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MAJOR HAZARDS CONTROL. Direktorat Pengawasan Norma K3 Kemenakertrans. MAJOR HAZARD. Danger of large accidents, with consequences not only on the plant site, but also in the surroundings : Many dead or wounded Heavy damage to buildings Wide and unfavorable publicity: press, radio,TV - PowerPoint PPT Presentation
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MAJOR HAZARDS CONTROL
Direktorat Pengawasan Norma K3
Kemenakertrans
MAJOR HAZARDDanger of large accidents, with consequences not only on the plant site, but also in the surroundings : Many dead or wounded Heavy damage to buildings Wide and unfavorable publicity: press, radio,TV Emotional public reactions Serious consequences for the company involved :
Production loss Investigation Insurance procedures Additional safety requirements Shutdown, perhaps : PERMANENT
MAJOR ACCIDENT
A major accident is defined in the regulation as :
“A sudden occurrence at facility causing
serious danger or harm to :
- a relevant person or
- an at risk community or
- property or
- the environment
whether the danger or harm occurs immediately
or at a later time”.(Australian Government – Comcare)
HARMFUL EFFECT ARISING FROM MAJOR CHEMICAL HAZARDS
1) DEATHS – immediate and delayed
2) PHYSICAL INJURIES – disabling and non disabling
3) MENTAL INJURIES – short term or long term
4) SOCIAL TRAUMA – short term or long term
5) DISRUPTION OF PEOPLE’S WAY OF LIFE – short term or long term
6) ENVIRONMENT DAMAGE – short term or long term
7) FINANCIAL LOSS; property damage; consequential loss
INCIDENT BHOPAL,INDIA (3/12/84)
Nature of occurrence : runaway reaction in storage tank released ca. 30 tons of MIC
Fatalities : Immediate : > 2000; delayed : ?? Physical injuries : + 200.000; disabled : ?? Mental injuries : extreme shock & panic,
prolonged & extreme anxiety Disruption of people’s way of live : ?? Environmental damage : ?? Financial loss : property damage £ 100 millions
INCIDENT MEXICO CITY (19/11/84)
Nature of occurrence : 18 hours conflagration of ca.6000 tons of LPG
Fatalities : Immediate : > 500; delayed : ?? Physical injuries : 7097; disabled : 100 Mental injuries : severe shock & panic Disruption of people’s way of live : 39.000
homeless or evacuated; hundreds of houses up to 300 meters destroyed
Environmental damage : ?? Financial loss : property damage >£ 13 millions
INCIDENT PIPER ALPHA OIL PLATFORM, NORTH SEA (6/7/88)
Nature of occurrence : explosion destroyed oil production platform
Fatalities : Immediate : 167; delayed : nil Physical injuries : 20; disabled : 7 Mental injuries : loss of public confidence; loss of
morale in workforce Disruption of people’s way of live : relief fund £
millions Environmental damage : 5 km oil slick formed Financial loss : property damage + £ 500
millions
SPECIFIC FACTORS CONTRIBUTING TO MAJOR ACCIDENT (1)
Poor management practices; e.g : inadequate supervision
Pressure to meet production target Inadequate Safety Management System Failure to learn lessons from previous accident Communication issues; e.g : between shifts, between
personnel and management Inadequate reporting system Complacency Violation / non compliance behavior
SPECIFIC FACTORS CONTRIBUTING TO MAJOR ACCIDENT (2)
Inadequate training, e.g : emergency response, fire and safety
Lack of competency Excessive working hours resulting in mental fatigue Inadequate procedures Modification /up date to equipment without operator
knowledge and/ or revised risk assessment Inadequate /insufficient maintenance Maintenance error
MAJOR HAZARD CONTROL is
Prevention of Major Accidents
Factors Influencing Major Incidents
MAJOR ACCIDENTS OCCUR ALWAYS UNEXPECTED
At night During the weekend When the factory is stopped During a power failure In very bad weather
CONTROL MEASURES
Avoidance of Risks Prevention of Accidents
Mitigation of Consequences
Sitting of the plantLay outDesignConstructionStart up
OperationMaintenanceRepairModificationDecommissioning
AVOIDANCE OF RISKS
Small Inventories Safer Substances Lower Pressure Lower Temperature Etc
REDUCE POTENTIAL
PREVENTION OF ACCIDENTS
Ensure adequate control instrumentation Reduce Failures Improve Detection Improve Shutdown Improve Relief
Site Layout Operator training Operation Maintenance
Work permit system Inspection, testing Accident - investigation Etc
REDUCE PROBABILITY
MITIGATION OF CONSEQUENCES
Detection systems Emergency action on site Choice of site Firefighting system First aid kit Personal service/ambulance Control development nearby Etc
REDUCE IMPACT
HUMAN FAILURE
LatentErrors
Unsafe Plant/ Condition
Unsafe acts
INCIDENT
Fail to recover situation
Failure of mitigation
ACCIDENTACCIDENTPERSON JOB
ORGANISATION
ACCIDENT MODEL
PERFORMANCE PERFORMANCE INFLUENCING FACTORSINFLUENCING FACTORS
PERSON JOB
ORGANISATION
ACCIDENT MODELPERSON :• aptitude• sifat• sistem nilai• kharakteristik• minat• motivasi• usia• jenis kelamin• pendidikan• pengalaman dll
JOB :• mesin• peralatan kerja• bahan• lingkungan fisik• metode kerja• dll
ORGANISATION :• kharakteristik perusahaan• sistem manajemen• diklat• pengawasan/supervisi• pengupahan• lingkungan sosial• dll
HUMAN FACTOR
The JOB – what people are ask to do (task/workload/procedures/environment/equipment)
The INDIVUAL – who is doing it (competence/attitude/capability/risk perception)
ORGANIZATION – how is the work organized (leadership/resources/culture/communication)
HUMANFACTOR
JOB
OR
GA
NIZA
TIONIN
DIV
IDU
AL
(Health & Safety Executive -1999)
EXAMPLES OF MAJOR HAZARD WORKS
Petrochemical Works Chemical Works LPG Storage Fertilizer Works Explosives Manufacture Bulk Use of Chlorine Pesticide factories Etc
CONTOHINDUSTRIAL MAJOR ACCIDENT
I. PELEDAKAN (Explosions) Cyxlohexane (Mati : 28; Cidera : 89) Flixborough –UK, 1974 Propylene (Mati : 14; Cidera :107) Beek, Netherland, 1975
II. KEBAKARAN (Major Fires) LPG (Mati : 650; Cidera : 2500) Mexico City, 1985
III. TOKSIK (Toxic Release) Methyl Isocyanate (MIC) (Mati :2000;Cidera :20000 Bhopal,
India, 1984
MAJOR ACCIDENT
BHOPAL – absence of system maintenance
PIPER ALPHA – an error in work organization and transmission of instruction
CHERNOBYL – breach of safety regulation
FLIXBOROUGH – a poorly designated modification
DESIGNATION OF MAJOR HAZARD PLANT
List of Substances considered to be dangerous
Threshold Quantities for each of substances on the list
PENETAPAN POTENSI BAHAYA INSTALASI
POTENSI BAHAYA BESAR :
Kuantitas Bahan yang Digunakan melebihi
Nilai Ambang Kuantitas (NAK)
Qs > TQ POTENSI BAHAYA MENENGAH : Kuantitas
Bahan yang Digunakan sama atau lebih kecil Nilai Ambang Kuantitas (NAK)
Qs = TQ atau Qs < TQ
KEWAJIBAN PENGUSAHA ATAU PENGURUS Persh. Potensi Bahaya Besar (I)
Mempekerjakan Petugas K3 Kimia : Sistem Kerja Non Shift min. 2 orang Sistem Kerja Shift min. 5 orang
Mempekerjakan Ahli K3 Kimia min. 1 orang Membuat Dokumen Pengendalian Potensi
Bahaya Besar Melaporkan Setiap Perubahan (bahan, kuantitas,
proses dan modifikasi instalasi)
KEWAJIBAN PENGUSAHA ATAU PENGURUS Persh. Potensi Bahaya Besar (II)
Melakukan Pemeriksaan dan Pengujian Faktor Kimia min. 6 bulan sekali
Melakukan Pemeriksaan dan Pengujian Instalasi min. 2 tahun sekali
Melakukan Pemeriksaan Kesehatan Tenaga Kerja min. 1 tahun sekali
KEWAJIBAN PENGUSAHA ATAU PENGURUS Persh. Potensi Bahaya Menengah (I)
Mempekerjakan Petugas K3 Kimia : Sistem Kerja Non Shift min. 1 orang Sistem Kerja Shift min. 3 orang
Membuat Dokumen Pengendalian Potensi Bahaya Menengah
Melaporkan Setiap Perubahan (bahan, kuantitas, proses dan modifikasi instalasi)
KEWAJIBAN PENGUSAHA ATAU PENGURUS Persh. Potensi Bahaya Menengah (II)
Melakukan Pemeriksaan dan Pengujian Faktor Kimia min. 1 tahun sekali
Melakukan Pemeriksaan dan Pengujian Instalasi min. 3 tahun sekali
Melakukan Pemeriksaan Kesehatan Tenaga Kerja min. 1 tahun sekali
DOKUMEN PENGENDALIAN POTENSI BAHAYA BESARBerisikan :
Identifikasi Bahaya, Penilaian dan Pengendalian Risiko
Kegiatan Tehnis, Rancang Bangun, Konstruksi, Pemilihan Bahan Kimia, Pengoperasian dan Pemeliharaan Instalasi
Kegiatan Pembinaan Tenaga Kerja Rencana dan Prosedur Penanggulangan
Keadaan Darurat Prosedur Kerja Aman
DOKUMEN PENGENDALIAN POTENSI BAHAYA MENENGAHBerisikan :
Identifikasi Bahaya, Penilaian dan Pengendalian Risiko
Kegiatan Tehnis, Rancang Bangun, Konstruksi, Pemilihan Bahan Kimia, Pengoperasian dan Pemeliharaan Instalasi
Kegiatan Pembinaan Tenaga Kerja Prosedur Kerja Aman
Faktor2 yg dipertimbangkan dlm memilih lokasi MH Instalasi :
1. Proximity to populated areas;
2. Proximity to public ways;
3. Risk from adjacent facilities;
4. Storage quantities;
5. Present and predicted development of adjacent properties;
6. Topography of the site, including elevation and slope;
Faktor2 yg dipertimbangkan dlm memilih lokasi MH Instalasi :
7. Access for emergency response;
8. Availability of needed utility;
9. Requirement for the receipt and shipment of products;
10. Local codes and regulation;
11. Prevailing wind condition;
IDENTIFICATION AND PRIOTISATION OF MAJOR HAZARD CONTROL
1. Factories
2. Installation
3. Plant Unit
PRIORITISATION OF MAJOR HAZARD FACTORIES IDENTIFIED
FACTORY RANKING FACTOR (FRF) :Consist of 5 rating factors :1) Hazard Rating (HR)2) Capacity Rating (CR)3) Population Rating (PR)4) Domino Effect Rating (DER)5) Special Object Rating (SOR)
FRF = HR + CR +PR + DER + SOR
HAZARD RATING (HR) The chemical & physical properties The hazardous substances
No. Group of Hazardous Substances Penalty Point
1. Extremely Toxic and Toxic Substances – gases (Cl2, NH3, Phosgene)
25
2. Flammable Substances (LPG, Butane, Propane, Propylene, Hydrogen)
20
3. Highly Reactive and Explosive Substances (NH4NO3,TNT) 15
4. Extremely Toxic and Toxic Substances – powder/solid (Parathion Methyl)
10
5. Liquid Flammable Substances – solvent (Toluen, naphta) 5
CAPACITY RATING (CR) Max. quantity Threshold quantity
No. Capacity ratio Penalty Points
1. CR < 10 4
2. 10 < CR < 50 8
3. 50 < CR < 100 12
4. CR > 100 16
CR = Max. Capacity ILO Threshold Quantity
POPULATION RATING (PR) Population in within a circle of 1 km
No. Number of People Penalty Points
1. PR < 1000 3
2. 1000 < PR < 5000 6
3. PR > 5000 9
DOMINO EFFECT RATING (DER) Major Hazard Installation
No. Domino Effect Rating Penalty Points
1. 1 MH Installation 0
2. 2 MH Installation 2
3. > 3 MH Installation 4
SPECIAL OBJECTS RATING (SOR)
Object such as : schools, hospitals, cinemas, markets, supermarkets etc
Within a circle of 1 km
No.
Categories SOR points
1. No special objects 0
2. 1 Special objects 1
3. > 2 Special objects 2
FACTORY RANKING FACTOR (FRF)
No.
Factories Categories FRF
I. Important MH Factories 12 < FRF < 27
II. More Important MH Factories 27 < FRF < 41
III. Most Important MH Factories 41 < FRF < 56
CONTOH 1
PT. X Jakarta, Informasi :LPG : 37.000 tonsPenduduk lebih dari 10.000 orang, tidakterdapat MH instalasi lainnya dan tidak ada spesial objekJawaban : HR = 20; CR = 37.000 : 25 = 1480 =>
CR > 100, CRp = 16; PR = 9; DER = 0 dan SOR = 0
Jadi FRF = 20+16+9+0+0 = 45 (Category III)
CONTOH 2
PT. X Cikampek, Informasi :
Chlorine : 113 tons
Penduduk lebih dari 1000 orang, tidak
terdapat MH instalasi lainnya dan spesial objek
sekolah dan rumah sakit
Jawaban : HR = 25; CR = 113 : 10 = 11
=> CRp = 8; PR = 6; DER = 0 dan SOR = 2
Jadi FRF = 25+8+6+0+2 = 41 (Category II)
IDENTIFICATION AND PRIORITISATION OF MAJOR HAZARD INSTALATION
Calculation of Designation Factor (DF) of a Major Hazard Installation :
DF = Q x CF/DQ
DF = Designation Factor of Major Hazard Installation.Q = Max. Quantity of Major Hazard Substance in kgCF = Condition FactorDQ = Designation Quantity of Major Hazard Substance in kg
CONDTIONS FACTOR (CF)
A measure for the conditions under which a Major Hazard Substances is present in the installation
Condition deviations and corrections
No. Condition Correction Factor
a Installation for Processing
Installation for storage1
0.1
b Installation out of doors
Installation in enclosure1
2
c Substance is in the gaseous phase
Substance is in the liquid phase (see table 1)Substance is in the solid phase (respirable powder only)
10
0.1 -10
0.1
d If the process temperature is equal or higher than ambient If the process temperature is lower than ambient (see table 2)
0
0 - 3
CONDITIONS FACTOR (CF)
CF = a x b x (c + d)
DESIGNATION QUANTITY (DQ) Quantity of hazardous substance when released suddenly,
can result in extreme danger for a worker within a radius of 100 m from the point of emission
The designation Quantity :a. Flammable Substances :10.000 kgb. Extremely Toxic Substances : 1 kg (based on LC < 20
mg/kg)c. Toxic Substances; reference = 300 kg Chlorined. Explosive Substances; reference = 1000 kg TNT
See list of Dangerous substances and Threshold Quantities
CORRECTION FACTOR c FOR LIQUIDS (I)Table 1 :
No Process Temperature (Tp – Tbp) Correction Factors
1. Tp>90˚c below the boiling point
80-90 below the boiling point
70-80 below the boiling point
60-70 below the boiling point
50-60 below the boiling point
40-50 below the boiling point
30-40 below the boiling point
20-30 below the boiling point
10-20 below the boiling point
<10 below or above boiling point
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
CORRECTION FACTOR c FOR LIQUIDS (II)
No Process Temperature (Tp – Tbp) Correction Factors
10 - 20˚c above the boiling point
20 - 30 above the boiling point
30 - 40 above the boiling point
40 - 50 above the boiling point
50 - 60 above the boiling point
60 - 70 above the boiling point
70 - 80 above the boiling point
80 - 90 above the boiling point
Tp> 90 above the boiling point
2
3
4
5
6
7
8
9
10
CORRECTION FACTOR d
Tabel 2 :
- 25˚C < boiling point < ambient ˚C : 0
- 75˚C < boiling point < - 25˚C : 1
- 125˚C < boiling point < - 75 ˚C : 2
boiling point < -125 ˚C : 3
MH INSTALLATION CATEGORIES
Designation Factor ( DF)
No.
MH Installation Categories DF
I. Important MH Installation 0 < DF < 100
II. More Important MH Installation 100 < DF < 500
III. Most Important MH Installation DF > 500
CONTOH 1
Instalasi produksi yang tertutup, berisikan 2.100 kg bahan kimia beracun Chlorine dalam bentuk cair pada temperatur proses 35˚C
Boiling Point Cl2 : - 34˚C
Threshold Quantity Cl2 : 300 kg. DF = ?
DF= (Q x CF)/DQ
CF = 1 (processing)x2(enclosed)x7(69˚C above atm bp) = 14
DF = (2100 x 14)/300 kg = 98 (Category I. Important MH Instalation )
CONTOH 2
PT.X Jawa Barat – LPG Instalasi penyimpanan yang di lapangan terbuka, berisikan 37000 ton; DQ = 10 ton
LPG mixture : 80% butane; 20% propaneTbp butane : - 2˚C; Tbp propane : - 45˚CStorage & ambient temp. (max. 35˚C)T proses antara 30 – 40˚C diatas utk Tbp butane dan 70 - 80˚C utk propane. DF = ?DF= (Q x CF)/DQDF = 80%x37000x0.1(4+0) + 20%x37000x0.1(8+0)/10
DF = 1776 (Category III. Most Important MH Instalation )
CLASSIFICATION OF PLANT ELEMENT
DOW INDEX FIRE, EXPLOSION & TOXICITY INDEX
(FE&T INDEX)
CLASSIFICATION OF PLANT ELEMENTCategory Fire and Explosion
IndexToxicity Index
Category I F < 65 T < 6
Category II
65 < F < 95
6 < T < 10
Category III F > 95 T > 10
SURVEY SAFETY STUDIES
Category I II III
Checklist 1 x x
Checklist 2 x
Hazard and Operability Study (HAZOPS) x
Accident Data x x x
Emission of Safety Devices x x x
CHECKLIST 1Causes (internal and external) that may lead to loss of containment of a hazardous material in the installation
Failure in The supply/discharge of
process substances The electric power
supply The cooling water supply The process water or
common water supply Air supply Steam supply Inert gas supply Fuel supply
Explosion and/or fire in the area
Extreme high open air temperature
Extreme low open air temperature
Flood Soil subsidence Stroke of lightning Mechanical impact
CHECKLIST 2 Causes that may lead to loss of containment of the hazardous substances from the installation
Exceeding safe limits Corrosion (internal) Corrosion (external) Erosion Mechanical stress,
fatigue Fouling and clogging Failure of seals
Thermal expansion Contraction Decomposition Incorrect sampling Stratification Control errors Fire in the observed
plant element
SEKIANSEKIAN