2nd Edition

System Safety Engineering and Risk Assessment A Practical Approach, Second Edition

By Nicholas J. Bahr Copyright 2015
    444 Pages 73 B/W Illustrations
    by CRC Press

    444 Pages 73 B/W Illustrations
    by CRC Press

    We all know that safety should be an integral part of the systems that we build and operate. The public demands that they are protected from accidents, yet industry and government do not always know how to reach this common goal. This book gives engineers and managers working in companies and governments around the world a pragmatic and reasonable approach to system safety and risk assessment techniques. It explains in easy-to-understand language how to design workable safety management systems and implement tested solutions immediately.

    The book is intended for working engineers who know that they need to build safe systems, but aren’t sure where to start. To make it easy to get started quickly, it includes numerous real-life engineering examples. The book’s many practical tips and best practices explain not only how to prevent accidents, but also how to build safety into systems at a sensible price. The book also includes numerous case studies from real disasters that describe what went wrong and the lessons learned.

    See What’s New in the Second Edition:

    • New chapter on developing government safety oversight programs and regulations, including designing and setting up a new safety regulatory body, developing safety regulatory oversight functions and governance, developing safety regulations, and how to avoid common mistakes in government oversight
    • Significantly expanded chapter on safety management systems, with many practical applications from around the world and information about designing and building robust safety management systems, auditing them, gaining internal support, and creating a safety culture
    • New and expanded case studies and "Notes from Nick’s Files" (examples of practical applications from the author’s extensive experience)
    • Increased international focus on world-leading practices from multiple industries with practical examples, common mistakes to avoid, and new thinking about how to build sustainable safety management systems
    • New material on safety culture, developing leading safety performance indicators, safety maturity model, auditing safety management systems, and setting up a safety knowledge management system

    Foreword
    Preface to the Second Edition
    Preface to the First Edition
    Acknowledgments
    Author

    Introduction
    Why Do We Need Safety Engineering?
    What Is Safety Analysis?
    System Safety and Risk Assessment
    Government Safety Regulations versus Safety from Industry’s Point of View
    Brief History of Safety
    References
    Further Reading

    Definitions and Concepts
    Makeup of an Accident
    How Safe Is Safe Enough?
    Case Study: Black Swan Extreme Events, Fukushima Nuclear Disaster
    The Accident
    What Went Wrong?
    Media Nightmare
    Lessons Learned of What Could Have Been Done Differently
    What Is a Hazard and Other Important Concepts
    System Safety versus Safety Management System
    System Safety Process
    Hazard Identification
    Hazard Control
    Risk Acceptance
    Risk Management versus Safety Management
    Hazard Reduction Precedence
    Design Out the Hazard
    Safety Devices
    Warning Devices
    Special Procedures and Training
    Safety Maturity Model and Safety Management Systems
    Leading and Lagging Safety Performance Indicators
    Use of Standards in Safety
    Government Standards
    Industry Standards
    Regional Standards, Example: Interoperability in the European Union
    International Standards
    References
    Further Reading

    Safety Analysis in Engineering: How Is It Used?
    Manufacturing
    Consumer Products
    Chemical Process and Oil and Gas Industry
    Aviation
    Mass Transit
    Military and Space
    Commercial Nuclear Power
    References
    Further Reading

    Safety Management Systems
    Safety in the System Life Cycle
    System Life Cycle
    Safety and the System Life Cycle
    Case Studies of Poor Application of Safety in the System Life Cycle
    Developing a Robust Safety Management System
    Elements of a Safety Management System
    Conducting a Diagnostic of Your Safety Management System
    Organizational Management and Safety
    Management Commitment
    Suggested Ideas to Enhance Management Involvement
    Safety Management System Organization
    System Safety Program: Keystone to a Robust Safety Management System
    Elements of a System Safety Program
    Setting Up a System Safety Program
    Evaluating Contractors and Subcontractors
    Emergency Preparedness Programs
    Case Study: How a Leading Global Personal Care Products Company Created a Best Practice Safety Program
    Common Mistakes in Implementing Safety Programs
    Closed-Loop Process
    Hazard Tracking and Resolution
    System Safety Reviews and Audits
    Case Study: Special Commission of Inquiry, Waterfall Rail Accident Safety Management System Audit
    Some Words on Safety Governance
    Voluntary Protection Program
    Safety Culture
    What Is Safety Culture?
    Measuring Safety Culture
    Designing Sustainable Safety Culture: Fitting a Global Company’s Corporate Safety Program into the Local Culture
    References
    Further Reading

    Hazard Analysis
    Hazard Analysis Methodology
    Preliminary Hazard List
    Passenger-Carrying Submersible Example
    Hazard Analysis: Preliminary, Subsystem, and System
    Facility Hazard Analysis
    Operations and Support Hazard Analysis
    Examples of Hazard Analyses
    Example Hazard Analysis of NASA Laser
    Brief Example of a Hazardous Waste Storage Facility Hazard Analysis
    References
    Further Reading

    Process Safety Analysis
    Process Hazard Analysis
    HAZOP
    What-If Analysis and Safety Checklists
    Brief HAZOP Example of an Ammonia Fill Station
    Example What-If/Safety Checklist for Pressure Test Equipment
    References
    Further Reading

    Fault Tree Analysis
    Fault Tree Symbols and Logic
    Finding Cut Sets
    Fault Tree Quantification
    Example of a Fault Tree Construction of a Motor–Pump Pressure System
    Common Mistakes in Fault Trees
    References
    Further Reading

    FMECA, Human Factors, and Software Safety
    Failure Modes and Effects Analysis
    Conducting a Failure Modes and Effects Analysis
    Failure Modes, Effects, and Criticality Analysis
    Human Factors Safety Analysis
    Performance and Human Error
    Conducting Human Factors Safety Analysis
    Brief Example of Human Factors Safety Analysis: Manual Switchover to Auxiliary Feedwater System
    Software Safety
    Software Safety Analysis
    Software Testing and IV&V
    References
    Further Reading

    Other Techniques
    MORT
    Energy Trace Barrier Analysis
    Sneak Circuit Analysis
    Cause–Consequence Analysis
    Root Cause Analysis
    Bow Tie Analysis
    Dispersion Modeling
    Test Safety
    Comparing the Various Techniques
    Advantages and Disadvantages
    References
    Further Reading

    Data Sources and Training
    Government Data Banks
    Industry Data Banks
    Creating Your Own Safety Knowledge Management System: Some Suggestions
    Safety Training
    Employee Safety Training
    Emergency Preparedness and Response Training
    Personnel Certification for Hazardous Operations
    Sample Safety Training Course Outline for a Microprocessor Production Plant
    Safety Awareness Training
    References
    Further Reading

    Accident Reporting, Investigation, Documentation, and Communication
    Anatomy of an Accident
    Accident Investigation Board
    Reporting the Accident
    Setting Up a Closed-Loop Reporting System
    Example of an Automated System
    Forming an Investigation Board
    Selecting the Investigation Board
    Conducting the Investigation
    Investigation Report
    Documenting the Accident
    Retention of Records
    Public Release of Information
    Accident Investigation Lessons Learned
    Communicating the Accident to the Public
    Developing a Crisis Communication Plan
    Common Mistakes: What Not to Say and Do
    References
    Further Reading

    Government Regulations and Safety Oversight
    Safety Regulatory Oversight
    Key Components of a Safety Regulatory Regime
    Description of Different Regulatory Oversight Models
    Case Study: Setting Up a Safety Oversight Body from Scratch
    Safety Oversight Functions and Governance
    More Effective Safety Service Delivery
    Safety Oversight Organization Options
    Sample Safety Oversight Organization
    Example Process Safety Oversight in the United
    States
    Aligning Resource Needs to the Oversight Organization: How to Do More with Less
    Case Study: U.S. Federal Aviation Administration, Improving Oversight through System Safety
    Common Mistakes in Government Oversight Programs
    References
    Further Reading

    Risk Assessment
    What Is Risk?
    Risk Perception
    Risk Assessment Methodology
    Identifying Risk in a System
    Risk Communication
    References
    Further Reading

    Risk Evaluation
    Probabilistic Approach
    Risk Analysis Model
    Developing Accident Scenarios and Initiating Events
    Event Trees
    Consequences Determination
    Uncertainty
    Risk Evaluation: The Use of Risk Profiles
    Calculating Safety Costs
    Brief Example: Risk Assessment of Launching a Space Shuttle Payload
    References
    Further Reading

    Appendix A: Typical Energy Sources
    Appendix B: Generic Hazard Checklist
    Appendix C: Generic Facility Safety Checklist
    Appendix D: Internet Sources
    Index

    Biography

    Nicholas J. Bahr is an internationally recognized expert in system safety, risk assessment, and enterprise risk management systems and has over 25 years of professional experience working around the world. He has set up safety management systems for companies and helped governments improve their safety oversight programs. Over his career, Mr. Bahr has conducted programs for commercial and government clients, detailed technical risk assessments, implemented enterprise risk management business processes, and developed regulatory oversight programs throughout the United States, United Kingdom, Europe, South America, Australia, the Middle East, and North Africa. His diverse experience and background covers many industries including aerospace, utilities, oil and gas, manufacturing, and transportation.

    After a high-profile rail accident in Australia, Mr. Bahr was asked to lead an international team conducting a safety management systems audit of both the regulator and the railway. The audit methodology is now considered the new international gold standard for safety management systems. His client engagements range from risk strategy for senior government and commercial executives, to detailed risk assessments for front-line management. He has helped CEOs, senior VPs, and senior government officials realize tangible and sustainable benefits from their safety and risk management programs. Mr. Bahr is a past U.S. delegate to various standards writing bodies. Currently, Mr. Bahr is a principal at Booz Allen Hamilton and is the regional manager for the Middle East and North Africa.

    "I found Nick’s chapters on Safety Management Systems and Government Regulations and Safety Oversight, to be very comprehensive, insightful and informative. As a practicing occupational health and safety regulator and a previous transport safety regulator, I will certainly keep Nick’s second edition on my book shelf as a ready reference, just as I do with his first edition."
    —Len Neist, Health & Safety Regulator, Australia