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The potential major hazard and the consequences if the hazard occurs in our plant was
determined by risk assessment. Hazard identification is the process finding, listing and
categorization of hazard. Thus, this method is important to eliminate the hazard or control the
The potential major hazard from each equipment’s in the plant will be analysed to identify
the possibility and consequence. The classification of the possibility and severity of the
Possibility/Frequency Description
Level A Frequent Likely to occur frequently
Level B Probable Will occur several times
in life of production
Level C Occasional Likely to occur sometime
in life of production
Level D Remote Unlikely, but possible to
occur in life of production
Level E Improbable Unlikely, assume no
occurrence
Severity Description
Class I Catastrophic Death
Loss of System
Class II Critical Severe injury or morbidity
Major damage to the system
Major loss of production
Class III Marginal Minor injury or morbidity
Minor damage to the system
Minor loss of production
Class IV Negligible No injury or morbidity
No damage to the system
Table 3: Risk Assessment criteria
Severity
Possibility/Frequency
Catastrophic (I) Critical (II) Marginal (III) Negligible (IV)
Frequent 1A 2A 3A 4A
Probable 1B 2B 3B 4B
Occasional 1C 2C 3C 4C
Remote 1D 2D 3D 4D
Improbable 1E 2E 3E 4E
In addition, some of the unit operation of MTBE plant operated at high pressure and
temperature that may leads to the failure of the maintenance and the design of the vessel. The
high pressure may cause the rupture of the vessel that lead to explosion due to emission of
chemical substances to the atmosphere for example methanol, MTBE, isobutylene and mixed
C4’s. The high temperature can cause the thermal runaway. However, some precaution steps
should be consider to avoid this accident occurs for example, installation of temperature, flow
and pressure sensor. Furthermore, installation of high pressure alarm, high temperature alarm
and high flow alarm to alert the operator. Lastly, monthly maintenance and inspection of all
equipment in order to lower the possibility of accident.