Unit Description and General Aims

The objective in presenting this unit is to impart to students the principles and application of the safety systems which are engineered to meet the demanding safety standards in the industry. The subject matter covered in this unit will include: hazard identification and protection – particularly in the context of international standards, certification and approvals; safety instrument and emergency shutdown principles and processes; and, the principles and practices of Hazard and Operability Studies (HAZOPS) – particularly in the context of managing safety in a team environment using the Six Level Life Cycle Method.

Learning Outcomes

On successful completion of this Unit, students are expected to be able to:

1. Identify risks in hazardous areas.
   Bloom's Level 4
2. Evaluate the hazard protection requirements and the principles of hazard management.
   Bloom's Level 5
3. Apply the relevant standards, certification, and approvals for hazardous areas.
   Bloom's Level 3
4. Perform risk assessment for potentially hazardous areas.
   Bloom's Level 5
5. Assess the safety instrumentation and emergency shutdown safety requirements for machines and processes.
   Bloom's Level 4
6. Perform HAZOP analysis.
   Bloom's Level 6

Student assessment

Overall requirements: Students must achieve a result of 50% or above in the exam itself to pass the exam and must pass the exam to be able to pass the unit. An overall final unit score of 50% or above must be achieved to pass the unit once all assessment, including the exam, has been completed.

Prescribed and Recommended Readings

Textbook

P. Gruhn, H. L. Cheddie, Safety Instrumented Systems - Design, Analysis, and Justification, 2nd Edition. ISA, 2006 - ISBN 978-1601193346 (available from the EIT eLibrary)

Reference

IDC Technologies, Practical HAZOPS, Trips and Alarms, IDC Technologies, Perth.
IDC Technologies, Practical HAZOPS for Engineers and Technicians, IDC Technologies, Perth.
IDC Technologies, Practical Hazardous Areas for Engineers and Technicians, IDC Technologies, Perth.

Journal, website

N/a

Notes and Reference Texts

Knovel library: http://app.knovel.com

IDC notes and Reference texts as advised

Other material advised during the lectures

Unit Content

Topic 1

Introduction to Hazard Identification and Protection

1. Hazardous areas - introduction (material properties, explosions)
2. Risk assessment and equipment classification (zone concept)
3. Standards (British, European, North American, International)
4. Certification and approvals (Principles of IEx, EEx, AEx)

Topics 2 and 3

Hazard Protection

1. Protection in hazardous areas (theory, definitions)
2. Use of a range of protection techniques (encapsulation, pressurization, oil-immersion, and etc.)
3. Installation (requirements, earthing, bonding, operation, tools and test equipment)
4. Inspection and maintenance (use of tools and test equipment)

Topics 4 and 5

Safety Instrumentation and Emergency Shutdown Safety Requirements of Machines and Processes – Part 1

1. Management of safety instrumented systems (risk reduction, Safety Integrity Levels (SIL))
2. Design and performance of safety control systems
3. Scope, application, and requirements of IEC61508 and IEC61511
4. Features of safety PLCs
5. Safety Life Cycle (hazard analysis, risk assessment, safety specification)
6. Risk reduction (demand, continuous)
7. SIL targets (LOPA, risk graphs)
8. Fault tolerance and redundancy

Topics 6 and 7

Safety Instrumentation and Emergency Shutdown Safety Requirements of Machines and Processes – Part 2

1. Essential features of field devices
2. Equipment selection and certification
3. Safety software systems
4. Reliability analysis
5. Diagnostic and proof testing
6. Safety certified and smart instruments

Topics 8 and 9

HAZOPS – Part 1

1. HAZOPS (principles and practices)
2. Hazard studies and regulations
3. Six Level Life Cycle Model
4. Managing safety in a team environment (safety teams, team leaders, reporting, and recording)

Topics 10 and 11

HAZOPS – Part 2

1. Typical SIS design features and application examples
2. Risk assessment and risk matrix
3. Risk reduction and protection layers
4. Hazard analysis methods (FMEA, FTA, and LOPA)

Topic 12

Project and Unit Review

In the final week, students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

Software/Hardware Used

Software

• OSHA's Hazard Identification Training Tool 
• Software: OSHA's Hazard Identification Training Tool 
• Version: N/A
• Instructions:  Remote Lab 13
• Additional resources or files: N/A

Hardware

• N/A

Unit Changes Based on Student Feedback