Basic Guide to System Safety

This book provides guidance on including prevention through design concepts within an occupational safety and health management system. Through the application of these concepts, decisions pertaining to occupational hazards and risks can be incorporated into the process of design and redesign of work premises, tools, equipment, machinery, substances, and work processes including their construction, manufacture, use, maintenance, and ultimate disposal or reuse. These techniques provide guidance for a life-cycle assessment and design model that balances environmental and occupational safety and health goals over the life span of a facility, process, or product. The new edition is expanded to include primer information on the use of safety assurance techniques in design and construction.

Table of Contents:
PREFACE xiii PART I THE SYSTEM SAFETY PROGRAM 1 1 System Safety: An Overview 3 Background 3 The Difference Between Industrial Safety and System Safety 7 System Safety and the Assessment of Risk 8 2 System Safety Concepts 15 Fundamentals 15 The System Safety Process 16 System Safety Criteria 18 Hazard Severity 18 Hazard Probability 18 The Hazard Risk Matrix 19 System Safety Precedence 20 Cost and Risk Acceptance 24 Quantitative Risk Assessment 25 Principles of Risk Management 27 Management Commitment 27 3 System Safety Program Requirements 29 The Safety Charter 29 Selling Safety to Management 30 The System Safety Effort 31 Closed-Loop Hazard Tracking System 32 Accident Risk Assessment 33 MishapAccidentIncident Reporting 33 Facility Inspection Reports 36 System Safety Analyses 36 Life Cycle Phases and the System Safety Process 36 Concept Phase 37 Design Phase 37 Production Phase 37 Operations Phase 39 Disposal Phase 39 4 The Industrial Safety Connection 41 The Occupational Safety and Health Act 41 The Human Factors Element 43 Accident Prevention Through System Design 44 The Process of Task Analysis 47 The Job Safety Analysis and System Safety 48 Guidelines for Preparing a Job Safety Analysis 50 Signatures and Approvals 56 Changes in HazardScope 56 System Safety: an Integral Part of the Overall Organization 57 5 Probability Theory and Statistical Analysis 61 Introduction 61 Probability 62 Statistics 64 Summary 67 PART II SYSTEM SAFETY ANALYSIS: TECHNIQUES AND METHODS 69 6 Preliminary Hazard Analysis 71 Introduction 71 The PHA Development Process 72 The PHA Report 78 PHA Example 78 System Description 79 System Operation 80 Preliminary Assessment 81 Evaluation of System Risk 81 Summary 90 7 Subsystem and System Hazard Analyses 91 Introduction 91 The Subsystem Hazard Analysis Report 92 SSHA Example 93 System Description 93 Evaluation of Subsystem Hazard Risk 95 Summary 98 8 Operating and Support Hazard Analysis 99 Introduction 99 Ergonomics 99 When to Perform the O&SHA 101 O&SHA Example 103 Scope and Purpose of the Example O&SHA 103 Risk Assessment 104 Risk Assessment 1: 1B 106 Risk Assessment 2: 1A 107 Risk Assessment 3: 2B 107 Summary 109 9 Energy Trace and Barrier Analysis 111 Introduction 111 The Energy–Barrier Concept 111 Uses of the ETBA 112 Performing the ETBA 112 The ETBA Worksheet 113 ETBA Example 114 System Description 114 The ETBA 114 Summary 118 10 Failure Mode and Effect Analysis 119 Introduction 119 Types of FMEAs 119 Performing an FMEA 120 The FMEA Report 121 FMEA Example 124 System Component Subassembly Description 124 System Operation 128 Failure Mode(s) and Effect(s) 128 Evaluation of Potential Subsystem or Component Failures 129 Summary 132 11 Fault or Functional Hazard Analysis 135 Introduction 135 The FHA Process 136 FHA Example 137 System Description 137 The FHA Process 139 The FHA 141 Summary 143 12 Fault Tree Analysis 145 Introduction 145 Qualitative and Quantitative Reasoning 146 Constructing a Fault Tree 146 Fault Tree Symbols 147 FTA Examples 150 Probability Values and the Fault Tree 153 Summary 156 13 Management Oversight and Risk Tree 157 Introduction 157 The MORT Analytical Chart 158 MORT Use 159 The MORT Event Tree 160 Symbols 160 MORT Analysis Example 161 MORT Color Coding 163 Procedure for MORT Analysis 165 Summary 165 14 HAZOP and What-If Analyses 167 Introduction 167 Background 168 Definitions 168 Objectives 169 Team Members 169 Reference Data Requirements 169 The Concept of “Nodes” 170 Conducting the What-If Analysis 171 What-If Analysis Steps 171 The What-If Analysis Worksheet 173 Conducting The HAZOP Study 175 The HAZOP Worksheet 175 The Analysis Report 176 Summary 177 15 Special Use Analysis Techniques 179 Introduction 179 Sneak Circuit Analysis 180 Types and Causes of Sneaks 180 SCA Input Requirements 181 Advantages and Disadvantages of the SCA 181 Software Hazard Analysis 183 Types of SWHA Techniques 183 Summary 185 Epilogue 187 Appendix A Sources of Additional InformationTraining 189 Appendix B Acronyms and Abbreviations 195 GLOSSARY OF TERMS 199 BIBLIOGRAPHY 223 INDEX 225

About the Author :
Jeffrey W. Vincoli, CSP is currently the Manager of Environmental, Safety and Health Compliance Assurance for Bechtel Corporation. Jeff has over three decades of experience in the practice of occupational and environmental safety and health to include work in system safety analysis, accident and incident investigation, professional training and consulting services, and hazard recognition and assessment. He is a Professional Member of the American Society of Safety Engineers and has assisted in a number of task force assignments and appointed positions focusing on improving the practice of occupational safety and health on a global basis. He has conducted safety reviews and analyses, investigations and training at major construction and engineering projects located on six continents. Jeff is the author of eight published books with three different publishing houses and more than two dozen articles in professional trade journals.