Preface |
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xix | |
Acknowledgements |
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xxi | |
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PART 1 Understanding Reliability Parameters and Costs |
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1 | (40) |
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Chapter 1 The History of Reliability and Safety Technology |
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3 | (12) |
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3 | (2) |
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5 | (1) |
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1.3 Predicting Reliability and Risk |
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5 | (3) |
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1.4 Achieving Reliability and Safety-Integrity |
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8 | (2) |
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10 | (2) |
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1.6 Contractual and Legal Pressures |
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12 | (1) |
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1.7 Reliability versus Functional Safety |
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13 | (2) |
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Chapter 2 Understanding Terms and Jargon |
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15 | (16) |
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2.1 Defining Failure and Failure Modes |
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15 | (2) |
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2.2 Failure Rate and Mean Time Between Failures |
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17 | (2) |
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2.2.1 The Observed Failure Rate |
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17 | (1) |
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2.2.2 The Observed Mean Time Between Failures |
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18 | (1) |
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2.2.3 The Observed Mean Time to Fail |
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18 | (1) |
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19 | (1) |
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2.3 Interrelationships of Terms |
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19 | (3) |
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2.3.1 Reliability and Failure Rate |
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19 | (2) |
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2.3.2 Reliability and Failure Rate as an Approximation |
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21 | (1) |
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2.3.3 Reliability and MTBF |
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22 | (1) |
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2.4 The Bathtub Distribution |
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22 | (2) |
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2.5 Down Time and Repair Time |
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24 | (2) |
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2.6 Availability, Unavailability and Probability of Failure on Demand |
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26 | (1) |
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2.7 Hazard and Risk-Related Terms |
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27 | (1) |
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2.8 Choosing the Appropriate Parameter |
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28 | (3) |
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30 | (1) |
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Chapter 3 A Cost-Effective Approach to Quality, Reliability and Safety |
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31 | (10) |
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3.1 Reliability and Optimum Cost |
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31 | (4) |
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35 | (1) |
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3.2.1 The Need for Optimization |
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35 | (1) |
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3.2.2 Costs and Savings Involved with Safety Engineering |
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35 | (1) |
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36 | (5) |
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PART 2 Interpreting Failure Rates |
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41 | (46) |
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Chapter 4 Realistic Failure Rates and Prediction Confidence |
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43 | (16) |
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43 | (2) |
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45 | (5) |
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4.2.1 Electronic Failure Rates |
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46 | (2) |
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4.2.2 Other General Data Collections |
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48 | (2) |
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50 | (1) |
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50 | (4) |
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52 | (2) |
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4.4 Confidence Limits of Prediction |
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54 | (2) |
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4.5 Manufacturers' Data (Warranty Claims) |
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56 | (1) |
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57 | (2) |
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Chapter 5 Interpreting Data and Demonstrating Reliability |
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59 | (14) |
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59 | (1) |
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5.2 Inference and Confidence Levels |
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59 | (2) |
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61 | (3) |
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5.4 Understanding the Method in More Detail |
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64 | (1) |
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5.5 Double-Sided Confidence Limits |
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65 | (1) |
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5.6 Reliability Demonstration |
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65 | (5) |
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70 | (1) |
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5.8 Setting Up Demonstration Tests |
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71 | (2) |
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72 | (1) |
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Chapter 6 Variable Failure Rates and Probability Plotting |
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73 | (14) |
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6.1 The Weibull Distribution |
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73 | (2) |
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6.2 Using the Weibull Method |
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75 | (8) |
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6.2.1 Curve Fitting to Interpret Failure Data |
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75 | (2) |
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77 | (3) |
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6.2.3 Using the COMPARE Computer Tool |
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80 | (1) |
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6.2.4 Significance of the Result |
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81 | (2) |
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6.2.5 Optimum Preventive Replacement |
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83 | (1) |
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6.3 More Complex Cases of the Weibull Distribution |
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83 | (1) |
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84 | (3) |
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85 | (2) |
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PART 3 Predicting Reliability and Risk |
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87 | (96) |
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Chapter 7 Basic Reliability Prediction Theory |
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89 | (16) |
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89 | (1) |
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90 | (3) |
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7.2.1 The Multiplication Rule |
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90 | (1) |
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90 | (1) |
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7.2.3 The Binomial Theorem |
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91 | (1) |
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92 | (1) |
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7.3 Reliability of Series Systems |
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93 | (1) |
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94 | (6) |
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7.4.1 General Types of Redundant Configuration |
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94 | (1) |
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7.4.2 Full Active Redundancy (Without Repair) |
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94 | (2) |
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7.4.3 Partial Active Redundancy (Without Repair) |
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96 | (1) |
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7.4.4 Conditional Active Redundancy |
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97 | (1) |
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98 | (2) |
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100 | (1) |
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7.5 General Features of Redundancy |
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100 | (5) |
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7.5.1 Incremental Improvement |
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100 | (2) |
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7.5.2 Further Comparisons of Redundancy |
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102 | (1) |
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7.5.3 Redundancy and Cost |
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103 | (1) |
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103 | (2) |
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Chapter 8 Methods of Modeling |
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105 | (32) |
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8.1 Block Diagrams and Repairable Systems |
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105 | (9) |
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8.1.1 Reliability Block Diagrams |
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105 | (2) |
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8.1.2 Repairable Systems (Revealed Failures) |
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107 | (3) |
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8.1.3 Repairable Systems (Unrevealed Failures) |
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110 | (2) |
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8.1.4 Systems With Cold Standby Units and Repair |
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112 | (1) |
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8.1.5 Modeling Repairable Systems with Both Revealed and Unrevealed Failures |
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112 | (1) |
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8.1.6 Allowing for imperfect proof tests |
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113 | (1) |
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8.1.7 Conventions for Labeling `Dangerous', `Safe', Revealed and Unrevealed Failures |
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113 | (1) |
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8.2 Common Cause (Dependent) Failure |
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114 | (8) |
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114 | (1) |
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115 | (2) |
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117 | (5) |
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122 | (10) |
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122 | (1) |
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123 | (3) |
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126 | (1) |
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126 | (4) |
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8.3.5 Allowing for Common Cause Failure |
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130 | (1) |
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8.3.6 Fault Tree Analysis in Design |
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130 | (1) |
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8.3.7 A Cautionary Note (Illogical Trees) |
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130 | (2) |
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132 | (5) |
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8.4.1 Why Use Event Trees? |
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132 | (1) |
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8.4.2 The Event Tree Model |
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132 | (2) |
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134 | (1) |
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134 | (1) |
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135 | (2) |
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Chapter 9 Quantifying the Reliability Models |
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137 | (22) |
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9.1 The Reliability Prediction Method |
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137 | (2) |
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9.2 Allowing for Diagnostic Intervals |
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139 | (3) |
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9.2.1 Establishing Diagnostic Coverage |
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139 | (1) |
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9.2.2 Modelling Diagnostic Coverage |
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139 | (1) |
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9.2.3 Partial Stroke Testing |
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140 | (1) |
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9.2.4 Safe Failure Fraction |
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141 | (1) |
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9.3 FMEDA (Failure Mode and Diagnostic Analysis) |
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142 | (3) |
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145 | (7) |
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145 | (1) |
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145 | (1) |
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9.4.3 HEART (Human Error Assessment and Reduction Technique) |
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146 | (2) |
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9.4.4 THERP (Technique for Human Error Rate Prediction) |
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148 | (1) |
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9.4.5 TESEO (Empirical Technique to Estimate Operator Errors) |
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148 | (1) |
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149 | (1) |
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9.4.7 Human Error Probabilities |
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149 | (2) |
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9.4.8 Trends in Rigor of Assessment |
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151 | (1) |
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152 | (6) |
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152 | (2) |
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154 | (4) |
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9.6 Comparing Predictions with Targets |
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158 | (1) |
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158 | (1) |
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Chapter 10 Risk Assessment (QRA) |
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159 | (24) |
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10.1 Frequency and Consequence |
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159 | (1) |
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10.2 Perception of Risk, ALARP and Cost per Life Saved |
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160 | (11) |
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10.2.1 Maximum Tolerable Risk (Individual Risk) |
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160 | (1) |
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10.2.2 Maximum Tolerable Failure Rate |
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161 | (2) |
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10.2.3 ALARP and Cost Per Life Saved |
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163 | (4) |
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167 | (3) |
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10.2.5 Production/Damage Loss |
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170 | (1) |
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10.2.6 Environmental Loss |
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170 | (1) |
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10.3 Hazard Identification |
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171 | (5) |
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171 | (4) |
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175 | (1) |
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10.3.3 HAZAN (Consequence Analysis) |
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175 | (1) |
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176 | (7) |
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176 | (1) |
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10.4.2 Lightning and Thunderstorms |
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176 | (2) |
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178 | (1) |
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179 | (2) |
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10.4.5 Meteorological Factors |
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181 | (1) |
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10.4.6 Other Consequences |
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181 | (2) |
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PART 4 Achieving Reliability and Maintainability |
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183 | (108) |
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Chapter 11 Design and Assurance Techniques |
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185 | (12) |
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11.1 Specifying and Allocating the Requirement |
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185 | (1) |
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186 | (4) |
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11.3 Environmental Stress Protection |
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190 | (1) |
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191 | (2) |
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11.4.1 Types of Failure Mechanism |
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191 | (1) |
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11.4.2 Failures in Semiconductor Components |
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192 | (1) |
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11.4.3 Discrete Components |
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193 | (1) |
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11.5 Complexity and Parts |
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193 | (2) |
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11.5.1 Reduction of Complexity |
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193 | (1) |
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194 | (1) |
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195 | (1) |
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11.6 Burn-In and Screening |
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195 | (1) |
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11.7 Maintenance Strategies |
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196 | (1) |
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Chapter 12 Design Review, Test and Reliability Growth |
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197 | (12) |
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197 | (1) |
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12.2 Categories of Testing |
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198 | (7) |
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12.2.1 Environmental Testing |
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199 | (1) |
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200 | (1) |
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12.2.3 High-Reliability Testing |
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201 | (1) |
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12.2.4 Testing for Packaging and Transport |
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201 | (1) |
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12.2.5 Multiparameter Testing |
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202 | (1) |
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12.2.6 Step-Stress Testing |
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203 | (2) |
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12.3 Reliability Growth Modeling |
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205 | (4) |
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12.3.1 The CUSUM Technique |
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205 | (1) |
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206 | (2) |
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208 | (1) |
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Chapter 13 Field Data Collection and Feedback |
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209 | (12) |
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13.1 Reasons for Data Collection |
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209 | (1) |
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13.2 Information and Difficulties |
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209 | (2) |
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211 | (1) |
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13.4 Spreadsheets and Databases |
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212 | (2) |
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13.5 Best Practice and Recommendations |
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214 | (1) |
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13.6 Analysis and Presentation of Results |
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215 | (1) |
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216 | (1) |
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217 | (1) |
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13.9 Examples of Failure Report Forms |
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217 | (1) |
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13.10 No-Fault-Found (NFF) |
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217 | (4) |
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Chapter 14 Factors Influencing Down Time |
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221 | (24) |
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221 | (8) |
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221 | (1) |
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221 | (1) |
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14.1.3 Built-in Test Equipment |
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222 | (1) |
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14.1.4 Circuit Layout and Hardware Partitioning |
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222 | (1) |
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223 | (1) |
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14.1.6 Displays and Indicators |
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224 | (1) |
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14.1.7 Handling, Human and Ergonomic Factors |
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225 | (1) |
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226 | (1) |
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14.1.9 Interchangeability |
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226 | (1) |
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14.1.10 Least Replaceable Assembly |
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227 | (1) |
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227 | (1) |
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14.1.12 Component Part Selection |
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227 | (1) |
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228 | (1) |
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228 | (1) |
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228 | (1) |
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229 | (1) |
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229 | (1) |
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14.2 Maintenance Strategies and Handbooks |
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229 | (16) |
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14.2.1 Organization of Maintenance Resources |
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230 | (1) |
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14.2.2 Maintenance Procedures |
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231 | (1) |
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14.2.3 Tools and Test Equipment |
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232 | (1) |
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14.2.4 Personnel Considerations |
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233 | (1) |
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14.2.5 Maintenance Manuals |
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234 | (2) |
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14.2.6 Spares Provisioning |
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236 | (6) |
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242 | (1) |
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14.2.8 The User and the Designer |
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242 | (1) |
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14.2.9 Computer Aids to Maintenance |
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243 | (2) |
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Chapter 15 Predicting and Demonstrating Repair Times |
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245 | (14) |
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245 | (9) |
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15.1.1 US Military Handbook 472 -- Procedure 3 |
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246 | (1) |
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15.1.2 Checklist -- Mil 472 Procedure 3 |
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247 | (7) |
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15.1.3 Using a Weighted Sample |
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254 | (1) |
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254 | (5) |
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15.2.1 Demonstration Risks |
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254 | (1) |
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15.2.2 US Military Standard 471A (1973) |
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255 | (2) |
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257 | (2) |
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Chapter 16 Quantified Reliability Centered Maintenance |
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259 | (10) |
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259 | (1) |
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16.2 The QRCM Decision Process |
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260 | (1) |
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16.3 Optimum Replacement (Discard) |
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260 | (3) |
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263 | (2) |
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265 | (1) |
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16.6 Condition Monitoring |
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266 | (3) |
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Chapter 17 Systematic Failures, Especially Software |
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269 | (22) |
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17.1 Random versus Systematic Failures |
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269 | (1) |
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17.2 Software-related Failures |
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270 | (3) |
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17.3 Software Failure Modeling |
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273 | (1) |
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17.4 Software Quality Assurance (Life Cycle Activities) |
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274 | (7) |
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17.4.1 Organization of Software QA |
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275 | (1) |
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17.4.2 Documentation Controls |
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275 | (3) |
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17.4.3 Programming (Coding) Standards |
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278 | (1) |
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17.4.4 Fault-Tolerant Design Features |
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279 | (1) |
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280 | (1) |
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17.4.6 Integration and Test |
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280 | (1) |
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17.5 Modern/Formal Methods |
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281 | (4) |
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17.5.1 Requirements Specification and Design |
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282 | (1) |
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283 | (2) |
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285 | (1) |
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285 | (6) |
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17.6.1 Organization of Software QA |
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285 | (1) |
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17.6.2 Documentation Controls |
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286 | (1) |
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17.6.3 Programming Standards |
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286 | (1) |
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287 | (1) |
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17.6.5 Code Inspections and Walkthroughs |
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288 | (1) |
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17.6.6 Integration and Test |
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289 | (2) |
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PART 5 Legal, Management and Safety Considerations |
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291 | (88) |
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Chapter 18 Project Management and Competence |
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293 | (10) |
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18.1 Setting Objectives and Making Specifications |
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293 | (1) |
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18.2 Planning, Feasibility and Allocation |
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294 | (1) |
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295 | (2) |
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18.4 Responsibilities and Competence |
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297 | (2) |
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18.5 Functional Safety Capability |
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299 | (1) |
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18.6 Standards and Guidance Documents |
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300 | (3) |
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Chapter 19 Contract Clauses and Their Pitfalls |
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303 | (14) |
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303 | (5) |
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304 | (1) |
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305 | (1) |
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19.1.3 Maintenance Support |
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305 | (1) |
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19.1.4 Demonstration and Prediction |
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306 | (1) |
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307 | (1) |
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308 | (2) |
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19.2.1 Reliability and Maintainability Program |
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308 | (1) |
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19.2.2 Reliability and Maintainability Analysis |
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308 | (1) |
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308 | (1) |
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309 | (1) |
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19.2.5 Safety-Related Equipment |
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309 | (1) |
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310 | (1) |
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310 | (1) |
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310 | (1) |
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310 | (1) |
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19.3.4 Quoted Specifications |
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310 | (1) |
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311 | (1) |
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311 | (1) |
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311 | (1) |
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311 | (3) |
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19.4.1 Apportionment of Costs During Guarantee |
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311 | (2) |
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19.4.2 Payment According to Down Time |
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313 | (1) |
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313 | (1) |
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19.5 Subcontracted Reliability Assessments |
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314 | (3) |
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Chapter 20 Product Liability and Safety Legislation |
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317 | (10) |
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20.1 The General Situation |
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317 | (2) |
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317 | (1) |
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318 | (1) |
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318 | (1) |
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319 | (1) |
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319 | (1) |
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319 | (1) |
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319 | (1) |
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20.3 The Consumer Protection Act 1987 |
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320 | (1) |
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320 | (1) |
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20.3.2 Provisions of the Act |
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320 | (1) |
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20.4 Health and Safety at Work Act 1974 |
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321 | (2) |
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321 | (1) |
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321 | (1) |
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321 | (1) |
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321 | (1) |
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20.4.5 European Community Legislation |
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322 | (1) |
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20.4.6 Management of Health and Safety at Work Regulations 1992 |
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322 | (1) |
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322 | (1) |
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323 | (1) |
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20.5 Insurance and Product Recall |
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323 | (4) |
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20.5.1 The Effect of Product Liability Trends |
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323 | (1) |
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20.5.2 Some Critical Areas |
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324 | (1) |
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324 | (1) |
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324 | (3) |
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Chapter 21 Major Incident Legislation |
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327 | (12) |
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21.1 History of Major Incidents |
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327 | (1) |
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21.2 Development of major incident legislation |
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328 | (3) |
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331 | (3) |
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21.4 Offshore Safety Cases |
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334 | (2) |
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336 | (1) |
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337 | (1) |
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21.7 Corporate Manslaughter and Corporate Homicide |
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337 | (2) |
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Chapter 22 Integrity of Safety-Related Systems |
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339 | (1) |
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22 A Safety-Related or Safety-Critical? |
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339 | (14) |
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22.2 Safety-Integrity Levels (SILs) |
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340 | (7) |
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340 | (4) |
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22.2.2 Assessing Equipment Against the Targets |
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344 | (3) |
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22.3 Programable electronic systems (PESs) |
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347 | (1) |
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347 | (3) |
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22.4.1 IEC International Standard 61508 (2010): Functional safety of electrical/electronic/programmable electronic safety--related systems: 7 parts |
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348 | (1) |
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22.4.2 IEC International Standard 61511: Functional safety -- safety instrumented systems for the process industry sector |
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348 | (1) |
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22.4.3 Institution of Gas Engineers and Managers IGEM/SR/15: Programmable equipment in safety-related applications -- 5th edition |
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348 | (1) |
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22.4.4 European Standard EN 50126: Railway applications -- the specification and demonstration of dependability, reliability, maintainability and safety (RAMS) |
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348 | (1) |
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22.4.5 UK Defence Standard 00-56 (Issue 3.0): Safety management requirements for defence systems |
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349 | (1) |
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22.4.6 RTCA DO-178B/(EUROCAE ED-12B): Software considerations in airborne systems and equipment certification |
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349 | (1) |
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22.4.7 Documents related to machinery |
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349 | (1) |
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22.4.8 Other industry sectors |
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350 | (1) |
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22.5 Framework for Certification |
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350 | (3) |
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22.5.1 Self-certification |
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350 | (1) |
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22.5.2 Third-party assessment |
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350 | (1) |
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22.5.3 Use of a Certifying Body |
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351 | (2) |
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Chapter 23 A Case Study: The Datamet Project |
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353 | (6) |
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353 | (1) |
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353 | (3) |
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356 | (1) |
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357 | (1) |
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358 | (1) |
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358 | (1) |
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Chapter 24 A Case Study: Gas Detection System |
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359 | (6) |
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24.1 Safety-Integrity Target |
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359 | (1) |
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24.2 Random Hardware Failures |
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360 | (2) |
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362 | (1) |
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363 | (1) |
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24.5 Life-Cycle Activities |
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364 | (1) |
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24.6 Functional Safety Capability |
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364 | (1) |
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Chapter 25 A Case Study: Pressure Control System |
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365 | (8) |
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25.1 The Unprotected System |
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365 | (1) |
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366 | (1) |
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367 | (1) |
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25.4 Reliability Block Diagram |
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367 | (1) |
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368 | (1) |
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25.6 Quantifying the Model |
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368 | (1) |
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25.7 Proposed Design and Maintenance Modifications |
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369 | (1) |
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25.8 Modeling Common Cause Failure (Pressure Transmitters) |
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369 | (1) |
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25.9 Quantifying the Revised Model |
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370 | (1) |
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370 | (1) |
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25.11 Architectural Constraints |
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371 | (2) |
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Chapter 26 Helicopter Incidents and Risk Assessment |
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373 | (6) |
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26.1 Helicopter Incidents |
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373 | (2) |
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26.2 Risk Assessment -- Floatation Equipment |
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375 | (2) |
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26.2.1 Assessment of the Scenario |
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375 | (1) |
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375 | (2) |
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26.3 Effect of Pilot Experience on Incident Rate |
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377 | (2) |
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379 | (10) |
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A1.1 Terms Related to Failure |
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379 | (2) |
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379 | (1) |
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379 | (1) |
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379 | (1) |
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380 | (1) |
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A1.1.5 Mean Time Between Failures and Mean Time to Fail |
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380 | (1) |
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A1.1.6 Common Cause Failure |
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380 | (1) |
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A1.1.7 Common Mode Failure |
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380 | (1) |
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380 | (1) |
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380 | (1) |
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381 | (1) |
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381 | (1) |
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381 | (1) |
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381 | (1) |
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A1.2.4 Failure Mode and Effect Analysis |
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381 | (1) |
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A1.2.5 FMEDA (Failure Mode Effect and Diagnostic Analysis) |
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381 | (1) |
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A1.2.6 Fault Tree Analysis |
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381 | (1) |
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A1.2.7 Cause Consequence Analysis (Event Trees) |
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381 | (1) |
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A1.2.8 Reliability Growth |
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382 | (1) |
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A1.2.9 Reliability Centered Maintenance |
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382 | (1) |
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A1.3 Maintainability Terms |
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382 | (1) |
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382 | (1) |
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A1.3.2 Mean Time to Repair (MTTR) |
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382 | (1) |
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382 | (1) |
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382 | (1) |
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382 | (1) |
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A1.3.6 Corrective Maintenance |
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383 | (1) |
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A1.3.7 Preventive Maintenance |
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383 | (1) |
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A1.3.8 Least Replaceable Assembly (LRA) |
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383 | (1) |
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A1.3.9 Second-Line Maintenance |
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383 | (1) |
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A1.3.10 Maximum Repair Time |
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383 | (1) |
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A1.4 Terms Associated With Software |
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383 | (2) |
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383 | (1) |
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A1.4.2 Programable Device |
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383 | (1) |
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A1.4.3 High-Level Language |
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383 | (1) |
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384 | (1) |
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384 | (1) |
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A1.4.6 Diagnostic Software |
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384 | (1) |
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384 | (1) |
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384 | (1) |
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384 | (1) |
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384 | (1) |
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384 | (1) |
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385 | (1) |
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A1.4.13 Automatic Test Equipment (ATE) |
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385 | (1) |
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385 | (1) |
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A1.5 Terms Related to Safety |
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385 | (2) |
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385 | (1) |
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385 | (1) |
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385 | (1) |
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385 | (1) |
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385 | (1) |
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386 | (1) |
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A1.5.7 Consequence Analysis |
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386 | (1) |
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A1.5.8 Safe Failure Fraction |
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386 | (1) |
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386 | (1) |
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A1.5.10 Safety-Integrity level |
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386 | (1) |
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A1.5.11 ALARP (As Low as Reasonably Practicable) |
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386 | (1) |
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A1.5.12 Cost Per Life Saved |
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386 | (1) |
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A1.5.13 GDF (Gross Disproportionality Factor) |
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386 | (1) |
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A1.5.14 FAFR (Fatal Accident Frequency) |
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387 | (1) |
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387 | (2) |
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A1.6.1 Availability (Steady State) |
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387 | (1) |
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A1.6.2 Unavailability (PFD) |
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387 | (1) |
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387 | (1) |
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A1.6.4 Confidence Interval |
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387 | (1) |
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387 | (1) |
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387 | (1) |
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387 | (1) |
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388 | (1) |
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388 | (1) |
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388 | (1) |
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388 | (1) |
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388 | (1) |
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388 | (1) |
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388 | (1) |
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388 | (1) |
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Appendix 2 Percentage Points of the Chi-Square Distribution |
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389 | (8) |
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Appendix 3 Microelectronic Failure Rates |
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397 | (2) |
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Appendix 4 General Failure Rates |
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399 | (8) |
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Appendix 5 Failure Mode Percentages |
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407 | (4) |
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Appendix 6 Human Error Probabilities |
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411 | (4) |
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Appendix 7 Fatality Rates |
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415 | (2) |
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Appendix 8 Answers to Exercises |
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417 | (1) |
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417 | (1) |
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417 | (1) |
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418 | (1) |
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418 | (1) |
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419 | (2) |
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420 | (1) |
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421 | (1) |
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422 | (5) |
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422 | (1) |
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25.4 Reliability Block Diagram |
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422 | (1) |
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25.6 Quantifying the Model |
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422 | (1) |
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423 | (1) |
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25.9 Quantifying the revised Model |
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424 | (1) |
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425 | (1) |
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25.11 Architectural Constraints |
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426 | (1) |
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427 | (2) |
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Appendix 10 Scoring Criteria for BETAPLUS Common Cause Model |
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429 | (6) |
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A10.1 Checklist and Scoring for Equipment Containing Programable Electronics |
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429 | (2) |
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A10.2 Checklist and Scoring for Non-Programable Equipment |
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431 | (4) |
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For Programable Electronics |
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433 | (1) |
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For Sensors and Actuators |
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433 | (2) |
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Appendix 11 Example of HAZOF |
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435 | (4) |
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435 | (1) |
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435 | (1) |
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A11.3 Potential Consequences |
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435 | (4) |
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437 | (2) |
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Appendix 12 HAZID Checklist |
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439 | (4) |
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Appendix 13 Markov Analysis of Redundant Systems |
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443 | (6) |
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Appendix 14 Calculating the GDF |
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449 | (8) |
Index |
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457 | |