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2012 IEHF North West branch - Task risk management

Presentation to the North West branch of IEHF. Includes slides presented at the Institutes's annual conference, with additional information about use of a flow loop simulator to test the principles with students.

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2012 IEHF North West branch - Task risk management

  1. 1. Tel: (+44) 01492 879813 Mob: (+44) 07984 284642 andy@abrisk.co.uk www.abrisk.co.uk 1 Task Risk Management A Process for Managing Risks with Task Analysis at its Heart Andy Brazier
  2. 2. Task risk management A four stage process 1. Develop a task list 2. Prioritise task analysis according to criticality 3. Analyse the most critical tasks 4. Use the findings 2
  3. 3. Questions for you this evening Is ‘Task Risk Management’ the a good name? Alternative = Critical Task Analysis Do you agree with the four stages? Would you add or remove any? Why do my clients struggle to ‘get’ task analysis? (before asking me to assist!!!) HSE tell them to do it Some have had bad experience with other consultants – may be because the client asks the wrong questions or does not engage in the process. 3
  4. 4. 1. Identify tasks Possible approaches Skip the step – people often want to dive straight into task analysis Existing procedures – assume they cover all tasks Structured brainstorming – process drawing 4 Filters Duty/standby Pumps Duty/standby DP Alarms Lo LoLo Hi Trip Storage tank Delivery tanker Group exercise
  5. 5. 1. Identify tasks This step is very simple – but encourages a systematic approach Uses for task lists ‘Gap analysis’ of procedures, training/competence systems; ‘On the job’ training programmes; Workload estimates; Managing organisational changes. 5
  6. 6. 2. Prioritise tasks for analysis Possible approaches ‘Gut feel,’ experience or ‘normal’ risk assessment HAZOP, Process Hazard Review (PHR) etc. Scoring system (see OTO 092 1999 – HSE) 6 Hazardousness of system Ignition/energy sources Changing configuration Error vulnerability Impact on safety devices Overall criticality Low Medium High 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 0-3 4-8 9-15
  7. 7. 2. Prioritise tasks for analysis Benefits of scoring tasks at stage 2 Objective Demonstration of why tasks were selected for analysis – safety reports/cases Highlight ‘anomalies’ without carrying out a detailed task analysis 7 Microsoft Excel Worksheet
  8. 8. 3. Analyse the most critical tasks Task analysis is tried and tested – but negative perceptions Time and effort Only doing it to keep the regulator happy Discoveries from every analysis - if done ‘properly’ 8
  9. 9. 3. Analyse the most critical tasks Group exercise – use a data projector People share experiences and concerns Accept procedure may not reflect reality Buy in to new methods An excellent training exercise for people involved Human error analysis Look at the task with ‘new eyes’ Identify where issues have been ‘glossed over’ 9
  10. 10. 4. Use the findings ‘Engineer out’ error potential New projects – human factors integration plan Process design modifications to eliminate task or error Review and improve performance influencing factors Procedures High criticality – print, follow and sign every time Medium criticality – reference procedures Low criticality – generic procedures and guidance How do you manage the risks the risks of critical tasks that are performed frequently? 10
  11. 11. 4. Use the findings Competence system How to perform tasks Understanding the risks Continuous review – proactive and reactive Consider all stages when examining failures 1. Why is a task missing from the list? 2. Why was criticality not assessed correctly? 3. Was the task analysis correct? 4. Were the findings used? 11
  12. 12. 12 Identify tasks Rank criticality Analyse the most critical 1. Task analysis 2. Human error 3. PIF Audit/review Yes Risk ALARP? No Use the output 1. Design2. Procedures3. Competence4. Incident analysis
  13. 13. Introducing people to task analysis Recent experience with a group of new graduates in the power industry Use of a ‘flow loop simulator.’ 13
  14. 14. Flow loop simulator 14
  15. 15. 15 Pump A Pump B Flow Control Tank (1m3 ) Reservoir Tank (1.5 m3 ) PI PI TI TT FL1/DA/003 FL1/DA/008 FL1/DA/011 FL1/DA/016 FL1/DA/018 FL1/DA/001 FL1/DA/055A FL1/DA/031A FL1/DA/055B FL1/DA/031B FL1/DA/042 FL1/DA/013 NRV FL1/DA/029A FL1/DA/026AFL1/DA/027A NRV FL1/DA/029B FL1/DA/026BFL1/DA/027B PRV FL1/DA/R038 PRV FL1/DA/R039 FL1/DA/024 Return to reservoir tank FL1/DA/TW01 Liquid Supply M Manual valve Motor operated valve Non-return valve Relief valve PI Pressure indicator PI FL1/DA/054
  16. 16. Simplified flow 16 Pump A Pump B Flow Control Tank (1m3 ) Reservoir Tank (1.5 m3 )
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  18. 18. Group 1 – Start circulation 18 Pump A Reservoir Tank (1.5 m3 )
  19. 19. Group 2 – Change circulation 19 Pump B Flow Control Tank (1m3 ) Reservoir Tank (1.5 m3 )
  20. 20. Group 3 – Fill flow control tank to maximum level then shutdown 20 Pump B Flow Control Tank (1m3 ) Reservoir Tank (1.5 m3 )
  21. 21. 21 The challenge for the groups Develop a method for performing a defined task (1 hour) Consider the potential for human error (30 minutes) Determine how you will communicate your task method to operators and prepare (1 hour) Operators carry out task (1 hour).
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  28. 28. Questions again Is ‘Task Risk Management’ a good name? Do you agree with the four stages? How can we help industry to ‘get it?’ Any more we can say about using the output? 28
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