Air Force System Safety Handbook, Designing the Safest Possible Systems Consistent with Mission Requirements and Cost Effectiveness

Chapter Page Forward ................................................................................i Table of Contents ................................................................ii Figures ................................................................................iv Abbreviations .......................................................................v Definitions ...........................................................................vi References........................................................................ viii 1.0 INTRODUCTION TO SYSTEM SAFETY 1.1 Definitions: System Safety and Safety System 1 1.2 System Safety Objectives.................................. 1 1.3 Need for System Safety..................................... 2 1.4 System Safety Costs ......................................... 2 1.5 Development of System Safety.......................... 3 1.6 Evolution of System Safety Principles ............... 3 2.0 SYSTEM SAFETY POLICY AND PROCESS 2.1 DoD Directives ........................................................ 13 2.2 USAF Policy............................................................ 13 2.3 Designing for Safety ............................................... 14 2.4 System Safety Process .......................................... 14 2.5 The Acquisition Cycle ............................................. 18 2.6 System Safety in the Acquisition Cycle.................. 18 3.0 RISK ASSESSMENT 3.1 Definitions ............................................................... 20 3.2 Types of Risks ........................................................ 20 3.3 System Safety Order of Precedence ..................... 20 3.4 Mishap Severity Categories and Probabilities. ...... 22 3.5 Mishap Risk Assessment ....................................... 23 3.6 Risk Acceptance ..................................................... 25 3.7 Residual Risk .......................................................... 26 4.0 SYSTEM SAFETY PROGRAM 4.1 System Safety Program Objectives and Requirements. ......................................................... 27 4.2 Program Balance .................................................... 28 4.3 Safety Interfaces..................................................... 31 4.4 Program Interfaces ................................................. 32 4.5 Tailoring ................................................................. 34 4.6 Tailoring Checklists ................................................ 35 4.7 Abuses .................................................................... 37 4.8 Small Programs ...................................................... 37 4.9 Government-Furnished Equipment........................ 38 4.10 Commercial and Nondevelopmental Items............ 38 5.0 SYSTEM SAFETY PROGRAM PLAN (SSPP) 5.1 SSPP--Task 102 ..................................................... 40 5.2 Program Scope....................................................... 40 5.3 System Safety Organization................................... 41 5.4 Program Milestones................................................ 41 5.5 Requirements and Criteria. .................................... 42 5.6 Hazard Analyses..................................................... 42 5.7 Safety Data ............................................................. 43 5.8 Safety Verification................................................... 43 5.9 Audit Program ......................................................... 43 5.10 Training ................................................................... 43 5.11 Mishap Reporting.................................................... 43 5.12 Interfaces ................................................................ 43 5.13 SSPP Authorship ................................................... 43 Chapter Page 6.0 OTHER MANAGEMENT TASKS (Ref 30) 6.1 Tasks List ................................................................ 45 6.2 Task 103--Contractor Integration .......................... 45 6.3 Task 104--System Safety Program Reviews......... 46 6.4 Task 105--System Safety Groups/ Work Group Support............................................... 46 6.5 Task 106--Hazard Tracking and Risk Resolution ................................................................ 46 6.6 Task 107--System Safety Progress Summary ...... 46 7.0 DESIGN AND INTEGRATION TASKS 7.1 Analyse .................................................................. 48 7.2 Procedures and Types ........................................... 48 7.3 Qualitative and Quantitative Analyses ................... 49 7.4 Design and Integration Tasks ................................ 53 7.5 Task 201--Preliminary Hazard List......................... 53 7.6 Task 202--Preliminary Hazard Analysis................. 53 7.7 Task 203--Requirements Hazard Analysis ............ 54 7.8 Task 204--Subsystem Hazard Analysis................. 55 7.9 Task 205--System Hazard Analysis....................... 56 7.10 Task 206--Operating and Support Hazard Analysis.................................................................... 56 7.11 Task 207--Health Hazard Assessment .................. 57 8.0 DESIGN EVALUATION, COMPLIANCE, AND VERIFICATION 8.1 Task 301--Safety Assessment ............................... 59 8.2 Task 302--Test and Evaluation .............................. 59 8.3 Task 303--ECPs, Deviations, and Waivers ........... 60 8.4 Task 401--Safety Verification ................................. 60 8.5 Task 402--Safety Compliance Assessment........... 60 8.6 Task 403--Explosive Hazard Classification and Characteristics Data ........................................ 61 8.7 Task 404--Explosive Ordnance Disposal Source Data ............................................................ 61 9.0 ANALYSIS TECHNIQUES 9.1 Fault Hazard Analysis............................................. 62 9.2 Fault Tree Analysis................................................. 63 9.3 Common Cause Failure Analysis .......................... 63 9.4 Sneak Circuit Analysis............................................ 63 9.5 Energy Trace .......................................................... 64 9.6 Evaluation of Analyses (General)........................... 66 9.7 Preliminary Hazard Analysis Evaluation ................ 68 9.8 Subsystem Hazard Analysis Evaluatio69 .............. 69 9.9 System Hazard Analysis Evaluation ...................... 71 9.10 Operating and Support Hazard Analysis Evaluation ................................................................ 71 9.11 Fault Tree Analysis Evaluation............................... 72 9.12 Quantitative Techniques Evaluations..................... 73 10.0 SYSTEM SAFETY LIFE-CYCLE ACTIVITIES 10.1 Concept Exploration Phase Activities .................... 75 10.2 Production Definition and Risk Reduction (PDRR) Activities .................................................................. 75 10.3 Engineering and Manufacturing Development (EMD) Activities .................................................................. 76 10.4 Production and Deployment Activities .................. 77 10.5 Operation and Support Activities ........................... 78 10.6 Major Modifications................................................. 79 10.7 Demilitarization and Disposal................................. 79 10.8 Facilities Construction Activities............................. 79 iii Chapter Page 11.0 PROGRAM OFFICE SYSTEM SAFETY 11.1 Program Office Description .................................... 80 11.2 System Safety Manager’s Role.............................. 82 11.3 System Safety Manager’s Responsibilities............ 83 11.4 Implementation ....................................................... 83 11.5 Interfacing ............................................................... 84 11.6 System Safety Groups............................................ 87 11.7 Key System Safety Personnel Qualifications ........ 88 12.0 CONTRACTING FOR SYSTEM SAFETY 12.1 Contracting Principles............................................. 90 12.2 Contracting Process ............................................... 90 12.3 Contracting for Safety............................................. 91 12.4 Statement of Objectives ......................................... 91 12.5 Statement of Work .................................................. 92 12.6 Contract Data Requirements List (CDRL) ............. 92 12.7 Bidders’ Instructions ............................................... 93 12.8 Specifications.......................................................... 93 12.9 Proposal Evaluation................................................ 94 12.10 Evaluation Standards ............................................. 95 13.0 EVALUATING CONTRACTOR SYSTEM SAFETY 13.1 Process ................................................................... 98 13.2 Six Levels of System Safety................................... 98 13.3 Management and Planning of a System Safety Program........................................................ 98 13.4 Engineering Effectiveness of a System Safety Program.......................................... 99 Atch I--Personnel Qual/Duties/Resp ............. 101 Atch II--System Safety Checklist ................... 103 14.0 FACILITIES SYSTEM SAFETY 14.1 Facilities System Safety Process......................... 109 14.2 Facility Life-Cycle Phases .................................... 109 14.3 Preliminary Hazard List (PHL).............................. 109 14.4 Facility Risk Categories ........................................ 109 14.5 Facility System Safety Working Group (SSWG) . 110 14.6 Preliminary Hazard Analysis (PHA) ..................... 110 14.7 System Safety Management Plan (SSMP).......... 110 14.8 Design Phase........................................................ 111 14.9 Construction Phase ............................................. 111 14.10 Facilities Safety Analysis (PHA) Example ........... 111 14.11 MIL STD 882 Guidance........................................ 111 15.0 SUPPLEMENTARY REQUIREMENTS 15.1 Acceptable/Unacceptable Risk ............................ 114 15.2 Industrial Safety .................................................... 114 15.3 Biomedical Safety ................................................. 118 15.4 Operational Safety ................................................ 118 16.0 NUCLEAR SAFETY 16.1 Nuclear Safety Program ....................................... 121 16.2 Responsibilities..................................................... 121 16.3 Nuclear Safety Goals............................................ 121 16.4 Nuclear Safety Analysis........................................ 121 16.5 Nuclear Safety Reviews ....................................... 122 16.6 Use in Space......................................................... 122 16.7 Radiological Safety ............................................... 123