major hazards control

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








<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







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

major hazards control

Documents

woundedheavy damage

delayedphysical injuries

nilphysical injuries

nature of occurrence

major incidentsmajor

oil slick formedfinancial

inadequate supervisionpressure

inadequate training