Human Factors Engineering in FLNG Projects D. Chandrasegaran, H. Al Sharifi, M.H. Mohd Noor, and M.K. Abdullah, TechnipFMC
This paper was prepared for presentation at the Gastech Conference held in Tokyo, Japan, 04–07 April 2017. This paper was selected for presentation by an Gastech program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been reviewed by the Gastech Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Gastech Conference, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Gastech Conference and the authors is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented.
Abstract
Human Factor Engineering (HFE) addresses interactions in the work environment between people, a facility and its management. FLNG projects bring new HFE challenges with more equipment items that are often larger and often more sophisticated than previously deployed offshore. Deployment of HFE is most cost efficient when started in the early design stages. Timely application of HFE can bring many benefits such as: • Designing to allow operation and maintenance throughout the facility’s life considering every
single task requiring handling of mechanical components and verification of the FLNG operation and maintenance teams’ resources.
• Holistic material handling system design • Better construction planning
This paper will present the findings and lessons learned from engineering and construction of
recent offshore LNG facilities by TechnipFMC. The perspective of operation and maintenance teams is considered in the HFE process to ensure that past experience and needs are incorporated in the new design. The findings and lessons learned are summarized under keywords for further discussion and recommendation.
Codes, standards and guidelines that are relevant to HFE and material handling are discussed to establish if there is adequate coverage of the requirements for the design, construction and operation of FLNG. Although the discussions of human factors are based on case studies from offshore facilities such as FLNG and large gas processing platforms, the observations and recommendations could be extended to other types of oil and gas facilities. Keywords: Facilities, Operations, Maintenance, Material Handling, Human Factors
Abbreviations:
BBS Behaviour Based Safety HFE Human Factors Engineering
DDE Detailed Design Engineering HMI Human Machine Interface
FEED Front End Engineering Design HSE Health, Safety and Environment
FLNG Floating Liquified Natural Gas LNG Liquefied Natural Gas
FPSO Floating, Production, Storage and Offloading
MH Material Handling
2 Human Factors Enginering in FLNG Projects
1. Introduction
Global liquefaction capacity stands at 301MTPA. This is almost double the capacities
10 years ago. The International Energy Agency (IEA) has projected that global energy demand
will rise and is set to grow by 30% by year 2040. In addition, natural gas demand growth fares
best in this projection, even though there would be a shift in capital expenditures towards low
carbon environment. Looking at these scenarios, investments on LNG facilities are expected
to increase in the foreseeable future.
LNG facilities cover liquefaction, regasification, land storage, and distributions, which
are mostly land-based. Recent technological developments have made it possible for similar
facilities to be built and operated offshore. This has since become a reality in the LNG sector
with the achievement of the first gas on Petronas’ first FLNG unit, SATU, on December 2016.
This technology had been under development for years, combining the design and installation
of liquefaction units with a traditional floating production, storage, and offloading facility;
enabling the development of stranded offshore gas resources economically. The design,
construction and operation of FLNG units present significant challenges compared to an
onshore plant - vessels motions, relatively small and congested environment, and harsh
marine conditions. Therefore, these constraints present further risks on the human factors front
in the work environment and much technical and human factors challenges that need to be
tackled.
In this paper, the deployment of human factors engineering in FLNG Unit projects in
general will be discussed. The benefits of HFE in early design stages of FLNG projects will be
highlighted. Considering the novelty and the new technologies in FLNG projects, there is a
lack of design and operation references. Nevertheless, proven standards, good engineering
practice, and valued operators’ experience form the basis of design.
Lessons learned during the engineering and construction of FLNG units by
TechnipFMC are shared here. Perspectives of past experiences of designing, constructing and
operating similar facilities are taken into account during the HFE process. In addition, codes,
standards and guidelines that are relevant to HFE and material handling are discussed.
1.1 Overview of FLNG Units
FLNG unit is a versatile floating LNG facility that relates to many technical skill sets that
require prior knowledge and experience. These include natural gas liquefaction, design and
construction of large FPSO units, and the design of the riser and mooring system that link
offshore gas fields to the floating unit. With FLNG units, stranded offshore gas resources could
be monetised well, especially when 60% of the world’s natural gas is located in areas which
conventional rigs and pipelines cannot access.
FLNG technology presents the hybridization of a 5-step process into a compact
structure. These are:
1) Resources: extraction of natural gas from the wellheads to the floating unit;
2) Pre-treatment: extracted natural gas processed on board prior to liquefaction;
3) Liquefaction: liquefies natural gas to approximately -150°C and shrinks the gas
volumes;
Human Factors Engineering in FLNG Projects 3
4) Storage: the liquefied natural gas is stored in dual membrane type cargo
containment system before offloading; and
5) Offloading: LNG is offloaded to the LNG carrier for delivery
Figure 1 encapsulates these steps in a sequential diagram.
Figure 1: FLNG 5-Step Process
Figure 2: Overview of know-hows required to develop FLNG
LNG production in the offshore setting presents serious challenges - bearing in mind
that FLNG whether in a large or small scale will be amongst the largest and most complex
capital investments in the oil and gas sector. Among them are:
1) Every part of conventional LNG facility needs to fit in a fraction of footprint of a
land-based facility, concurrently without compromising the level of safety;
2) LNG containments must be able to withstand the forces due to sea waves and
current motions, affecting facility safety, integrity, reliability and operations;
3) Safety concerns such as eliminating ignition sources and cryogenic spills, reducing
flammable inventories, and providing a safe haven for operating personnel;
4) Equipment for FLNGs are generally larger and heavier than that of FPSOs’. In
addition, FLNG may have a number of tall vertical columns and exchanger as part
Resource Pretereatment Liquefaction Storage Offloading
4 Human Factors Enginering in FLNG Projects
of the process system. Performance of these equipment is critical to maintain the
availability and production of the FLNG unit; and
5) There is little historical data available to benchmark weight and cost estimates.
Nevertheless, past experiences in building offshore modules and FPSOs would
help to provide some confidence in this area. In addition, lessons learned from
designing and building FPSOs and onshore LNG modules could be integrated
when executing FLNG projects.
FLNG projects, once it overcame its challenges, present significant gas field
development opportunities in the offshore oil and gas sector. Figure 2 shows the technology
know-how required to develop this FLNG innovation.
2. Human Factors Engineering
Human Factors Engineering in the oil and gas sector are interpreted more broadly and
is approached at a multidisciplinary level; encompassing people, environment, equipment,
organisation and work. This is done with the aim of addressing risks issues, reducing
consequences of human errors and improving user acceptance of the facilities or equipment.
In fact, major players in the industries recognise that human factors engineering has a
significant role in ensuring quality, safety and fit for the purpose the equipment and facilities
are used in the oil and gas industry. Figure 3 presents the model for human factors based on
the OGP model.
Figure 3: A human factors model based on OGP
Facilites & Equipment
•workspace•design•maintenance•reliability•physical characteristics
People
•human characteristics•behaviour• fitness•stress• fatigue
Management
• leadership•procedures•hazard identification•risk assessment• training•commitment•change management
Human Factors Engineering in FLNG Projects 5
2.1 Human Error
Generally, we come across “human error” many times as a cause for mishaps in the
workplace and facilities while operating, constructing or designing. Rarely, it is due to a single
mistake by any one person; as shown by Reason’s Swiss cheese model. Therefore, it is
important to know where the deviations occur and understand where simple human failure may
prove detrimental to the facilities.
Human errors generally could be defined in two groups, which are skill-based and rules-
based; relating to slips and mistakes. Other than that, violations are defined where operators
deliberately carry out an action contrary to the procedures. Lapses are due to failure of
memory. Slips arise from the right intention of the operator, but where fault occurs during
execution. Meanwhile, mistakes occur during decision-making based on the operators’
knowledge or the procedure concerned.
Once we understand the nature of the errors that we may make, it is necessary to
consider the management of these errors when engineering the system, equipment or
facilities. These would be the main aim of Human Factors Engineering during the project
execution.
2.2 Facilities and Equipment
Facilities and equipment is one of the components of the HF model; in consideration of
physical characteristics, workspace, maintenance and reliability concerns. Also, it covers a
wide range of topics from initial design up to the labelling at completion. In this section, three
key items will be elaborated on, which are the equipment design, facilities and workstation
design, and HMIs.
The main aim when performing equipment design is to address the relationship
between man and machine (or equipment) in a synergistic manner. People have different traits
such as physical capabilities and skills that need to be matched with the equipment’s design
parameters. These overlapping areas could be summarised in nine-point human factors design
principles:
Suitability
Simplicity
Labelling
Accessibility
Detectability
Availability
Logic and consistency
Flexibility
Conformity with user
experience
These design iterations which should be taken care of holistically should consider the
processes involved and the people who operate it. Tools such as BBS and standards provide
guidance to achieve these principles. Meanwhile, for workplace and facilities, a good design is
reflected when it satisfies biomechanical, physiological and psychological needs of the users.
It should accommodate to the extremes of the user population and be physically accessible.
Also, other environmental conditions such as lighting and comfort are considered. Facilities
operation and maintenance cost time and resources. Operators must be able to access the
equipment safely and easily. Apart from that, equipment must be designed for easy
6 Human Factors Enginering in FLNG Projects
maintenance. Task analysis and checklists methods could be used during the early design
stage to assess potential HF issues and appropriate interventions could be made in time.
Human-Machine Interfaces or more commonly known as HMIs, key purpose is to
interact with the control systems. Botches when dealing with control systems usually result in
catastrophic events. HF elements that involve HMIs are the ergonomics with the computer
equipment, operators’ interaction with the software, and individual human characteristics.
Significant technological leaps in the past decades have made it more reliant on control
software and its various display devices. Also, process control software information are being
delivered in a compact manner; audio and visually. Therefore, audio–visual devices or VDUs
design are becoming more important and necessitates for HF intervention. Presently, there is
not a single set of guidelines or standard that addresses all the HF concerns related to it.
Nevertheless, there are guidelines documents from other industries which could be adopted.
2.3 People
The People component relates to the individual contribution; in terms of skills,
perceptions, communications, fatigue and more. At times, it overlaps with human machine
interface subject. A few key topics under this subject are touched on in the succeeding
paragraphs.
Training is related to development of skills within the people or available human
resource. They tend to be trained in many areas; some are skill-based, technical or managerial.
An overall training and human resources development programme should be established in
any organisation. This would enable the workforce to meet the ever-changing demands,
technical needs and hazards of operation. The issues here revolve around the training design,
its quality, and alignment with job needs.
Many incidents at the workplace occur due to breakdown in communications. In any
situation, intention and meaning must be transmitted correctly. Therefore, a feedback system
should be present to ensure that correct information is transmitted. One form of communication
is through writings or documents. Documentation should be designed from the users’
perspective, considering users’ perception of experiences, knowledge and psychology. There
are document design guidelines from a number of sources that could assist in the development
of new documents and reviewing existing ones. In current times, it is important to have
documentation and information that could transcend the cultural differences and is effective in
conveying the necessary intent and information.
Environmental factors such as lighting, noise, vibration and temperature are also
aspects that fall under People. These factors should be within the comfort range of the
operators. Staffing levels should commensurate with the workload available. In other words,
adequate resources are provided to complete the task in hand. Ideal workload should be
sufficiently challenging to get the worker’s attention and interest as well. There are specific
design tools available to assess the needs of the operator (from environment condition to
workloads) and implement the requirements during the design phase.
Human Factors Engineering in FLNG Projects 7
2.4 Management Systems
A management system refers to the structure where the work is carried out. It could be
broadly linked to procedures, planning, safety practices, competencies management, change
management and emergency preparedness. All these and many more should contribute
positively to the risk management within the organisation. One of the key management
elements within the organisation is safety culture which will be elaborated here.
Every organisation endeavours to develop a positive health, safety and environment
climate throughout its people; which in turn, impacts the HSE performance. When members
of the organisation engage in HSE as a value system, it would be meaningful and practical for
them to take action on it, especially on their day-to-day tasks - consequently contributing to
successful business performance to the organisation as well.
There are many theoretical models available to develop a safety culture in an
organisation; the focus would be on Schein’s, Cooper’s and Reason’s. These also have
evolved to a certain extent to suit the organisational needs. Positive outcomes are expected in
terms of hardware, management system, people, behaviour and organisational climate factors
when safety culture programmes are implemented successfully. For instance, a good plant
design and working conditions will be tangible results that could be achieved with positive
safety culture. Many safety culture improvement programmes have been conducted
successfully worldwide and the interest is growing also. In the end, it would help the personnel
in project and operating plant have a good understanding on how their individual behaviour
influences safety performance and to take ownership of improvement actions throughout the
project life-cycle.
2.5 Material Handling
All offshore facilities including FLNGs comprise many sub-systems that require routine
inspection, maintenance and repairs, ensuring they achieve the intended production and
reliability. In order to facilitate such activities efficiently, material handling as a specialty topic
has been of much interest in recent years. During the engineering stage, MH methodology,
accessibility and equipment are identified as well-procured.
In the oil and gas sector, many operators have defined manual handling limits at 25 kg
for a single person. Consequently, MH equipment will be utilised for lifting of parts that exceed
the pre-determined limits. Also, customised solutions or complex methodology will be
employed to complete the MH and maintenance activities. For example, an offshore platform
crane is a major feature of material handling system within the platform—specifically, for
personnel transfer and equipment transfer. For these reasons, platform cranes can be
considered among the most high-risk and high-demand equipment, hence inspections and
maintenance of platform cranes are scheduled throughout its life. Provisions to carry out
maintenance activities are usually included as part of its supply—for instance, jib cranes to lift
lube oil drums, and walkways along the crane boom to inspect the wire rope. Gas turbines for
offshore use are designed for that as they are able to withstand harsh climates and heavy-duty
usage. As such, condition-monitoring and preventive maintenance must adhere to a strict
schedule. Gas turbine frames and casings are generally split axially to lift them from the top.
Without removing the rotor, variable inlet guide vanes can be removed radially, and bearing
liners can be replaced using an integral monorail hoist within the package.
8 Human Factors Enginering in FLNG Projects
3. Industry Guidance on HFE
Application of HFE had been scattered all over the oil and gas industry, succinctly said
inconsistent. However, efforts had been shown to implement HFE programme in major capital
projects in recent years. Lessons and experienced gained through this implementation are of
great value to the industry; improving safety records. The succeeding paragraphs will give an
overview of the current state.
Regulators are major drivers in coming up with the requirements, ensuring compliance
and raising the expectations on HFEs. Several regulators and industry bodies such as
Norway’s Petroleum Safety Authority and American Bureau of Shipping have come up with
their HFE design standards and guidelines for the oil and gas sectors within their jurisdiction.
Some of the oil and gas companies have also cited the design standards and developed their
in-house or project specific HFE documents. For example, company specific design manual is
created to provide guidelines on egress dimension for a plant access and layouts. The
International Association of Oil and Gas Producers had produced a practical document that
gives an overview of recommended HFE activities over five main project phases. This
documents reflects a simplistic model that could implemented in a cost effective way compared
to earlier mentioned HFE design standards of which are more comprehensive.
Looking from far, it could be said there are sufficient HFE reference documents for the
oil and gas sector. Also, a list of commonly agreed HFE methodologies could be established
for the offshore project with concurrence with all industry players. Nevertheless, the application
of it remain inconsistent so far due to various reasons.
4. Integrating HFE in FLNG Projects
Safety performance has improved with the application of human factors
programme, especially in reducing accident rates. In the past decades, many oil and gas
operators had taken significant steps in integrating human factors requirement as part of the
project design process, realising that HFE programmes are most efficient during the design
phase. This is when hazards could be designed out. Also, mitigation plans such as procedures
and barriers are put into place effectively. Subsequently, verifications are done during the
construction and commissioning phase. Active implementation of HFE programmes during
project phases will deliver facilities that are better in terms of cost, safety, reliability and
maintainability.
4.1 Engineering Design
HFE implementation through the project lifecycle could be summarised in three stages.
These are conceptual, FEED and detailed engineering stages. The succeeding paragraphs
will elaborate more on this.
First and foremost, leading HFE integration in the project environment is a large
responsibility. They are important tasks that are handled by HFE Specialist and HFE-focused
engineering group. In addition, this should also be advocated by the project management team
and the operating client or end-user; who have the benefit of influencing project direction. HFE
Specialist is required to have the appropriate academic qualification and experience in this
field. In addition, engineers within the focus group shall be HFE-trained as well. Usually,
qualifications that should be attained by the HFE-focused engineering team are well defined
Human Factors Engineering in FLNG Projects 9
by the operating client or end-user. A qualified, credible and experienced HFE team is essential
in determining the successful implementation, especially in giving the right direction to all
project team members on HFE matters from conceptual to handover of the facilities.
During the conceptual phase, HFE strategy or a high level HFE plan will be spelt out.
Also, HFE Specialist and associated team will be assembled to formulate the required
philosophy and in ensuring that the key design documents take into account the HFE design
requirements and its activities.
HFE design requirements are compiled by the HFE Specialist from existing technical
references and standards that will be mandated by the Client or end-user. These requirements
are then imparted to all the design documents including design basis memorandum and
layouts. HFE strategy will define that HFE principles shall be applied during the early design
phase, where it can have a critical impact on the usability and operators’ HSE concerns, and
an appropriate level of HFE activities are outlined. At this stage, HFE screening exercise will
be executed with the project team.
Product of the conceptual phase will be HFE Plan for the subsequent FEED phase.
This describes the HFE tasks that should be performed during the next project phase. It also
establishes the work scope such as review workshops, schedules, deliverables and
responsibilities of those involved in implementing it - contractors and vendors.
HFE activities during FEED phase will be based on the HFE plan developed earlier.
Key activities here covers detailed HFE specifications development, HFE analysis and
verification. The point to note is that HFE activities during the FEED phase are most critical,
where all activities are design-focused and HF risks are mitigated through design.
In general, sub-systems within the facility will be analysed using HFE tools and
methodologies. HF analysis during FEED may encompass these:
Safety critical task analysis;
Valve criticality analysis; and
3D model reviews.
In addition, certain scope may require more detailed study efforts and this could be
cascaded to next phase. These special studies may include:
Alarm management;
Material handling;
Manning assessment; and
Human machine interface for process control.
HFE awareness training is provided to all project team members by the HFE Specialist
and his/ her team. The content and length of training should be customised to the target groups
such as designers and engineers. The HFE-focused team will also be providing assistance to
the engineers and designers in order to allow transfer of key outcomes from the HF analyses
and studies promptly; whether through documents, drawings and layouts. The FEED phase
HFE activities are concluded with an HFE report that demonstrates all analyses’ outcomes and
recommendations that have been implemented or justified accordingly.
10 Human Factors Enginering in FLNG Projects
In the detailed design engineering phase, HFE activities revolve around validation and
ensuring the contractors follow through with the implementation. Here, significant information
from vendors and suppliers will be received and updated into the design documents. It may be
necessary for specific HFE analysis to be conducted to provide input for other engineering,
safety and risk studies based on the current information. In addition, the HFE Specialist and
his/ her team will assist the vendor in improving their design and addressing HFE requirements.
This could be achieved by means of guidelines, checklists or specific review sessions. Other
than that, development of operation and maintenance documentations and procedures may
require input to ensure adherence to HFE design requirements. Similar to the FEED phase,
an HFE report will be issued to mark the closure of HFE activities in DDE phase.
5. Lessons Learnt and Discussions
Based on recent execution of FLNG projects, it would be useful to consider some of
the lessons learned for future improvements and approach that could be taken to address it.
5.1 HFE as Part of Safety Culture
Management commitment needs to be demonstrated by integrating HFE as an
important point in the safety culture messages. Even though the importance of HFE in the
project and its benefit are evident in the long run, this has to be reflected in the project
environment itself. This has to be shown clearly to all of the project team members and evident
in their day to day activities. For example, a project office should provide ergonomically suitable
workstation and furniture to reflect the commitment to HFE. In a nutshell, consistency should
be reflected between the safety culture messages and HFE implementation in the project.
5.2 Prioritising Resources
At times, it has been viewed that adherence to HFE requirements are not necessary. It
may even cost more in terms of money, effort and time. It is imperative that for successful
integration of HFE in a project, the HFE is mandated through design specifications, contractor’s
bidding package and others. This could only be achieved through focused effort and adequate
provision of resources. Professional HFE practitioners with the approapriate qualifactions must
be available to convey the HFE agenda and advise on it. Project management team should
ensure that adequate resources are provided for HFE activities in terms time, staffing and
budgets.
5.3 Training on HFE Principles
Generally, HFE awareness session will be conducted before the design activities goes
into full swing, especially during the FEED phase. This training usually lasts between 2 hours
to 4 hours. However, a good understanding of HFE principles could only be established with
field experience coupled with classroom session. For long term development of designers with
HFE knowledge, this aspect should be considered as part of the competencies development
within the engineering team. Then only, any HFE issues at design level could be tackled
promptly. In addition, awareness training should be expanded to suppliers, vendors,
inspectors and others as required.
Human Factors Engineering in FLNG Projects 11
5.4 Operating Experience
FLNG Unit are the first being deployed in offshore environment. Therefore, many of the
equipment and systems suppliers have almost no prior experience constructing and operating
it for the offshore environment. As highlighted earlier, equipment is larger and expected to fit
in smaller footprint area; all these pose additional challenges to the designers and operators.
Nevertheless, this should be taken as the first benchmark case and where experience will be
built upon.
5.5 Single Point of Reference for HFE
It is very important that HFE design inputs are consistent throughout the project
lifecycle. HFE design input shall be based on the correct standards and have been agreed with
the operator client or end-user. Most of the time, HFE related information are located across
many clients’ general specifications and even with the experience client personnels.
Therefore, it would be most efficient to implement the “Golden Book” approach, whereby all
the HFE references are consolidated in a single reference point. This will also be used to audit
HFE implementation from operability, maintainability and egress point of view.
5.6 Vertical module arrangements
In the FLNG layouts, equipment and process modules are arranged vertically to
optimise the foot-print requirements. There will be scenarios that equipment location and its
critical valve and auxiliaries for frequent access will be located on another level. These
arrangements should have followed by smooth movements, clear identification and instruction
for an efficient operation. Therefore, during critical tasks analsyis, these scenarios should be
considered for detailed evaluation. When possible, such arrangements should be minimized
all together. Other than that access, handling and escaper routes should be at the same level
between one module to another.
5.7 Crane Operation
On the major equipment related to operation and maintenance activities is crane.
Location of the crane on the FLNG is usually determined during FEED phase. Location should
enable lifting sequences done in a safe and efficient manner. Line of the sight from the crane
operator’s cabin to the laydown or maintenance areas should not be hindered by equipment
or other decks. Otherwise more operation personnel would be required to coordinate the lifting
activities and incurring higher operation costs.
5.8 Efficient Reviews
It would be expected to have numerous review sessions in order to produce a good
design that take into account the multiple stakeholders’ interest. Design progress of each
equipment and process module may differ due to the complexities and information level. HFE
reviews which are too brief tend to overlook critical area or design changes that may have
impact on operations. HFE reviews should be conducted at the appropriate time when the
design is mature and all the concerned parties available. Then, the findings would be significant
and meaningful. In short, good reviews done at the right time produces good results.
12 Human Factors Enginering in FLNG Projects
5.9 Material handling equipment selection
Material handling equipment includes hoists, cranes, trolleys and any other aids that
intends to reduce the human effort during operation and maintenance activities. Due to the
novelty of the process, many of the equipment will have special tools and equipment that need
to be deployed offshore. A calculated approach must be taken considering the needs and
practicality to have it available onboard FLNG all the time. Some of the requirement could be
streamlined, so that a reduction in quatities and storage could be achieved.
6. Conclusions
The importance of implementing HFE in projects is evident. This would contribute
positively to the quality and reliability of FLNG facilities and others related to it. The project
team including the managers and designer have the responsibilities of ensuring successful
implementation of HFE principles in the project to benefit the end-user many years into the
operation phase. Nevertheless, it is acknowledged that the journey has just started with the
first FLNG put into operation.
Acknowledgement
Authors thank and acknowledge the support provided by TechnipFMC in presenting
this paper in Gastech Conference 2017.
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