Basic Guide to System Safety E-Book

Jeffrey W. Vincoli

• Herausgeber: John Wiley & Sons
• Kategorie: Wissenschaft und neue Technologien
• Sprache: Englisch

Seitenzahl: 366

Veröffentlichungsjahr: 2014

Beschreibung

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.

Leseprobe

Basic Guide to System Safety

Third Edition

Jeffrey W. Vincoli

Manager of Compliance Assurance and Support Services Bechtel Global Corporation

Copyright © 2014 by John Wiley & Sons, Inc. All rights reserved.

Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada.

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Library of Congress Cataloging-in-Publication Data:

Vincoli, Jeffrey W., author. Basic guide to system safety / Jeffrey W. Vincoli. -- Third edition. p. ; cm. Includes index. ISBN 978-1-118-46020-7 (hardback) I. Title. [DNLM: 1. Occupational Health. 2. Safety. 3. Safety Management. WA 485] T55 658.3′82--dc23 2013051270

To my loving wife, Rosemary

Of all my accomplishments in this life, my greatest achievement was convincing you to be my wife. After more than 30 years together, I do not know how people go through life alone. I am blessed in many ways, but none more than having you as my wife. Thank you for always being there with your patience, your charm, your perspective, and your love. You are and will always be the most cherished thing about my life.

Contents

Preface

Acknowledgments

Part I: The System Safety Program

Chapter 1: System Safety: An Overview

Background

The Difference Between Industrial Safety and System Safety

System Safety and the Assessment of Risk

Chapter 2: System Safety Concepts

Fundamentals

The System Safety Process

System Safety Criteria

Cost and Risk Acceptance

Management Commitment

Chapter 3: System Safety Program Requirements

The Safety Charter

Selling Safety to Management

The System Safety Effort

Life Cycle Phases and the System Safety Process

Chapter 4: The Industrial Safety Connection

The Occupational Safety and Health Act

The Human Factors Element

Accident Prevention Through System Design

The Process of Task Analysis

The Job Safety Analysis and System Safety

Guidelines for Preparing a Job Safety Analysis

System Safety: An Integral Part of the Overall Organization

Chapter 5: Probability Theory and Statistical Analysis

Introduction

Probability

Statistics

Summary

Part II: System Safety Analysis: Techniques and Methods

Chapter 6: Preliminary Hazard Analysis

Introduction

PHA Example

Summary

Chapter 7: Subsystem and System Hazard Analyses

Introduction

SSHA Example

Summary

Chapter 8: Operating and Support Hazard Analysis

Introduction

Ergonomics

When to Perform the O&SHA

O&SHA Example

Summary

Chapter 9: Energy Trace and Barrier Analysis

Introduction

Etba Example

Summary

Chapter 10: Failure Mode and Effect Analysis

Introduction

FMEA Example

Summary

Chapter 11: Fault or Functional Hazard Analysis

Introduction

FHA Example

Summary

Chapter 12: Fault Tree Analysis

Introduction

Summary

Chapter 13: Management Oversight and Risk Tree

Introduction

The MORT Event Tree

Procedure for MORT Analysis

Summary

Chapter 14: HAZOP and What-If Analyses

Introduction

Background

Team Members

Reference Data Requirements

THE CONCEPT OF “NODES”

CONDUCTING THE WHAT-IF ANALYSIS

Conducting The Hazop Study

The Analysis Report

Summary

Chapter 15: Special Use Analysis Techniques

Introduction

Sneak Circuit Analysis

Summary

Epilogue

Appendix A: Sources of Additional Information/Training

Appendix B: Acronyms and Abbreviations

Glossary of Terms

Bibliography

Index

End User License Agreement

List of Tables

Chapter 2

Table 2.1

Table 2.2

Table 2.3

Chapter 4

Table 4.1

Chapter 6

Table 6.1

Chapter 8

Table 8.1

Table 8.2

Chapter 10

Table 10.1

Chapter 12

Table 12.1

Chapter 14

Table 14.1

Table 14.2

Table 14.3

Table 14.4

Chapter 15

Table 15.1

List of Illustrations

Chapter 1

Figure 1.1 The “fly-fix-fly” approach, or more accurately “safety-by-accident,” focused on fixing design issues after an accident event rather than focusing on accident prevention through design.

Figure 1.2 The system safety engineering process (

Source:

Larson and Hann 1990).

Figure 1.3 The systems approach to the consideration of safety from the design phase through product disposal or project termination.

Figure 1.4 The “OSHA Cowboy” as first depicted by J.N. Devin in 1972.

Chapter 2

Figure 2.1 The elements of the system safety process (

Source:

Stephenson 1991).

Figure 2.2 Hazard reduction order of precedence process flow.

Figure 2.3 Expected loss index.

Chapter 3

Figure 3.1 Typical system safety program process flow.

Figure 3.2 Sample hazard report form.

Figure 3.3 Typical closed-loop hazard tracking system flow.

Figure 3.4 Project life cycle phases and the system safety process.

Chapter 4

Figure 4.1 The U.S. NIOSH Prevention through Design (National Initiative) concept, modified to show system safety integration into the process.

Figure 4.2 Typical Job Safety Analysis (JSA) form.

Figure 4.3 Example of a partially completed JSA form.

Chapter 5

Figure 5.1 Histogram of distribution values.

Figure 5.2 Curve of empirical distribution.

Figure 5.3 Curve of normal distribution (“bell curve”).

Figure 5.4 Human life cycle curve.

Figure 5.5 Reliability curve (“bathtub curve”).

Chapter 6

Figure 6.1 Sample generic hazard evaluation checklist.

Figure 6.2 Sample energy source evaluation checklist.

Figure 6.3 Sample preliminary hazard list (PHL) worksheet.

Figure 6.4 Sample preliminary hazard analysis (PHA) worksheet (

Note:

Worksheet will provide for hazards identification, evaluation, and resolution).

Figure 6.5 Sample preliminary hazard matrix (

Note:

Examples have been used under “Potential Areas For Failure”).

Figure 6.6 Proposed vapor degreasing operation work area: planar view.

Figure 6.7 Proposed vapor degreasing operation work area: dimensional view.

Figure 6.8 Vapor degreaser: generic hazard evaluation checklist.

Figure 6.9 Vapor degreaser: generic energy source evaluation checklist.

Figure 6.10 Vapor degreaser: preliminary hazard list worksheet.

Figure 6.11 Vapor degreaser: preliminary hazard analysis worksheet.

Chapter 7

Figure 7.1 Sample subsystem/system hazard analysis (SSHA) worksheet.

Figure 7.2 Hydraulic elevator system.

Figure 7.3 Plunger joint.

Figure 7.4 Elevator plunger subsystem/system hazard analysis worksheet.

Chapter 8

Figure 8.1 Sample operating and support hazard analysis (O&SHA) worksheet.

Figure 8.2 Close-up of existing crane operator's control console.

Figure 8.3 Close-up of modified crane operator's control console after the O&SHA analysis.

Figure 8.4 Crane operator's control console O&SHA worksheet.

Chapter 9

Figure 9.1 Sample energy trace and barrier analysis (ETBA) worksheet.

Figure 9.2 Schematic diagram of Memorial Hospital oxygen system.

Figure 9.3 Completed energy trace and barrier analysis worksheet for oxygen system.

Chapter 10

Figure 10.1 Sample failure mode and effect analysis (FMEA) worksheet.

Figure 10.2 The combination 10-ton/1.5-ton overhead bridge crane system.

Figure 10.3 Runway and bridge travel distances for the combination 10-ton/1.5-ton overhead bridge crane.

Figure 10.4 The partially completed failure mode and effect analysis worksheet for the crane system.

Chapter 11

Figure 11.1 Sample system functional/fault hazard analysis (FHA) worksheet.

Figure 11.2 Simple automobile brake/master cylinder system design (

Source:

Larson and Hann, 1990).

Figure 11.3 The completed system FHA for the automobile brake system (

Source:

Larson and Hann, 1990).

Figure 11.4 Automobile brake/master cylinder system redesign following FHA (

Source:

Larson and Hann, 1990).

Figure 11.5 Close-up view of the redesigned master cylinder, showing dual hydraulic chambers (

Source:

Larson and Hann, 1990).

Chapter 12

Figure 12.1 The fault tree concept.

Figure 12.2 Standard Fault Tree Analysis (FTA) symbology.

Figure 12.3 The use of exclusive OR gates when proper conditions exist.

Figure 12.4 Sample fault tree analysis (FTA) showing structure, event and symbol placement, and cut-set identification.

Figure 12.5 Demonstrating the use of AND gates and OR gates in the building of a simple fault tree.

Figure 12.6 The concept of joint probability of events. (

Source:

Spurr and Bonini 1973).

Figure 12.7 The top events of a fault tree analyzing safe work behavior.

Figure 12.8 Probability values in fault tree analysis.

Chapter 13

Figure 13.1 The management oversight and risk tree (MORT) process.

Figure 13.2 MORT Symbology (

Source:

DOE).

Figure 13.3 The top branches of the MORT analytical event tree (

Source:

DOE).

Figure 13.4 Sequence of work through a MORT Analysis Chart (

Source:

DOE).

Chapter 14

Figure 14.1 Sample What-If Analysis worksheet.

Figure 14.2 Partially completed What-If analysis worksheet for the vapor degreaser system.

Figure 14.3 Sample HAZOP worksheet.

Figure 14.4 Partially complete HAZOP worksheet for the vapor degreaser system.

Chapter 15

Figure 15.1 Sample sneak circuit analysis worksheet.

Epilogue

Figure E.1 Summary of the system safety process.

Guide

Cover

Table of Contents

Preface

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