surface changes.
c. Stairs.
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d. Ladders.
e. Work Areas.
f. Bunds and Drain pans.
g. Equipment Components.
h. Connections
i. Valves
j. Local Instruments
General Office lighting is covered in the Occupational Health Management Standard HSE-OH-ST11.
The level of illumination needed generally depends on the task performed. The more visually intense the task (i.e., smaller details or lower contrast) the higher the illumination level required, up to a maximum, where the performance levels off no matter how much more illumination is increased.
Table 9-1 Recommended Illumination Levels for Different Types of Activities below presents ranges of illumination levels (in lux) recommended for different types of visual work activities and areas. Local task lighting should be used to provide illumination levels above 1000 lux. The average age of the workforce may be considered when determining the illumination levels to address the general decrease in visual acuity with age. For specific lighting requirements see the Electrical Design Guide AGES-GL-02-001
Table 9-1 Recommended Illumination Levels for Different Types of Activities
Activity
Public area navigation
Illumination Range (Lux)
20-50 (recommended). Minimum of : 5 for walkways (non process) and light traffic area 1 for carparks 10 for slow moving traffic areas
Occasional visual tasks
Visual tasks with large objects and high contrast, reading printed material
100-200
200-500
Reading poorly printed material with medium contrast or small objects
500-1000
Reading very poorly printed material with low contrast and very small objects for a short period
Reading very poorly printed material with low contrast and very small objects for a long period
1000-2000
2000-5000
Difficult visual tasks such as inspection or fine assembly
5000-10000
Difficult visual tasks with very low contrast and very small objects
10000-20000
Illumination levels recommended for selected tasks in process areas are presented in Table 9-2 below
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Table 9-2 Recommended Illumination Levels for Selected Tasks in Process Areas
Process Area
Illumination Range (Lux)
Control room/Instrument room/Telecoms Room
Rear of Panels
Manual Sampling Points
Compressor House
Loading racks
Loading Point General Area
Platforms Main operating areas Ordinary area
500 150
215
160
110 32
55 22
Stairways, walkways and ladders (frequent use)
100 (for Offshore the minimum is 25)
Walkways in non-operational areas (limited attendance)
Exchanger area
Streets
0.5
32
5
Illumination levels should not change dramatically in adjacent areas, so the operator’s eyes do not have to suddenly adjust to a large change of light intensity (See section 10.1.1.3).
9.2.1
Lighting Quality
Lighting color, glare and illumination ratio also have a direct effect on task visual performance.
Lighting Color
The color of an object is determined by:
a. The wavelengths of visible light it absorbs and reflects.
b. The color of the incident light.
The color rendering index (CRI) and color “temperature” of the incident light determine how the color of the object is affected by the incident light.
The CRI quantifies how well the light source reproduces the natural color of an object and varies from 0-100. As the CRI increases, color judgement errors decrease. Light sources with a CRI below 60 should be avoided when accurate color judgement is important. Ideally a CRI of greater than 80 should be used.
Color temperature is an indication of a lamp’s color and is expressed in Kelvins (K). Color temperatures up to 3000K are considered “warm” and make reds more vibrant. Color temperatures greater than 4000K enhance greens and blues. Between 3000K and 4000K most colors are enhanced equally and should be used where accurate color judgement is important.
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Glare
Blinding occurs when a certain area has greater brightness than the rest in the field of view. This leads a potential decrease in visual performance and can cause annoyance and discomfort.
Direct glare is caused when a light source is directly in the field of view (e.g., and light source next to an instrument or sun glare). Indirect glare is caused by reflected light from polished or reflective surfaces.
Glare should be avoided when there is direct interference with visibility and visual performance. Positioning of plant lighting should be carefully considered to ensure there is no impact of glare where operators and maintenance staff are required to read instruments etc. This includes considering glare from sunlight and plant lighting. Light sources should not be directly in the field of vision. Where required, shades or glare shields can be used to reduce glare. Using multiple lower intensity light sources instead of fewer higher intensity light sources may be preferable.
Luminance Ratio
The Luminance Ratio is the ratio of the brightness of the object of interest to the brightness of the surrounding visual field. The greater the difference in luminance level, the greater the problem of transient adaption, which can affect visibility, visual comfort and performance.
Flicker
Light flicker is rapid repeated changes of light intensity. Some flicker frequencies can cause visual discomfort, visual fatigue and general distraction. Some individuals are more sensitive to flicker; in particular those with epilepsy can find some frequencies of flicker can trigger seizures. Flicker often occurs with lamps coming to the end of their life and should be changed promptly.
Vibration
Vibration is any movement of a body about its fixed position and can be regular or irregular. Vibrations are characterized by direction, frequency, amplitude and acceleration.
See also HSE-OH-ST08 Physical Health Hazards Standards for further discussion on the effects and methods of reducing impact.
Effects of Vibration on Performance
The main effect of vibration is reduced motor control and visual control (lack of hand steadiness and eye fixation). Vibration has no noticeable effects on cognitive functions, reaction times etc.
Vibration can have residual effects that may last for a short period after exposure to vibration. The impact on manual performance depends on the intensity of the vibration and whether the task demands movement in the same axis in which the person is being vibrated. Visual impacts are typically blurred vision and reduced visual acuity.
Effects of Vibration on Health
Hand-Arm Vibrations (HAV) are typically caused by handheld power tool usage and can lead to vascular, bone joint, nervous and muscle disorders, including Vibration White Finger and Raynaud’s Syndrome.
Whole Body Vibration (WBV) are typically caused by vibration along the vertical axis when standing or sitting. The most common effects are abdominal pain, chest pain, spinal disorders (particularly lower back and neck), and blood in urine (probably due to kidney damage), along with headaches and muscular tension.
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Temperature
The human body tries to maintain a core temperature between 36 and 37.5oC. The body generates heat through metabolism and physical activity, and tries to maintain the correct temperature in a number of ways (e.g., changes in blood circulation to the skin, sweating and shivering). See HSE-OH-ST08 Physical Health Hazards Standard and HSE-OH-ST11 Occupational Health Management Standard.
Indoor moderate thermal environments should be designed to ISO 7730:2005.
Equipment at high or low temperature needs to have protection to prevent injury. This includes:
a. Atmospheric vents should be located and orientated away from access ways, stairways etc. The location should consider prevailing wind conditions with respect to access ways and routine operational areas.
b. Drains, vents, bleed sampling and inspection ports etc., should be capable of operation without risk of
exposing the operator to thermal hazards, preferably without the need for additional PPE.
c. Any thermal insulation or guarding shall be designed and installed such that it does not pose a risk to
operators from sharp edges.
9.4.1
Effects of Heat
Effects of Heat on Cognitive Tasks
For simple cognitive tasks, heat does not significantly affect performance, however for more complex cognitive tasks, high temperatures (starting between 30 and 33oC) have a negative effect on performance. The need for operators to work on complex cognitive tasks should therefore be avoided if they are subjected higher temperatures.
Effects of Heat on Physical Activities
Physical work in higher temperatures, particularly with high humidity may cause physical fatigue and exhaustion. In addition, an increase in temperature may also lead an increase in unsafe behavior (Ramsey, J.; Burford, C., Beshir, M. and Jensen, R. (1983) “Effects of Workplace Thermal Conditions on Safe Work behaviour.” Journal of Safety Research 14, pp..105-114). The requirement for operators/maintenance staff to perform heavy physical work in a high temperature environment should be minimized by appropriate design
Effects of Heat on Health
Exposure to excessive heat can impact a person’s health in numerous ways, causing:
a. Heat rash
b. Heat Cramps
c. Heat Syncope
d. Heat Exhaustion
e. Heat Stroke
Individual tolerance to heat stress is also determined by a number of factors.
a. Age (tolerance decreases with age).
b. Sex (women are less tolerant to heat than men).
c. Physical fitness.
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d. Body fat levels (higher levels leads to less tolerance to heat).
e. Medications can also affect a person’s tolerance to heat.
See HSE-OH-ST08 Physical Health Hazards Standard
9.4.2
Effects of Cold
In general, the body can tolerate increased heat than cold. The effects of cold can vary due to differences in airflow (causing cold drafts), humidity, duration of exposure, differences to exposure to different parts of the body and individual physiological/biological differences.
Effects of Cold on Cognitive Tasks
Performance on mental tasks decreases with colder temperatures when performing complex cognitive tasks, especially those requiring high levels of concentration and short-term memory, and therefore the requirement for operators to work on cold environments when high concentration and short-term memory is important should be minimized. Exposure to cold can also result in altered behavioral responses, including perception, mood, personality and apathy. However cold does not tend to affect the cognitive efficiency of well-motivated individuals.
Effects of Cold on Physical Activities
Physical work is significantly affected by cold. Cold can cause reduced motor skill ability, loss of touch sensitivity, reduction in muscular control, reduction in dexterity, reduction in muscle strength and reduction in endurance. There is also a possible reduction in performance due to shivering.
Thermal PPE (e.g., gloves and thermal clothing) can protect operators against the effects of cold environments, however these can cause additional issues, such as lack of dexterity. Any tasks that require an operator or maintenance worker to work in a cold environment needs to consider the impact of cold and any additional PPE requirements.
Effects of Cold on Health
Exposure to excessive cold can lead to shivering and then, vasoconstriction of blood vessels which can then lead to frostbite to exposed body tissues.
Individual tolerance to cold is determined by a number of factors:
a. Body composition (those with higher body fat can tolerate cold better).
b. Body size and weight
c. Physical fitness
Ventilation
The working environment within building spaces can be impacted by the following factors:
a. The presence of soiled or spoiled air
b. Temperature fluctuations and draughts
c. Excessive heat and cold
d. Excessively high (>70%) or low (<20%) humidity
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Indoor moderate thermal environments should be designed to ISO 7730:2005 Ergonomics of the Thermal Environment.
Fresh air should be supplied, and stale air removed at a minimum rate of 36m3/hour per person, this can be by natural ventilation or be mechanically controlled. Natural ventilation can be difficult to control, mechanical ventilation requires proper and regular maintenance.
The temperature maintained is dependent on the activities taking place, (i.e., a lower temperature if the workforce are more physically active). Windows and skylights etc. shall be designed to ensure there is no excessive solar gain. Any equipment in the workplace shall not cause excessive heat build-up in the workplace.
Other factors that will affect the comfort of the workforce, such as draughts (air speed), vertical temperature differences, hot or cold floors and radiation asymmetry, shall also be considered. These factors should be minimized.
A Humidity level around 50% should be maintained.
See Indoor Air Quality Standard HSE-OH-ST12
Weather Protection
The design shall consider any weather protection for the operators. This can be related to:
a. Platform and vessel orientation
b. Explosion Protection
c. Module layout
d. Weather cladding
If the operator’s performance may be negatively affected by exposure to adverse weather, this should be identified and where possible the design shall include weather protection for the operator. This includes operator shelters.
In high temperature areas where physical work is regularly performed, adequate ventilation should be provided to maintain the temperature below 32oC. In other areas where there may be non-routine work conducted, space and utilities for temporary ventilation shall be provided.
For offshore facilities, muster points and lifeboat embarkation areas should have areas that give shelter from the elements.
HUMAN RELIABILITY AND PERFORMANCE
Impact of Personal Factors
The operator is continuously receiving information about their environment and the status of the plant they are operating. They need to process that information to enable them to make decisions on how to respond. That response may take the form for manual manipulation of controls or valves, checking other information etc.
How well the operator can do this is dependent on several personal factors, including their visual sense, auditory sense, cognitive function and their physical strength, size and endurance. The other senses (touch, smell and taste) usually have a smaller role.
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10.1.1 Visual
Accommodation of the Eye.
Accommodation refers to the ability of the eye to focus on objects at different distances by changing the shape of the lens in the eye. Some individuals are short sighted and cannot focus on distance objects, others may be far sighted and cannot focus on near objects. Shortsightness and farsightedness can both be corrected with glasses.
As individuals get older the ability of the eyes to accommodate reduces.
The workforce should be encouraged to get regular eye tests to ensure that any factors that may affect their vision are detected and can be corrected.
Visual Field
The visual field defined as what can be seen when the head/eyes are kept fixed and is divided roughly into the three areas.
The optimal field of view, with an angle of view of 1o where objects are sharp, and detail can be seen clearly.
The middle field with a visual angle between 1o and 40o, where objects are not in sharp focus, but movements and strong contrasts will be noticed.
The outer field with a visual angle ranging between 40o and 70o, where objects are not sharp. Objects need to be moving to be noticeable.
Objects that the operator needs to see clearly therefore must be located in their optimal field area.
Adaptation Process
Adaption is the ability of the eye to adjust to different levels of light intensity. The eyes need time to adjust before they can see discriminate details.
Adjusting from light to dark (dark adaptation) can take from 30 minutes to an hour depending on the initial illumination levels.
Adjusting from dark to light (light adaptation) is relatively fast and can take a few minutes.
In the work environment, it is therefore important to avoid excessive changes to illumination levels. Where these changes are unavoidable, the operator should be allowed sufficient time for their eyes to adapt.
Color Vision
Color can help distinguish objects in the visual field. Certain colors can have specific meanings (e.g., red is a warning).
Different lighting conditions affect the eyes’ sensitivity to color. In bright light, eyes are more sensitive to red and less sensitive to blue. In lower levels of illumination, the reverse is true. Perceived color is also dependent on the color rendering index (CRI). See 9.2.1.1 for further details.
Color blindness (especially red-green) is not uncommon and affects about 8% of the male population and 1% of the female population.
Therefore color shall not be the primary method of ‘coding’ information and should be used as an additional method in conjunction with other methods.
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Visual Acuity
Visual acuity is the ability to see fine details. Visual acuity depends on a number of personal factors, including the accommodation of the eyes, visual field, illumination levels and adaptation to them, color vision and age. Other factors include the size of the object and the viewing distance.
Visual acuity needs to be considered, for instance, when designing signs on plant, specifying gauge sizes or visual displays in the control room. The required height of any text is dependent on the normal maximum viewing distance.
For favorable conditions, the following formula should be used.
H=D/200
Where:
H is the character height
D is the distance.
(the units of measurement are the same for both H and D but can be inches, millimeters etc.).
Favorable conditions means that the contrast is high, (e.g., black characters on a white background), the illumination levels are optimal, without glare, the operator has sufficient time to focus on the object to be able to focus and take in detail and there no movement of the object.
For less favorable conditions, the following formula should be used.
H=D/120
Effects of Age on Vision
Visual performance declines with age in various ways and for various reasons. Therefore, the average age and the range of ages of the workforce may need to be accounted for during design.
Decrease in visual acuity is caused by a number of changes to the eyes due to age.
a. Yellowing of the lens, which reduces the light entering the eye.
b. Decrease in accommodation of the eye (as discussed in section 10.1.1.1) which tends to start at around
the age of 40.
c. Retina and nervous system changes around the age of 60. This affects the size of the visual field and
reduced sensitivity to low levels of light.
10.1.2 Auditory
The two characteristics of sound are frequency (tone or pitch) and intensity (loudness). Hearing is an important part of communicating the status of the process whether it be communications between operators or hearing audible signals/alarms.
The design may need to consider whether to use an auditory or visual presentation of the information to the operator. The choice depends on:
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a. The nature of the message. If an alarm needs immediate action, then it should be auditory, so it does not
rely on the operator to be looking at an alarm.
b. The average age and age range of the workforce. Younger people tend to have better hearing than older
people.
c. Local conditions. In a noisy environment, it will be difficult for an operator to hear over other noise and they may be wearing ear defenders. However, if their visual field is overburdened then a buzzer or similar will be more noticeable than another visual indication.
10.1.3 Cognitive Function and Mental Load
The individual senses receive information from the environment (predominately from eyes and ears) and pass them to the brain for processing.
This information processing involves several different processes: attention, perception, memory and decision making. The receiving and interpreting of information needs knowledge, experience and mental alertness.
Operators who are neurodiverse (e.g., have ADHD, dyslexia etc.) may have different cognitive abilities that may impact how they process information.
Attention
People have limited capacity to process information from the environment around them, so must select the important information. ‘Attention’ is this process of filtering the information to be processed further. This process is limited as people can only process one thing at a time and can only process information at a constant rate and are not able to multitask. Therefore tasks shall be designed so operators can adequately focus their attention appropriately.
Selective attention is a conscious decision to pay attention to important information, e.g., scanning the visual display to detect unexpected but important events such as excessive temperature.
Focused attention is the filtering out of all the unwanted information and concentrating on one source of information.
Divided attention happens when someone needs to do several things at once, e.g., monitor a display whilst talking to other operators.
Sustained attention is when someone is monitoring something for a longer period of time.
Perception
Information from the environment is interpreted by the brain to try and produce a recognizable pattern. This is perception and is entirely subjective as it influenced by an individual knowledge, experiences and expectations.
Perception is a complex process. It can override what an individual knows to be true and takes place subconsciously. Perception does not need to correspond with reality. An individual’s behavior is determined by their perception rather than actual information.
It is therefore important that the design ensures that the actual outcome of a task or process aligns with the operator’s perception of what they expect to happen.
‘Adaption’ can affect the individual’s expectations when deciding how to respond. E.g., if an operator experiences a high number of false alarms, they then expect all following ones to be false as well. If a true alarm then occurs the operator is likely to perceive it as false and ignore it. (See section 7.1)
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The ‘direction of movement’ between controls and displays needs to be designed to meet the local stereotypes, so that the action the operator expects reflects what will happen. E.g., if the local stereotype for a switch is to push the switch up to switch a piece of equipment on, then the design shall reflect that.
Memory
Memory is the mechanism of storing and retrieving information. Memory is based on the individual’s training and experience.
There are three stages of memory.
Sensory memory is automatic in nature and is specific to the sensory system. Visual memory storage lasts for about 1 second, auditory memory storage lasts for about 3-5 seconds. After that time the information decays and if it has not passed to the short-term memory (see below) it is lost.
Therefore sensory memory is a limiting factor if the operator is conducting a sequence of tasks, so it is important to consider this during the design if the operator will have a series of tasks.
Short-term memory is the stage where an individual pays attention the information. The information can be then organized, encoded and transferred to the long-term memory, typically through a process of rehearsal.
Short-term memory is, as described, short term and lasts a few seconds, but if an individual pays attention and uses the process of rehearsal (e.g., repeating the information or writing it down) the information can be retained and transferred to the long-term memory.
Short-term memory can also be affected by distraction, disruption and interference.
The capacity of the short-term memory is also limited, typically to five to nine independent chunks of information (e.g., digits, words, procedure steps). This can be improved by ‘chunking’ information and using information and association to help (e.g., repeating the information several times, splitting a long number into groups of smaller numbers, associating the letters/numbers with something more rememberable, recognizing a pattern).
However, task design should try to ensure that an operator does not need to rely on short term memory to complete the task, to eliminate potential mistakes.
Transfer of information from the short-term memory to the long-term memory relies on attention, rehearsal and involves the use of association. Recall of information is limited but recognition is much better (e.g., an individual is very unlikely to remember a 25-step process but would probably notice if one of those steps was incorrect or missing).
Memory abilities tend to decline with age, so the average age and age range of the workforce may be considered during the design of tasks requiring memory.
Decision Making
Decision making is the process of evaluating the information provided and selecting an action to take.
The ability to make an appropriate decision is affected by the information available and the time given to make a decision.
To improve the human decision-making process for the operator the following should be considered:
a. Design in support systems to aid the operator. E.g., eliminate the need for the operator to make a manual
calculation and build it into the control system, reduce the use of ‘codes’ in favor of simple descriptions.
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b. Use decision tools and aids, e.g., using an expert system together information from a number of sources to calculate and predict future outcomes, rather than the operator needed to decide what information to look for.
c. Training and simulation. This is especially useful for abnormal situations that the operator will not normally
experience.
10.1.4 Physical capabilities
For the body to move, reach, push buttons, turn valves, move objects etc. requires the musculoskeletal system. This comprises of the muscles, bones and connective tissues such as tendons and ligaments.
Any physical activity that an operator performs must be within their physical capabilities. This capability is determined by both their body size/dimensions (anthropometry) and their biomechanics (the mobility of their bones, joints etc)
Muscular Strength and Endurance
Muscles have limits to their strength and ability to maintain that strength.
Strength is defined as the maximum force an individual can exert and can be classed into one of two types.
Static work, which is long term muscle contraction without any additional body movement. This includes sitting, standing etc.
Dynamic work involves body motion as well as muscular contraction, e.g., walking.
Most physical activities will involve both static and dynamic work.
Factors affecting strength include:
a. Age. Strength tends to reach its peak in the mid to late twenties and then starts decreasing, particularly in the 50s and 60s. Therefore, the design should account for the average age and range of age of the workforce.
b. Sex. The overall strength of women tends to be lower than men. In addition, the distribution of that strength is different; men tend to have significantly better upper body strength, whereas women tend to have better lower body strength.
c. Occupation. An operator will tend to be stronger than an office worker, due to their normal day to day
activities.
d. Physical training. This can increase muscular strength and endurance considerably.
e. Others.
i. Gloves. This can result in the loss of strength due to the reduction of grip. If gloves are required for a task then this should be considered when establishing the maximum force the operator can exert e.g., to turn a valve.
ii. Body dimensions.
iii. Body Position.
iv. Diet. Poor nutrition will decrease body strength.
v. Other personal factors, such as genetics, health, fatigue, medication and motivation.
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Muscular endurance refers to the ability of the muscle to continue to work. The force that can be maintained depends on the length of time it needs to be maintained, and this shall be accounted for in task design. For example, if a task requires an operator to operate hand-held tools for a period of time, then the endurance of the operator must be considered, and the strength required reduced appropriately.
Body Size (Anthropometry)
The design of equipment, plant layout, tools etc. should be based on the physical size and characteristics of the workforce.
Structural Anthropometry relates to the physical dimensions of the body, e.g., height, weight, arm length. The data for these dimensions are usually based on unclothed individuals, therefore it is important to make additional allowances for increases to body size due to clothing and PPE (e.g., increased height due to hard hats and safety footwear) and consider the impact of clothing and PPE on the range of movement.
Functional anthropometry relates to the range of motion.
Various factors can influence body size and shape and these factors should be considered:
a. Age. Body dimensions tend to be stable between the ages of 20 to 40 and then decline as part of the aging process. The use of anthropometric data during design may need to account for the average age of the workforce
b. Sex. On average men are generally larger than women. There are also proportional differences. However, women tend to be larger than men in chest depth, hip breadth and circumference, thigh circumference and skin fold thickness.
c. Ethnicity. E.g., those from an Asian background tend to be smaller than those of a European background.
d. Historical trends. The average size of people is increasing, in part due to better nutrition, health care etc. Therefore, for facilities with an expected long life span, the design should account for an increase in the average size of the workforce.
As stated in section 6.4, the design shall reflect the requirements of the local workforce, including anthropometric data. The design shall consider the range from the 5th percentile woman to the 95th percentile man, and account for the various ethnicities of the workforce. Ideally outliers (i.e., those below the 5th percentile and above the 95% percentile) should be included if this is easily accommodated and practicality/cost issues do not significantly outweigh the benefit.
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HUMAN FACTORS SCREENING
HFE screening should quickly identify whether there are any significant issues or opportunities associated with the facilities being developed that would benefit from further HFE considerations.
A HFE screening review should be led by an experienced facilitator (preferably by a HFE competent person) and include representative from operations and maintenance, as well as other engineering discipline specialists as appropriate.
In general, the following should be addressed.
a. Will Equipment of facility design require operations or maintenance personnel to
b. Work in abnormal environmental conditions requiring PPE or temporary measures due to
i.
ii.
iii.
iv.
v.
Ambient temperatures (hot or cold)
Air Quality
Lighting
Noise
Vibration
c. Work in small, confined spaces (restricting movement, cannot stand up, walk around etc.) for extended
periods of time
d. Perform tasks requiring the manual handling of materials, repetitive motions or unusual body position.
e. Perform complex tasks (especially if required during a night shift). Such as
i.
ii.
Having a high number of sequential steps
Have a high information processing load (e.g., The operator would have to consider many process readings, alarms etc. and then decided on the right actions).
f. Perform tasks that, if not done correctly, have significant safety. Health, environmental or production
consequences.
g. Operate a process or wok on equipment that is new to the plant (little or no experience) or for which
experience demonstrate that incidents occur more frequently.
h. Work in a situation that are not typical for the site, such as batch processes at a site that historically has
managed continuous processes only or a has significantly different level of process control.
Are there tasks associated with the venture that:
a. Have the potential for high health, safety or environmental consequences.
i.
ii.
Planned HSE critical tasks, such as to respond to a critical alarm
Production-critical tasks (abnormal situations) with HSE implications, such as response to loss of power.
b.
Involve interactions with several other personnel (especially during high demand situations).
c. Require PPE beyond the basic site requirements. (e.g., breathing apparatus).
d. Be difficult to recover from a mistake.
e. Unplanned, time-critical, or complex tasks.
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During the review the team needs to decide the level at which to screen. This could be
a. An overall process area or processing unit (such as a processing train, subsea well heads, buildings, tank
farms etc.)
b.
Individual equipment items (e.g., compressor packages, gas dehydration units, flowlines and manifolds, control rooms etc.)
c. Operations (e.g., turnarounds on individual units, unit start-ups, oil movements ship loading etc.)
All factors are detailed in the following tables with possible ratings and guide words. These should be adapted and agreed to suit project requirements.
Table A1-1 Task Complexity – How Complex are the Manual Activities Involved in operating, Maintaining and Supporting the Item
Rating
Simple
Meaning
There are only a few manual tasks, and they are inherently simple discrete actions with minimal mental demands (such as pressing Start/Stop buttons, reading gauges, etc.).
Guideword
Operations
Definition
Is the item likely to impose a substantial? amount of work on operations personnel – plant, field or panel?
Moderate
Neither Simple, nor complex
Maintenance
Is the item likely to impose a substantial? Amount of work on maintenance or technical personnel?
Complex
There are a reasonable number of tasks to be performed (>10), AND/OR Tasks can be difficult, complex, time consuming or require very high levels of human reliability
Physically demanding
Is the work likely to be physically demanding (climbing, pulling, lifting, etc.)?
Unknown
No information available
Mentally demanding
Does the work require high levels of concentration and vigilance, or does it make a lot of demands on thinking, reasoning, calculating or decision- making? Is a human expected to monitor or take account of trends over time, or to detect relationships between a number of items or parameters?
Labor intensive
Does the task require several individuals to complete or repetitive actions of the same few individuals?
Time Consuming
Does the task take a lot of time to complete?
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Other
Table A1-2 Unit Criticality – Is the Unit Critical for Operations or Hazard Control, or is it Involved in Hazardous Service.
Rating
Yes
Probably
Meaning
Guideword
Definition
No doubt. The item is critical or very hazardous.
Start- up/shutdown
Is this item integral for safe & efficient start up or shutdown?
More than a 50/50 chance that if the unit did not perform as designed, either production would be affected, or people would be exposed to hazards.
Production
Is the equipment essential for production/unit reliability/on stream factor?
Possibly
There is less than a 50/50 chance, but not negligible.
Product quality
Is the equipment essential to ensuring product meets quality specifications?
No
Would not affect production and would not expose anybody to hazards.
Process Safety
If the item did not perform as designed, could it represent a major risk to process safety, or does it provide a control against loss of integrity? (Explosion, fire, release of hazardous materials, etc.)
Personnel safety
Could it introduce a major risk to personnel safety? (e.g., loss of protection).
Health
Could it introduce a major risk to health? (e.g., exposure to chemicals, radiation, noise, fumes).
Environment
Could there be a major breach of environmental controls (e.g., spillage of hydrocarbons or chemicals)?
HSE control
Does the equipment keep a medium or high risk to people, asset, and environment under control?
Sour service
Yes: H2S in the process stream is >10% Possibly: H2S in the process stream >1%
Benzene
Yes: More than >10% benzene? Possibly: More than 1%
Above auto- ignition temp
Does the item routinely contain hydrocarbons above their auto-ignition temperature?
High pressure service
Is the equipment normally operated under high pressure?
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High temperature service
Is the external temperature of the equipment high?
Other
Other ways in which the unit is considered critical (be specific).
Table A1-3 – Task Frequency – How Frequently are People Likely to Need to Interact with the Item (Other Than Routine Operator Rounds)
Rating
Frequent
Meaning
Guideword
Definition
Significant work on the item more than once every 3 months
Start- up/shutdown
How frequently might the item need to be manually started up or shutdown?
Occasional
more than once per year
Trips
What is the expected frequency that the item might trip?
Rare
less than once per year.
Routine Ops
The frequency of routine operations?
Unknown
No information available
Routine maintenance
The frequency of routine maintenance activities (including change-out of major components).
Breakdown
The frequency that the unit might be expected to breakdown.
Inspections
The frequency of major inspections (other than visual checks)
Cleaning
The frequency of cleaning
Transportation Frequency of moving the item or its
components.
Re-supply
Frequency of re-supplying the item or its components.
Other
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Table A1-4 Novelty – Will the Item Require the Workforce to Gain New Knowledge, or Skill, or Will it Introduce New Produces, Work Practices or Organizational Structures.
Rating
Same
Variant
Similar
Meaning
More or less identical to existing units at the asset.
Guideword
Asset
A variant of items that are well known to the local workforce.
Business
Definition
New to the asset, but not new to the Business Unit (BU). Experience available at other assets.
New to the business unit, but not new to the company. Experience available in other BUs.
A new type of unit, though generally consistent with existing competencies and experience.
Company
New to the company. Experience available in the industry.
New
A new unit. Little or no relevant experience at the asset.
Industry
Not previously used (or not used in the same way) anywhere in the industry.
Unknown
Capacity
Significant change in capacity from existing units.
Feed
Will be used with a different feedstock.
Process
Not previously used for the intended process.
Competencies Will introduce requirement for new
competencies at the asset.
Procedures Will require new procedures that are
significantly different in content, or major changes to existing procedures.
Organization Will require significant changes to the
organizational structure (team-working, supervision, shiftwork or overtime arrangements, etc.).
Use of contractors
Reliance on contractors/vendors to carry out new functions.
Other
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Table A1-5 Design Scope – To What Extent is There Scope to Influence Control Over HFE Aspects of Design, Procurement or Layout of the Item
Rating
A lot
Meaning
Item will not be “off-the-shelf” and has not yet been procured. Vendor’s scope of supply includes design activity. There is still a lot of scope to influence both item design and positioning on the plant.
Guideword
Integral
A little
There is some opportunity to influence the design of the item itself, but it will be limited.
Plant layout
Definition
The design, location & positioning of components integral to the item. Includes the location and space around valves, flanges, sample points, etc, as well as the design and location of instruments, labels, and signs. (If there is no opportunity, further screening may be of limited value).
The positioning and orientation of the item on the plant, the space around it, and provision of access (including for escape), walkways, lay-down areas, etc.
Plant layout only
No opportunity to influence the design of the item itself. Can still influence location, orientation and local space on the plant.
Control panels
Local instrument panels. HMI Human Machine interface to ICSS or other IT systems, including graphics.
None
Item has already been bought or will be entirely off-the-shelf’. Vendor scope of supply does not include any new design. Location already frozen.
Instrumentation Design of instrumentation, including
alarm set-points, to assist panel operators detect abnormalities and diagnose faults from the control room.
CCTV
Provision of CCTV monitoring of the item, of leakages, or of the safety of people working in the area of the item.
Lighting
Local lighting arrangements.
Noise and vibration
Noise and/or vibration control measures.
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Is there a history of problems associated with the design or layout of the item? Concern is with issues that can affect operations, health and safety, process safety or environmental integrity.
Table A1-6 Known Problems
Rating
Major
Minor
Meaning
There are known to have been significant issues with similar items in the past
There have been some issues where the design has not been as good as it might have, though they are not considered major problems.
Guideword
Escape routes/ congested space
Equipment access
Definition
Inadequate escape routes or space for escape, including escape wearing arctic clothing and/or BA. Space for stretchers, or ease of access for emergency teams carrying emergency response equipment.
Access ways and space to bring in equipment needed to start-up, inspect, or maintain the item.
None
Not aware of any previous issues with similar equipment or operations.
Awkward or static posture
Excessive force/weight
Repetitive motions
Material handling
People are forced to adopt awkward or uncomfortable postures, involving twisting or bending of the spine, hips or neck, or excessive reaching with the hands and arms. Especially where there is a need to apply force while twisted or extended, or to maintain a static awkward posture for extended periods.
People required to apply unreasonably high levels of force (especially when combined with awkward postures) or to carry heavy weights (especially above torso height, or at a distance from the body).
People being required to perform the same physical movements repetitively over extended periods (e.g., regularly having to repeat the same movements of the fingers, hands, arms, legs or head/neck every few minutes over periods in excess of an hour).
Difficulties manually handling materials. Due to weight, size or shape, lack of space to adopt safe posture, poor grip, PPE, or poor communication/ cooperation between people working together.
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Rating
Meaning
Guideword
Poor lighting
Definition
Inadequately lit workspaces. Lighting not repaired. Lighting too bright. Insufficient light to read, perform visual inspections or to see manual activities.
Weather
Exposure to extreme heat, cold, wind, dust, mist, fog etc.
Comms/ noise/radios
Procedures
- confusing, conflicting
Mistakes/ human errors
Mistakes/ human errors
Issues around difficulties of communication. As well as high noise levels, could include lack of direct line of sight, radio ‘black-spots, cross- language issues, delayed information, errors (e.g. in permits), etc.
Procedures that are badly written, contradictory, illegible, not clear, unnecessarily complex or otherwise difficult to follow. Documented procedures (including their HMI implementation, e.g., in DCS screens or alarm set points) that do not reflect current operational practice or experience.
A history of human error, including mistakes, failure to complete tasks correctly, or procedure violations. Situations where human error has led to incidents including breach of safety or environmental control or production upsets. Includes error by ‘front- line’ workforce, as well as support or admin staff, contractors, or during commissioning, construction or turnarounds.
A history of human error, including mistakes, failure to complete tasks correctly, or procedure violations. Situations where human error has led to incidents including breach of safety or environmental control or production upsets. Includes error by ‘front- line’ workforce, as well as support or admin staff, contractors, or during commissioning, construction or turnarounds.
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Rating
Meaning
Guideword
Other
Definition
Any other history of known problems affecting the ability to work efficiently and safely.
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GUIDANCE FOR HFE PLANS
A2.1.
FEED HFE Plan
If the FEED Contractor is responsible for executing HFE activities, then contractor scope of work shall include the delivery of a HFE plan. This shall specify the HFE activities, roles and responsibilities required for the FEED stage of the project.
The HFE Plan to include HFE activities to be considered as part of the design shall be submitted to and approved by the COMPANY Human Factors Technical Authority/Discipline engineers.
The HFE will typically include, but not be limited to:
a. Plan Summary
b. The Definition and Objectives of HFE
c. Competency, roles and responsibilities of project HFE personnel and those in related roles
d. Reference to any HFE concerns
e. Reference to any Project Specific HFE risks and how these will be addressed (e.g., in reviews or
workshops)
d. Activities to be conducted
i. Awareness Training for project personnel
vi. Applicable Standards
vii. HFE Design Studies
viii. Support requirements for other Design Studies
ix. ALARP Demonstration
x. Document and Drawing review.
xi. Documentation and tracking of HFE actions. (HFE Issues Register)
xii. HFE Plan preparation for the subsequent project stage
xiii. Support and review participation for other discipline reviews and activities
e. Technical Assurance
A2.2.
EPC HFE plan for Construction Phase
If the EPC contractor is responsible for executing HFE activities, then contractor scope of work shall include the delivery of a HFE plan. This shall specify the HFE activities, roles and responsibilities required for the EPC stage of the project.
This HFE plan shall be submitted to, approved by the COMPANY Human Factors Technical Authority/Disciplines Engineers.
The HFE will typically include, but not be limited to:
a. Plan Summary
b. The Definition and Objectives of HFE
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c. Competency, roles and responsibilities of appointed project HFE personnel and those in related roles. This
includes:
i. Who shall conduct HFE inspections and their competency requirements.
ii. The frequency of HFE inspections.
iii.
Inspection checklists
a. The HFE Plan shall include the specifications for the application of HFE by contractors, subcontractors,
package vendors etc.
b. The plan shall include a list of all HFE and related design standards appropriate to the construction stage.
c. The plan shall include details for HFE awareness and competency training for construction workers
appropriate to their role.
d. The Plan shall include details regarding HFE validation and verification activities to be carried out during
construction.
e. The plan shall include details of the HFE action log to record HFE non compliances raised during HFE
inspections and include who is responsible for updating and maintaining the HFE action log.
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SAMPLE QA/QC HFE CHECKLIST
This checklist should be tailored to suit the project.
Concerns to be Appraised
Project Stage
1
2
3
4
Access and Spacing
1 Equipment Layout
Normal walkthrough paths
Emergency operations paths
Maintenance Access
X
X
X
Emergency Block Valve stations
control
X
Utility Stations
Manual Sampling points
Safety Showers
Access for mobile stairs/platforms
Firefighting facilities
2 Structural Design
Interference with access paths at equipment
Access to battery limit and emergency block valves
Access from platforms to frequently operated equipment (eg filters, air fin coolers, instruments and controls)
Access at vessel manways
Access to blinds, bleeds etc
Headroom under structures
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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X
X
X
X
X
X
X
X
X
X
X
X
X
Trolley beams for lifts
Connected platforms
3 Package Units (eg chemical compressor lube units)
injections,
Access to equipment
Space around the skid/unit
Location of controls
4 Fired Heaters
X
X
X
X
X
X
X
Access to burners/pilots
X
X
5 Compressor/Blowers
Access to filters
Access to probes
Access to controls
6 Piping Design
Valve reach
Valve spacing
Valve position indication
Access to safety valves
Access to instruments
Manual sampling points
Control Interface
1 Control Panel Layouts
Alarm layout/location
Controls layout/location
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X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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Types of emergency shutdown (ESD) switches
Display Convention
Consistency of controls
Visibility in daytime and nighttime
Labels
2 Audible Alarm Data
Alarm variability (Gas - HC, H2S, fire etc.)
Alarm locations/audibility
3 Control Room (CR) Console Drawings
Priority 1 alarm layout/location
Communication module
CCTV/TV monitors
Storage space for manuals etc.
Electrical Interface
1 Building layout, doors, ramps, breaker lifts
2 Transformers
3 Switchgear
4 Battery Storage
5 Motor Control Center
6 Labels/tagging
Work Environment
1 Lighting Layout
Night illumination
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X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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2 Climate Control Design
Temperature control
Humidity control
Labels
1 Label System Data
Equipment/Piping
Instruments/Controls
Tagging requirements info
Label size/colour/font/visibility
2 Color Coding Data
Emergency Valves
X
X
X
X
X
X
X
X
- Time sequence at stage of execution
1 Kick off meeting/training session
2 Vendor drawings (compressors, furnaces, control panels etc)
3 Contractors detailed drawings (plot plans, piping layouts etc)
4 Final 3D Model reviews
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Project: Q-32859 - NMDC - Ruwais Folder: RFQ Files