It has been estimated that up to 90% of all workplace accidents have human error as a main cause. Error must be accepted as a normal component of human behavior. Exhortations to ‘be professional’ or to ‘be more careful’ are generally ineffective, because most errors are committed inadvertently by people who are already trying to do their job professionally and carefully. They did not intend to commit the error. Many factors influence human operator failure probability that some factors are physiological (‘not doing what you meant to do’), some factors are psychological (i.e. making the wrong decision).and some are both. It has been well understood by safer professionals that human factor greatly contribute to success or failure of process safety programs in the chemical process industries as well as represent the area needing the most emphasis to reduce risk. Well-designed human systems can produce inherently safer plant designs and operating procedures. If we understand how humans work and how human error occur, we can design better systems for managing, supervising, designing, training, auditing and monitoring. This has been visualized in a real accident; which has been analyzed as a case study.

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