Theme Parks and Leisure HSG175 ADIPS Design Review Assessment of Conformity to Design Initial Test Annual Examination Training

Case Studies Safety Verification British Waterways Falkirk Wheel Cariba Creek Colossus Winder Testing

Design Review

We have developed our design review methodology over the last ten years to provide a systematic, traceable system that allows easy audit of work done, by whom and when. Previous versions of assessments made are stored in their entirety with date and time details. Our methodology incorporates any hazards raised as part of a designer’s risk assessment into our hazard lists and quickly allows a review of the manufacturer’s stated risk control methods.

1. Functional System Structure. The first step is to produce the Functional System Structure (FSS). This provides the basis for all further analysis by grouping and listing the functional elements of the entire system in a hierarchical tree, and describing the functional intent for each.
2. Hazard Identification. The hazard identification process (HAZID) enables HSEC to identify hazards associated with the interface between the ride and the rider at a system level. This will focus on hazards related to the design and operation of the system, but also begin to deal with hazards associated with the failure of the ride to perform intended functions. The process for hazard identification is based on that described in BS EN 1050:1996, supplemented by those contained within BS EN 13814:2004 ‘Fairground and Amusement Park Machinery and Structures - Safety’.
3. Failure Mode, Effects and Criticality Analysis (FMECA). The FMECA is a detailed analysis of each of the functional elements identified during the production of the Functional System Structure. Ways in which each element could fail to achieve its functional intent are postulated and potential causes and consequences of these failure modes identified and described. The frequency of the causes and severity of the consequences are then ranked. The potential for detection of the failure mode before the identified consequence ensues is then described. This may include detection through either maintenance or automatically by the control system. Once described, the detection is ranked. The three rankings for Frequency, Severity and Detection are then multiplied together and a Risk Priority Number (RPN) is generated.
4. Assessment of Safety Criticality. Each functional element of the Functional System Structure is assigned a level of safety criticality.
5. Summary Sheet and Hazard Close-out. Once the FMECA is completed for a functional element, a summary sheet will be compiled. This sheet will demonstrate how the manufacturer of the ride has closed-out all the hazards identified. The detail level of this assessment will be dependent on the level of safety criticality assigned. This serves to ensure that engineering expertise is devoted primarily to areas of the rides where the risk is highest. Compliance with relevant standards is often one means of controlling many hazards. Critical and other items to be checked during Conformity Assessment are logged to be included in a schedule of inspections required to be completed to confirm the ride conforms to design. Performance aspects that it is essential to witness during initial test are similarly identified as part of the review and logged.
6. Approval. Each summary sheet assessment is subject to an internal check prior to being individually approved by another member of the engineering team. This check includes both procedural and technical details.
7. Hazard Log. Each failure mode or hazard raised during the review is compiled into a log detailing where it was raised and how it is closed out. It is in addition to any hazard log produced by the manufacturer/designer. This is an essential part of the process since it ensures that the review is both thorough and systematic.
8. Recommendations. Any recommendations relevant to a particular item are logged on the Summary Sheet for inclusion in our report. Following recent discussion with clients, our summary sheet system has been adapted to allow HSEC to easily audit and track which recommendations have been completed, when and by who. This allows outstanding recommendations to be systematically completed and compliance to be monitored and reported upon. All recommendations are listed in our verification report.