System safety for the 21st century : the updated and revised edition of System safety 2000

382 Pages·2004·2.376 MB·English

by  Richard A Stephans, Joe Stephenson, Dr

SYSTEM SAFETY FOR
THE 21ST CENTURY
SYSTEM SAFETY FOR
THE 21ST CENTURY
THE UPDATED AND REVISED EDITION
OF SYSTEM SAFETY 2000
Richard A. Stephans, PE, CSP
ARES Corporation
A JOHN WILEY & SONS, INC., PUBLICATION
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10 9 8 7 6 5 4 3 2 1
CONTENTS
FOREWORD TO SYSTEM SAFETY FOR THE 21ST CENTURY xi
FOREWORD TO SYSTEM SAFETY 2000 xiii
PREFACE xv
ACKNOWLEDGMENTS FOR SYSTEM SAFETY FOR THE
21ST CENTURY xvii
ACKNOWLEDGMENTS FOR SYSTEM SAFETY 2000 xix
PART I INTRODUCTION TO SYSTEM SAFETY 1
1. The History of System Safety 3
The 1960s—MIL-STD-882,DOD,and NASA 4
The 1970s—The Management Oversight and Risk Tree 5
The 1980s—Facility System Safety 5
The 1990s—Risk-Based Process System Safety 6
The 2000s—Quest for Intrinsic Safety 7
2. Fundamentals of System Safety 11
Basic Definitions 11
Fundamental Safety Concepts 11
System Safety Fundamentals 15
System Safety Tenets 22
3. Current Approaches to System Safety 25
Department of Defense 25
NASA 31
Facility System Safety 34
The Chemical Industry 37
Department of Energy 39
4. Problem Areas 43
Standardization 44
Risk Assessment Codes 46
Data 47
Communications 47
v
vi CONTENTS
Life Cycle 48
Education and Training 48
Human Factors 49
Software 49
5. The Future of System Safety 51
More First-Time Safe Systems 51
Cost-Effective Management Tools 51
The New Face of System Safety 52
Proactive or Reactive? 55
PART II SYSTEM SAFETY PROGRAM PLANNING
AND MANAGEMENT 57
6. Establishing the Groundwork 59
Generic Model 59
Product Safety 60
Dual Programs 60
Planning and Development Methodology 60
7. Tasks 63
Hazard Identification 64
Hazard Analysis and Control 66
System Safety Support Tasks 69
8. System Safety Products 71
System Safety Program Plan 71
Preliminary Hazard List 73
Preliminary Hazard Analysis 74
Hazard Tracking Log 76
Subsystem Hazard Analysis 77
System Hazard Analysis 80
Operating Hazard Analysis 82
Change Analysis Report 83
Accident Analysis Report 84
9. Program Implementation 87
PART III ANALYTICAL AIDS 103
10. Analytical Trees 105
Purposes 107
Tree Construction 107
Fault Trees Versus Fault Tree Analysis 114
CONTENTS vii
11. Risk Assessment and Risk Acceptance 121
Risk Management Concepts 121
Risk Assessment Shortcomings 129
Total Risk Exposure Codes 130
12. Human Factors 135
Human Reliability 135
Human Error Rates 137
Improving Human Reliability 139
Human Factors for Engineering Design 142
PART IV SYSTEM SAFETY ANALYSIS TECHNIQUES 147
13. Energy Trace and Barrier Analysis 149
Purpose of ETBA 149
Input Requirements 149
General Approach 150
Instructions 150
14. Failure Mode and Effects Analysis 155
Purpose of FMEA 156
Input Requirements 156
General Approach 157
Instructions 157
Appendix:Sample FMEA 160
15. Fault Tree Analysis 169
Purpose of FTA 170
Input Requirements 170
General Approach 171
Instructions 172
Appendix:Sample FTA 181
16. Project Evaluation Tree 189
Purpose of PET 190
Input Requirements 190
General Approach 191
Instructions 192
Appendix:PET User’s Guide 197
viii CONTENTS
17. Change Analysis 211
Purpose 211
Input Requirements 212
General Approach 212
Instructions 213
18. Management Oversight and Risk Tree 217
Purpose of MORT and Mini-MORT 221
Input Requirements 221
General Approach 221
Instructions 229
19. Event and Causal Factors Charts 253
Purpose 253
Input Requirements 254
General Approach 254
Instructions 254
20. Other Analytical Techniques 261
Software Hazard Analysis 261
Common Cause Failure Analysis 262
Sneak Circuit Analysis 262
Extreme Value Projection 264
Time-Loss Analysis 267
Additional Techniques 270
PART V PROCESS SAFETY 275
21. Process Safety Management 277
Introduction 277
Background 277
Future 284
Summary 284
Appendix:List of Highly Hazardous Chemicals,Toxics and
Reactives 287
22. EPA’s Equivalent Process Safety Requirements—
Risk Management Program (RMP) 291
Background 291
Overall Risk Management Program 292
CONTENTS ix
Summary 296
Appendix:Seventy-six Substances Listed Under 40 CFR 68 299
23. Process Safety Implementation 303
Introduction 303
PSM Implementation 303
RMP Implementation 312
Implementation Lessons 314
Summary 315
24. Process Safety Reviews 317
Introduction 317
Mechanics of an Individual Audit 320
Lessons 322
Summary 324
PART VI PROFESSIONALISM AND PROFESSIONAL
DEVELOPMENT 327
25. Professionalism and Professional Development 329
Introduction 329
What is Professionalism? 329
Professional Development 332
Accreditation of Certifications 332
Why Become Certified? 334
Summary 337
APPENDICES 339
Appendix I: The Scope and Functions of the Professional Safety
Position 339
Appendix II: System Safety Society Fundamental Principles and
Canons 345
Appendix III:Professional System Safety and Related Societies and
Organizations 351
GLOSSARY 357
REFERENCES 369
INDEX 373
FOREWORD TO SYSTEM SAFETY FOR
THE 21ST CENTURY
I just heard it again.A colleague of mine said that he has always taken the
“systems view” with regard to system safety. I was once again surprised,
shocked is probably a better word, that not everyone had that view. It
reminded me that there remain varying views of the scope of system safety.
The scope of the system safety discipline is broad,just like the industries that
use the discipline.The system safety discipline has expanded well beyond the
U.S.Department of Defense community and U.S.borders and,as such,its rec-
ognized discipline approach and broad scope are becoming better define.
The System Safety Society and most system safety professionals take a
broad view of the scope of system safety, a “system view.” It considers the
system safety discipline as analyzing all safety aspects for any size system (with
a product being just a small system) throughout its entire life cycle.It uses a
disciplined systems approach to manage safety risk by tapping into the known
knowledge bases and using specific tools and techniques for analysis where
knowledge bases do not exist or are insufficient for the technologies used in
the system.Known knowledge bases include existing safety codes,safety stan-
dards,and lessons learned that have been developed in all technology areas.
The system safety professional focuses more attention,however,where there
are nonexistent or insufficient knowledge bases from which to draw upon.In
this case,the system safety professional uses the specific tools and techniques
available in the system safety profession to augment the lack of information
in existing knowledge bases.The top-level analyses identify where new safety
requirements are necessary and where existing safety codes and standards can
be used.The system safety discipline bridges the gap when existing knowledge
bases are lacking and manages safety risks by identifying hazards from the
known knowledge bases and the tools and techniques of this profession.
Because the system safety professional focuses more attention where there
are no or insufficient knowledge bases, some in industry perceive that the
scope of the system safety discipline is just in those areas,where little or no
knowledge bases exist.However,the scope of the system safety discipline is
much broader and the system safety professional must have a complete under-
standing of how to use and apply the existing safety resources,in addition to
when to use other system safety analyses to evaluate the entire system
throughout its entire life cycle.Some colleagues refer to system safety as the
“umbrella”safety,since you must draw upon all safety resources for the tech-
xi
xii FOREWORD TO SYSTEM SAFETYFOR THE 21ST CENTURY
nologies involved in the design.The system safety discipline has an established
methodology and unique tools for analysis.It establishes acceptable levels of
risk as part of the process and does not necessarily seek zero risk or rely only
on checklists or standards. It considers rare events and life-cycle operations
and analyzes both normal and abnormal circumstances. The discipline
manages for success using training, independent assessments, management
commitment, and lessons learned and it plans for failure by establishing
emergency response procedures, graceful degradation, surveillance, and
maintenance.
This system safety discipline is unique because it addresses the safety of an
entire system and its operations using existing knowledge bases and, where
knowledge bases are insufficient, the tools of this profession. I am of the
opinion that the methodology and tools of the system safety discipline should
be applied to every system. I believe every company should develop and
implement a system safety program that addresses the hazards in its organi-
zation,the products it purchases,and the systems that it designs and operates.
Only the degree and depth of the system safety program will vary from system
to system.As one colleague stated, I wouldn’t spend too much time on the
analysis of a paper clip.Using the system safety discipline,I am convinced that
a company will apply its resources more effectively and achieve success in its
ability to effectively manage safety risks.
The second edition of this book not only updates the text with the current
information on standards such as MIL-STD-882D,it also adds another impor-
tant tool and approach for the system safety engineer:a discussion on process
safety in the chemical industry.Dick Stephans provides in-depth information
of how to apply the system safety process to this specialized discipline: the
users,distributors,or manufacturers of hazardous chemicals and related mate-
rials such as flammables and explosives. Historical accidents have demon-
strated the need for legislation and specific legislative requirements from the
Occupational Safety and Health Administration (OSHA) and the Environ-
mental Protection Agency (EPA) are presented along with examples to rein-
force understanding.Dick Stephans highlights the value of the system safety
philosophy,in this case,to the chemical process standards and the application
of methodologies to satisfy those requirements.
It is common now to see the application of the system safety approach,
tools, and techniques in more and more industries without using the words
system safety.This is evident by the more than 100 techniques described in the
System Safety Analysis Handbook.While I am thrilled that the philosophy con-
tinues to expand,it is important to understand the basis for which most of the
techniques are derived to ensure that they are applied appropriately.
Past President,System Safety Society (1999–2001) PaigeV.Ripani