05-Jul-20

Alvin Alfiyansyah

 HSE Club
Indonesia

Safety In Design (SID) - Human Factor

Engineering (HFE) with ergonomic approach
in relation with inherently safer strategy
Presented for SHED Community start @10:00 WIB, 11 July 2020

Purpose
The purpose of this presentation is to:
o Introduce Safety In Design (SID) or Human Factor Engineering
(HFE) to achieve ergonomic workplace for facility, plant, and
buildings.
o Increase our awareness on HFE/SID requirements and
implementation.
o Give a brief explanation in relation to inherently safer concept

This module comprise brief explanation of Safety in

Design or Human Factor Engineering work combining with
inherently safer concept

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Reference for developing comprehensive

HFE / SID for safe comfort workplace
 Annual Book of ASTM Standard
 NEMA codes
 NFPA 101
 ASTM F 1166  ISO codes
 ANSI A 1264.1
 ANSI A64.1
 API 12B
 ANSI A14.3
 ASME B20.1
 API RP 11ER
 IEC & API standards for Electrical
 ANSI ICC A117.1
 ANSI Z358.1
 ASTM F1166
 OSHA for Excavation
 Shareholder Manual or Company Manual

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HSE Moment

Incident Pyramid

1 Fatality

Lost Time Injury

10
First Aid
100
Near Miss
1,000
Unsafe Condition and
At-risk Behavior
10,000

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Incident does happen !

Piper Alpha Alon Refinery

Crane Sudirman Palace bp Texas LUSI

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Inherently Safer
strategy

Minimize
Substitute
Moderate
 (Limitation of Effects)
Simplify

Risk = Opex2

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Build Inherently Safer Perception

Sample : Space in offshore platform

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Sample concept of design installation

Sample : Space in offshore platform

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Add : spare of pump & valves control

Sample : Space in offshore platform

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Build layer of protection

Sample : Space in offshore platform

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Add : instrument air and valves

Sample : Space in offshore platform

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Add : GD, FD, PSV, BDV and electrical

Sample : Space in offshore platform

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Add : Fire Pump & Maintenance Access

Sample : Space in offshore platform

Work as per right & approved procedure

Sample : Space in offshore platform

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Brainstorming
SID / HFE & Plant Basic Functions

impacts many basic plant

HFE / SID
functions that people do

One basic plant function/job that people

do is walk through the plant. How
many other plant functions can you
name?
Engineers must make every effort in
building trust and building relationships
?
?
?
??
with operators to ensure they ascertain
the right information to do the job. ?
?
Only in this way can engineers be
assured that their designs will not only ?
?
? ?
?
be safe and reliable, but will also serve ?
?
?
?
the customer in the best way possible.
? ?
?
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Brainstorming
HFE/ SID & Hazardous Condition Identifications

HFE/SID prevents
hazardous conditions
from occurring.

HFE/SID prevents hazardous

conditions from occurring.
?
?
?
?
??
How many hazardous
conditions can you identify? ?
?
?
?
? ?
?
?
?
?
?
? ?
?
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Brainstorming
SID / HFE & Potential Injury Identifications

HFE/SID helps to prevent injuries

?
?
?
? SID prevents injuries from occurring.

??
How many types of personal injuries can you
?
?
?
?
? ?
? identify that HFE/SID is helpful in preventing?

?
?
?
?
? ?
?

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BACKGROUND

Human Factor Engineering (HFE) or

Safety in Design (SID) with Ergonomic
human factor approach to achieve safe
comfort workplace (inherently safer)

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What is SID? Safety in Design

 1st Edition : 1934
 2nd Edition : 1986
 3rd Edition : 1997
 4th Edition : 2007 Industry
Standards

Company Policies

Facility Documents

Federal, State
& Local Codes
A summary of the industry standards,
legal codes, and company guidelines
relating to safe facility design.
Other name: Ergonomic Specification or Human Factor
Engineering or Specification to Human Factor

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Purpose of SID / HFE Manual

• Provides consistent approach to implementing safe
designs
• Provides easy references to safety requirement
and recommendation
• Addresses the most often missed company and
code-related topics that can create unsafe
working conditions
• Can be used either as a field manual or inserted
directly into a project contract as a specification

COMPANY
C O M P A NY
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Why we need HFE /SID?

• HFE/SID reduces the number of incidents.
• HFE/SID addresses conditions and practices that prevent
operations and maintenance personnel from performing
their daily work in a safe manner.
• HFE/SID provides cost-effective, safe and healthful facilities.
• HFE/SID supports the Project Engineering or Project
Phases to provide guidance in safe comfort workplace
• HFE/SID represents good judgment and sound engineering
practice.

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Business Drivers for Companies

• The Company Way (Elaboration of Vision and Mission)
• Operational Excellence or HSE Management System
• Shareholders Expectation to have safe comfort workplace
(inherently safer)

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Business framework

77MTPA
LNG

COM
PANY

Challenge:
MERGERS
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Alvin Alfiyansyah Source: QG The Pioneer magazine edition 155, 156, 157, 158

The Chevron Way – example

Protecting People and the Environment
We place the highest priority
on the health and safety of
our workforce and
protection of our assets
and the environment.
We aim to be admired for
world-class performance
through disciplined application
of our Operational Excellence
Management System.

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Problem Statement – Example in Upstream

Technical Challenges

HFE

HSEQ/
PSM

HSEQ/
PSM

25 Source: Alvin’s Library – Project & Operations Management

Operational Excellence – example

Safety, Environment, Health, Reliability and Efficiency

The Tenets of Operational Excellence - We always

do these things:
1. Operate within design or environmental limits
2. Operate in a safe and controlled condition
3. Ensure safety devices are in place and functioning
4. Follow safe work practices and procedures
5. Meet or exceed customer’s requirements
6. Maintain integrity of dedicated systems
7. Comply with all applicable rules and regulations
8. Address abnormal conditions
9. Follow written procedures for high risk or unusual situations
10. Involve the right people in decisions that affect procedures and equipment

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Implementasi Manajemen Keselamatan

Pendekatan Umum dalam Proyek

MOC
CSMS
FID (Final Investment Decision) Safe
Operation
BBS/IIF
RBI
PSM

HFE

FEED (Pre Project)

Basic Engineering
EPC (Eng, Procure, Constr)
Detail Engineering
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Causes of HFE / SID Rework

49% Design 66% Design

16% Construction 7% Construction

35% Vendor/Fab 27% Vendor/Fab

Total Total Dollars

Items for Rework

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HFE / SID Impact on Total Repair Cost

1. Recent trends at Company indicate that significant reductions in total repair costs due to rework are possible when SID practices are implemented at the design and
construction phases of projects. In fact, the earlier the project phase SID becomes involved the greater its impact value in terms of project savings.
2. As shown in the slide, the front-end cost of implementing SID early on in a project is worth it, in terms of reduction in overall project costs. Do not be “penny wise and
pound foolish” by simply concentrating on design and construction costs and ignoring the potential rework costs associated with SID non-compliance.
3. For a typical $50 million project:
1. SID related rework averages in excess of $100,000.
2. $25,000-$35,000 for a SID specialist can save SID rework costs plus increase probability of safer and more operable/maintainable designs.
4. Latest statistics from OSHA - > $100,000 is average cost per recordable incident.
5. Design contractors are reimbursed on the basis of labor hours spent and do not live with the consequences of their designs - COMPANY -end users do.

SID
Phase Not
Phase
Phase 4 Used
3
2

Cost of SID Project

Involvement (Columns represent the same
(as fraction of Total project with SID introduced at
Repair Cost) different project phases)

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Important Definitions
 Shall, Is Required, or Must
 A legal requirement, or required by the Company. This indicates something that
will be done unless a variance or deviation is granted by Company using the
Business Unit or Project change management process and documentation is
provided that proves the proposed method provides equivalent level of safety.

 Should, Preferred, or Recommended

 A recommendation that has been generally and successfully used within the
Company, and that represents safe design practices. Other designs may be
implemented but shall provide an equivalent level of safety.

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Important Notes
1. HFE/SID is critical to the success of Incident Free Operation
because it involves Safety and Reliability.

2. Ergonomics enhances the positive impact of HFE/SID on

company facilities operations because it:

 makes employees comfortable to perform their jobs

 promotes planning and compliance with codes and

standards

 creates good operability and maintainability

 avoids placing humans at risk

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Important Notes
3. The compliance on HFE/SID manual early in the
design phase will significantly reduce cost compared
to compliance during construction phase.
4. The HFE/SID Manual does not provide complete
fabrication or construction details.
5. Company standard drawings or other company
publications should be referred to for complete
fabrication and construction details.

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 HFE / SID OVERVIEW

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Lay out document – example

 Chevron HFE/SID Manual consists of 12 sections.
Each section contains:
 Scope
 References
 Detail requirements / guidelines
 Examples of typical safety in design features (figures, notes)

Plus Introduction Section in which the SID

implementation flow chart is attached.
 Other Companies HFE manual consist of similar chapter
with additional information on labelling and signaling,
control Room lay out and design where in Chevron SID
manual - this chapter written in different document.
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Table of Content – example

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Section 1, 2, 3 and 4: Access & Space

 These sections relate to personnel access to equipment and valves,
safe movement within facilities equipment, requirements for railings,
stairways, walkways, platforms and ladders
 They provide the most frequently used guidelines and, therefore,
identify where the more frequent errors occur.
 Common problems include:
 inadequate overhead clearance
 limited access space
 valve access and operation
 improper landing area
 ladder obstructions

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Section 1, 2, 3 and 4: Access & Space

Common Problems

Key Word: Access Space

SID Requirement:
Provide 30 inches (76.2 cm)

X of access space (short

passageway) around
equipment, valves, etc.
which must be operated or
maintained routinely.
Additional space should be
provided when operating or
maintenance needs dictate.

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Section 1, 2, 3 and 4: Access & Space

Common Problems

Key Word: Overhead Clearance

X SID Requirement:
A minimum of 6 feet 8 inches
(204 cm) overhead clearance
from the ground, floor or
platform shall be maintained in
aisles and around equipment,
valves, etc. where operators
pass

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Section 1, 2, 3 and 4: Access & Space

Common Problems
Key Word: Landing Area
SID Requirement:
30 x 30 inch (76.2 cm2)
minimum landing area is
required for the base of
stairways and ladders.

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Chapter 1, 2, 3 and 4: Access & Space

Common Problems

X
Key Word:
Valve Operation
SID Requirement:
See the guidelines of valve
installation. In this case, the
valve stem is in horizontal
orientation. See the picture
on the right.

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Chapter 1, 2, 3 and 4: Access & Space

Common Problems
Key Word: Ladder Obstruction
SID Requirement:

7 inches (18 cm) minimum

clearance behind the ladder
X rung centerline is required
throughout the length of the
ladder.

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Chapter 1, 2, 3 and 4: Access & Space

Common Problems

Top Rung

Platform
Landing

Platform
Landing

X
Top Rung

Key Word: Improper Top Rung

SID Requirement:

One rung of the ladder (top rung) shall be

located at the level of the platform landing.
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Section 5: Guards
 This section contains important features to protect
employees from mechanical, hot surface, and chemical
spray hazards.
 The nature of the hazard will determine the type of
guard to be used.

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Section 5: Guards
Proper Guards

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Section 6: Electrical Equipment

 This section provides guidance for the design and use of electrical
equipment, safe distance and working space around electrical equipment.
 Installing the proper electrical equipment, maintaining work clearances,
and replacing equipment covers properly are some of the ways to
protect personnel.

X
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Section 7: Access for Physically Disabled

Employee
 This section provides guidance for the design of facilities for
wheelchair access.
 It is company policy and the law to accommodate physically disabled
employees and visitors.
 Common problems are that adequate turning radius and resting
platforms can be overlooked.

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Section 8: Safety Shower & Eye Wash

This section provides guidance for design requirements of
shower/eye-wash units and chemical goggles areas in
accordance with current regulations and company policy.
Safety showers and eye-wash units should be a safe
distance from potential hazards and must be designed so
they can be used quickly in case of emergency.

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Section 9: Occupational Environment

 This section provides requirements on the use of safety signs,
lighting, local ventilation, noise, and labelling of pipelines.

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Section 10: Safe Maintenance &

Equipment/Material Handling.
 This section defines the requirements for mechanical
handling of equipment, valves, piping and electrical in
maintenance/repair situations within operating facility.

X
X

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Section 11: Offshore Facilities

 All SID requirements and practices contained within the other
sections apply to offshore facilities except as explicitly explained in this
section. The exceptions are due to regulatory requirements, the
significant space and weight limitations, emergency response
considerations and the marine feature of floating facilities.

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Section 12: Construction Activities

 This section provides basic requirements on construction activities,
such as shoring and bracing, scaffolding, lifting and rigging activities.

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Extra Information – additional section

Control Rooms and Control Panels
Visual Displays
Visual Access for Shared Displays
Controls
Control Panel Labels
Alarms
Other Work Areas

Working Environment
Lighting Signing and Labeling
Thermal Environment Pipe Labels
Vibration Reduction and Control Electrical Wire and Cable Labels
Noise Reduction and Control Equipment Labels
Ventilation Equipment Signs
Weather Protection Hazard Signs
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Example of SID Implementation during

project phase
 Run a HFE / SID survey with following objectives:
 The survey was done to asses XXX Installation to check
compliance of minimum human factors (ergonomic) design Adobe Acrobat
Document
requirements related to typical operation and maintenance
activities in normal and emergency operating conditions. The survey
is a way to preserve ergonomically new fitted facilities for future
operations and maintenance and provide safer start up and
commissioning activity. The scope of the survey are :
 Valves-include its accessories, electrical devices and distribution
system provided with ergonomic design for operation and
maintenance
 Sensors, Instrumentations and detector installation
 Structure and environmental protection aspect for maintenance
activity
 To prioritize minimum cost, less construction effort, optimum
ergonomic design change prior pre start up safety review (PSSR)
with optimum operation and maintenance representatives availability.

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THE VALUE
What is the value of this presentation?

SAFE AND INCIDENT FREE OPERATIONS

FATALITY

1 Lost Time Injury √

Reportable Injury
10
First Aid
100
Near Miss
1,000
At Risk Behaviors and
10,000 Hazardous Conditions

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Semoga Bermanfaat & Sukses Buat Semuanya

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Questions?

Thank You

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Alvin Alfiyansyah, praktisi HSE profesional bersertifikat Insinyur Profesional dengan spesialisasi di
keselamatan proses yang mempunyai pengalaman kerja lebih dari 20 tahun di sektor minyak dan gas di
Indonesia dan luar negeri baik untuk fasilitas laut, darat, laut dalam, dan fasilitas berisiko besar. Bertugas di Luar
Negeri sebagai Insinyur Utama lapangan yang bertindak sebagai Insinyur Kepala beberapa aset dalam
About
pengelolaan hal keselamatan proses fasilitas produksi LNG, saat ini bertugas pula sebagai Satgas penanganan
wabah Covid-19 untuk KBRI Doha. Bekerja dan tinggal bersama keluarga dengan visi dan misi selalu beribadah
kepada Allah SWT dengan restu orang tuaPlace & Date
dan keluarga dalamof Birth hasil pekerjaan terbaik dan berguna
memberikan
bagi masyarakat banyak dan WNI khususnya. Lahir Palembang,
di Palembang, 43 43
years
tahunago lalu per tahun 2020.

Education
1995 Bachelor Degree
Institut Teknologi Nasional BDG
ALVIN ALFIYANSYAH Chemical Engineering
LEAD LOSS PREVENTION ENGINEER
Overseas 2010 Master Degree
January 2020 until now IPMI Jakarta
MBA
Process Safety Specialist – Overseas Nov 2018- Jan 2020 2012 Master Degree
Senior LP Engineer – Overseas Juni 2012 – Nov 2018 Heriott Watt University
MSW Champion - Chevron Des 2008 – Juni 2012 Safety & Risk Management
Project Safety Engineer - Chevron Agus 2007 – Des 2008
SHEQ Advisor – Amec Oct 2006 – Jun 2007
2015 Professional Engineer
Lead Process & Safety Engineer - Technip Apr 2002 – Okt 2006 PII and ASEAN Engineer
Project Sales Engineer – PT UDM Apr 2002 – Des 2000
20XX Doctoral ….
MEMBERSHIP & ACTIVITY To Be Determined
PAKKEM – Anggota Aktif Sejak 2020
PII – Anggota Aktif BKK 2015 – 2020 Contact
IATMI Qatar Vice Chairman 2016 – 2020
IAFMI Qatar Area Coordinator 2018 – 2020 alvin.alfiyansyah@gmail.com
Komunitas Migas Indonesia – Ex Kaltim 2003 - 2020 +974 3310 7518
Chairman & Moderator Keahlian HSE
Alvin Alfiyansyah

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