X, Iec 61882, Hazard And Operability Studies (hazop Studies) – Application Guide 3g3012

AS IEC 61882—2003 IEC 61882:2001

AS IEC 61882

Australian Standard™

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Hazard and operability studies (HAZOP studies)—Application guide

This Australian Standard was prepared by Committee QR-005, Reliability and Maintainability. It was approved on behalf of the Council of Standards Australia on 29 May 2003 and published on 25 July 2003.

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The following are represented on Committee QR-005: AirServices Australia Australian Organisation for Quality Certification Bodies (Australia) Department of Defence (Australia) Institution of Engineers Australia University of New South Wales

Keeping Standards up-to-date Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased. Detailed information about Standards can be found by visiting the Standards Australia web site at www.standards.com.au and looking up the relevant Standard in the on-line catalogue. Alternatively, the printed Catalogue provides information current at 1 January each year, and the monthly magazine, The Global Standard, has a full listing of revisions and amendments published each month. We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. us via email at [email protected], or write to the Chief Executive, Standards Australia International Ltd, GPO Box 5420, Sydney, NSW 2001.

This Standard was issued in draft form for comment as DR 03254.

AS IEC 61882—2003

Australian Standard™ Hazard and operability studies (HAZOP studies)—Application guide

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First published as AS IEC 61882—2003.

COPYRIGHT © Standards Australia International All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher. Published by Standards Australia International Ltd GPO Box 5420, Sydney, NSW 2001, Australia ISBN 0 7337 5433 3

ii

PREFACE This Standard was prepared by the Standards Australia Committee QR-005, Reliability and Maintainability. This Standard is identical with, and has been reproduced, from IEC 61882:2001, Hazard and operability studies (HAZOP studies) — Application guide. The objective of this Standard is to provide a guide for HAZOP studies of systems utilizing the specific set of guide words defined in this document. It also gives guidance on the application of the technique and on the HAZOP study procedure, including definition, preparation, examination sessions and resulting documentation and follow-up. As this Standard is reproduced from an International Standard, the following applies: (a)

Its number does not appear on each page of text and its identity is shown only on the cover and title page.

(b)

In the source text ‘this International Standard’ should read ‘this Australian Standard’.

(c)

A full point should be substituted for a comma when referring to a decimal marker.

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None of the normative references in the source document have been adopted as Australian or Australian/New Zealand Standards.

iii 61882  IEC:2001

–3–

CONTENTS CONTENTS

INTRODUCTION .................................................................................................................... v 1

Scope ............................................................................................................................. 1

2

Normative references ...................................................................................................... 1

3

Definitions....................................................................................................................... 1

4

Principles of HAZOP ....................................................................................................... 2 4.1 4.2 4.3

5

Overview ............................................................................................................... Principles of examination ....................................................................................... Design representation ............................................................................................ 4.3.1 General...................................................................................................... 4.3.2 Design requirements and design intent ...................................................... Applications of HAZOP ...................................................................................................

2 5 6 6 7 7

5.1 5.2 5.3 5.4

6

General.................................................................................................................. 7 Relation to other analysis tools .............................................................................. 8 HAZOP limitations ................................................................................................. 8 Hazard identification studies during different system life cycle phases ................... 9 5.4.1 Concept and definition phase ..................................................................... 9 5.4.2 Design and development phase ................................................................. 9 5.4.3 Manufacturing and installation phase ......................................................... 9 5.4.4 Operation and maintenance phase ............................................................. 9 5.4.5 Decommissioning or disposal phase ......................................................... 10 The HAZOP study procedure ......................................................................................... 10

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6.1 6.2

7

Initiation of the study............................................................................................. 10 Definition of scope and objectives of the study...................................................... 10 6.2.1 Scope of the study .................................................................................... 10 6.2.2 Objectives of the study.............................................................................. 10 6.3 Roles and responsibilities ..................................................................................... 11 6.4 Preparatory work .................................................................................................. 12 6.4.1 General..................................................................................................... 12 6.4.2 Design description .................................................................................... 13 6.4.3 Guide words and deviations ...................................................................... 13 6.5 The examination ................................................................................................... 14 6.6 Documentation...................................................................................................... 18 6.6.1 General..................................................................................................... 18 6.6.2 Styles of recording .................................................................................... 18 6.6.3 Output of the study.................................................................................... 18 6.6.4 Reporting requirements ............................................................................. 19 6.6.5 g off the documentation ................................................................... 19 6.7 Follow-up and responsibility.................................................................................. 19 Audit .............................................................................................................................. 20

iv

Annex A (informative) Methods of reporting ......................................................................... 21 A.1 A.2 A.3 Annex B B.1 B.2 B.3 B.4 B.5 B.6

Reporting options.................................................................................................. 21 HAZOP worksheet ................................................................................................ 21 HAZOP study report.............................................................................................. 22 (informative) Examples of HAZOP ......................................................................... 23 Introductory example ............................................................................................ 23 Procedures ........................................................................................................... 29 Automatic train protection system ......................................................................... 33 B.3.1 The application ......................................................................................... 33 Example involving emergency planning................................................................. 36 Piezo valve control system.................................................................................... 41 Oil vaporizer ......................................................................................................... 47

Bibliography ......................................................................................................................... 52 Table 1 – Basic guide words and their generic meanings....................................................... 5 Table 2 – Guide words relating to clock time and order or sequence ..................................... 6 Table 3 – Examples of deviations and their associated guide words ..................................... 14 Table B.1 – Example HAZOP worksheet for introductory example ........................................ 25 Table B.2 – Example HAZOP worksheet for procedures example ......................................... 30 Table B.3 – Example HAZOP worksheet for automatic train protection system ..................... 34 Table B.4 – Example HAZOP worksheet for emergency planning ......................................... 37 Table B.5 – Example HAZOP worksheet for piezo valve control system ............................... 44 Table B.6 – Example HAZOP worksheet for oil vaporizer...................................................... 48 Figure 1 – The HAZOP study procedure ................................................................................ 4 Figure 2a – Flow chart of the HAZOP examination procedure – Element first sequence ...... 16 Figure 2b – Flow chart of the HAZOP examination procedure – Guide word first sequence ............................................................................................................................. 17 Figure B.1 – Simple flow sheet ............................................................................................. 24

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Figure B.2 – Train-carried ATP equipment............................................................................ 33 Figure B.3 – Piezo valve control system ............................................................................... 42 Figure B.4 – Oil vaporizer..................................................................................................... 47

v 61882  IEC:2001

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INTRODUCTION INTRODUCTION The purpose of this standard is to describe the principles and procedures of Hazard and Operability (HAZOP) Studies. HAZOP is a structured and systematic technique for examining a defined system, with the objective of: •

identifying potential hazards in the system. The hazards involved may include both those essentially relevant only to the immediate area of the system and those with a much wider sphere of influence, e.g. some environmental hazards;

•

identifying potential operability problems with the system and in particular identifying causes of operational disturbances and production deviations likely to lead to nonconforming products.

An important benefit of HAZOP studies is that the resulting knowledge, obtained by identifying potential hazards and operability problems in a structured and systematic manner, is of great assistance in determining appropriate remedial measures. A characteristic feature of a HAZOP study is the ”examination session” during which a multidisciplinary team under the guidance of a study leader systematically examines all relevant parts of a design or system. It identifies deviations from the system design intent utilizing a core set of guide words. The technique aims to stimulate the imagination of participants in a systematic way to identify hazards and operability problems. HAZOP should be seen as an enhancement to sound design using experience-based approaches such as codes of practice rather than a substitute for such approaches. There are many different tools and techniques available for the identification of potential hazards and operability problems, ranging from Checklists, Fault Modes and Effects Analysis (FMEA), Fault Tree Analysis (FTA) to HAZOP. Some techniques, such as Checklists and What-If/analysis, can be used early in the system life cycle when little information is available, or in later phases if a less detailed analysis is needed. HAZOP studies require more details regarding the systems under consideration, but produce more comprehensive information on hazards and errors in the system design.

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The term HAZOP has been often associated, in a generic sense, with some other hazard identification techniques (e.g. checklist HAZOP, HAZOP 1 or 2, knowledge-based HAZOP). The use of the term with such techniques is considered to be inappropriate and is specifically excluded from this document. Before commencing a HAZOP study, it should be confirmed that it is the most appropriate technique (either individually or in combination with other techniques) for the task in hand. In making this judgement, consideration should be given to the purpose of the study, the possible severity of any consequences, the appropriate level of detail, the availability of relevant data and resources. This standard has been developed to provide guidance across many industries and types of system. There are more specific standards and guides within some industries, notably the process industries where the technique originated, which establish preferred methods of application for these industries. For details see the bibliography at the end of this text.

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vi

NOTES

1 AUSTRALIAN STANDARD 61882  IEC:2001

– 11 –

HAZARD AND OPERABILITY STUDIES (HAZOP STUDIES) – APPLICATION GUIDE

1

Scope

This International Standard provides a guide for HAZOP studies of systems utilizing the specific set of guide words defined in this document. It also gives guidance on application of the technique and on the HAZOP study procedure, including definition, preparation, examination sessions and resulting documentation and follow-up. Documentation, as well as a broad set of examples encoming various industries, illustrating HAZOP examination is also provided.

2

Normative references

The following normative documents contain provisions which, through reference in this text, constitute provisions of this International Standard. For dated references, subsequent amendments to, or revisions of, any of these publications do not apply. However, parties to agreements based on this International Standard are encouraged to investigate the possibility of applying the most recent editions of the normative documents indicated below. For undated references, the latest edition of the normative document referred to applies. of IEC and ISO maintain s of currently valid International Standards. IEC 60300-3-9, Dependability management – Part 3: Application guide – Section 9: Risk analysis of technological systems IEC 60812, Analysis techniques for system reliability – Procedure for failure mode and effects analysis (FMEA) IEC 61025, Fault tree analysis (FTA)

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IEC 61160, Formal design review

3

Definitions

For the purposes of this International Standard, definitions contained in IEC 60050(191) as well as the following and definitions apply: 3.1 characteristic qualitative or quantitative property of an element NOTE

Examples of characteristics are pressure, temperature, voltage.

3.2 design intent designer’s desired, or specified range of behaviour for elements and characteristics

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AS IEC 61882-2003 Hazard and operability studies (HAZOP studies) - Application guide

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