PETRONAS TECHNICAL STANDARDS

TECHNICAL SPECIFICATION

HUMAN FACTORS ENGINEERING - APPLICATION DURING CONSTRUCTION

PTS 30.00.60.14

DECEMBER 2012

2012 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner

PTS 30.00.60.14 December 2012

Page 2

This revision of PTS 30.00.60.14 Human Factors Engineering Application during Construction (December 2012) has been updated to incorporate PETRONAS Lessons Learnt, Best Practice and new information issued by relevant industry code and standards. The previous version of this PTS 30.00.60.14 (Jan 2005) will be removed from PTS binder/ e-repository from herein onwards. The custodian of this PTS is: Name: M K Shrivastava Tel. No: 03-2783 6508 Please direct any questions regarding this PTS to the above-named.

Document Approval

Revision History

PTS Circular 2012 - 1

PTS No: 30.00.60.14 PTS Title: Human Factors Engineering Application during Construction

PTS 30.00.60.14 December 2012

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PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication, of PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction, operation and maintenance of processing units and facilities. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor.

The right to use PTS rests with three categories of users : 1) PETRONAS and its affiliates.

2) Other parties who are authorised to use PTS subject to appropriate contractual arrangements.

3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated to PETRONAS that may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any company or person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS. The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users implement this requirement.

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TABLE OF CONTENTS 1. INTRODUCTION ........................................................................................................ 5 1.1 SCOPE ........................................................................................................................ 5 1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 5 1.3 DEFINITIONS ............................................................................................................. 5 1.4 CROSS-REFERENCES ............................................................................................. 6 1.5 SUMMARY OF CHANGES ......................................................................................... 6 2. MANAGEMENT SUMMARY ....................................................................................... 7 3. HFE ACTIVITIES ........................................................................................................ 8 3.1 GENERAL ................................................................................................................... 8 3.2 ACTIVITY DESCRIPTIONS ........................................................................................ 8 3.3 TASKS, AUTHORITIES AND RESPONSIBILITIES ................................................. 12 4. REFERENCES ......................................................................................................... 13

APPENDICES APPENDIX 1 EXAMPLE SPECIFICATION FOR APPLICATION OF HFE WITHIN

CONSTRUCTION ............................................................................................ 14 APPENDIX 2 EXAMPLE HFE ACTION PLAN CONSTRUCTION PHASE ........................ 19

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1. INTRODUCTION

1.1 SCOPE This new PTS specifies requirements and gives recommendations for Human Factors Engineering (HFE) activities during a projects construction phase. Its aim is to ensure that the operational and maintenance HFE criteria specified during the project engineering phases (FED/1/2/3, Implementation) are met. In particular this PTS covers the requirements for the application of HFE to systems, installations and constructions that are engineered and installed by a Construction Contractor (CC), not to pre-engineered designs. The purpose is to ensure that the implementation of HFE in CC engineered/fabricated installed units and/or systems results in units and/or systems that can be operated and maintained by personnel in an easy manner with minimum effort and within human capabilities and restrains. This PTS is applicable both to projects where construction management is a responsibility of the Principal and to projects where that responsibility is delegated to a Contractor. It is relevant for the Principals project and construction managers, construction supervisors, operations and maintenance staff, and Construction Contractors. This PTS should be read in conjunction with the following PTS: PTS 30.00.60.10 Human Factors Engineering - Project Design Procedure PTS 30.00.60.12 Human Factors Engineering - Investment Justification Model PTS 30.00.60.13 Human Factors Engineering - Valve Analysis PTS 30.00.60.15 Human Factors Engineering - Human Machine Interface and

Control room design

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by PETRONAS, the distribution of this PTS is confined to companies forming part of the PETRONAS group or managed by a Group company, and to Contractors nominated by them.

This PTS is intended for use in oil and gas drilling facilities.

If national and/or local regulations exist in which some of the requirements may be more stringent than in this PTS the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this PTS which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this PTS as closely as possible.

1.3 DEFINITIONS 1.3.1 General definitions

The Contractor is the party that carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party that manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party that initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal

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may also include an agent or consultant, authorised to act for, and on behalf of the Principal. The word shall indicates a requirement. The word should indicates a recommendation.

1.3.2 Specific definitions and abbreviations AFC Approved for Construction CAD Computer Aided Design CC Construction Contractor CM Construction Manager CSU Construction Supervisor FED Front-end design FEEEM Front End Ergonomics Evaluation Matrix design analysis FPHFEC Focal Point HFE Construction: responsible party within Construction

Contractor for coordination of HFE activities during Construction phase FPHFED Focal Point HFE Design: responsible party within Engineering and

Procurement (FED/1/2/3, Implementation) for coordination of HFE activities during the Conceptual and Implementation Phase

HFE Human Factors Engineer(ing) HFE verification round

Weekly walk-through review by construction and operational staff

HSE Health, Safety and Environment HSE-MS Health, Safety and Environment Management System I(S)BL Inside Battery Limit JV Joint Venture MAC Managing Contractor O(S)BL Outside Battery Limit PEFS Process Engineering Flow Schemes PFS Process Flow Schemes PHFET Project HFE Team Work system System in which one or more workers and equipment act together to

perform a task that is relevant to the functioning of the system

1.4 CROSS-REFERENCES Where cross-references to other parts of this PTS are made, the referenced section number is shown in brackets. Other documents referenced in this PTS are listed in (4).

1.5 SUMMARY OF CHANGES The PTS has been reissued without any changes.

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2. MANAGEMENT SUMMARY The objective of HFE during a projects construction phase is to ensure that the operational and maintenance HFE criteria specified during the engineering phases (FED/1/2/3, Implementation) are satisfied. The result is a more efficient worksystem with fewer bottlenecks, and overall lower operating and maintenance costs. In particular, the PTS is intended to prevent field run materials and equipment from being installed incorrectly. For example, if electrical or instrumentation items (e.g., facility lighting, power outlets, junction boxes and cable trays, etc.), small bore piping or tracing are installed in work areas, routine operation and maintenance tasks may be less efficient and HSE bottlenecks created. Construction workers are often unaware of the adverse effects that incorrectly installed field run materials and equipment can have. Without realising the consequences, they tend to select the most convenient routing for their own purposes, often restricting operability for subsequent personnel operating at the workstation. Therefore, a key objective is to ensure that Construction workers are made aware of the operational and maintenance difficulties that might surface later, and that they are given the knowledge, tools, and time to avoid them. The optimum HFE installation is achieved by: Engineering the installation as far as practical to avoid field fitting, providing detailed

installation drawings and notes. Where field fitting is expected, enough space should be provided so that this can be done in an operable manner.

Including requirements in construction contracts and providing construction typicals, check lists, and objectives for each type of field fit task.

Appointing responsible construction staff. Creating workers ownership through e.g.: o Providing training (complete with practice sessions and refreshers) for building

awareness of operation/maintenance objectives and means for achieving them. Training should include foremen, workers, and inspectors. As the workforce often expands and contracts throughout a project, the training program shall be continuous to ensure all workers are included.

o Providing time in the work plan to address operability. o Creating a culture of operability awareness in construction e.g. a reward system that

encourages construction workers to excel in this area of craftsmanship. o Including operability discussions in tool box / tailgate safety meetings.

Conducting weekly/fortnightly HFE verification rounds; Conducting audits.

The benefits identified are: Better Facility lay out, Reduction of re-work, Schedule advantage, Reduction of operations and maintenance life-cycle costs, Improvement of Client commitment level.

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3. HFE ACTIVITIES

3.1 GENERAL The Principal should designate a Focal Point for HFE during Construction (FPHFEC). This person will coordinate all HFE-related activities for all project phases of the project. A brief description of each HFE activity during the construction phase is given below. In addition, a work flowchart is illustrated in Figure 1 and a procedural scheme in Table 1, and tasks, authorities, and responsibilities are outlined in section 3.3. An example of the HFE requirements to be integrated in the construction contractors contracts, aiming at a proper management of field run installed material and/or equipment, is given in Appendix 1. An example of an HFE Action Plan - Construction Phase is given in Appendix 2.

3.2 ACTIVITY DESCRIPTIONS 1. Requirements for the construction contractor contracts

Towards the end of the Detailed Engineering phase the FPHFED shall make available an inventory or list of field run materials and/or equipment in the project and associated installation standards, if available. Based on this input the FPHFEC formulates requirements for the construction contracts. For this purpose, a generic document is available which is then tailored for each project: see Appendix 1 and Appendix 2, sections 4.1 and 4.2. Further inputs might be available, such as HFE analysis reports (e.g. FEEEM reports), 3 D CAD model review results and/or other design review results.

2. Construction HFE kick-off Early in the Construction phase, Construction management appoints the PHFET members. The prime tasks of the PHFET is to develop the HFE for construction plan, assure HFE competence for team members and conduct HFE verification rounds, including reporting on the findings at regular intervals. Minimum composition of PHFET: Operations and/or Maintenance personnel of operator/owner; FPHFEC; HFE Focal Point for Construction of MAC, backed up by Human Factors Engineer; and depending on scope a selection of engineering representatives (Mechanical, Electrical and Instrumentation, Rotating and Static equipment, etc.) and / or HSE co-ordinator. Some EP businesses arrange a so-called IPOP (Implementing Project On Paper) meeting, between contractor, subcontractors, Operations crew and Project Team to ensure all technical and safety issues are covered. It may be advisable to combine the HFE construction kick off and the IPOP meeting. Additional items on a kick-off meeting agenda may be (see Appendix 2, section 4.3): - Use of 3D CAD models on site; - Use of standardised 3D CAD equipment displays showing small-bore piping, etc.; - Arrangements concerning audits.

3. Determine training requirement Training requirement shall be defined for two categories of personnel (see Appendix 2, section 4.4): - Training for PHFET members: a 1-day workshop. - Briefing session for Construction Contractors; an approx. 30 min. meeting attended by

foremen and direct labour of Construction Contractors. 4. Conduct training

For the PHFET members, a 1 day workshop on HFE in the petrochemical industry is generally sufficient. The briefing sessions for installation personnel last approx. 30 min.;

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maximum number of participants per briefing session is approx. 20, depending on presentation medium employed. See Appendix 2, section 4.4.

5. Schedule for HFE verification rounds; develop project specific checklist A planning schedule shall be drawn up after Installation contractors are selected and before field run installation activities begin (in general during 20 % construction phase), including list of participants. A project-specific checklist shall be drawn up based on, for example, an HFE analysis report, e.g. FEEEM report, and other relevant documentation. Results of model reviews can also be used as input for this checklist. See Appendix 2, section 9.

6. Conduct HFE verification rounds During a walk-through the layout of the facility is checked against the project-specific checklist. This may include specific items such as checking operators round, checking logistic routes, accessibility of pumps, free hoisting space, checks on sources of noise emissions, etc.

7. Implement corrections If (potential) misfits are identified, these shall be dealt with immediately and on the spot in consultation with the Construction Contractor, in order to stress the pro-active nature of this activity. A (digital) photograph is taken of the situation concerned for reporting back to and informing the project team. Deviations from the standard are dealt with under the relevant procedure; e.g. through a Field Change Request or similar change management procedure of the Contractor.

8. Write HFE verification round report A report shall be drawn up according to standard format, including (digital) photographs in order to facilitate communication and distribute to parties concerned. See Appendix 2, section 12.

9. Approval of Construction HFE report Construction Management signs off the completed Construction HFE report.

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Figure 1 Flowchart of HFE Activities during construction

Start

Stop

DEP 30.00.60.10-Gen.

Draw-up requirementsf or CC contracts

Specif ication f orapplication of ergonomics

within construction

Constructionkick-of f /appoint

FPHFC's

Determinetraining requirement

HFEv erif ication

round/checklist

HFEv erif ication round

Carry out training:A. Training f or PHFET membersB. Brief ing f or Construction Contractors

In-process correction

Write ConstructionErgonomics Status report

Approv eConstruction HFE

Status report

ConstructionHFE Status report

ConstructionHFE Status report

signed of f

1

2

34

Yes

No

5

6

7

8

9

Plan of action

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Table 1 PROCEDURAL SCHEME (typical example for EPC contract form) Activities CM

Principal HFE

FPHFEC Principal

CM MAC

CSU MAC/ Principal

FPHFEC MAC

FPHFEC CC

1. Draw up HFE requirements for CC contracts

App Check Exe Chk Con Con Con

2. Construction HFE kick-off

Con Con Exe Con Con Con Con

3. Determine training requirements

Inf Chk Exe Con Con Con Con

4. Carry out training

Inf Exe Con Con Con Con Con

5. Schedule HFE verification rounds and develop project specific checklist

Inf Inf Exe Inf Con Exe Con

6. Conduct HFE verification rounds

Con Exe Con Con Con

7. Implement corrections

App Inf App Con Exe Con

8. Write HFE verification round report

Con Chk Exe Inf Con Exe Con

9. Approval of Construction HFE report

App Chk Con Con Inf Inf Inf

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3.3 TASKS, AUTHORITIES AND RESPONSIBILITIES

Parties Tasks Authorities Responsibilities

CM Principal Sign off HFE Construction Report. Approval of changes.

Ensures that agreed HFE requirements are fulfilled.

HFE Principal

Ensures competence via training PHFET. Initiates or contributes towards the HFE Plan for Construction. Helps to draw up the Construction HFE checklist. Participates in verification rounds. Conducts audit at request of CM Principal or Project manager Principal.

Advise CM Principal on progress, conducting of audits, etc. Proposes design standards for field run installed equipment.

Assures working process as regards agreed HFE requirements.

FPHFEC Principal

Participates in HFE verification rounds. Proposes improvements.

Reports to CM. Coordinator of Plan of action for Construction. Proposes design standards for field run installed equipment/items.

Liaises with HFE principal. Confirms the list of field run equipment/items delivered at end of detailed engineering Pro-active identification of operational and maintenance bottlenecks. Checks work done.

CM MAC Consults CM principal on in-process corrections. Appoints PHFET.

Suspends work pending further consultation with CM Principal in event of drastic changes.

Ensures that construction satisfies HFE requirements.

CSU Principal and CSU MAC

Participates in HFE verification round. Pro-active identification of misfits.

FPHFEC MAC

Identifies and lists all field run equipment. Draws up requirements concerning construction contractors contracts. Draws up planning schedule and conducts HFE round. Consults with FPEC Principal CC on proposed improvements.

Pro-active identification of misfits. Ensures that HFE requirements are transmitted to construction team.

FPHFEC CC Participates in HFE verification rounds. Nominates foremen for training.

Pro-active identification of misfits. Check execution of work.

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4. REFERENCES

In this PTS reference is made to the following publications: NOTES: 1. Unless specifically designated by date, the latest issue of each publication shall be used (together

with any amendments/supplements/revisions thereof).

PETRONAS STANDARDS

Human Factors Engineering Project Design Procedure

PTS 30.00.60.10

Human Factors Engineering Investment Justification Model

PTS 30.00.60.12

Human Factors Engineering Valve Analysis PTS 30.00.60.13 Human Factors Engineering Human Machine Interface and Control room design

PTS 30.00.60.15

INTERNATIONAL STANDARDS

Ergonomic principles in the design of work systems-Second Edition

ISO 6385

Issued by: International Organization for Standardization Case Postale 56 Geneva, Switzerland CH-1211

Copies can also be obtained from national standards organizations.

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APPENDIX 1 EXAMPLE SPECIFICATION FOR APPLICATION OF HFE WITHIN CONSTRUCTION

The document in this Appendix is a typical example. SUMMARY This document describes the HFE requirements to be integrated in construction contractors contracts aiming at proper management of field run installed materials and equipment. INTRODUCTION DEFINITION OF HFE HFE is a multidisciplinary field that considers the integrated knowledge of human capabilities, limitations and needs in the interaction between humans, technology and the working environment. HFE is applied to the design of work systems, workplaces and products, with the following objectives: 1. To increase the operational performance, safety, health and comfort of the work system (through attention to safety, operability, maintainability and constructability in design). 2. To reduce the likelihood of or prevent human errors and/or limit the consequences (through attention to human and systems reliability in design). 3. To enhance the productivity of human efforts (through attention to efficiency in design) 4. To enhance overall system performance by improving the ease and efficiency of use (through attention to usability issues in design). 5. To incorporate user knowledge in the design of the system/product (through attention to user acceptability and marketability). SCOPE DEFINITION This specification covers the requirements for the application of HFE to systems, installations and constructions engineered and installed by Construction Contractors (CC). INTENDED USE AND PURPOSE This specification is applicable to all CC working on the project. The purpose is to ensure that the implementation of HFE in CC engineered/fabricated installed units and/or systems results in units and/or systems that can be operated and maintained by COMPANY personnel in an easy manner with minimum effort and within human capabilities and restrains. Unrestricted access will thereby be provided for operation personnel and easy access and workspace for personnel and maintenance equipment, without undue disassembling for regular maintenance activities. CC is not responsible for the location of equipment, valves, nozzles, etc., specified on approved-for-construction (AFC) drawings and designed by others or lifting devices for free-issued materials. In case of obvious discrepancy between designs specified on AFC drawings and this HFE specification, the CC shall notify MC immediately to avoid rework. QUALITY ASSURANCE It is essential to assure the input of HFE in a project by means of a Quality Assurance System.

APPLICABLE CODES, STANDARDS The following shall constitute the minimum requirements for this specification. ERGONOMICS CODES AND SPECIFICATIONS ISO 6385, Ergonomics principles in the design of work systems.

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GENERAL STANDARDS AND TECHNICAL SPECIFICATION This specification shall be used in conjunction with all codes, standards and specifications applicable according to the scope of work for each contract. CONFLICTING REQUIREMENTS Compliance with the requirements of this specification shall not relieve the CC of its obligation to follow sound engineering and installation practice throughout. In case of conflicting requirements with any other specification or standard issued on the Project, CC shall inform MC immediately. GENERAL NOTES AND EXAMPLES This paragraph gives a brief summary of key issues on HFE, which shall be considered and implemented where applicable in layouts and installations. GENERAL Layout shall be such that operation and maintenance can be carried out adhering to

sound ergonomic principles. Primary and secondary ways are clearly defined. Clearance required to allow proper maintenance of equipment, e.g. pump, package

units, compressors, PETRONAS and tube exchangers etc., by human effort. Clearance required to allow proper removal of machinery, control valves or parts thereof

during periodical and incidental maintenance. Clearance required at access ways and escape routings. Clearance reserved for temporary installation or removal of equipment. Clearance required for lifting areas above and/or under equipment to allow easy

removal without obstructions.

Clearance required at platforms or grade to allow entrance into equipment, especially into column/vessel manways when scaffolding structures need to be erected to gain sufficient height for access.

Clearance required around fire extinguishing equipment and other safety devices like eyewash and safety showers, air mask stations etc.

Clearance required to operate valve handweels, sample points, pushbuttons stations, etc. for sample points, not only clearance but also easy access shall be provided e.g. stairs instead of monkey ladders, walkways, etc. especially if samples need to be taken frequently. Ensure sufficient lighting at sample point areas.

Clearance required to allow installation of bolt tensioning equipment at equipment nozzles and pipe flanges.

Clearance required to observe manometers, thermometers and/or readable instruments to allow proper operation by operators from dedicated locations.

Provisions to allow easy removal without extensive removal of other parts not relevant to the intent of the expected maintenance work (eg. break-out provisions).

Lifting of any component designed and installed by CC heavier than 250 N shall be possible by hoist, mobile crane, forklift truck, etc.

All elements designed and installed by CC requiring regular maintenance and/or operation shall be accessible from grade or platform.

Layout shall be based on the physical dimensions of human beings and tailored to local user population.

Maximum manual force to be applied in any action (lifting, pushing and pulling) shall not exceed 250 N (25 kg). There shall be enough space for the use of lifting and transportation gear where lifting or transportation of more than 25 kg is required.

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For equipment/objects of mass 25kg to 200 kg, space for use of adequate lifting and transportation devices (permanent or temporary, e.g. elephant cranes, A-frames, beam clamps etc.) shall be provided.

Permanent arrangements (e.g. monorails, pad eyes) shall be installed for material handling of equipment/objects > 200 kg.

In addition, when the accommodation of permanent or temporary lifting equipment is designed, the estimated frequency of the lifting operations shall also be taken into account. For frequent/or routine lifting operations, permanent equipment shall be installed.

Installation of valve handweels shall be within the areas for HFE operation with the optimum area as first choice (see PTS 30.00.60.13).

Silencers and outlets of atmospheric vents shall be directed away from places frequented by personnel and silencers or noise control measures shall be installed where applicable.

SPECIFIC Free Areas

Clearance around 3 sides of pump and motor: minimum 800 mm horizontal and 2100 mm vertical for personnel access.

Clearance around flanges requiring regular maintenance: minimum 400 mm x 400 mm. Lifting and transport zone above vertical pumps: minimum 3500 mm vertical with

minimum 500 mm horizontal at both sides for manoeuvrability. Clearance around pump disassembling flanges: sufficient for use of spanners. Clearance for pulling suction strainers. PETRONAS and tube heat exchangers: sufficient clearance for tube bundle pulling. Working heights Optimum working height for flanges is 1150 mm (minimum 600 mm and maximum 1400

mm). Tracing For valve tracing, the tracers shall be installed so that the valve can be easily removed

to an open area. Insulation

Insulation ends at flanges shall be designed so that bolts can be removed without the insulation having to be removed as well.

If flanges are insulated, the removable covers shall be such that when removed, the bolts can be taken out without further insulation removal.

Vent and drains shall be kept outside insulation for operation purposes. Noise enclosures shall be provided, if required, with removable covers. Small Bore Piping Seal and flush lines shall be provided with flanges to allow easy removal. Drain lines shall be routed as much as possible under other piping (never in walkways

or access ways).

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Electrical and Instrument Items

Pump cabling shall be run so as to minimise obstructions for maintenance and allow vertical removal by mobile equipment.

Easily accessible (by normal standing person) light fittings shall be installed where specified. Otherwise, lamp changing and cleaning, etc by means of multi-functional mobile scaffold devices shall be possible.

Instruments, junction boxes and the like shall not be installed in front of manholes and covers. An advisable installation height for junction boxes is between shoulder and hip height.

CC shall make available one off example units to facilitate right-first-time installation on site. E.g. instrument air manifold, electrical pump hook-up, level transmitter hook-up, etc., for HFE approval by CM and Focal point HFE Principal.

Local instruments shall be installed so that they are fully observable from the operation location, preferably at eye height.

In general, no instrumentation, including control valve instrumentation, shall be operated from a cage ladder.

Pressure gauges shall not stick out and obstruct passageways. ESD Kill knobs shall be mounted so that they cannot be accidentally activated but are still accessible for quick and easy activation.

Valves (see PTS 30.00.60.13) Valves are in principle installed so that they can be operated and so shall be accessible. Some valves however, are installed for other reasons than operation and do not require permanent accessibility, e.g.: A. Hot tap valves (installed only to enable hot tapping). B. Branch valves on utility headers (installed only for convenience to extensions without

Facility shutdown). C. Hydrostatic test vent and drain valves (only used during and after hydro tests). D. Various instrument block valves such as orifice tappings in piperacks.

If the optimum valve spindle orientation is other than specified on contractual documents, the Principal and MC may decide to alter the position during regular HFE verification rounds. DESIGN AIDS, ADDITIONAL REQUIREMENTS, ETC. CC shall indicate how to deal with HFE in its quality plan, which shall be submitted to MAC before start of site activities. CC shall propose to MAC technical solutions, where possible, to meet the HFE requirements.

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ATTACHMENTS The following attachments shall be taken into consideration by CC during engineering, design and installations: Attachment I Access ways widths. Attachment II Ergonomics in the operation handweels. Attachment III Operation areas for equipment/display-control layout for standing

operator. Attachment IV Ergonomics of mounted light fixtures. Attachment V Lifting equipment for small equipment. Attachment VI Typical vertical pump maintenance areas. Attachment VII Typical cable routing and sprinkler installation for pumps. Attachment VIII Installation instruction for spectacle blinds.

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APPENDIX 2 EXAMPLE HFE ACTION PLAN CONSTRUCTION PHASE

1. INTRODUCTION An HFE Action Plan construction phase has been written for the in accordance with PTS 30.00.60.10 and PTS 30.00.60.14. The Plan is designed to ensure compliance with construction-related project specifications derived from the HFE analysis (e.g. FEEEM analysis) and model reviews, and to prevent HFE bottlenecks resulting from incorrectly located field run items. Moreover, previous projects have revealed that an HFE Action Plan increases acceptance by prospective users of the new design, due to the systematic, early and pro-active involvement of the Project Team, Operations representatives and commissioning teams.

The HFE Action Plan describes the following activities: Preparation of construction phase, Organisation, consultation structure and planning activities with a view to incorporating

HFE design considerations in the construction phase, Reports, including a Construction HFE Status Report.

2. PARTIES INVOLVED

Name Function

Project Manager I(S)BL Construction Manager Revamp/O(S)BL Construction Manager Focal point HFE construction (FPHFEC) / Project resident

engineer

HSE-co-ordinator

Chief Field engineer, Champion HFE Rounds Leader

Operational representative Principal; HFE Rounds participant

Maintenance representative Principal; HFE Rounds participant

Representative of Installation (field run) contractor Representative of eng. Discipline (I, E, Piping, etc.) Human Factors Engineer, Principal

3. SCOPE OF PROJECT Ensuring compliance with the project specifications, derived from the HFE analysis (e.g. FEEEM analysis) and HFE model review action list.

4. DESCRIPTION OF ACTIVITIES 4.1 IDENTIFICATION OF FIELD RUN EQUIPMENT

In order to ensure that field run equipment complies with HFE specifications, the inventory of critical field run equipment in the project needs to be confirmed.

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This actual inventory should been drawn up before the end of detailed engineering by the Focal Point HFE Design. This field run equipment inventory will serve as a basis for the specifications to be prepared for construction/installation contractors. Action parties HFE, FPHFED, FPHFEC, Construction mgt.

4.2 SPECIFICATIONS FOR APPLICATION OF HFE BY CONTRACTORS For the construction contractors, a document containing equipment installation specifications is to be drafted. For this purpose, use will be made of project specifications from the HFE analysis (e.g. FEEEM reports), HFE project action list (incl. specifications derived from the model reviews) and the field run equipment installation standards employed by contractor. The document will be drawn up in accordance with the Example for HFE within Construction, see Appendix 1) Action parties HFE, FPHFEC.

4.3 PROJECT HFE TEAM (CONSTRUCTION PHASE) 4.3.1 Institution of a Project HFE Team (construction)

For the project, a Project HFE Team will be appointed by the Construction Manager. This Project Ergonomics Team (construction phase) will consist of Project representatives, representatives of e.g. the JV construction team, Operations and Maintenance representatives and the construction contractors focal points. Section 8 shows the organigram of the Project HFE Construction Team.

4.3.2 Terms of Reference (TOR) of the Project HFE Construction Team The Project HFE Team is responsible for ensuring compliance with HFE specifications and dealing with bottlenecks during the construction phase. Its tasks are:

To create a culture of operable construction through construction worker engagement, training, outfitting, and reward.

To draft a project-specific checklist, based on the checklist in section 9, the HFE analyses reports and the HFE project action list.

To ensure that time is allocated in the schedule for operability review and execution on each field fit task.

To provide construction worker training, initially and ongoing refreshers. To conduct HFE Rounds at regular intervals according to a flow scheme drawn up for

that purpose. See section 10 Flow Scheme for HFE Rounds and section 11 Model of Site Instruction Note for use in HFE Verification Rounds.

To write a report on the findings of the HFE verification rounds and take appropriate action (see section 10).

To communicate generic construction-related HFE issues to the relevant construction contractors and personnel.

To write a Construction HFE Report for project/construction management approval. The authorities of the Project HFE Construction Team shall be drawn up by the construction manager and appended to the organigram see Appendix 2, section 8. Action parties

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Construction manager, FPHFEC, HFE. 4.4 CONSTRUCTION ERGONOMICS WORKSHOPS: BRIEFING CONSTRUCTION

PERSONNEL AND INFORMING THE COMMISSIONING TEAMS 4.4.1 General

For the project, competence improvement in crirtical operation and maintenance activities and practices is considered a success factor. Workshops and briefing sessions are planned for all project stakeholders.

4.4.2 Determining training requirements and nominating participants Prior to the Workshop, the training requirements of the construction contractors and PETRONAS representatives will have to be determined. Participants in the Construction HFE Workshop will be nominated according to their involvement in the HFE Plan of action. At least the following staff will take part: Construction management representatives Project HFE Construction Team Other Principal representatives, as appropriate Installation contractors management representatives Installation contractors supervisors/foreman Other Supervisory staff

4.4.3 Construction HFE Workshop In the project, a Construction HFE Workshop will be held for the Project HFE Team and construction contractor personnel. It will be organized by FPHFEC and given by , HFE engineer. For this purpose, use will be made of the acceptable standard training tool by PETRONAS.

4.4.4 Briefing of Construction/Installation contractor personnel Construction/installation contractor personnel will be briefed by the Project HFE Construction Team, as part of normal work consultation, on the incorporation of HFE specifications in day-to-day construction phase activities. For this purpose, use will be made of tools available on site (see subsection 4.5 below, HFE tools for the construction phase). Construction/installation contractor personnel will be regularly involved in the HFE Rounds.

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4.4.5 Informing the Commissioning teams The commissioning teams will be informed at separate meetings about the incorporating of HFE specifications in the various project phases. At these meetings, any major layout dilemmas in the project, and how these have been coped with in the design, will be reported. A better understanding of design dilemmas by the commissioning team members will reduce the operability and maintainability issues that have to be reported. Action parties Construction management, HFE, FPHFEC and PHFET.

4.5 HUMAN FACTORS ENGINEERING TOOLS FOR THE CONSTRUCTION PHASE At the kick-off meeting for construction contractors, the relevant personnel will be informed about the tools available on site to assist the incorporating of HFE specifications during the construction phase. For the project, the following tools are available on site: 3D CAD model of project, incl. operations and maintenance soft boxes. Digital camera for evaluating misfits and communicating preferred typicals. Instructional CD ROM for construction phase for Installation contractors: HFE during

construction, Management of field run equipment Standardised 3D CAD equipment set-ups for routing of small-bore piping and secondary

cable trays; e.g. vertical pump arrangement. FPHFEC to make relevant typicals/standards available to the project.

The HFE analysis (e.g. FEEEM ) reports, HFE action list and print-outs of the 3D CAD model of critical construction items and locations.

Model review action list (30%, 60% and 90%). Action Parties FPHFEC and HFE to make relevant typicals/standards available to the project.

5. AUDITING During the construction phase, two audits will be conducted in order to monitor progress of the HFE Action Plan during the construction and pre-commissioning phases. First and second audit will be executed by FPHFEC and project HFE. These reviews/audits will be conducted at the 30% (i.e. immediately after start of first field run activities) and 60% construction phases.

6. STANDARDS AND GUIDELINES construction HFE checklist (ref. Appendix 2, section9), FEEEM reports, HFE action list and other relevant documentations. Note: Checklists (per unit) to be drawn up by Project HFE Team (construction).

7. ADDITIONAL REQUIREMENTS None.

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8. ORGANOGRAM OF HFE DURING CONSTRUCTION Example not included.

9. CHECKLIST FOR HFE CONSTRUCTION AND FIELD RUN EQUIPMENT EQUIPMENT INSTALLATIONS

The document in this section is a typical example. SUMMARY This document provides the project management team with the necessary guidance when considering the development of a checklist for HFE construction and field run equipment installations. The reader is presented with a list of considerations for many typical projects in the areas of:

General lay out Steam Tracing Insulation

Small Pipe Work Valves

Electrical and Instrumentation Notes are provided to guide project management in considering who is responsible for HFE input not only in the design phase but also assurance of its input in the engineering and construction. INTRODUCTION DEFINITION OF HFE HFE is the process of integrating human capabilities in the design of products, work places or work systems (plant or facility) resulting in the effective, efficient, safe and healthy functioning of human beings, thereby improving operational and maintenance tasks. The benefits identified are both in business (economics) and in working conditions (HSE aspects) resulting in a reduction of life cycle costs of facilities. SCOPE DEFINITION This specification covers the requirements for the application of HFE to construction contractor (CC) engineered and installed systems, installations and constructions engineered and installed by Construction Contractor (CC). INTENDED USE AND PURPOSE This specification is applicable to all CC working on the project. The purpose is to ensure that the implementation of HFE in CC engineered/fabricated installed units and/or systems results in units and/or systems that can be operated and maintained by COMPANY personnel in an easy manner with minimum effort and within human capabilities and restrains. Unrestricted access will thereby be provided for operation personnel and easy access and workspace for personnel and maintenance equipment, without undue disassembling for regular maintenance activities. CC is not responsible for the location of equipment, valves, nozzles, etc., specified on AFC drawings and designed by others or lifting devices for free-issued materials. In case of obvious discrepancy between designs specified on AFC drawings and this HFE specification, the CC shall notify MC immediately to avoid rework.

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QUALITY ASSURANCE It is essential to assure the input of HFE in a project by means of a Quality Assurance System. Use of a HFE document in isolation may lead to unsuccessful implementation of HFE in engineering and projects.

CHECKLIST Date inspection round: Unit: Participants:

CHECKLIST ITEM NOTES/REMARKS

GENERAL Clearance required: For maintenance of equipment, e.g., pumps, package

units, compressors, air fan coolers, PETRONAS and tube exchangers etc.

For proper removal of machinery or parts thereof

For bundle pulling of PETRONAS and tube heat exchangers.

For access ways and/or escape routings. For lifting areas above and/or under equipment to allow

easy removal without obstructions.

For temporary installation or removal of equipment.

At platforms or grade to allow entrance into equipment. Around fire equipment and other safety devices like

safety showers, air mask stations etc.

For operating envelopes of valve hand wheels, sample points etc.

For installation of bolt tensioning equipment, at equipment nozzles and pipe flanges.

For observation of manometers, thermometers and or other readable instruments

STEAM TRACING (if applicable)

Install breakout flanges for suction and discharges pipe spools.

Install tracing at underside of vertical pump. Install tracers at side of valve to allow easy removal of

valve to open area.

INSULATION

Insulation termination at a flange shall be installed so that the bolting can be removed without the insulation having to be removed.

If flanges are insulated the removable covers shall be designed so that when removed, bolts can be taken out without further insulation removal.

Keep vent and drains outside insulation to allow operation.

Provide noise enclosures with removable covers.

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CHECKLIST ITEM NOTES/REMARKS

SMALL PIPE WORK

Seal and flush lines to be provided with unions or flanges to allow easy removal.

Route small bore piping as much as possible under other piping. Never in walk access ways or spaces required for maintenance with hand tools.

Attention items:

Steam/condensate tracer lead lines. Late added drain lines.

Pipe supports not shown in 3D model.

VALVES Valves are in principle accessible for normal operation. Some valves however do not require permanent accessibility, e.g.: Hot tap valves, Branch valves on utility headers, Hydrostatic test vent and drain valves. During regular HFE inspection rounds, check whether optimum valve spindle orientation has been observed (this may deviate from the drawings).

See PTS 30.00.60.13 Valve Analysis

ELECTRICAL AND INSTRUMENTATION

Run pump cabling so as to minimise obstructions for maintenance and to allow vertical removal by mobile equipment.

Install easy to reach light fittings where specified and otherwise ensure that lamps can be changed or cleaned from multifunctional mobile scaffold devices.

Do not install instruments, junction boxes and the like in front of manholes, covers or in maintenance and operating areas, etc.

Install local instruments so that they are fully observable from the operation location preferably at eye height.

Items to be considered

Lighting fixtures. Secondary cable trays or ladders.

E tracing of items which are subject to removal for maintenance/operations.

Analyser lines.

Instrumentation impulse lines and PIs/PTs. Control Valves. Senior Orifice fittings. Cable ladders.

Poly flow systems/water spray lines. Fire and Gas detection system.

NOTES FOR IMPLEMENTATION

1. Checklist should be tailor made using inputs like: HFE analysis report, e.g. FEEEM reports, model review results and other relevant documentations.

2. For maintenance and safety/escape purposes, reserved areas in PDMS 3D have been projected throughout the entire Facility. Those areas are illustrated as soft boxes in the 3D model.

4. For field run installations erected by CC (Construction Contractor) that are in conflict with the HFE requirements, a non conformance report shall be raised by MC (Main Contractor) in accordance with the

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procedures, unless a written agreement between MC/CC to deviate from the requirements can be produced.

5. CC shall ensure that an HFE approach and subsequent requirements are fully considered and applied during field detailed design engineering and installation.

6. Design tools used for detailed design and engineering shall allow CONTRACTOR (MC) to review the layout. As a minimum, composition layout drawings shall be made showing all elements which occupy physical space, to enable adequate detailed reviews of operations and maintenance aspects to be carried out.

7. CC shall propose to Principal technical solutions, where possible, to meet the HFE requirements.

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10. EXAMPLE FLOW SCHEME OF HFE ROUNDS DURING CONSTRUCTION

- HFE Focal Point- Construction Supervisor / Engineer- Shell HFE Focal Point - or discipline Engineer- Maintenance rep., or Operation rep.)

SCHEMATIC HFE VERIFICATION ROUNDS Attachment-1

CONSTRUCTION HFE TEAMMEMBERSfor weekly review round

In principle the weekly HFE roundwill start at 13:00 every Monday(duration appr 2 hrs.), the teamwill meet in room.

- Use Checklist (make notes about observations, non conformance- Digital camera can be used to illustrate findings

Human FactorsEngineering advisor will

participate every 4-6 weeks.

Non conformancefound?

NCR to be raised, using the sitesystem to record and close outnon conformances. These nonconformances will be filed in theHFE file for later reference andproject lessons learned (Filing by).

Fill in a short note onA4 sheet for the HFEfile stating inspectionwas carried out (date,persons etc.) with asatisfactory result.Perhaps positiveremarks can bementioned. No furtheractions required.

yes

no

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11. EXAMPLE SITE INSTRUCTION NOTE FOR USE IN HFE VERIFICATION ROUNDS

NOTE Date:

From: Construction mgt.

To:

Copy: HFE HFE VERIFICATION ROUNDS DURING CONSTRUCTION During the entire construction phase HFE VERIFICATION ROUNDS will be carried out for I(S)BL and O(S)BL to ensure correct application of HFE criteria of field run installations. These (inspection) rounds are an integrated part of the Plan of action HFE during construction and pre-commissioning phase. The rounds will be done on a weekly basis. Although there could be some overlap, it is certainly not the intention of these verification rounds to cover the normal (turnover) punch list items twice or at the wrong time, but to achieve a pro- active focus on compliance with operational and maintenance requirements as specified in the design (HFE analysis, e.g. FEEEM reports) and other relevant specifications. The benefit gained from these HFE verification rounds is that Non compliance is picked up early in the construction phase when corrective action can be done in an efficient manner. The overall I(S)BL and O(S)BL area of the project has been divided into 4 areas. Every week a verification round will take place in a different area with the above mentioned HFE team. See attachment 1 for the weekly review schedule and attachment 2 for a layout showing the numbered areas.

The HFE verification team (HFE Team) will consist of following persons. Fixed HFE team members are (or other discipline enigeer), the Field Supervisor for a particular areas will be nominated by FPEC. The project team members will be mainly (Maintenance) or (Operations). The non-compliance findings from the HFE inspection rounds will be followed up in accordance with the normal site procedure for Non Conformance Reports. However it has been agreed that a file for the CONSTRUCTION HFE findings will be set-up and maintained by . Finally, attachment 3 is the Checklist for HFE/Construction Field Run Installation. This checklist, together with the data from PDMS Soft boxes and other drawings can be used as tools for the HFE verification inspection rounds. Regards, Construction management

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Last page of this PTS

12 TEMPLATE OF CONSTRUCTION HFE REPORT

The following refers as basis of software tool development to facilitate reporting and the communications of findings within the project.

CONSTRUCTION HFE STATUS REPORT PROJECT IBL/OBL

Notes: Please find the status of HFE action points as per 00-00-00. List of abreviations used in the database FIELDS

CAT MECH CIVIL ELEC INSTR STRUC REASON DESCRIPTION GENERAL Lay-out, maintenance, operation TRACING Electrical- and steam tracing INSULATION removal bolts fl.connections, removable covers, SM. BORE PIPING Seal/flush/instrument and sprinkler systems VALVES Operability, optimum valve spindle position ELECTRICAL Earthing/cables/lighting, RCUs etc INSTRUMENTS Position local instruments/junction box position ACTION STATUS DESCRIPTION R Rejected I In hand C Closed Out (Action completed and confirmed) L Add to lessons Learned NO Already actioned = NO action req'd NCR Non Conformance Report Req'd A Action to be taken INITIATOR NAME CFHFET Construction Field Run HFE Team XXX Maintenance Engineer XXX Operation XXX Discipline Project Engineer XXX Chief Field Eng.

From To