ANSI API RP 755-2010 Fatigue Risk Management Systems for Personnel in the Refining and Petrochemical Industries (First Edition).pdf

1、Fatigue Risk Management Systems for Personnel in the Refining and Petrochemical IndustriesANSI/API RECOMMENDED PRACTICE 755FIRST EDITION, APRIL 2010Fatigue Risk Management Systemsfor Personnel in the Refining andPetrochemical IndustriesDownstream SegmentANSI/API RECOMMENDED PRACTICE 755FIRST EDITION

2、, APRIL 2010Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.Neither API nor any of APIs employees, subcontractors, consultants, committees, or other assignees m

3、ake any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication

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5、and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities h

6、aving jurisdiction with which this publication may conflict.API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are not intended to obviate the need for applying sound engineering judgment regarding when and whe

7、re these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsi

8、ble for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transm

9、itted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.Copyright 2009 American Petroleum InstituteForewordImplementation of the rec

10、ommendations in this document are intended to produce a step-change in fatigue management and are not to be thought of as the end point, but rather the beginning. To ensure this, it is anticipated that stakeholders and interested members of the scientific and academic communities will evaluate the e

11、ffectiveness of the implementation of these guidelines over the next five years. At the end of this five year period, if not sooner, this document will be opened for review and amendment. Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise,

12、for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.Shall: As used in a recommended practice, “shall” denotes a mini

13、mum requirement in order to conform to the RP.Should: As used in a recommended practice, “should” denotes a recommendation or that which is advised but not required in order to conform to the RP. This document was produced under API standardization procedures that ensure appropriate notification and

14、 participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of

15、 Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director.Generally, API standards are reviewed and revised, reaffirmed, or withdrawn a

16、t least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 1220 L Street, NW,

17、Washington, DC 20005.Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18、. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normative References. . . . . . . . . . . . . . . . . . . . . . . .

19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Terms and Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Components of a Comprehensive Fatigue Risk Ma

20、nagement System (FRMS). . . . . . . . . . . . . . . . . . . . . . 24.1 Roles and Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.2 Positions Covered by the Fatigue Risk Management System . . . . . .

21、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.3 Staff-Workload Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.4 Safety Promotion: Training, Education, and Communication . . . . . . . .

22、. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.5 Work Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.6 Individual Risk Assessment and Mitigation. . . . . . . . . . . . . . . . .

23、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.7 Incident/Near Miss Investigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.8 Hours of Service Limits . . . . . . . . . . . . . . . . . . . . . .

24、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.9 Periodic Review of the FRMS to Achieve Continuous Improvement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Table1 Hours of Service Guidelines for 8-, 10-, and 12-hour Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9v1Fatigue Risk Management Systems for Personnel in the Petroleu

26、m and Petrochemical Industries1 ScopeThis recommended practice (RP) provides guidance to all stakeholders (e.g. employees, managers, supervisors, contractors) on understanding, recognizing and managing fatigue in the workplace. Owners and operators should establish policies and procedures to meet th

27、e purpose of this recommended practice. This RP was developed for refineries, petrochemical and chemical operations, natural gas liquefaction plants, and other facilities such as those covered by the OSHA Process Safety Management Standard, 29 CFR 1910.119. This document is intended to apply to a wo

28、rkforce that is commuting daily to a job location. 1.1 OverviewIt has been documented that excess workplace fatigue is a risk to safe operations and that prescriptive Hours of Service rules should be supplemented as necessary. Thus, fatigue mitigation should be addressed through a comprehensive fati

29、gue risk management system (FRMS) that is integrated with other safety management systems, as necessary. Similar to other safety management systems, everyonethe workforce and senior managementhas a role in recognizing the importance of workplace fatigue risk mitigation and actively working to suppor

30、t the goals of the FRMS. The FRMS should be based on sound science and recognize operational issues, and shall include consultation with key stakeholders in the development and implementation of the local application of the FRMS. The FRMS should include a process to review and enhance the FRMS, as n

31、eeded, with a goal of continuous improvement. 2 Normative ReferencesThis document contains no normative references. For a list of documents and articles associated with API RP 755 and fatigue risk management, please see the Bibliography. 3 Terms and DefinitionsFor the purpose of this publication, th

32、e following definitions apply.3.1call-out Summoning an employee to the work site to perform work that (s)he was not scheduled to perform.3.2extended shifts Time an employee is assigned to work that extends outside their regularly scheduled shift hours and into other shifts.3.3fatigue Reduced mental

33、and physical functioning caused by sleep deprivation and/or being awake during normal sleep hours. This may result from extended work hours, insufficient opportunities for sleep, failure to use available sleep opportunities, or the effects of sleep disorders, medical conditions or pharmaceuticals wh

34、ich reduce sleep or increase sleepiness.2 API RECOMMENDED PRACTICE 7553.4holdovers A periodic, occasional extended shift, where employees are at work beyond their regular shift to participate in training, safety meetings and the like. This does not include time needed for normal shift handoff. 3.5no

35、rmal operationsOperations that are not during outages.3.6open shiftsForeseeable or planned vacancies where the vacancy is known at least one week in advance and overtime will be required to fill the vacancy (non-emergency). Examples include extended sick leave, special assignment or vacation. 3.7out

36、agesPlanned or unplanned interruption in the normal operations of a unit or plant, including mobilizing and de-mobilizing. Outages include, but are not limited to, such things as turnarounds, unit shutdowns, operational responses, etc.3.8shift work An organization of work where workers succeed each

37、other at the same workplace while performing similar operations at different times of the day thus allowing longer hours of operation than feasible for a single worker. 3.9work sets Consecutive shifts with a minimum of 36 hours off before starting another work set.4 Components of a Comprehensive Fat

38、igue Risk Management System (FRMS)4.1 Roles and Responsibilities The FRMS should clearly define the roles and responsibilities for positions including, but not limited to the following: senior management; immediate supervisors; individual employees; contract companies and their employees; key suppor

39、t functions (e.g. medical, HR, safety, workforce planning and scheduling).4.2 Positions Covered by the Fatigue Risk Management SystemThese guidelines are intended for all employees working night shifts, rotating shifts, extended hours/days, or call outs involved in process safety sensitive actions.

40、They should also be considered for others making process safety-sensitive decisions.On-site contractors involved in process safety sensitive actions shall have fatigue risk management systems equivalent to the criteria outlined in this document.FATIGUE RISK MANAGEMENT SYSTEMS FOR PERSONNEL IN THE RE

41、FINING AND PETROCHEMICAL INDUSTRIES 34.3 Staff-Workload BalanceThe FRMS includes an initial and periodic assessment of the staffing levels and workload balance, such that the implementation of the hours of service guidelines discussed below are feasible and that fatigue risk is adequately managed. T

42、he FRMS should recognize the workload variability across shifts, weeks and months taking into account start-ups and shut-downs, as well as unplanned events (e.g. hurricane recovery) and emergency management situations. These assessments should also assess current and anticipated turnover and absente

43、e issues.NOTE Each company should define “periodic” for their FRMS.4.4 Safety Promotion: Training, Education, and Communication The FRMS shall include a process for educating all stakeholders on the causes, risks and potential consequences of fatigue. This education should acquaint all stakeholders

44、with the basic scientific principles of sleep, sleep disorders, alertness, circadian, and fatigue physiology so that they can make informed decisions which will help them reduce the fatigue risk for themselves, their colleagues and the people they may supervise or manage. This education should also

45、provide information designed to increase family member awareness of how they can help the stakeholder keep alert, safe and healthy.The FRMS should provide specific training programs and supporting education and communications materials appropriately tailored to the responsibilities, duties, and work

46、 environment of the stakeholder. All stakeholders should receive initial and recurring training that includes the following: the scientific basis, the structure and the management of the corporate FRMS, and how it is integrated within the corporate safety management system; basic sleep, circadian, a

47、nd fatigue physiology; strategies for achieving good quality, restorative sleep; recognizing the symptoms of sleep disorders and how to obtain appropriate medical advice and treatment; managing an alert and healthy lifestyle; understanding the specific risks of fatigue impairment in their own work e

48、nvironment and work duties; recognizing the signs of fatigue impairment and knowledge on the healthy and effective ways of mitigating them.In addition, those who supervise or manage other employees or provide instructions to contractors should receive initial and recurring training that includes the

49、 following: the influence of staffing levels on employee fatigue; the effects of work and rest scheduling on employee fatigue, and how to schedule work to minimize the risk; how to manage a team of employees to minimize fatigue risk within the group; how to detect when employees are excessively fatigued; understanding policies and procedures for times when employees or contractors should be removed from duty due to fatigue; the continuous improvement process for assessing, updating, and increasing the effectiveness of the FRMS through a data-driven process.4 API RECOM