Senior design project for students from Wright State University examined the impact of different job aids on operator performance of a tank line-up task. Labeling, procedures, diagrams, and checklists were all tested on university students manipulating a simulated manifold made of PVC piping. Results showed that performance was close to 100% using some of the aids, but less than 60% when no aides were provided.
This student project tests the human performance of the valve realignment task, with time to perform and performance accuracy likely variables to measure using a mock up of an actual refinery manifold. The different job aid combinations included:
- The manifold with no job aid
- A drawing of the valves
- Labeled valves
- Labeled valves and a drawing
- A matrix of proper open/closed status for all valves
- A matrix of proper open/closed status for all valves with labeled valves
- A matrix of proper open/closed status for all valves with a drawing
- A matrix of proper open/closed status for all valves with labeled valves and a drawing.
Which job aid or combination of job aids would be most beneficial to implement in an oil refinery setting?
A process unit at an oil refinery typically makes several products that are sent to storage or other units. The alignment of where those products go is typically done at a manifold, consisting of numerous valves and piping. Changing the alignment requires usually two valves to be changed, closing the one where it is currently going and opening the one where it is desired to go. In an upset, this may need to be done quickly and in poor conditions (weather, dark), with significant economic consequences if done incorrectly. At best, the piping might be labeled as to where the flow is from and where it goes.
Final Report and Presentation to COP Member Board