Module 26 – Safety Culture & Human Factors

Objective:
By the end of this module, a trainee will be able to:

1. Understand the concept of safety culture in a petrochemical plant.

2. Recognize human factors that contribute to operational errors.

3. Apply situational awareness to prevent accidents.

4. Promote teamwork and communication for safe operations.

5. Identify strategies to reduce human errors and unsafe behaviors.

26.1 – Introduction to Safety Culture

Definition:

• Safety Culture = the shared attitudes, beliefs, and practices regarding safety within an organization.

Importance:

• Strong safety culture reduces incidents and near-misses.

• Encourages employees to prioritize safety over speed or convenience.

• Ensures compliance with regulations and internal safety standards.

Operator Role:

• Follow safety procedures consistently.

• Speak up about unsafe conditions or behaviors.

• Participate in safety meetings, drills, and training.

Analogy:

• Safety culture = “everyone in a team looking out for each other to prevent mistakes, like a sports team practicing safe plays.”

26.2 – Human Factors in Petrochemical Operations

Definition:

• Human Factors = elements of human behavior, capability, and limitation that affect safety and performance.

Common Human Factor Issues:

1. Fatigue – reduced attention, slow reaction.

2. Stress – impaired judgment or decision-making.

3. Distraction – missing alarms, readings, or instructions.

4. Complacency – routine tasks performed carelessly.

5. Miscommunication – unclear instructions or assumptions.

Operator Tips:

• Recognize personal fatigue and take necessary rest.

• Focus on tasks and minimize distractions.

• Follow checklists and SOPs to reduce human error.

Analogy:

• Human factors = “driver’s alertness and attention affect car safety.”

26.3 – Situational Awareness

Definition:

• Situational Awareness = knowing what is happening around you and understanding its implications.

Key Elements:

1. Perception – detect alarms, process trends, and abnormal conditions.

2. Comprehension – understand the significance of observations.

3. Projection – anticipate potential consequences of deviations.

Operator Role:

• Constantly monitor process, equipment, and environment.

• Anticipate risks before they escalate.

• Adjust actions proactively within SOP limits.

Analogy:

• Situational awareness = “chess player seeing the whole board and anticipating opponent moves.”

26.4 – Teamwork & Communication

Importance:

• Safety and efficiency improve when operators coordinate effectively with peers, control room, and maintenance.

• Clear communication prevents misunderstandings that can lead to incidents.

Best Practices:

1. Use standardized handover procedures (shift change, maintenance handover).

2. Speak clearly and confirm instructions.

3. Encourage open reporting of near-misses and unsafe conditions.

4. Support colleagues in emergency or abnormal situations.

Analogy:

• Teamwork = “orchestra playing together; one mistake can affect the whole performance.”

26.5 – Reducing Human Errors

Strategies:

• Standard Operating Procedures (SOPs): follow step-by-step guidance.

• Checklists: ensure critical tasks are completed.

• Training & Simulation: practice abnormal situations safely.

• Automation Assistance: use alarms, interlocks, and DCS/PLC feedback.

• Fatigue Management: proper rest, breaks, and shift rotation.

• Peer Observation: team members watch for unsafe actions.

Operator Tips:

• Don’t take shortcuts even during routine tasks.

• Pause to verify readings before taking action.

• Learn from past incidents and near-misses.

Analogy:

• Reducing human errors = “double-checking your parachute before skydiving.”

26.6 – Common Safety Culture Practices

Safety Walks

• Routine inspection of plant safety

• Participate and report unsafe conditions

Near-Miss Reporting

• Document events that could have caused accidents

• Submit detailed reports

Toolbox Talks

• Short team discussions on safety topics

• Engage actively and share experiences

Drills & Exercises

• Simulated emergencies

• Practice procedures, evaluate response

Continuous Learning

• Attend refresher courses

• Update knowledge and skills

Operator Tips:

• Treat near-misses as learning opportunities.

• Share safety observations openly.

• Incorporate safety thinking into daily tasks.

26.7 – Quiz / Knowledge Check

1. What is safety culture and why is it important?

2. Name three human factors that can affect operator performance.

3. What are the three elements of situational awareness?

4. Why is teamwork and communication critical in a petrochemical plant?

5. List two strategies to reduce human errors.

6. Give an analogy for situational awareness.

26.8 – Media Sites Integration

• Videos:

  • Safety drills and situational awareness exercises

  • Operator handover and teamwork demonstration

  • Near-miss reporting and feedback session

• Diagrams / Infographics:

  • Human factors and error causation diagram

  • Situational awareness model

  • Safety culture pyramid

• PDF Downloads:

  • Shift handover checklist

  • Near-miss report template

  • Human factors awareness guide

• Interactive:

  • Embedded quizzes

  • Scenario exercises: identify human factors and suggest corrective actions

26.9 – Summary & Key Takeaways

1. Safety culture is the foundation for safe and reliable operations.

2. Human factors like fatigue, distraction, and stress can contribute to errors.

3. Situational awareness allows operators to detect, understand, and anticipate risks.

4. Teamwork and clear communication prevent misunderstandings and enhance safety.

5. Using SOPs, checklists, training, and proactive observation reduces human errors and incidents.