The document outlines Mike Hurd's workshop on "Safety in Design" at the 2023 South Australian Safety Symposium. The workshop will cover the 11 steps to consider for safety in design planning as part of the engineering design lifecycle. It emphasizes that safety should be built into the design from the beginning rather than added later. It also provides information on Mike Hurd and his company Engineering Systems Management, which focuses on safety engineering consulting.

1. SouthAustralianSafety
Symposium 2023
SALUS 2023
Workshops
Safety in Design
Mike Hurd, Director
Engineering Systems
Management
Construction
Damian Raspe,
Director
Safety DIT
Psychosocial Risk
Jason Mavrikis, WHS
Advisor
South Australian
Government

2. The Steps of Safety in Design
P R E S E N T E D B Y M I K E H U R D
E N G I N E E R I N G . S Y S T E M S . M A N A G E M E N T .
2 0 T H O C T O B E R 2 0 2 3
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3. Taking action during design to ensure that hazards
to people who will interact with the asset or
product being designed, throughout its lifecycle,
are eliminated or, if they cannot be eliminated,
the risk is minimised.
Safety in Design
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD

4. Safety in Design
Lifecycle
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
Design
Construct &
Commission
Operate
Maintain /
Refurbish
As Required
Retire /
Dispose
Pre-design work

5. Safety in Design
Lifecycle
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
Design
Construct &
Commission
Operate
Maintain /
Refurbish
As Required
Retire /
Dispose
Pre-design work
Safety in Design activities

6. Safety in Design
Lifecycle
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
Safety in Design activities
Hazard exposure
Design
Construct &
Commission
Operate
Maintain /
Refurbish
As Required
Retire /
Dispose
Pre-design work

7. Safety in Design
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
Concept
&
Specification
Design Manufacture &
Construction
Supply
&
Installation
Operation
&
Maintenance
Decommission,
Demolition &
Disposal
Cost of
Implentation
Ease of
Implementation

8. Safety in Design
Design and SiD
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
Safety in Design
Finalise the
design
Construct
Initial Design

9. Safety in Design
Design and SiD
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
Safety in Design
Finalise the
design
Construct
Initial Design
“Do a SiD”

10. Safety in Design
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD

11. Safety in Design
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12. Arc-Explosion Vents
If it can happen,
it will happen…
Nice place to stand
Safety in Design
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X X

13. Making a Design that is Safe SFAIRP
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14. Design Context
• Comprehensive set of requirements
Design Framework
• Procedures
• Competent people
Hazard Management
• Considering the interactions between people, the design and its surroundings,
throughout its lifecycle to identify, control and communicate hazards.
Making a Safe Design
Key Elements
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD

15. Function
Performance
Environmental compliance
Safety Engineering
OH&S
Delivery
Cost/financial
Project Management: normal vs. fast-track projects
Policy
Interfaces – External to System
Interfaces – Internal to System
Interfaces – Environment (impact on)
Though-Life Support
Physical characteristics
Resources (people, money, time, tools, materials)
Design Process
Security or privacy
QA. QC & certification
Making a Safe Design
Design Context - Comprehensive Requirements
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
Lifetime
Availability
Reliability
Maintainability
Access, egress
Spares
Refurbishment
End of Life
Replacement
Decommissioning
Disposal

16. Procedures
• Engineering process or procedure
• Safety in Design Planning
• Design Verification and Validation processes
• Design Change Control procedure, through-life
• Engineering Authority Structure / escalation path for safety and design
decision-making
People
• Qualifications and Experience (Competence)
Making a Safe Design
Design Framework – Procedures and People
© 2023 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD

17. 1. Identify Hazards (CONSIDER INTERACTIONS / INTERFACES)
2. Identify Hazard Controls
3. Determine, then do, what is Reasonably Practicable
4. Maintain Records and Communication
Hazard Management
© 2022 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD

18. Using foresight - as per previous section
Lessons Learned from the past
Research (information from similar designs)
Site Assessment (feedback from end-users)
Site visits and virtual reality walk-throughs
Consultation (meetings, workshops)
Analysis
Hazard Identification
Hazard Identification Techniques
© 2022 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD

19. Hazard Management
“Analysis” Hazard Identification Tools
© 2022 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
SAFETY IN DESIGN
PLANT RISK
ASSESSMENT
PLANT HAZOP
AS 61882
SYSTEM-LEVEL
HAZOP / CHAZOP
AS 61882
FAULT / EVENT
TREE ANALYSIS
FUNCTIONAL
SAFETY
AS 61508/511
FMEA / FMECA
AS IEC 60812
ENGINEERING
MANAGEMENT
CONSTRUCTION
HAZARD
ASSESSMENT
LAYERS OF
PROTECTION
ANALYSIS
RELIABILITY-
CENTRED
MAINTENANCE
ROOT-CAUSE
ANALYSIS
SAFETY IN DESIGN
REVIEWS

20.  Comprehensive set of requirements
 Safety in Design Planning
 Engineering and design process(es)
 Designer competency
 Hazard identification – do what is reasonable
 Identify Hazard Controls
 Determine, then do, what is Reasonably Practicable
 Maintain Records and Communication
 Communication between parties
 Design Verification and Validation processes
 Design Change Control procedure, through-life
 What else?
Steps so far…
© 2022 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD

21. The Engineering
Lifecycle and SiD
Making sense of Safety
in Design
© 2022 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD

22. The Steps of Safety in Design
The Engineering Lifecycle and Safety in Design
© 2022 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
?

23. The Steps of Safety in Design
The Engineering Lifecycle
© 2022 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD

24. The Steps of Safety in Design
© 2022 ENGINEERING. SYSTEMS. MANAGEMENT. PTY LTD
1. Seek Lessons Learnt
2. Safety in Design Planning
3. Early Engagement of End-Users
(Operation and Maintenance)
4. Conduct Safety Studies
5. Align Understanding
6. Early Engagement of End-Users
(Construction & Commissioning)
7. Live Hazard Tracking
8. Information Transfer
9. Verify And Validate Safety In Design Actions
10. Capture Lessons Learnt
11. Design change control - throughout the lifecycle

25. SiD is part of the engineering and design lifecycles. It starts at the beginning.
‘Built-in, not bolt-on’ (like quality).
There are 11 steps to be considered in your SiD planning.
Summary
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26. Copyright and Disclaimer
Unless prior, written agreement exists in the contrary, copyright in this material is owned by or licensedto Engineering.Systems. Management. Pty Ltd
(E.S.M.).Permission to publish,modify, commercialiseor alter this material must be sought directly from E.S.M.
E.S.M. gives no warranty and accepts no liabilityfor any loss or damage incurred because of reliance on this information.
Copyright and Disclaimer
Unless prior, written agreement exists in the contrary, copyright in this material is owned
by or licensed to Engineering. Systems. Management. Pty Ltd (E.S.M.). Permission to
publish, modify, commercialise or alter this material must be sought directly from E.S.M. .
E.S.M. gives no warranty and accepts no liability for any loss or damage incurred because of
reliance on this information.
© 2023 Engineering. Systems. Management. Pty Ltd
Suite 613, 147 Pirie Street
Adelaide, South Australia 5000
M: 0432 858 958
E: info@esmconsulting.com.au
W: esmconsulting.com.au
Thank-you

27. SouthAustralianSafety
Symposium 2023
SALUS 2023
Afternoon Tea
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