1 Guide to safety analysis for accident prevention Lars Harms-Ringdahl IRS Riskhantering AB
2 Guide to safety analysis for accident prevention Copyright 2013 Lars Harms-Ringdahl All rights reserved. This is a non-commercial work; no content may be sold for profit or distributed without the written permission of the copyright holder. The electronic version is subject to revision; it is not permitted to put copies on the internet without the prior permission of the copyright holder. Drawings by Nils Peterson Diagrams and photos by the author Published by IRS Riskhantering AB, Bergsprängargränd 2A, Stockholm, Sweden ISBN The updated electronic version can be found Paperback Also available as paperback: In the Nordic countries:
3 3 Contents Preface 7 1 Accidents in a systems perspective The accident concept The size of the accident problem Critical accidents 19 2 Safety work and accident prevention Safety work Elements in safety work Theories and principles Assumptions and priorities A challenge 34 3 A framework for safety analysis A starting point Safety analysis procedure Safety analysis in context The probabilistic tradition An accident investigation framework Relationships In conclusion 53 4 A brief summary of methods Selection of methods Types of methods Examples of methods Do we need more than one method? 59 5 Evaluation of risks and systems Basics of evaluation Direct Risk Evaluation Quantitative evaluations The Risk Matrix Other evaluation approaches Critical issues 86 6 Energy Analysis Principles Energy Analysis procedure Example Comments 100
4 4 7 Direct Hazard Analysis Principles Job Safety Analysis Example of a Job Safety Analysis Deviation Analysis On deviations Principles of Deviation Analysis Deviation Analysis procedure Examples Comments Hazop Principles Hazop procedure Hazop example Hazop comments Fault Tree Analysis Introduction Principles and symbols Fault Tree Analysis procedure More on Fault Tree Analysis Strict and informal fault trees Example of a fault tree Comments Barriers and safety functions The analysis of safety Barrier concepts and methods Concept of safety function Safety Function Analysis Evaluation of SFs Improvements to safety functions Example Some further methods Introduction Failure Mode and Effects Analysis Event Tree Analysis Cause-Consequence Diagrams Human error methods Task Analysis Management-oriented methods Coarse analyses 224
5 5 13 Methods for event analysis Introduction STEP Simple Event Mapping The AEB method Events and Causal Factors Analysis MTO Analysis AcciMap Change Analysis Deviation Analysis of events Safety Function Analysis of events Tree analysis of events Planning and implementation Decisions before the analysis Performing the analysis Improvements and conclusions Reporting and decisions Quality aspects Choice and summary of methods Basic considerations Methods of system analysis Methods of event analysis Methods of evaluation Choosing method Examples of safety analysis Introduction Analysis of incidents in hospital care Household gas fire Accident investigation at a workshop Safety analysis at a workshop Safety analysis of a school kitchen Safety analysis at a medical care centre Safety analysis of an outdoor convention Analysis at a pharmaceutical company Concluding remarks References Index 345
7 7 Preface This book is about safety analysis as a tool for accident prevention. The methods can be used to analyse systems and to investigate accidents, and thereby generate knowledge for systematic improvements. The prevention of accidents is an extensive and complex subject. In the accident prevention arena, many practices and theories exist side by side. There are different traditions involved in explaining accidents, and investigating, and preventing them. The variations are not necessarily problematic, but they suggest that accident prevention in practice is not as efficient as it could be. The variety is fascinating in many ways, and I have had the opportunity to see it from different perspectives and in various roles. Over the years, I have had the privilege to work with safety in a number of fields. At the beginning, it was in the industrial sector, including paper mills, and the engineering, chemical, and pharmaceutical industries, where the focus was on occupational accidents. In stages, my scope has widened to encompass other areas, and it has been interesting to test the arsenal of industry-based methods in new settings. Examples are: Power production Railway and other transportation Hospital care Emergency services Safety work at societal level There are many similarities between safety analyses and accident investigations, and often similar methods can be applied. It is also possible to apply a general methodology that can be efficiently applied in many different sectors. This has been one of my motives in attempting to write a generalised description of safety analysis and how it can be applied. Safety analysis Safety analysis is a central concept in this book, and it is here defined as a procedure for analysing systems in order to identify and evaluate hazards and safety characteristics. The definition is wide, and covers many ways of analysing. It includes quantitative and qualitative risk analyses, accident investigations, and also some other applications. The rationale for this wide scope will be discussed further on.
8 8 Guide to safety analysis Safety analysis can be used to: Support efficient accident prevention. Contribute to an understanding of how accidents can occur at the specific workplace under examination. Increase awareness and communication. Demonstrate systematic safety work. About this book The aim of this book is to explain general methods of safety analysis, which can be used for accident prevention in different fields. The idea is to give simple straightforward descriptions, and relate them to practical experiences. The ambition is to promote wider use of the methodology, which offers a potential for better accident prevention. The book builds further on earlier publications (Harms-Ringdahl, 1987, 1993, 2001), which had a focus on occupational accidents. The material has been developed from the specialised literature, and from the author s own work on the analysis and prevention of accidents. Many important lessons have been learned from teaching on training courses in safety analysis and accident investigation. The most obvious feature of the new book is that it will be published as an electronic book that is free to download. The reason for this is that it will make for a larger circulation, which will spread the methodology more widely. There will be no economic obstacles to looking at the book, and if it is found useful, it can be applied directly. There are other advantages to having an electronic version, since you can easily search and jump between pages. The use of links makes it easy to look at other references. But some people prefer paper versions, and it is possible to obtain a print-on-demand version. General comments The ambition has been to be general in descriptions, since the principles of many methods can be applied to different types of systems. This might make the descriptions harder to follow, but, on the other hand, it makes the methodology more general applicable. The book suggests a general framework for accident prevention and safety analysis. Several methods of analysis will be described. Some selected methods are thoroughly described and practical suggestions given almost like in a cookbook. The intention is that the reader should get sufficient advice to perform a fairly good analysis on the basis of the description.
9 Preface 9 The general perspective means that the methodology can be applied to a variety of systems and situations where safety is an important issue. They may concern a mechanical workshop, a ward at a hospital, or children in a school. They all have it in common that some kind of organised activity is involved. The word company comes up throughout the book, and this should usually be interpreted in a wide sense. It refers to any type of organised activity in the public or private sector. Safety analyses and accident investigations have many common features, which will be further explained in the framework discussion (Chapter 2). Both approaches can be applied: To identify problems and hazards in a given situation, e.g., in a workplace To understand how a situation can be made safer To develop safety improvements To be important tools for safety management within the organisation The basic idea underlying the book is to show how safety analysis can be practically applied. Its emphasis lies on explaining how different methods work. It is important to consider theories of accident causation, system behaviour, management, human error, and so on. However, they are kept to a minimum in order to limit the number of pages. The reason for this is that the book is mainly intended as a guide for people who would like to employ the methodology. For this reason, there is no stress on theory. A bibliography is provided for those who want to go further theoretically. Looking in the literature, you will find a large number of different methods, which are more or less thoroughly documented. The book presents a set of methods that are described in detail, and a selection of others that are more cursorily explained. Chapter 4 gives a short overview, and a more extensive one can be found in Chapter 15. The main focus is on qualitative methods, which can be beneficial in large application areas. Quantitative and probabilistic methods are only briefly presented. One reason for this is that there is already a large literature available, which is more directed at technical and/or hierarchical systems. Sections in the book The book is built up in four major sections: 1) Background to and framework for analysis 2) Methods of analysis 3) Planning and accomplishment 4) Examples
10 10 Guide to safety analysis The framework section concerns the analytic procedure, i.e., the various stages that make up an analysis and how these are related to one another. This section also aims to give a perspective on how you can get an integrated and consistent framework for how different methodologies can be applied. The method section presents a number of methods. It starts with techniques for risk evaluation, such as the risk matrix. The book describes methods for both analyses of systems and accident investigations. The number of existing methods is large, and a limited selection has therefore been made. The planning section discusses the practical aspects of an analysis. One basic step is to define the aim of the analysis and the type of results desired. In order to achieve this, careful planning is essential. An analysis should be seen as a supplement to a company s own safety activities. The section also considers quality aspects, as well as arguments for and against specific methods of safety analysis. The examples section presents case studies of accident investigations and analyses of systems from different application areas. Use and practical reading This book is primarily intended for practitioners, but may also be useful for researchers. Persons most interested in practical applications can skip over several of the chapters. An important readership consists of those who intend to do some kind of a safety analysis themselves, such as: Safety professionals Fire engineers Designers Consultants in different specialities Another important group consists of persons who, in one way or another, have an interest in the results of an analysis: The customer, who is to commission an analysis and get a sufficiently good result The manager, who can use safety analysis to support the planning of a new system Other stakeholders, such as employees, whose safety is concerned Safety committee members, who want to be able to question management on what methods have been used to assess risks Officials from a supervising authority, who need to know if an analysis is accurate enough
11 Preface 11 For these people, the advice on planning and the methodological overview might be most relevant (chapters 14 and 15). Web and paper versions The web and paper versions are intended to be as similar as possible. However, the electronic version can be updated more frequently. Version numbers will be provided to keep track of updates. Positive features of the web version are: Contents easily accessible as bookmarks in the left-hand column Links to other places in the book and to outside material A search function, which can help in finding words and phrases of special interest (accessed by pressing Ctrl + Shift +F) Acknowledgements The material in this book has been developed over several years through contacts and collaboration with many people. My thanks go to my research colleagues and friends in Sweden and other countries, and to the many others who have encouraged the application and development of safety analysis in occupational and other contexts. For collaboration in recent years, I would like especially to mention Anders Bergqvist, Celeste Jacinto, and Mattias Strömgren. Also, I wish to thank Jon Kimber for his careful checking of the text. Many thanks to the Swedish Council for Working Life and Social Research (FAS) for the financial support they have provided for this book, and for some of the projects on which it is based. My deep appreciation goes to Karin Michal for valuable discussions and positive support over many years.
12 12 1 Accidents in a systems perspective 1.1 The accident concept Common meanings The meaning of accident is often seen as simple and straightforward. A common definition is that accidents are unplanned or unforeseen events causing injury or damage. From a legal perspective, the term accident can mean that the damage was not intended, and/or that the event cannot be regarded as involving a crime. Definitions vary between different fields, and sometimes over time. One example can be taken from the field of occupational safety (DNBIJ, 2006), which runs: A personal injury caused by an incident or exposure which occurs suddenly or within 5 days. Within the medical tradition and in epidemiology, the term injury is prevalent, and more common than the term accident. A short definition from WHO (2004) is: An injury is the physical damage that results when a human body is suddenly or briefly subjected to intolerable levels of energy. A more comprehensive descriptive definition used by WHO (2004) is: Injuries are caused by acute exposure to physical agents such as mechanical energy, heat, electricity, chemicals, and ionizing radiation interacting with the body in amounts or at rates that exceed the threshold of human tolerance. In some cases (for example, drowning and frostbite), injuries result from the sudden lack of essential agents such as oxygen or heat. The injuries are divided into unintentional (accidental) and intentional (suicide or violence). Definition in this book Here, however, it can be useful to apply a broad definition, since accidents concern many different fields and also because ideas change over time. In this book, we will apply a general definition: An accident is an event that causes damage or injury, but which was not intended to have a negative outcome.
13 Accidents in a systems perspective 13 Or more briefly: An accident is an event that causes unintentional damage or injury. The rationale for this is discussed below, where it is found that the meanings of unintentional and unexpected have their ambiguities. Damage is a broad term, which includes injury to humans; for clarity, it is spelled out in the definition. Attributes From the examples above, it is obvious that the concept of accident refers to a number of elements, such as: A short time scale an event Unintentional consequence Unexpected or unforeseen consequence Negative consequence injury or damage A situation in which the accident occurred The time perspective The accident event is usually a rather brief and physical occurrence. But, from a broader perspective, the time scale can be fairly long. Exposure to chemicals may have a negative effect after a short time, but it may be a long time before more symptoms are manifested. Another example is working in cold weather, where freeze injuries sometimes take hours to develop. Unintentional on the part of whom and how That an accident is unintentional might at first appear a straight-forward statement. The affected person did not want to be injured, and if he had foreseen the injury, he would have avoided the situation. When a system perspective is adopted, it is obvious that the role of different actors in what happened must be considered. The actor can be: The victim (injured person) Another person (co-worker, a driver on the road, a patient in the hospital) The manager who decides what to do immediately The company manager who has overall control and responsibility The supplier, designer or similar, who is associated with the performance of the equipment, etc.
14 14 Guide to safety analysis We could also examine intention and make a list of various types of intentions, such as: Acting carefully and considering safety Acting normally but not considering safety especially Acting confused or unbalanced, but without any intention to cause damage Taking risks deliberately but thinking that they are manageable (e.g., driving fast and taking short cuts, knowing that it is dangerous) Violation of clear rules Intention to cause injury These intentions can concern the victim or, in general, all the other types of actors. The final points can be seen as covering criminal behaviours. Unexpected or unforeseen There are issues over what unexpected means in this context. The first concerns the person to whom the event was unexpected, e.g., the victim, a person ignorant of the situation, or an experienced worker. A second concerns degree of expectance, ranging from being completely unexpected to the hazard being well known, which is related to how much foresight you can expect. The general conclusion is that the meaning of unexpected is unclear, and the term should not be used as an element in an accident definition. Range of consequences Consequence is related both to what is damaged and to the magnitude of the damage. A specific accident can have a number of consequences at the same time. Table 1.1 shows different types of consequences, related to what can be damaged. The magnitudes of the consequences also have a wide span, ranging from major accidents with huge damage, to events with almost negligible effects. The term function, as used in the table, has a general meaning. It can concern operations, work, and services of different kinds, such as health care, and food distribution. Different types of consequences are listed.
15 Accidents in a systems perspective 15 Table 1.1 Different types of consequences of accidents Subject Consequence Comments and examples Persons Injury Relatively acute effects; the terminology is usually limited to physical damage. Sometimes lost income is included. Environment Mental effects Reduced health Insecurity Environmental damage Acute mental effects, such as shock, confusion and anxiety Physical or mental consequences; short or longterm effects over a fairly short time Fear, lack of safety, lack of information Poisoning, contamination, harm to biosphere, loss of recreational facilities Function Complete loss Distribution of electricity, telecommunications, or provisions, etc. This can concern persons, companies or the community. Insufficient Information disturbance Increased vulnerability Quantity and/or quality are insufficient Wide area of application, which can concern distorted or lost data, errors in decision-making, or threats to personal integrity There can be secondary effects, which depend on how sensitive the function is to disturbances Economy Losses Direct losses, such as medical care or damaged equipment. Damage to housing, production facilities or other properties. Indirect losses, such as increased costs, lost profit or opportunities. Other Decline in trust Can affect the authorities, companies and other organisations Loss of values Secondary effects on more intangible values, emotional, aesthetic, and historical, concerning individuals and society
16 16 Guide to safety analysis 1.2 The size of the accident problem Accidents are a major health problem in all societies. Here, we will discuss a few accounts of the magnitudes of injuries and other damage. There are statistics from various sources, based on different perspectives, which means that a comprehensive overview is hard to obtain. WHO statistics The World Health Organization (WHO) presents statistics on injuries in a program called Violence and Injury Prevention and Disability. It is estimated that 5.8 million people died from injuries world-wide in 1998 (Krug, 1999). This corresponds to a death rate of 0.98 per 1000 persons. A conclusion of the study was that injury is the leading cause of death in all age groups. It should be remembered that, for every person who dies, many more are injured and perhaps permanently disabled. The magnitude of the problem varies considerably by age, sex, region, and income. In 1998, the death rate of males was almost double that of females. WHO s injury statistics do not identify where injuries occur. This means that the data do not permit comparisons between hazards at work, in traffic, in the home, etc. Information about accidents in different arenas can be obtained from other sources. Table 1.2 Fatal injuries in the EU by cause of death, all ages (from Eurosafe, 2009) Cause of death Comments Part Accidents Road traffic accidents 20% 47% (unintended) Accidental falls 17% Accidental poisoning 5% Accidental drowning and submersion 3% Accidents caused by fire and flames 2% Suicide Self-inflicted injuries 23% Intended Interpersonal violence 2% Other causes Other code or unknown 29% Occupational accidents a global perspective The International Labour Organization (ILO) compiles statistics for occupational accidents and diseases. In a large number of countries, both industrialised and less developed, the frequency of fatal accidents has fallen since the 1960s. A statistical analysis has been performed by Hämäläinen et al. (2006). In the world during the year 1998, the estimated number of fatal occupational accidents was , and there were 264 million non-fatal
17 Accidents in a systems perspective 17 accidents causing at least 3 days absence from work. The study found an average fatal occupational-accident rate of 13.8 per workers. However, the differences between different countries are huge. The figures are high, but they are also uncertain mainly due to missing data. The public health perspective The European Association for Injury Prevention and Safety Promotion (Eurosafe, 2009) has presented a summary of injuries in the European Union (EU) over the years 2005 to The data collection was based on medical records. The study emphasises the scale of the problem, and states that every year more than inhabitants of the EU die due to the external causes of injury and poisoning. For all age groups, injuries are the fourth leading cause of death, after cardiovascular diseases, cancer and diseases of the respiratory system. Table 1.2 gives an overview of different causes of fatal injuries (Eurosafe, 2009, p. 27). Road traffic accidents and falls dominate among accidents, but it can also be seen that suicide is the most important single cause. The data show large variation between countries; a factor of four or even higher between the lowest and highest values can be seen for some causes. Table 1.3 Fatal injuries and hospital admissions in different sectors (Eurosafe, 2009) Sector Deaths Hospital Admissions n Share n Share School 100 1% Sports 600 8% Home, Leisure, % Combined % % Road traffic 51 20% % Workplace 6 2% 300 4% Total unintentional injuries % % Homicide, assault 6 2% 300 4% Suicide (including attempted) 59 23% 400 6% Total all injuries 244 ~ % 100% n = number in thousands The same study (Eurosafe, 2009, p. 7) also shows the sectors in which injuries have occurred, and a summary is provided in Table 1.3. The home, leisure, sports, and school sectors have been clustered together in the deaths columns, but their shares in hospital admissions are presented separately. It
18 18 Guide to safety analysis appears that home and leisure accidents and injuries constitute by far the largest arenas in which injuries occur. This is followed by suicides, which also appear to be a very large problem. Road traffic shows high numbers, which might have been expected. In this summary, the number of workplace accidents is high, but they still make up only a small proportion of all injuries. Medical accidents in hospitals The risk of accidents in hospital care has been known for a long time, but has only received serious attention during the last ten years. It appears that conventional ways of collecting accident data do not identify accidents in hospitals. A number of studies in different countries have been based on reviewing medical records. These have shown a high injury rate during hospital treatment due to medical errors, which are often called avoidable adverse events in the medical terminology. A study (Kohn et al., 2000) concluded that, in the USA, between and Americans die each year as a result of medical errors. A Swedish study (Socialstyrelsen, 2008) of a set of medical records of in-patients found that 8.6% were injured due to avoidable errors. The results can be extrapolated to Sweden as a whole, which gives deaths per year, and a mortality rate of around 33 per inhabitants. In 2005, WHO established the World Alliance for Patient Safety, with the aims of coordinating, disseminating and accelerating improvements in patient safety world-wide. In information from WHO (2012), it is stated that: Patient safety is a serious global public health issue. Estimates show that in developed countries as many as one in 10 patients is harmed while receiving hospital care. In developing countries, the probability of patients being harmed in hospitals is higher than in industrialized nations. The risk of health care-associated infection in some developing countries is as much as 20 times higher than in developed countries. Accident arenas Clarification of arenas where accidents occur is important from a preventive perspective. Table 1.3 shows that there are many sectors and arenas that must be considered. There is also large variation in the conditions and situations that affect the accident rate, such as: Standard of living in the country Resources for accident prevention in the country
19 Accidents in a systems perspective 19 Political systems Large or small enterprises It is difficult to make reasonably accurate comparisons between countries and between accidents across different problem areas. The scope, accuracy and availability of the statistics vary a lot, which makes prioritisation problematic. There are, however, many valuable summaries, such as those from which the tables above are taken. Another study (Takala, 1999) shows rates of fatal occupational accidents in the world in eight different main regions. There are differences between low and high values of more than a factor of four. 1.3 Critical accidents The magnitude of the accident and injury problem is really dreadful. There are an estimated 5.8 million deaths by injury every year according to WHO sources (Krug, 1999). This corresponds to around 30 jumbo jet crashes every day, which would not pass unnoticed. However, most accidents and injuries are seen as normal, and these everyday disasters do not get much attention. The statistical information on injuries and accidents is not complete, making overall comparisons highly uncertain. The statistics may look different in different regions, but it is important that accident prevention is directed where it is most needed. Looking at Swedish death accidents, there are about 15 times as many avoidable adverse events in hospitals as there are fatal road traffic events. Therefore, I will make an attempt to make a ranking list of accident occurrence relevant to Sweden and similar Western countries: 1) Medical accidents in hospitals 2) Home and leisure accidents 3) Road traffic accidents 4) Sport accidents 5) Work accidents 6) School accidents Looking at the broader accident panorama, accident prevention is an issue that calls for greater attention and concern than is expressed today. Finding more efficient ways of preventing accidents and injuries is a real challenge. The use and adaption of systematic methods would be of great benefit.
20 20 2 Safety work and accident prevention 2.1 Safety work The previous chapter has presented a broad perspective on accidents, which has gone beyond some of the traditional perspectives. This section will consider the concepts of safety work and accident prevention generally. It is based on a study (Harms-Ringdahl, 2007) performed for the Swedish Rescue Services Agency, which was supposed to have an overview of national safety work in Sweden. Safety work is generalized here to include the prevention of losses and injuries in most situations. In this book, the following definition is used: Safety work consists in activities and measures that can contribute to reductions in injuries and losses. Demands for safety Formal Informal Safety intention Other intentions Safety work Decisions Safety actions Results Safety situation Actors Evolution Figure 2.1 A general model of safety work A simple model of safety work has three major elements: decisions, safety actions, and results (Figure 2.1). Results represent the outcomes of activities that will affect the safety situation. In order to get results, we must assume that one or more actors participate in safety work in some way, such as by taking safety-oriented decisions, or by supporting safety actions. In order to
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