HAZOP_GUIDE_BRITISH_STANDARD_IEC_61882_2001

A hazop study is carried out to examine ways in which

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Unformatted text preview: ; g) remove blended mixture into 3 ´ 5 k g bags; h) wash out blender; i) add 50 l of resin to mixing vessel; j) add 0,5 kg of hardener to mixing vessel; k) add 5 kg of mixed powder (“A” and “B”); l) stir for 1 min; m) pour mixture into moulds within 5 min. A HAZOP study is carried out to examine ways in which below-specification material might be produced. As a procedural sequence, the parts under examination during the HAZOP process are the relevant sequential instructions. Extracts from a HAZOP study of the sequence are given in Table B.2. A “by exception” reporting system has been employed. 34 43 43 © BSI 28 1002−80ISB © 1002−80 ISB August 2001 Licensed Copy: Puan Ms. Norhayati, Petroliam Nasional Berhad 4397000, 01 October 2003, Uncontrolled Copy, (c) BSI STUDY TITLE: P ROCEDURES SHEET : 1 of 3 PROCEDURE TITLE: S MALL SCALE MANUFACTURE OF COMPONENT X REVISION No. : DATE : TEAM COMPOSITION: B K, JS, LE, PA INSTRUCTION 1: T AKE 12 kg of POWDER 'A' PART CONSIDERED: Element 1 Take powder A NO 2 Take powder A 3 Take powder A 4 Take 12 kg MORE 5 Guide word Possible causes Consequences Safeguards Comments No 'A' taken Operator error Final material will not set Operator should see mass in blender is much too small. Colour would also be far too bright Complete absence of material 'A' charge not considered credible AS WELL AS Additional material is added with 'A' Material 'A' is contaminated with impurities Colour specification may not be met. Final mix may not set properly Sample from all deliveries of 'A' are tested prior to use Check quality assurance procedures at manufacturer ’ s OTHER THAN Material other than 'A' is taken Operator uses a Mix cannot be used. bag of wrong Financial loss material Only bags of 'A', 'B' and blend to be kept in blender area Check house-keepin g BK standards on a weekly basis. Consider having uniquely colored bags for each raw material and blended product Too much 'A' taken Faulty weighing/ Operator error Colour specification will not be met Check weighing carried out weekly. JS to emphasize to operators the need for accurate weighing JS Faulty weighing/ Operator error As above As above JS Take 12 kg LESS Deviation Too little 'A' taken Weighing machine serviced every 6 months As above Actions required Action allocated to None BK – 96 – No. MEETING DATE: 6 8812 E I2:C100 © BSI 28 August 1002−80 ISB © 2001 Table B.2 – E xample HAZOP worksheet for procedures example BS IEC 61882:2001 35 53 Licensed Copy: Puan Ms. Norhayati, Petroliam Nasional Berhad 4397000, 01 October 2003, Uncontrolled Copy, (c) BSI STUDY TITLE : PROCEDURES SHEET : 2 of 3 PROCEDURE TITLE: S MALL SCALE MANUFACTURE OF COMPONENT X REVISION No: DATE: TEAM COMPOSITION: B K, JS, LE, PA INSTRUCTION 2: P LACE IN BLENDER PART CONSIDERED: No. Element Guide word MEETING DATE: Deviation Possible causes 6 Blender OTHER THAN Material 'A' is placed other than in the correct blender Operator error 7 Add hardener NO No hardener is added Operator error Consequences Add hardener AS WELL AS OTHER THAN Additional material is added with hardener Material other than hardener is added Hardener is contaminated with impurities Actions required Action allocated to Final mix will not set properly Final mix may not be usable Review the position if there are proposals to fit additional blenders BK Operator has to sign batch sheet confirming hardener has been added. Mold testing of strength of final item Review error rate to see if additional safeguards are required BK Quality assurance guarantees from supplier None – 17 – 9 Add hardener Comments There is currently only one blender Financial loss 8 Safeguards Sample testing on all deliveries Final mix will not be usable 6 8812 E BS IEC 61882:2001 I2:C100 36 63 Table B.2 ( continued) Physical segregation of different hardeners Operator checks If proposal to order pre-weighed, bags of hardener is adopted, scope for mix-up is further reduced Await outcome of hardener. Purchasin g enquiry and review JS © BSI 28 August 2001 1002−80 ISB © Licensed Copy: Puan Ms. Norhayati, Petroliam Nasional Berhad 4397000, 01 October 2003, Uncontrolled Copy, (c) BSI S TUDY TITLE : PROCEDURES SHEET : 3 of 3 PROCEDURE TITLE: S MALL SCALE MANUFACTURE OF COMPONENT X REVISION No: DATE: TEAM COMPOSITION: B K, JS, LE, PA INSTRUCTION 2: P LACE IN BLENDER PART CONSIDERED: No. 10 11 Element Guide word Add 0,5 kg MORE Add 0,5 kg LESS MEETING DATE: Deviation Possible causes Too much hardener is added Faulty weighing/ Too little hardener As above Operator error Consequences Safeguards Comments Actions required Action allocated to Component will be too brittle; may fail catastrophically Weekly check weighing. Weighing machine serviced every 6 months Safeguards not considered adequate Investi g ate possibility JS of obtaining hardener in pre-wei g hed 0,5 k g bags. Sample checks on each delivery Final mix will not set properly As above As above As above 6 8812 E I2:C100 © BSI 28 August 1002−80 ISB © 2001 Table B.2 ( continued) JS Financial loss – 37 – BS IEC 61882:2001 37 73 BS IEC 61882:2001 6 1882 Ó I EC:2001 B.3 – 39 – Automatic train protection system Th...
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