Engineering Systems Safety Design and Control



Catalogue Data: Safety is one of the key dimensions of engineering asset management. Safety by design or prevention through design is in the core for maintaining engineering systems safety. It considers a holistic approach integrating the key elements of an engineering system, namely hardware, software and humanware. Engineering systems safety evolves around socio-technical system theory keeping technology at the core and aligning hazard control mechanisms around the core. It also integrates quality management principles with system safety tools. In this course, the focus will be on engineering system safety design and control.

Course Objective: To impart knowledge on different facets and aspects of engineering systems safety, focusing on tools, techniques and methodologies needed for prevention of occurrences of unsafe operations and accidents under different industrial settings. Upon completion of the course, the students will be equipped with concepts of engineering systems safety, dimensions of engineering systems safety, safety design and analysis mathematics, design for engineering systems safety and control for safety, and integrating safety with other operational goals such as quality.

Textbooks and References: (i) Industrial Accident Prevention, Heinrich et al., McGraw Hill, 1980. (ii) Techniques for safety management - A systems approach, Petersen D, ASSE 1998. (iii) Probabilistic Risk Assessment for Engineering and Scientists, Komamoto and Henley, IEEE Press, 1995. (iv) Lee's Loss Prevention in the Process Industries, Sam Mannan, Elsevier, 2005. (v) Productive Safety Management, Tania Mol, Butterworth Heinemann, 2003. (vi) Human Error, James Reason, Cambridge University Press, 2007. (vii) Normal Accidents, Charles Perrow, Princeton University Press, 1999.

Course Outline

Sl. No.

Topic*

Lecture Hour(s)

1

Introduction to the course

1

2

Safety issues in process plants, manufacturing and material handling

2

3

Key concepts, terminologies, and safety quantification

1

4

Hazard analysis – PHA, HAZOP, FMEA

3

5

Quiz/class test

1

6

Probability models

3

7

Fault tree analysis

4

8

Event tree analysis

2

9

Bow-tie

1

10

Quiz/class test

1

11

Petri nets (PN)

3

12

Qualitative risk assessment

1

13

Mechanical integrity for safety assurance

2

14

Life cycle safety analysis and pre-startup review

2

15

Quiz/class test

1

16

Probabilistic risk assessment (PRA)

2

17

Monte Carlo simulation

2

18

Uncertainty modeling in PRA

2

19

Bayesian believe networks (BBN)

3

20

Quiz/class test

1

21

Safety function deployment

2

22

OSHAS 18001 & OSHMS

2

23

Accident investigation and training

1

24

A case study on integrated safety management

2

25

Design for safety

2

26

Safety related decision models

2

27

Accident modeling (including VR)

4

28

Quiz/class test

1