Sandia National Laboratories (Sandia) has refined a process for develo
ping inherently safer system designs based on methods used by Sandia t
o design detonation safety into nuclear weapons. The process was creat
ed when Sandia realized that standard engineering practices did not pr
ovide the level of safety assurance necessary for nuclear weapon opera
tions, with their potential for catastrophic accidents. A systematic a
pproach, which relies on mutually supportive design principles integra
ted through fundamental physical principles, was developed to ensure a
predictably safe system response under a variety of operational and a
ccident based stresses. Robust, safe system designs result from this t
hematic approach to safety, minimizing the number of safety critical f
eatures. This safety assurance process has two profound benefits: the
process avoids the need to understand or limit the ultimate intensity
of off-normal environments and it avoids the requirement to analyze an
d test a large array of accident environment scenarios (e.g., directio
nal threats, sequencing of environments, time races, etc.) to demonstr
ate conformance to all safety requirements.