feat: IACE 28 operational hazard patterns (HP066-HP093)

Fault Clearing (HP066-HP072): Jammed parts releasing, hose bursts,
unexpected restart, stored energy, intervention in running machine,
material jam, falling parts during fault clearing

Maintenance (HP073-HP079): Missing LOTO, falls from platforms,
hot parts contact, hazardous substances, electric shock, ergonomic
access, uncontrolled hydraulic lowering

Setup/Changeover (HP080-HP085): Crushing during tool change, burns
from hot tools, heavy tool drops, unintended stroke in setup mode,
wrong parameters, test cycle hits personnel

Transport/Install/Decommission (HP086-HP090): Machine tipping,
crushing during installation, uncontrolled commissioning movement,
residual media, sharp edges

Cleaning (HP091-HP093): Slipping, chemical exposure, draw-in

Lifecycle keywords expanded: werkzeugwechsel, stoerung, fehlersuche,
klemm, blockier, stau → trigger fault_clearing phase patterns

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>

ai-compliance-sdk/internal/iace/hazard_patterns_operational.go

@@ -0,0 +1,275 @@
+package iace
+
+// GetOperationalHazardPatterns returns patterns for non-normal operating states:
+// fault clearing, maintenance, setup, changeover, LOTO, stored energy.
+// These hazards are lifecycle-phase-specific — they fire only when the relevant
+// phases are present in the project scope.
+func GetOperationalHazardPatterns() []HazardPattern {
+	return []HazardPattern{
+		// ================================================================
+		// Störungsbeseitigung / Fault Clearing (HP066-HP072)
+		// ================================================================
+		{
+			ID: "HP066", NameDE: "Verklemmung loest sich unkontrolliert", NameEN: "Jammed part releases uncontrolled",
+			RequiredComponentTags: []string{"moving_part", "high_force"},
+			RequiredLifecycles:    []string{"fault_clearing", "maintenance"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M001", "M054"},
+			Priority: 94,
+			RequiresExpertCalculation: true,
+			ExpertHintDE: "Energiefreischaltung (LOTO) vor manuellen Eingriffen zwingend erforderlich.",
+		},
+		{
+			ID: "HP067", NameDE: "Schlauch platzt unter Druck", NameEN: "Hose bursts under pressure",
+			RequiredComponentTags: []string{"hydraulic_part", "high_pressure"},
+			RequiredLifecycles:    []string{"normal_operation", "fault_clearing"},
+			GeneratedHazardCats:   []string{"pneumatic_hydraulic"},
+			SuggestedMeasureIDs:   []string{"M131", "M054"},
+			Priority: 92,
+			ExpertHintDE: "Schlauch-Fangvorrichtungen und Druckentlastung vor Wartung vorsehen.",
+		},
+		{
+			ID: "HP068", NameDE: "Unerwarteter Wiederanlauf nach Stoerung", NameEN: "Unexpected restart after fault",
+			RequiredComponentTags: []string{"moving_part", "programmable"},
+			RequiredLifecycles:    []string{"fault_clearing"},
+			GeneratedHazardCats:   []string{"mechanical_hazard", "safety_function_failure"},
+			SuggestedMeasureIDs:   []string{"M106", "M054"},
+			Priority: 96,
+			RequiresExpertCalculation: true,
+			ExpertHintDE: "Wiederanlaufsperre mit manueller Quittierung erforderlich. SIL/PL-Nachweis.",
+		},
+		{
+			ID: "HP069", NameDE: "Restenergie nach Abschaltung (gespeichert)", NameEN: "Residual stored energy after shutdown",
+			RequiredComponentTags: []string{"stored_energy"},
+			RequiredLifecycles:    []string{"maintenance", "fault_clearing"},
+			GeneratedHazardCats:   []string{"mechanical_hazard", "electrical_hazard"},
+			SuggestedMeasureIDs:   []string{"M054", "M001"},
+			Priority: 93,
+			ExpertHintDE: "Energiefreischaltung, Wartezeit und Messung vor Beginn der Arbeiten.",
+		},
+		{
+			ID: "HP070", NameDE: "Eingriff in laufende Maschine bei Stoerung", NameEN: "Intervention in running machine during fault",
+			RequiredComponentTags: []string{"moving_part"},
+			RequiredLifecycles:    []string{"fault_clearing"},
+			ExcludedComponentTags: []string{"interlocked"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M005", "M051"},
+			Priority: 97,
+			ExpertHintDE: "Betriebsartenwahlschalter mit reduzierter Geschwindigkeit fuer Stoerungsbeseitigung.",
+		},
+		{
+			ID: "HP071", NameDE: "Materialstau loest sich schlagartig", NameEN: "Material jam releases suddenly",
+			RequiredComponentTags: []string{"moving_part", "gravity_risk"},
+			RequiredLifecycles:    []string{"fault_clearing"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M001", "M054"},
+			Priority: 88,
+		},
+		{
+			ID: "HP072", NameDE: "Herabfallende Teile bei Stoerungsbeseitigung", NameEN: "Falling parts during fault clearing",
+			RequiredComponentTags: []string{"gravity_risk"},
+			RequiredLifecycles:    []string{"fault_clearing", "maintenance"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M051", "M141"},
+			Priority: 82,
+		},
+
+		// ================================================================
+		// Wartung / Instandhaltung (HP073-HP079)
+		// ================================================================
+		{
+			ID: "HP073", NameDE: "Wartung ohne LOTO (Lockout/Tagout)", NameEN: "Maintenance without LOTO",
+			RequiredComponentTags: []string{"moving_part"},
+			RequiredLifecycles:    []string{"maintenance"},
+			GeneratedHazardCats:   []string{"maintenance_hazard"},
+			SuggestedMeasureIDs:   []string{"M054"},
+			Priority: 96,
+			RequiresExpertCalculation: true,
+			ExpertHintDE: "LOTO-Verfahren (Lockout/Tagout) fuer alle Energiequellen definieren und schulen.",
+		},
+		{
+			ID: "HP074", NameDE: "Sturz von Wartungsbuehne / Leiter", NameEN: "Fall from maintenance platform / ladder",
+			RequiredComponentTags: []string{"structural_part"},
+			RequiredLifecycles:    []string{"maintenance", "cleaning"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M051"},
+			Priority: 78,
+		},
+		{
+			ID: "HP075", NameDE: "Kontakt mit heissen Teilen bei Wartung", NameEN: "Contact with hot parts during maintenance",
+			RequiredComponentTags: []string{"high_temperature"},
+			RequiredLifecycles:    []string{"maintenance"},
+			GeneratedHazardCats:   []string{"thermal_hazard"},
+			SuggestedMeasureIDs:   []string{"M054", "M141"},
+			Priority: 80,
+			ExpertHintDE: "Abkuehlzeit definieren. Temperaturanzeige oder -messung vor Arbeitsbeginn.",
+		},
+		{
+			ID: "HP076", NameDE: "Kontakt mit Gefahrstoffen bei Wartung", NameEN: "Contact with hazardous substances during maintenance",
+			RequiredComponentTags: []string{"chemical_risk"},
+			RequiredLifecycles:    []string{"maintenance", "cleaning"},
+			GeneratedHazardCats:   []string{"material_environmental"},
+			SuggestedMeasureIDs:   []string{"M141"},
+			Priority: 75,
+		},
+		{
+			ID: "HP077", NameDE: "Elektrischer Schlag bei Wartungsarbeiten", NameEN: "Electric shock during maintenance",
+			RequiredComponentTags: []string{"high_voltage"},
+			RequiredLifecycles:    []string{"maintenance", "fault_clearing"},
+			GeneratedHazardCats:   []string{"electrical_hazard"},
+			SuggestedMeasureIDs:   []string{"M054"},
+			Priority: 95,
+			RequiresExpertCalculation: true,
+			ExpertHintDE: "Freischaltung, Sicherung gegen Wiedereinschalten, Spannungsfreiheit feststellen.",
+		},
+		{
+			ID: "HP078", NameDE: "Ergonomische Belastung bei Wartungszugang", NameEN: "Ergonomic strain at maintenance access",
+			RequiredComponentTags: []string{"structural_part"},
+			RequiredLifecycles:    []string{"maintenance"},
+			GeneratedHazardCats:   []string{"ergonomic"},
+			SuggestedMeasureIDs:   []string{"M141"},
+			Priority: 55,
+		},
+		{
+			ID: "HP079", NameDE: "Unkontrolliertes Absenken hydraulischer Last", NameEN: "Uncontrolled lowering of hydraulic load",
+			RequiredComponentTags: []string{"hydraulic_part", "gravity_risk"},
+			RequiredLifecycles:    []string{"maintenance", "fault_clearing"},
+			GeneratedHazardCats:   []string{"pneumatic_hydraulic", "mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M131", "M054"},
+			Priority: 94,
+			ExpertHintDE: "Mechanische Absturzsicherung oder Abstuetzung vor Beginn der Arbeiten.",
+		},
+
+		// ================================================================
+		// Einrichten / Umruesten / Werkzeugwechsel (HP080-HP085)
+		// ================================================================
+		{
+			ID: "HP080", NameDE: "Quetschen bei Werkzeugwechsel", NameEN: "Crushing during tool change",
+			RequiredComponentTags: []string{"crush_point", "high_force"},
+			RequiredLifecycles:    []string{"changeover", "setup"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M001", "M054"},
+			Priority: 92,
+			ExpertHintDE: "Werkzeugwechsel nur bei gesichertem Stossel/Stempel. LOTO erforderlich.",
+		},
+		{
+			ID: "HP081", NameDE: "Verbrennung bei Werkzeugausbau (heiss)", NameEN: "Burns during hot tool removal",
+			RequiredComponentTags: []string{"high_temperature"},
+			RequiredLifecycles:    []string{"changeover"},
+			GeneratedHazardCats:   []string{"thermal_hazard"},
+			SuggestedMeasureIDs:   []string{"M141"},
+			Priority: 78,
+			ExpertHintDE: "Abkuehlzeit einhalten. Schutzhandschuhe verwenden.",
+		},
+		{
+			ID: "HP082", NameDE: "Schweres Werkzeug faellt bei Wechsel", NameEN: "Heavy tool drops during change",
+			RequiredComponentTags: []string{"gravity_risk", "high_force"},
+			RequiredLifecycles:    []string{"changeover"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M051"},
+			Priority: 85,
+			ExpertHintDE: "Hebezeug fuer Werkzeuge ueber 25 kg verwenden.",
+		},
+		{
+			ID: "HP083", NameDE: "Unbeabsichtigter Hub bei Einrichtbetrieb", NameEN: "Unintended stroke in setup mode",
+			RequiredComponentTags: []string{"moving_part", "crush_point"},
+			RequiredLifecycles:    []string{"setup"},
+			GeneratedHazardCats:   []string{"mechanical_hazard", "safety_function_failure"},
+			SuggestedMeasureIDs:   []string{"M106"},
+			Priority: 94,
+			RequiresExpertCalculation: true,
+			ExpertHintDE: "Einrichtbetrieb nur mit reduzierter Geschwindigkeit und Zweihandschaltung.",
+		},
+		{
+			ID: "HP084", NameDE: "Falsche Parametereinstellung nach Umruestung", NameEN: "Wrong parameters after changeover",
+			RequiredComponentTags: []string{"programmable"},
+			RequiredLifecycles:    []string{"changeover", "setup"},
+			GeneratedHazardCats:   []string{"safety_function_failure"},
+			SuggestedMeasureIDs:   []string{"M106"},
+			Priority: 82,
+			ExpertHintDE: "Parameterverifikation nach jedem Werkzeugwechsel. Checkliste verwenden.",
+		},
+		{
+			ID: "HP085", NameDE: "Testzyklus trifft Einrichter", NameEN: "Test cycle hits setup personnel",
+			RequiredComponentTags: []string{"moving_part", "crush_point"},
+			RequiredLifecycles:    []string{"setup", "commissioning"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M005", "M106"},
+			Priority: 90,
+			ExpertHintDE: "Schutztuer geschlossen bei Testzyklen. Alternativ: Tippbetrieb mit Zustimmtaster.",
+		},
+
+		// ================================================================
+		// Transport / Montage / Demontage (HP086-HP090)
+		// ================================================================
+		{
+			ID: "HP086", NameDE: "Kippen der Maschine beim Transport", NameEN: "Machine tipping during transport",
+			RequiredComponentTags: []string{"structural_part"},
+			RequiredLifecycles:    []string{"transport"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M051"},
+			Priority: 85,
+		},
+		{
+			ID: "HP087", NameDE: "Quetschen bei Montage/Aufstellung", NameEN: "Crushing during installation",
+			RequiredComponentTags: []string{"high_force", "gravity_risk"},
+			RequiredLifecycles:    []string{"assembly"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M051"},
+			Priority: 82,
+		},
+		{
+			ID: "HP088", NameDE: "Unkontrollierte Bewegung bei Inbetriebnahme", NameEN: "Uncontrolled movement during commissioning",
+			RequiredComponentTags: []string{"moving_part", "programmable"},
+			RequiredLifecycles:    []string{"commissioning"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M005", "M106"},
+			Priority: 90,
+		},
+		{
+			ID: "HP089", NameDE: "Restmedien bei Demontage (Oel, Gas, Druck)", NameEN: "Residual media during dismantling",
+			RequiredComponentTags: []string{"hydraulic_part"},
+			RequiredLifecycles:    []string{"decommissioning", "disposal"},
+			GeneratedHazardCats:   []string{"material_environmental", "pneumatic_hydraulic"},
+			SuggestedMeasureIDs:   []string{"M054"},
+			Priority: 75,
+		},
+		{
+			ID: "HP090", NameDE: "Scharfe Kanten bei Demontage", NameEN: "Sharp edges during dismantling",
+			RequiredComponentTags: []string{"cutting_part"},
+			RequiredLifecycles:    []string{"decommissioning", "disposal"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M141"},
+			Priority: 60,
+		},
+
+		// ================================================================
+		// Reinigung (HP091-HP093)
+		// ================================================================
+		{
+			ID: "HP091", NameDE: "Ausrutschen auf nassem/oeligem Boden", NameEN: "Slipping on wet/oily floor",
+			RequiredComponentTags: []string{"chemical_risk"},
+			RequiredLifecycles:    []string{"cleaning", "normal_operation"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M141"},
+			Priority: 65,
+		},
+		{
+			ID: "HP092", NameDE: "Chemische Exposition bei Reinigung", NameEN: "Chemical exposure during cleaning",
+			RequiredComponentTags: []string{"chemical_risk"},
+			RequiredLifecycles:    []string{"cleaning"},
+			GeneratedHazardCats:   []string{"material_environmental"},
+			SuggestedMeasureIDs:   []string{"M141"},
+			Priority: 70,
+		},
+		{
+			ID: "HP093", NameDE: "Einziehen in rotierende Teile bei Reinigung", NameEN: "Draw-in by rotating parts during cleaning",
+			RequiredComponentTags: []string{"rotating_part"},
+			RequiredLifecycles:    []string{"cleaning"},
+			ExcludedComponentTags: []string{"interlocked"},
+			GeneratedHazardCats:   []string{"mechanical_hazard"},
+			SuggestedMeasureIDs:   []string{"M001", "M054"},
+			Priority: 88,
+		},
+	}
+}

ai-compliance-sdk/internal/iace/narrative_parser.go

@@ -49,20 +49,28 @@ var techSpecPattern = regexp.MustCompile(`(\d[\d.,]*)\s*(kN|Tonnen|tonnen|kJ|kW|
 var lifecycleKeywords = map[string]string{
 	"betrieb":            "normal_operation",
 	"normalbetrieb":      "normal_operation",
-	"automatikbetrieb":"auto_operation",
+	"automatikbetrieb":   "auto_operation",
 	"einricht":           "setup",
 	"umruest":            "changeover",
+	"werkzeugwechsel":    "changeover",
 	"wartung":            "maintenance",
 	"instandhalt":        "maintenance",
 	"instandsetz":        "repair",
 	"reinig":             "cleaning",
 	"transport":          "transport",
 	"montage":            "assembly",
+	"installation":       "assembly",
 	"inbetriebnahme":     "commissioning",
 	"ausserbetriebnahme": "decommissioning",
 	"demontage":          "disposal",
+	"entsorgung":         "disposal",
 	"reparatur":          "repair",
-	"stoerungsbeseitig":"fault_clearing",
+	"stoerungsbeseitig":  "fault_clearing",
+	"stoerung":           "fault_clearing",
+	"fehlersuche":        "fault_clearing",
+	"klemm":              "fault_clearing",
+	"blockier":           "fault_clearing",
+	"stau":               "fault_clearing",
 }
 
 // roleKeywords maps German text patterns to role IDs.

ai-compliance-sdk/internal/iace/pattern_engine.go

@@ -59,6 +59,7 @@ func NewPatternEngine() *PatternEngine {
 	patterns = append(patterns, GetExtendedHazardPatterns()...) // HP045+ from rule library
 	patterns = append(patterns, GetPressHazardPatterns()...)    // HP045-HP058 press-specific
 	patterns = append(patterns, GetCobotHazardPatterns()...)    // HP059-HP065 cobot-specific
+	patterns = append(patterns, GetOperationalHazardPatterns()...) // HP066-HP093 operational states
 	return &PatternEngine{
 		resolver: NewTagResolver(),
 		patterns: patterns,