Learning and Relearning Equipment Complexity: Achieving Safety in Engineering Complex Systems

Description

With industrial systems becoming ever more mechanized and reliant on advanced technology, the complexity of equipment, especially in risky industries, is increasing on a daily basis. A thorough understanding of operations and providing safety for these complex systems has become a firm requirement for many. This book offers the knowledge required by safety professionals to provide and maintain the safety of engineering complex systems. Through a scientific and engineering approach to designing, implementing, operating, and maintaining complex systems, Learning and Relearning Equipment Complexity: Achieving Safety in Engineering Complex Systems details the need for more engineering and scientific knowledge to understand and maintain their safety. It gives clear explanations of reasons for a system’s complexity, based on control systems and non-linear dynamics. In addition, the book addresses the necessary changes in the approach and the procedures for the safety assessment of engineering complex systems. The reader will develop a thorough understanding of what complex systems are, why they are complex, and how they are utilized. This book will appeal to any safety professional tasked with complex systems. This extends to professionals in risky industries such as aviation, nuclear power, chemicals, railway and transport, and pharmaceuticals. Cover Half Title Series Title Copyright Contents Preface Author Biography Acronyms and Abbreviations Introductory Explanations Regarding the Book Part I Engineering Complex Systems Chapter 1 Introduction to Complexity and Complex Systems 1.1 Introduction 1.2 How Do We (Humans) Define Complexity? 1.3 Definition of Engineering Complex Systems 1.4 Complicated Systems and Complex Systems 1.5 General Systems Discussion 1.6 How the Ordinary Systems Became More Complex (Complicated)? 1.7 Difference between Engineering Complex Systems and Other Complex Systems 1.8 Characteristics of Engineering Complex Systems 1.8.1 Set of Subsystems 1.8.2 Interdependencies and Interactions 1.8.3 Hierarchy 1.8.4 Emergent Properties 1.8.5 Control Subsystems 1.8.6 The Necessity for a Team 1.8.7 Adaptability 1.8.8 System Boundaries 1.9 Variables, Parameters, and Working Point of the Systems 1.10 Uncertainty and Complex Systems 1.11 System Engineering Chapter 2 Understanding Complex Systems 2.1 Introduction 2.2 Reductionism (Classical Method) 2.3 Modeling 2.4 Simulations 2.5 Reverse Engineering 2.6 Trial-and-error Method 2.7 Interrelations Diagrams 2.8 Markov Chains 2.9 System Theory 2.10 The Most Recent Methods for Understanding Complex Systems 2.10.1 Machine Learning 2.10.2 Deep Learning 2.10.3 Some Other Aspects of Artificial Intelligence 2.11 Pitfalls with Tries to Understand Complex Systems Chapter 3 Complex System’s Operations 3.1 Introduction 3.2 Tolerances in Industry 3.3 Measurement System Analysis 3.4 Statistical Process Control 3.5 Reliability 3.5.1 The Basics of Reliability 3.5.2 Reliability of Complex Systems 3.5.3 Reliability of Complex Systems and Reliability of the Service 3.5.4 Reliability of Humans and Organizations 3.5.5 Using Reliability for Probability Calculations Chapter 4 Stability of Complex Systems 4.1 Introduction 4.2 Stability and Variability 4.3 General Explanations about Analysis of Stability of Engineering Systems 4.3.1 Transfer Function 4.3.2 Laplace Transform 4.4 General Consideration about Stability 4.5 Transfer Function in Time as Inverse Laplace Transform 4.6 Additional Methods for Calculating Stability of Linear Systems 4.6.1 Routh–Hurwitz Criterion 4.6.2 Root Locus Method 4.6.3 Bode Diagram 4.6.4 Nyquist Diagram 4.7 Stability and Resilience Engineering Chapter 5 Control of the Complex Systems 5.1 Introduction 5.2 Control Systems 5.3 Characteristics of Control Systems 5.4 Linear Systems in Mathematics 5.5 Different Control System’s Configurations 5.5.1 Open-loop Control System 5.5.2 Closed-loop Control System (Feedback) 5.5.3 Feedforward Control System 5.5.4 Cascade Control System 5.5.5 Adaptive Control System 5.6 Providing Resilience to the Control Systems 5.7 Computer-based Control Systems Part II Non-linearity in Complex Systems Chapter 6 Introduction to Dynamics of Systems 6.1 Introduction 6.2 States of Systems in Nature Chapter 7 Non-linear Dynamical Systems 7.1 Introduction 7.2 Introduction to Dynamics of Non-linear Systems 7.3 Non-linear Systems 7.4 Description of Non-linear Dynamical Systems 7.4.1 Non-linear Dynamical System Described by Differential Equations 7.4.2 Dynamics of the States of the Non-linear Systems 7.4.3 Non-linear Dynamical System Described by Difference Equations 7.5 Pendulum as Simple Example of Stable and Unstable Fixed Points 7.6 Bifurcations 7.7 Non-linear Dynamics of Two-dimensional Systems 7.8 Calculation of Fixed Points in Two-dimensional Systems 7.9 Types of Fixed Points in Two-dimensional Systems 7.10 Bifurcations in Two-dimensional and Multidimensional Systems 7.11 Stability of Non-linear Systems 7.12 Catastrophe Theory 7.13 Epilogue to the Chapter . . . Chapter 8 Theory of Chaos 8.1 Introduction 8.2 A Short History of Chaos 8.3 Fractals of Chaos 8.4 Sensitive Dependence on Initial Conditions 8.5 Resetting the Chaotic System Chapter 9 Non-linearities in Real Complex Systems 9.1 Introduction 9.2 Things to Be Remembered about Non-linear Systems 9.3 Time Response of the Complex System 9.4 The Most Common Non-linearity in Industry: The Feedback Control 9.5 Memoryless Non-linearities and Non-linearities with Memory 9.5.1 Memoryless Non-linearities 9.5.1.1 Dead Zone 9.5.1.2 Relay 9.5.1.3 Saturation 9.5.1.4 Quantization 9.5.2 Non-linearities with Memory 9.5.2.1 Backlash 9.5.2.2 Hysteresis 9.5.2.3 Electronic Devices with Inductors and Capacitors 9.6 Turbulence Chapter 10 Vibrations 10.1 Introduction 10.2 Resonance 10.3 Types of Vibrations 10.4 Non-linear Mathematics behind Vibrations 10.5 Analyzing the Vibrations 10.6 Vibration’s Measurement 10.7 Solving the Problems with Vibrations—Damping Part III Safety of Complex Systems Chapter 11 Achieving Safety of Complex Systems 11.1 Introduction 11.2 Different Types of Safety 11.3 Different Approaches through History to Achieve Safety 11.4 Safety-III . . . 11.4.1 STAMP (System-Theoretic Accident Model and Process) 11.4.2 STPA (System-Theoretic Process Analysis) Chapter 12 Root Cause 12.1 Introduction 12.2 Definitions of Root Cause 12.3 Examples to Support “My” Definition of Root Cause 12.4 Preventive Maintenance and Root Cause 12.5 Fixing Root Cause after Fault/Failure 12.6 Determining the Root Cause in Post-event Investigation 12.7 What If the Root Cause Is Not So Easy to Find? 12.8 The Humans and the Complex Systems Chapter 13 Design of the Complex System 13.1 Introduction 13.2 The Design . . . 13.3 Uncertainty and Its Influence on the Design of Complex System 13.4 Designing a System Scientifically 13.5 Taguchi Design (Design for Robustness) 13.6 Design for Safety 13.6.1 Design of Hardware and Software for Road Vehicles 13.6.2 Design for Aviation Hardware 13.7 STECA – System-Theoretic Early Concept Analysis 13.7.1 CONOPS 13.7.2 Producing a Model 13.7.3 Model Analysis Chapter 14 Software Development 14.1 Introduction 14.2 Failures of Software 14.3 Software in Aviation 14.3.1 ESARR 6 14.3.2 RTCA DO-178C Document 14.4 Software in Other Industries 14.4.1 Software for Automotive Industry 14.4.2 Software for Nuclear Industry 14.5 Software and Human Factors Chapter 15 How to Improve Safety of Complex Systems? 15.1 Introduction 15.2 Measures for Elimination or Mitigation of the Risk 15.3 How We Should Assess the Safety of the Complex Systems? 15.4 Change of the Perception toward Complex Systems 15.5 How Successful Can Be a Risk Management? 15.6 Procedure for Risk Assessment of Installed Complex Systems Chapter 16 Final Words Index