Ranjana Mehta, PhD Texas A&M University

Transcription

1 Fatigue Risk Assessment and Management in High-Risk Environments (FRAME) Applications for Oil and Gas Operations Ranjana Mehta, PhD Texas A&M University

2 Occupational fatalities in the 2 Oil and Gas Industry Fatality rate in the Oil and Gas industry is EIGHT times that for all U.S. workers Source: BLS CFOI/QCEW (2013). Rate per 100,000 workers per year

3 OGE Occupational Fatalities 3 # of Deaths # of Deaths (Oil and Gas) Fatality Rate (Oil and Gas) Fatality Rate (All industries) Fatality rate (/100,000 workers) Source: BLS CFOI/QCEW (2013). Rate per 100,000 workers per year

4 Fatality Characteristics, Source: BLS CFOI/QCEW (2013). Rate per 100,000 workers per year. Includes NAICS 211, ,

5 5 BP Texas City Explosion On the day of the incident, the Day Board Operator was likely fatigued, experiencing both acute sleep loss and cumulative sleep debt. He had worked 12-hour shifts for 29 consecutive days and generally slept five to six hours per 24-hour period, although he reported feeling most rested with seven hours of sleep per night. The Night Lead Operator, who filled the tower from the satellite control room, worked consecutive days, from February 18 March 23, The Day Lead Operator who was training two new operators, dealing with contractors, and working to get a replacement part to finish the ISOM turnaround work had been on duty for 37 consecutive days, from February 14 until March 23, Finally, an experienced operator, who was helping the Day Lead Operator, worked 31 consecutive days, February 21 March 23, All of these individuals were working 12-hour shifts.

6 Deepwater Horizon Oil Spill 6 Transocean implemented 21-day hitches (called 3 and 3 ) across all North American Division rigs in October 2009; prior to that time, both 14- and 21-day hitches were used. The analyses conducted, and rationale given, by Transocean to switch its Gulf regional fleet from a 14-day hitch to a 21-day hitch expressly focused on schedule predictability, interchangeability of crews from rig to rig, more time for crew training, and financial savings. Missing from the analysis is consideration of sleep science. The driller and one assistant driller working the evening of April 20 were on shift 20 of their 21-day hitch; the second assistant driller was on shift 19 of 21; the day shift toolpusher was on day 20 of his hitch; all 12-hour shifts Overall, sufficient information is not available for a causal connection to the blowout. Yet, the facts outlined here raise sufficient concern for the offshore industry to address fatigue as a safety issue.

7 What is Fatigue? 7 A physiological state of reduced mental or physical performance capability resulting from sleep loss or extended wakefulness, circadian phase, or workload that can impair a crew member s alertness and ability to safely operate an aircraft or perform safety related duties - International Civil Aviation Organization to the Oil and Gas Industry?

8 OGE Workers Perceptions of Fatigue 8 Industry focuses on sleep/shiftwork, but workers emphasized physical, cognitive, and emotional fatigue

9 9 Fatigue Management Strategies Fatigue management: Individual-led OR company-led, burden on fatigue management falls on workers

10 Fatigue is 10 Complex! Task/Industry dependent is a process that results in the impairment of wellbeing, capacity, comfort or performance as a result of [work] activity. is Not Just Falling Asleep

11 Measuring Fatigue 11 No ONE definition of fatigue Research perspective Practical perspective Need for R2P efforts

12 Fatigue Assessment Methods 12

13 Considerations for Assessments 13 Validity What does the data mean? Feasibility Size, cost, comfort, interruption? Reliability Can we trust the data? Sensitivity How can it help us design Controls for different tasks? Technology Expertise, instrumentation required, integrated with personal devices? Organization Privacy issues, operator trust and acceptance?

14 Current OGE Fatigue 14 MANAGEMENT Practices Fatigue Management Practices examples: Training In-Vehicle Monitoring Systems (IVMS) Journey Management Shift-change during hitch Addressing transportation-related fatalities identified through BLS fatalities reports FRMS: API 755 Some may have unintended consequences! For petrochemical industries Others company specific Mehta, RK (2017)

15 API RP 755: Fatigue Risk Management System RP 755: Fatigue Risk Management Systems (FRMS) Mitigates fatigue through a comprehensive system Should be informed by sound science Primary focus is on Hours of Service Covers: Refineries, petrochemical and chemical operations, natural gas liquids extraction plants, and other facilities covered by OSHA Process Safety Management Standard, 29 CFR Does not apply to locations where employees are housed on-site Onshore/offshore fatigue risk assessment???!!

16 Components of RP 755 Safety Promotion Work Environment Individual Risk Assessment & Mitigation Staff-Workload Balance Incident/Near Miss Investigation Roles and Responsibilities FRMS Hours of Service Limits

17 Review of RP 755 Not the result of an effective consensus process It does not provide firm requirements for employers in certain essential elements of an effective fatigue prevention management system, but rather suggests options employers can consider; It unduly emphasizes subjective or personal components of fatigue prevention programs, such as permitting self-evaluation by employees, evaluation by supervisors, and training and education, without objective evidence to support these components; Requirement of the limits on hours and days at work generally more permissive and less protective based on current scientific knowledge API Technical Report 755-1, (Circadian)

18 Gaps in Hours of Service Guidelines Comprehensive FRMS Compensates for excessive hours and days at work Workset Design Consistently working at limits is NOT sustainable May lead to chronic sleep debt Worksets should be designed to prevent employees from frequently working at or near limits WIDELY Outside Acceptable Scientific Range 14 consecutive 12 or 10-hour shifts have NEVER been peer reviewed 19 consecutive 8- hour shift exceeds scientific recommendation by far

19 Fatigue pilot study in the Gulf of Mexico Monitoring 10 offshore workers over three weeks, across different job categories, through: Ambulatory sensors The only clinically validated INTRINSICALLY SAFER sensors on the market! Self-reports measuring perceptions of: Fatigue, physical, cognitive, and psychosocial demands Semi-structured interviews, obtaining perceptions around fatigue and barriers to effective fatigue monitoring and control

20 Results: Physiological Patterns 20 ~19-72% increase in HR during ambulatory work bouts HR remained elevated for some operators stationary tasks had HR ~ 80 bpm 200 Activity x Day Avg HR (bpm) Day Stationary HR Ambulatory HR

21 Lessons learned on Naturalistic 21 Physiological responses Big data analytics! Fatigue Assessments Compliance with sensors for daily monitoring Issue regarding being intrinsically safer still remains Existing surveys Not comprehensive, relevant or related to physiological outcomes Semi-structured interviews More helpful than I would like to admit!! Need for simple, feasible, sustainable fatigue assessment tools for fatigue monitoring in hazardous environments that guide effective management strategies Mehta et a., (2017). Journal of Loss Prevention in the Process Industries

22 Barriers to Fatigue Assessments in OGE Operations 22 Fatigue is unresolvable Insufficient incident reporting on fatigue factors No systematic investigation on how different risk factors interact Major focus on sleep and shift-work Ignoring the impacts of physical and cognitive overload during hitch No systematic fatigue assessment practices identified in the OGE industry Inherently hazardous environments: barrier to objective fatigue assessment ( intrinsically safer methods needed) Need simulated well control scenarios to test assessment tools and worker behavior

23 Motivation 23 Scenario planning helps stakeholders consider what might happen in the future and how they would act to encourage, inhibit or respond to those possible futures. Define the scope of possible scenarios Identify the major stakeholders Identifying basic trends Identify key uncertainties Construct initial scenario themes Check for consistency and plausibility Develop learning scenarios Identify research needs Develop quantitative methods Evolve toward decision scenarios Current scenario planning efforts do not comprehensively integrate human factors elements, such as fatigue, in the uncertainties Fatigue has shown to affect operator performance, however due to the complex etiology, the effects are highly variable (Schoemaker, 1995)

24 Motivation (cont.) Critical role of the driller in maintaining safety Drill plan is a dynamic, complex, series of tasks Task complexity require greater cognitive resources Frequency of tasks training on the job Criticality detection and responding to a kick Operator performance and situation awareness may be impacted by task complexity and criticality In addition to shiftwork..all of which increases overall fatigue

25 Offshore Drilling Simulation Study 25 Aim : To quantify fatigue indicators of 12-hour day and night shifts in simulated offshore well control scenarios To demonstrate that fatigue is a consequence of the interactions of various risk factors (sleep, shift, physical or cognitive work) We conducted a high-fidelity simulation of offshore drilling operations at the UT RAPID Lab

26 26 Methods A high-fidelity simulation study 13 experienced offshore male drillers were recruited (35 (9) years) At least 2 years of offshore drilling experience Available for 5 days 4 nights in Austin TX Arrive in Austin, TX Consent, Baseline assessments, Familiarization (~8 hrs) Day shift (~12 hrs) Night shift (~12 hrs) Rest and Depart from Austin, TX Pre- Shift Fatigue Assessm ent (1 hr) Simulations of procedural tasks (3 hrs) Lunch (1hr) Well control simulations (6-8 hrs) Post- Shift Fatigue Assessm ent (1 hr)

27 Offshore RAPID Lab, UT Austin Actual Offshore Drill Cage Offshore well control simulation

28 Task Based on the skills and information to be monitored Well Control Tasks in the Drilling Simulator Criticality Quantified by the likeliness of adverse event presented Tripping/Non- Failure Tripping/Failure To increase workload during the course of a shift to induce cognitive fatigue Drilling/Non- Failure Drilling/Failure

29 Fatigue Metrics and Analysis Psychomotor Vigilance Test PVT: Sensitive to sleep, shift, cognitive load HR and HRV Analysis Iowa Gambling Task IGT: Risky decisions made under fatigue Purdue Pegboard Task PPT: Impaired motor coordination with fatigue Statistical Analysis 2 cognitive fatigue (Pre vs Post) x 2 shift (Day shift vs Night shift)

30 Operator Vigilance Performance metrics Comparable performance for Cognitive Fatigue or Shift (all p>.299) Response speed % correct # lapses HR (bpm) Pre Day Night Post Physiological response Heart rate (in bpm) Higher for Night Shift (p=.07; ES=.5) Higher for Pre shift (p=.023) Heart rate variability RMSSD Lower for Pre shift during the Night Shift (ns, ES >.3) HRV-RMSSD (ms) Pre Day Night 30 Post

31 15 Operator Risky 10 Behavior NET SCORE 5 0 B1 B2 B3 B4 B5-5 Performance metrics -10 DAY PRE DAY POST NIGHT PRE NIGHT POST Worse for Pre Shift (p=.031) 100 Similar for Day and Night Shift Physiological response Heart rate (in bpm) Higher for Night Shift (p=.096, ES=.46) HR (bpm) Pre Post Higher for Pre Shift (p=.006) Only for the Night Shift (p=.023) Heart rate variability LF/HF Higher for Night shift (p=.039) HRV - LF/HF (%) Day Pre Post 31 Night 2 0 Day Night

32 Operator Motor Coordination Performance metrics No effects on right, left hand tasks Pre Post For the assembly task, time to complete Longer for Night shift (p=.002) HR (bpm) Physiological response 40 Heart rate (in bpm) 20 Higher for Pre Shift (p=.007) 0 Day Night Only during Night Shift (p=.037) Heart rate variability RMSSD LF/HF Lower for Night Shift (ns, ES:.3) Higher for Night shift (p=.039) HRV - LF/HF (%) Pre Post Higher for Post Shift (ns, ES:.6) 0 Day Night

33 Summary Variability in vigilance and risky behavior performances Vigilance was not found to be sensitive to shift Not expected Risk taking can be learned, thus not a practical measure of fatigue in real-world applications Need better objective measures of risk-taking with fatigue (Balloon Analogue Risk Task, BART) Motor coordination negatively impacted by shift (implications for HCI in shiftwork applications) Physiological responses provide insight on operator performance Higher cardiovascular loading during Night shift Greater sympathetic activation with Night shift (response to stress) Lower regulation to homeostatis with Night shift (capability to recover) Likely that performance measures remained comparable because Operator performance = task performance + (neuro)physiological cost

34 Limitations, Future Directions Small sample, single driller setting Night shift always after Day shift Multiple days to test adaption to swing shifts is needed Scenarios may not have induced cognitive fatigue Performance metrics Pre/Post may not provide information on fatigue development during course of shift (ideal: every 2-3 hrs) Neurophysiological metrics (eye tracking, functional connectivity): May provide better insights on operator performance Opportunities to monitor, predict, enhance operator performance in real-world setting

35 35 Conclusion Definition of fatigue needs to be comprehensive and relevant to the industrial setting Implications for FRMS assessments Obtain worker feedback! Develop/Modify existing fatigue assessment tools based on how outcomes will be used to develop controls When technology is not an option, rely on stakeholder input using traditional interview methods

36 Collaborators Principal Investigators Dr. Ranjana Mehta Dr. S. Camille Peres Doctoral Students: W. Sloane Hoyle Ashley E. Shortz Yibo Zhu Collaborators: Dr. Eric VanOort Dr. Mitch Pryor Doctoral Students: Hong-Chih Chan Melissa Lee Gurtej Singh Sain

37 Thank you ANY QUESTIONS?