Liquid Pipeline Operator's Control Room Human

Liquid Pipeline Operator’s Control Room Human Factors Risk Management Guide Page i LIQUID PIPELINE OPERATOR’S CONTROL ROOM HUMAN FACTORS RISK ASSESSMENT AND MANAGEMENT GUIDE Prepared by: Marvin McCallum and Christian Richard Prepared for: Pipeline and Hazardous Materials Administration and Pipeline Research Council International November 26, 2008 Liquid Pipeline Operator’s Control Room Human Factors Risk Management Guide Page i This research was co-funded by the Department of Transportation, Pipeline and Hazardous Materials Safety Administration (PHMSA) and by the Pipeline Research Council International, Inc. (PRCI). The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of PHMSA or the U.S. Government. This document is furnished to Pipeline Research Council International, Inc. (PRCI) under the terms of PRCI contract Project No. PR-003-03405, between PRCI and Battelle Memorial Institute, Battelle Columbus Operations. Publication and dissemination of this report by PRCI should not be considered an endorsement by PRCI or Battelle of the accuracy or validity of any opinions, findings, or conclusions expressed herein. In publishing this report, neither PRCI nor Battelle make any warranty or representation, expressed or implied, with respect to the accuracy, completeness, usefulness, or fitness for any particular purpose of the information contained herein, or that the use of any information, method, process, or apparatus disclosed in this report may not infringe on privately owned rights. Neither PRCI nor Battelle assume any liability for damages, including but not limited to any direct, special, punitive, incidental or consequential damages, resulting from the use or misuse of, any information, method, process, or apparatus disclosed in this report. Liquid Pipeline Operator’s Control Room Human Factors Risk Management Guide Page iii ACKNOWLEDGEMENTS The Battelle researchers would like to acknowledge the Government agencies, industry associations, and the individuals who supported this project. This project was co-funded and ably co-managed by the Pipeline and Hazardous Materials Safety Administration (PHMSA) and Pipeline Research Council International (PRCI). Several past and present managers from seven separate pipeline operating companies actively supported this project through their participation in planning meetings, coordination of company resources, and their review and comment on numerous interim project products. Risk analysis professionals from two participating companies played a critical role in shaping the final risk assessment methodology. More than 200 individual pipeline Controllers and control room supervisors from participating companies provided the detailed operational information that allowed the resulting methodology to be tailored to the realities of pipeline monitoring and control operations through their interview participation, Controller Survey completion, and risk likelihood rating participation. Finally, the authors of this report relied heavily on the excellent database management and analysis support provided by Jim Brown of Battelle and the outstanding administrative support, data entry, and document preparation and management skills of Diane Williams of Battelle. Liquid Pipeline Operator’s Control Room Human Factors Risk Management Guide Page v TABLE OF CONTENTS Acknowledgements ...................................................................................................................iii Glossary ............................................................................................................................vii Introduction ..............................................................................................................................1 Background.............................................................................................................................1 Human Factors Risks in the Control Room.............................................................................1 Mitigating Control Room Human Factors Risks ......................................................................3 Project Objectives, Activities, and Products............................................................................4 Organization of this Guide.......................................................................................................5 Methodology Overview...............................................................................................................7 Methodology Organization ......................................................................................................7 Step 1: Assemble the Human Factors Risk Management Team.............................................9 Step 2: Administer the Controller Survey...............................................................................10 Step 3: Administer the Risk Likelihood Rating Activity ..........................................................11 Step 4: Calculate Risk Levels and Rank-order Human Factors Topics for Operational Review...................................................................................................12 Step 5: Select Operational Review Topics ............................................................................14 Step 6: Conduct and Summarize Operational Reviews.........................................................15 Step 7: Develop a Risk Mitigation Strategy ...........................................................................16 Step 8: Develop and Implement Risk Mitigations ..................................................................17 General Issues in Applying this Guide ..................................................................................18 Risk Management Process Overview ...................................................................................21 Appendix A Step 1 Human Factors Risk Management Team Guidance ......................... A-1 Step 1 Human Factors Risk Management Team Assembly Guidance ............................... A-3 Risk Management Team Guidance Handouts .................................................................... A-5 Appendix B Step 2 Controller Survey and Administration Instructions ......................... B-1 Step 2 Controller Survey Administration Instructions.......................................................... B-3 Liquid Pipeline Control Room Human Factors Taxonomy .................................................. B-7 Controller Survey .............................................................................................................. B-15 Appendix C Step 3 Risk Likelihood Rating Activity Materials and Administration Guidance ...................................................................................................................C-1 Step 3 Risk Likelihood Rating Activity Administration Guidance......................................... C-3 Risk Likelihood Rating Activity Materials.............................................................................C-7 Appendix D Step 4 Risk Level Calculation Instructions, Sample Results, and Summary Sheets ............................................................................................... D-1 Step 4 Risk Level Calculation Instructions and Example .................................................... D-3 Risk Level Score Calculation Example ............................................................................... D-5 Preliminary Industry Risk Norm Data .................................................................................. D-8 Risk Level Calculation Summary Sheets .......................................................................... D-17 Page vi Liquid Pipeline Operator’s Control Room Human Factors Risk Management Guide Appendix E Step 5 Operational Review Topics Selection Guidance and Documentation Sheet............................................................................................... E-1 Step 5 Operational Review Topics Selection Guidance...................................................... E-3 Operational Review Topics Selection Documentation Sheet.............................................. E-7 Appendix F Step 6 Control Room Operational Review Guidance and Worksheets ...... F-1 Step 6 Operational Review Guidance................................................................................. F-3 Operational Review Worksheets....................................................................................... F-13 Detailed Operational Review Guidance ............................................................................ F-39 Appendix G Step 7 Risk Mitigation Strategy Development Guidance and Worksheets ...............................................................................................................G-1 Step 7 Risk Mitigation Strategy Development Guidance ....................................................G-3 Step 7 Mitigation Assessment Worksheet and Guidance ...................................................G-5 Risk Mitigation Descriptions................................................................................................G-9 Appendix H Step 8 Mitigation Development and Implementation Guidance and Worksheet .................................................................................................................H-1 Step 8 Risk Mitigation Development and Implementation Guidance .................................

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