FIRE LOSS CONTROL -Water was applied at 30 cubic meters per minute ABC extinguishers are red.
cubic meters per minute ABC extinguishers are red. On campus, they range in size from
Fire can be friend or foe, depending on how well it is managed.
Four components of fire : fuel, oxygen, heat, chain reaction.
Important role of Front Line Supervisors in fire prevention:
-They have the day-to-day knowledge of the materials
manufactured, used or stored
within the facility
-They know the hazards created by day-to-day conditions,
practices and changes
Four major methods of combating fires : 1 Remove the fuel,
2 Exclude the oxygen, 3 Reduce the heat, 4 Interrupt the chain
reaction
Four classification of fires and extinguishers
1. Class A (Ordinary combustibles), ex : Wood, paper, cloth,
trash, plastics— solids that are not metals.
2. Class B (flammable liquids), ex : Flammable liquids—
gasoline, oil,grease, acetone. Includes flammable gases.
3. Class C (Electrical equipment), ex : Electrical—energized
electrical equipment.As long as it‘s ―plugged in.‖
4. Class D (Combustible metals), ex : Metals—potassium,
sodium, aluminum, magnesium. Requires Metal-X, foam,
and other special extinguishing agents.
Key Terms of Industrial Fire
-Siting – fix or build something in a particular place
-Egress – pathways for entering and exiting
-Suppression – extinguishing or containing of fire
-Extinguishability – ability to completely disrupt fire process
-Compartmentation – ability to isolate particular areas from
other area
For common workplace conditions,fire safety may be
achieved bysimple methods:
-Enforcement of approved fire codes and standards : National
Fire Protection Association (NFPA) / International Building
Codes (IBC)
-Local or national fire officials and chiefs
Facility Siting and Location : • Safe separation distances (-
Flame radiation -Toxic and/or flammable vapor clouds -Blast
waves) • Water supply access and reliability (-Susceptibility to
drought
-Robust supply of water) •Safe egress, rescue, and manual fire
fighting (-Egress to adjacent protected building or designated
area -Distance from fire department -Site accessibility) • Hazard
segregation and isolation (-Grouping similar hazardous
chemicals -Isolating and protection special or targeted dual use
chemicals -Isolation and elimination of ignition sources)
Facility Siting Incidents (Sandoz Basel Fire, 1986 in
Switzerland)
-Textile and agrochemical manufacturing facility
-Structural steel framed building that was 90m long, 50m wide
with two 12m high peaks. 12cm brick wall in the middle to
create two separate buildings
-Original use was for machinery storage,
converted over to flammable liquids storage
^Explosion-proof electrical fixture ^Sealed sewer
drains^Installed three water curtains to be operated by plant
fire brigade
-No automatic sprinklers or smoke detectors
-Chemicals stored in plastic bags, plastic & steel
drums
-Materials stacked to maximum height of 8m
-Storage at the time of incident
859 metric tons of organophosphate insecticide
12 metric tons of a phenyl-urea derivative used for
weed control
73 metric tons of di-nitrocresol derivative herbicide
26 metric tons of fungicide
11 metric tons of water soluble organic mercury
compounds
5.6 metric tons of misc. agrochemicals
364 metric tons of various formulating agents
-Most have flash points of 30°C and higher
-Incident occurred on October 31, 1986
-Key points to the incident
 Palletized chemicals were plastic shrink wrapped andthen
finished by using a blow torch
 Plastic wrap could ignite if exposed for sufficientduration
 Chemicals in the warehouse (e.g., Prussian Blue dye) could
burn flamelessly, smokelessly, and slowly thus eluding early
detection by workers
 No automatic suppression or smoke detection
-Initial fire responders determined that fire spread was too rapid
to control
◦ Fire foam was used, but proved to be ineffective
◦ Responders directed to cool surrounding buildings
◦ Limited success as steel drums were propelled from the
building of fire origin to adjacent structures
has potential for causing damage to people, property, or the
-Containment basins filled quickly and toxic chemicals flowed
into the Rhine River
-Extensive environmental impacts
^Most fish were killed by mercury poisoning in a 250km
section of the Rhine downstream of Basel
^Subsoil water levels had to be pumped away to preserve
the municipal underground water supply
^Wind carried the smoke produced by the fire over
residential communities causing eye and respiratory issues
-Extensive financial impacts
^$60M US in settle charges
^Figure does NOT include environmental clean-up and
restoration efforts
Construction Considerations
-Fire resistant construction
^Fire walls – hour rating
^Fire doors – prevents smoke form passing under
^Roofing – connecting areas, fastened to fire walls
-Smoke control (Isolation/Ventilation)
-Fire suppression systems (Not only water but could include
foams, dry chemical, carbon dioxide, halon,dll)
Storage Flammable Chemicals
-Chemical properties must be considered ( Flash point
Auto-ignition temperatures; Extinguishability)
-Storage tanks (Capacity; Tank spacing; Emergency ventilation;
Fire suppression;General designs should be approved to meet
specification )
Lessons Learned
• Need for fire walls and other passive barriers
• Need for roof deck fire spread tests
• Need to regularly test sprinkler water flow rates and to
fixed known impairments
• Need for fire resistant electrical cables
• Need for containment of contaminate water run-off
Fire Extinguisher Training
Fire Triangle (Together, they produce the CHEMICAL
REACTION that is fire) :
1. Enough OXYGEN to sustain combustion
2. Enough HEAT to reach ignition temperature
3. Some FUEL or combustible material
(jauhkan bahan bakar dan sumber nyala utk padamin)
*Fires are classified according to the type of
fuel that is burning. If you use the wrong type of fire
extinguisher on the wrong class of fire, you might make matters
worse.
The 3 most common types of fire extinguishers :
-Water (APW). Large silver fire extinguishers that stand about
2 feet tall and weigh about 25 pounds when full. APW stands
for ―Air- Pressurized Water.‖ Filled with ordinary tap water and
pressurized air, they are essentially large squirt guns. APW‘s
extinguish fire by taking away the ―heat‖ element of the Fire
Triangle. For Class A fire only. Using water on a flammable
liquid fire could cause the fire to spread. Using water on an
electrical fire increases the risk of electrocution.If you have no
choice but to use an APW on an electrical fire, make sure the
electrical equipment is un-plugged or de-energized.APWs will
be found in older buildings, particularly in public hallways, as
well as in Residence Halls. They will also be found in computer
laboratories. It is important to remember, however, that
computer equipment must be disconnected from its electrical
source before using a water extinguisher on it.
- Carbon Dioxide (CO2). The pressure in a CO2
extinguisher is so great, bits of dry ice may shoot out of the
horn! CO2 cylinders are red. They range in size from 5 lbs to
100 lbs or larger. On larger sizes, the horn will be at the end of
a long, flexible hose. CO2‘s are designed for Class B and C.
CO2s will frequently be found in laboratories, mechanical
rooms, kitchens, and flammable liquid storage areas. In
accordance with NFPA regulations (and manufacturers‘
recommendations), all CO2 extinguishers at OSU undergo
hydrostatic testing and recharge every 5 years. Carbon dioxide
is a non-flammable gas that takes away the oxygen element of
the fire triangle.
Without oxygen, there is no fire. CO2 is very cold as it comes
out of the extinguisher, so it cools the fuel as well. Carbon
Dioxide Fire Extinguishers A CO 2 may be ineffective in
extinguishing a Class A fire because it may not be able to
displace enough oxygen to successfully put the fire out. Class A
materials may also smolder and re-ignite.
-Dry Chemical (ABC, BC, DC) Dry chemical extinguishers
put out fire by coating the fuel with a thin layer of dust.
This separates the fuel from the oxygen in the
air. The powder also works to interrupt the chemical reaction of
fire.These extinguishers are very effective at putting out fire.
event initiation followed by the impact of the safety systems •
5 to 20 lbs. At OSU, ―ABC‖ fire extinguishers are filled with a
fine yellow powder.The greatest portion of this powder is
composed of monoammonium phosphate.The extinguishers are
pressurized with nitrogen.
• DC (for ―Dry Chemical‖)
• ABC (can be used on Class A, B, or C fires). in public
hallways of new buildings, in laboratories, break rooms,
offices, chemical storage areas, mechanical rooms,
University vehicles, etc.
• BC (designed for use on Class B and C fires). may be
located in places such as commercial kitchens and areas
with flammable liquids.
How to Use a Fire Extinguisher : PASS (pull, aim , squeeze,
sweep). Start using the extinguisher from a safe distance away,
then slowly move forward.
Once the fire is out, keep an eye on the area in case
it re-ignites.
- Pull the pin. This will allow you to discharge the extinguisher
- Aim at the base of the fire.Hit the fuel. If you aim atthe flames
the extinguishing agent will fly right through and do no good.
-Squeeze the top handle. This depresses a button that releases
the pressurized extinguishing agent.
- Sweep from side to side until the fire is completely out
when a fire is discovered…
-Assist any person in immediate danger to safety, if it can be
accomplished without risk to yourself.
-Call 911 or activate the building fire alarm. The fire
alarm will notify the fire department and other building
occupants and shut off the air handling system to prevent the
spread of smoke.
*If the fire is small (and Only after having done these 2 things),
you may attempt to use an extinguisher to put it out.
before deciding to fight the fire, keep these
things in mind:
-Know what is burning.If you don‘t know what‘s burning, you
won‘t know what kind of extinguisher to use.
-Even if you have an ABC fire extinguisher, there may be
something in the fire that is going to explode or produce toxic
fumes.
*Chances are you will know what‘s burning, or at least have a
pretty good idea, but if you don‘t, let the fire department handle
it.
-Is the fire spreading rapidly beyond the point where it
started?The time to use an extinguisher is at the beginning
stages of the fire.
-If the fire is already spreading quickly, it is best to
simply evacuate the building.
* As you evacuate a building, close doors and windows behind
you as you leave.This will help to slow the spread of smoke and
fire.
Do not fight the fire if:
 You don‘t have adequate or appropriate equipment. If you
don‘t have the correct type or large enough extinguisher, it
is best not to try fighting the fire.
 You might inhale toxic smoke.When synthetic materials
such as the nylon in carpeting or foam padding in a sofa
burn, they can produce hydrogen cyanide, acrolein, and
ammonia in addition to carbon monoxide. These gases can
be fatal in very small amounts.
 Your instincts tell you not to.If you are uncomfortable with
the situation for any reason, just let the fire department do
their job.
*The final rule is to always position yourself with an exit or
means of escape at your back before you attempt to use an
extinguisher to put out a fire.
*In case the extinguisher malfunctions, or something
unexpected happens, you need to be able to get out quickly.You
don‘t want to become trapped.
Risk Assessment
Definisi quantitative risk assessment : ―QRA is Method that
identifies where operations, engineering, or management
systems can be modified to reduce risk ‖. QRAs are used to
evaluate potential risks when qualitative methods cannot
provide an adequate. Risk assessment includes incident
identification and consequence analysis : – Incident
identification describes how an accident occurs. It frequently
includes an analysis of the probabilities. – Consequence
analysis describes the expected damage. This includes loss of
life, damage to the environment or capital equipment, and days
outage
Definisi2 : • Frequency : Number of occurrences of an event
per unit of time • Hazard : A chemical or physical condition that
Selection of A release incident : • Typical Incidents might
environment
• Incident : The lost of containment of material or energy • Risk
: A measure of human injury, environmental damage or
economic loss in terms of both incident likelihood and the
magnitude of the loss or injury • Risk analysis : The
development of quantitative estimate of risk based on
engineering evaluation and mathematical techniques for
combining estimates of incident consequences and frequencies •
Risk assessment : The process by which the results of a risk
analysis are used to make decisions, either through a relative
ranking of risk reduction or through comparison with risk
targets
QRA Prosedur : • Defining the potential event sequences and
potential incidents • Evaluating the incident consequences •
Estimating the potential incident frequencies • Estimating the
incident impacts on people, environment, and property •
Estimating the risk by combining the impacts and frequencies,
and recording the risk using a graph similar to Figure in the
next slide
Hazard identification
Hazard identification : • Process Hazard Checklist • Hazard
Surveys • HAZOP • Scenario Identification
HAZOPs Prosedur : 1. Begin with a detailed flow sheet 2.
Choose a study node (vessel, line, operating instruction) 3.
Describe the design intent of the study node 4. Pick a process
parameter : flow, level, pressure, etc 5. Apply a guide word to
the process parameter to suggest possible deviations. Table in
the next slide 6. If the deviations is applicable, determine
possible causes and note any protective system 7. Evaluate the
consequences of the deviation (if any) 8. Recommend action
(what? by whom? by when?) 9. Record all information 10.
Repeat steps 5 through 9 until all applicable guide words have
been applied to the chosen parameter 11. Repeat steps 4
through 10 until all applicable process parameters have been
considered for the given study node 12. Repeat steps 2 through
11 until all study nodes have been considered for the given
section and proceed to the next section on the flow sheet
HAZOPs
Accident probability what’s coming : • Event Tree Analysis •
Fault Tree Analysis
Event tree analysis : • Even trees begin with an initiating event
and work toward a final result • The method provides
information on how failure can occur and the probability of
occurrence • The event tree approach includes the effects of an
The event tree is written from left to right and the initiating
even is written first in the center of the page on the left
Event tree analysis - Typical Steps in Event Tree Analysis:
1. Identify an initiating event of interest 2.Identify the safety
functions designed to deal with the initiating even 3.Construct
the event tree 4.Describe the resulting accident event sequences
Fault tree analysis : • Fault trees are a deductive method for
identifying ways in which hazards can lead to accidents • The
approach starts with a well-defined accident, or top event, and
works backward the various scenarios that can cause the
accident • Events in fault tree are not only restricted to
hardware failures but also include software, human and
environmental factors • For reasonably complex chemical
processes a number of additional logic functions are needed to
construct a fault tree
Fault tree analysis : • Preliminary steps before the actual fault
tree is drawn
• Next steps : to
draw the fault tree
developing the fault tree until all branches have been terminated
by basic, undeveloped, or external events
Fault tree analysis : Disadvantages • For any reasonably
complicated process the fault tree will be enormous • The
developer of a fault tree can never be certain that all the failure
modes have been considered • Fault trees also assume that
failures are ―hard‖, that a particular item of hardware does not
fail partially • Fault trees developed by different individuals
are usually different in structure • If the fault tree use to
compute a failure probability for the top event, then failure
probabilities are needed for all events. These probabilities are
not known accurately Advantages
that provide enormous insight into the various ways for top
application of computers
Accident Consequences Analysis: o Selection of a Release
Incident o Source Models o Dispersion Models o Fire and
Explosion Models o Effect Models
include
•
Release mechanism are classified into
Limited aperture case • Wide aperture case
ple : Over pressuring and
explosion of a storage tank • Limited aperture case
is released at slow enough rate that upstream conditions are
frequently valid. See figure in the next slide
Fire and Explosion Model : Explosions Parameters
significantly affecting the behavior of explosions : • Ambient
temperature • Ambient pressure • Composition of explosive
material • Physical properties of explosive material • Nature of
ignition : type, energy and duration • Geometry of surroundings
: confined or unconfined • Amount of combustible material •
Turbulence of combustible material • Time before ignition •
Rate at which combustible material is released Vapor Cloud
Explosions (VCEs) • Most dangerous and destructive
explosions in the chemical process industries • These
explosions occur in a sequence of steps : 1. Sudden release of
large quantity of flammable vapor 2. Dispersion of the vapor
throughout the plant site while mixing with air 3. Ignition of
the resulting vapor cloud
PSM: OSHA Process Safety Guidance and Information
OSHA Process Safety Guidance and Information •
Introduction • Applicability • Exceptions • Requirements •
Process Safety Information • Employee Involvement • Process
Hazard Analysis • Operating Procedures • Training •
Contractors • Pre-startup Safety Review • Mechanical Integrity
• Hot Work • Management of Change • Incident Investigation
• Emergency Planning and Response • Compliance Audits •
Trade Secrets • Regulations • Guidelines and further
information
Introduction : • 29 CFR 1910.119 is intended to prevent or
minimize the consequences of a catastrophic release of toxic,
reactive, flammable or explosive HHC's from a process. • A
process is any activity or combination of activities including
any use, storage, manufacturing, handling or the on-site
movement of HHC's. • A process includes any group of vessels
which are interconnected and separate vessels which are located
such that a HHC could be involved in a potential release. • The
rule intends to accomplish its goal by requiring a
comprehensive management program integrating technologies,
procedures, and management practices • The OSHA Process
Safety Management (PSM) standard (29 CFR 1910.119) was
published in the Federal Register on Monday, February 24,
1992. The compliance dates for Process Safety Information and
Process Hazards Analysis is as follows: At least 25% must be
finished by May 26, 1994. At least 50% must be finished by
May 26, 1995. At least 75% must be finished by May 26, 1996.
All must be finished by May 26, 1997. OSHA has added two
more elements to the final rule in addition to the twelve
elements contained in the proposed standard;: employee
participation and trade secret protection
Applicability : • The standard applies to a process which
contains a threshold quantity or greater amount of a toxic or
reactive HHC as specified in Appendix A. • Also, it applies to
10,000 pounds or greater amounts of flammable liquids and
gases and to to the process activity of manufacturing explosives
and pyrotechnics.
Exceptions : • The standard does not apply to retail facilities,
normally unoccupied remote facilities and oil or gas well
drilling or servicing activities. • Hydrocarbon fuels used solely
for work place consumption as a fuel are not covered, if such
fuels are not part of a process containing another HHC covered
by the standard. • Atmospheric tank storage and associated
transfer of flammable liquids which are kept below their normal
boiling point without benefit of chilling or refrigeration are not
covered by the PSM standard unless the atmospheric tank is
connected to a process or is sited in close proximity to a
covered process such that an incident in a covered process
could involve the atmospheric tank
Requirements : 1. Process Safety Information Requires
compilation of written process safety information (PSI)
including – hazard information on HHC's, – technology
information and – equipment information on covered processes
Process • Block flow or process flow diagram • Process
chemistry • Maximum intended inventory • Safe upper/lower
limits for such items as temperatures, pressures, flows or
compositions • Consequences of deviations, e.g. runaway
Equipment : • Materials of construction •
P&IDs • Electrical Classification • Relief system design &
design basis • Ventilation system design • Design codes and
standards • Material & energy balances • Safety systems 2.
Employee Involvement : • Requires developing a written plan
of action regarding employee participation; • consulting with
employees and their representatives on the conduct and
development of process hazard analyses and on the
development of other elements of process safety management
required under the rule; • providing to employees and their
representatives access to process hazard analyses and to all
other information required to be developed under the rule. •
Employees include work site and contractor employees 3.
Process Hazard Analysis : • Specifies that process hazard
analyses (PHA's) must be conducted as soon as possible for
each covered process using compiled PS in an order based on a
set of required considerations. • At least twenty-five percent of
initial process hazard analyses must be completed by May 26,
1994; 50 percent by May 26, 1995; 75 percent by May 26,
1996; and 100 percent by May 26, 1997. • Process hazard
analyses must be updated and revalidated at least every five
years and must be retained for the life of the process. Definisi :
Organized and systematic effort to identify and analyze the
significance of potential hazards associated with the processing
or handling of highly hazardous chemicals •
Causes/consequences of fires & explosions • Releases of toxic
or flammable chemicals • Major spills of hazardous chemicals •
Methodology depends on the process & its characteristics. •
PHA Focuses On : 1. Equipment 2. Instrumentation 3. Utilities
4. Human Actions 5. External Factors • PHA Methods : 1. What
If? 2. Checklist 3. What If?/Checklist 4. Hazard & Operability
Study (HAZOP) 5. Failure Mode & Effects Analysis (FMEA)
6. Fault Tree Analysis (FTA) • PHA must address : 1. Hazards
of the process 2. Engineering & administrative controls 3.
Consequences of failure of controls 4. Facility siting 5. Human
factors 6. Evaluate potential effects to on-site personnel from
failure of controls 7. Identification of previous incidents • PHA
Team : 1. Expertise in engineering & process operations 2. One
member to have knowledge of & experience with process being
evaluated 3. One member knowledgeable in specific PHA
methodology used for evaluating the process 4. Other members
with specific knowledge: instrumentation, chemistry, etc
Employer PHA Actions : 1. Establish system for prompt
response 2. Ensure timely resolution of findings &
recommendations 3. Document actions taken 4. Develop
written schedule for completions 5. Complete actions ASAP 6.
Communicate actions to affected employees 4. Operating
Procedures • Must be in writing and provide clear instructions
for safely conducting activities involving covered process
consistent with PSI; • Must include steps for each operating
phase, operating limits, safety and health considerations and
safety systems and their functions; • Be readily accessible to
employees who work on or maintain a covered process, and be
reviewed as often as necessary to assure they reflect current
operating practice; • Must implement safe work practices to
provide for special circumstances such as lockout/tagout and
confined space entry • Provide clear instructions for safely
conducting activities involved in each covered process
consistent with the process safety information • Address at least
the listed element Steps for Each Operating Phase : 1. Initial
startup, operation, shutdown 2. Temporary & emergency
operations, emergency shutdown 3. Startup following
shutdowns Operating limits : • consequences of deviations •
prevention of deviations Safety & Health Considerations : •
Chemical properties and hazards • Precautions to prevent
exposure • Control measures if contact or airborne exposure
occurs • Quality controls for raw materials • Control of
hazardous chemical inventories • Special or unique hazards •
Safety systems & their functions • Operating procedures readily
accessible • Reviewed as necessary to reflect current
procedures and changes • Certified annually as current &
accurate • Develop & implement safe work practices to provide
for the control of hazards during operations, e.g. ( –
lockout/tagout – confined space entry, – opening equipment &
pipes – facility entry) • Apply to employees & contractor
employees 5. Training : • Employees operating a covered
process must be trained in the overview of the process and in
the operating procedures addressed previously. • This training
must emphasize specific safety and health hazards, emergency
operations and safe work practices. • Initial training must occur
before assignment or employers may certify that employees
involved in the process as of May 26, 1992, have required
knowledge, skills and abilities. • Documented refresher training
is required at least every three years. Training meliputi : 1.
Process overview 2. Process hazards 3. Operating procedures 4.
Emergency procedures 5. Refresher training at least every 3 yrs
6. Documentation 6. Contractors : • Identifies responsibilities of
work site employer and contract employers with respect to
contract employees involved in maintenance, repair,
turnaround, major renovation or specialty work, on or near
covered processes. • Contract employers are required to train
their employees to safely perform their jobs, and document that
employees received and understood training, and assure that
contract employees know about potential process hazards and
the work site employer's emergency action plan, assure that
employees follow safety rules of the facility, and advise the
work site employer of hazards contract work itself poses or
hazards identified by contract employees 7. Pre-startup Safety
Review : • Mandates a safety review for new facilities and
significantly modified work sites to confirm that the
construction and equipment of a process are in accordance with
design specifications; • to assure that adequate safety,
operating, maintenance and emergency procedures are in place;
and to assure process operator training has been completed. •
For new facilities, the PHA must be performed and
recommendations resolved and implemented before start up. •
Modified facilities must meet management of change
requirement. Done when: 1. New processes 2. Modified process
• Pre-startup Review Verifies : – Construction: conforms to
design – Procedures: adequate, in place – PHA
recommendations resolved or implemented – Management of
change requirements met – All affected workers trained 8.
Mechanical Integrity : • Requires the on-site employer to
establish and implement written procedures for the ongoing
integrity of process equipment particularly those components
which contain and control a covered process. PSM Mechanical
Integrity : 1. Pressure vessels, storage tanks 2. Piping systems,
components 3. Relief & vent systems, devices 4. Emergency
shutdown systems 5. Controls: monitoring devices, sensors,
alarms, interlocks 6. Pumps Mechanical integrity meliputi : 1.
Written procedures 2. Training: process hazards, job tasks 3.
Inspections 4. Testing 5. Corrective action 6. Records 9. Hot
Work : Hot work permits must be issued for hot work
operations conducted on or near a covered process Hot Work
Permits :1. Welding, cutting, brazing 2. Control of ignition
sources 3. Verify safe conditions 4. Authorization
10.Management of Change : • The work site employer must
establish and implement written procedures to manage changes
except "replacements in kind" to facilities that effect a covered
process. • The standard requires the work site employer and
contract employers to inform and train their affected employees
on the changes prior to start-up. • Process safety information
and operating procedures must be updated as necessary
Management of Change meliputi: 1. Establish written
procedures 2. Develop management support 3. Evaluate safety
of any changes to: o process chemicals facility o technology
equipment MOC Procedures Must Address : 1. Everything
except ―replacement in kind‖ 2. Temporary as well as
permanent changes 3. Technical basis for change 4. Safety &
health effects 5. Modified operation procedures 6. Time
necessary for change 7. Authorization for change 8. Ways to
inform & train workers before change 11.Incident Investigation:
• Requires employers to investigate as soon as possible (but no
later than 48 hours after) incidents which did result or could
reasonably have resulted in catastrophic releases of covered
chemicals. • The standard calls for an investigation team,
including at least one person knowledgeable in the process
involved, (a contract employee when the incident involved
contract work) and others with knowledge and experience to
investigate and analyze the incident, and to develop a written
report on the incident. • Reports must be retained for five years.
Incident Investigation Goals : Identify incident causes and
implement steps to prevent reoccurence Incident Investigation :
1. Every incident 2. Prompt investigation 3. Knowledgeable
team 4. Documentation & report 5. Recommendations &
findings 6. Resolutions & corrective actions 12.Emergency
Planning and Response : 1. Requires employers to develop and
implement an emergency action plan. 2. The emergency action
plan must include procedures for handling small releases
Emergency Planning & Response : 1. Develop Emergency
Action Plans 2. Pre-plan for catastrophe 3. Train & equip
workers 4. Drills 13.Compliance Audits : • Calls for employers
to certify that they have evaluated compliance with process
safety requirements at least every three years. • Prompt
response to audit findings and documentation that deficiencies
are corrected is required. • Employers must retain the two most
recent audit reports Compliance Safety Audits : 1. Certify all
elements of standard 2. Knowledgeable audit team 3. Report &
recommendations 4. Address all finding & recommendations 5.
Conduct every three years 14.Trade Secrets : • Sets
requirements similar to trade secret provisions of the 1910.1200
Hazard Communication standard requiring information required
by the PSM standard to be available to employees (and
employees representatives). • Employers may enter into
confidentiality agreement with employees to prevent disclosure
of trade secrets
Regulations : • OSHA Regulations (Standards - 29 CFR) -
1910 - Table of Contents. • OSHA Regulations (Standards - 29
CFR) - 1910.119 - Process Safety Management of Highly
Hazardous Chemicals. • OSHA Regulations (Standards - 29
CFR) - 1910.119 App A - List of Highly Hazardous Chemicals,
Toxics and Reactives (Mandatory). • OSHA Regulations
(Standards - 29 CFR) - 1910.119 App B - Block Flow Diagram
and Simplified Process Flow Diagram (Nonmandatory). •
OSHA Regulations (Standards - 29 CFR) - 1910.119 App C -
Compliance Guidelines and Recommendations for Process
Safety management (Nonmandatory). • OSHA Regulations
(Standards - 29 CFR) - 1910.119 App D - Sources of Further
Information (Nonmandatory).
Emergency Management
Definition •―An unforeseen combination of circumstances or
the resulting state that calls for immediate action‖ •―An urgent
need for assistance or relief‖ •―May occur without advance
warning‖
Emergencies•Hazardous materials releases
–Accidental –Intentional
•Fires •Explosions •Medical •Natural Occurrences
–Earthquakes, typhoons, fires, floods,etc.
•Other incidents
–Bomb threat
–Terrorism
EmergencyManagement•Planning
–A continuous process –Purpose: •Avoid the emergency
•Reduce the impact •Response/Mitigation –Requires highly-
trained personnel•Recovery/Stabilization –Community or
government support
Emergency Planning General Plant Emergency Plan •Involve
engineering, safety, & security •Distribute to and train all
employees •Include in the plan: –Roles and responsibilities –
Procedures for reporting emergencies –Emergency phone
numbers –Procedures for specific emergencies –Maps
•Evacuation routes •Assembly areas •Have an evacuation map
POST IT •Post each area with:
–Emergency phone numbers –After hours phone numbers –
Person(s) to be contacted –Alternate person(s) –Unique hazards
& procedures Plant Emergency Response Procedures •Evacuate
or shelter in place? •Respond? •Who will respond? –On-site
HAZMAT (hazardous materials) team? •Require training –
Community fire department? •Establish memorandum of
understanding •Medical support –In-house? –When to call for
outside assistance •Emergency shutdown procedures
•Decontamination procedure
General Fire Protection
–Identify your fire and life safety codes –Inventory your
flammable materials •Quantity •Location –Secure appropriate
flammable liquid storage –Identify & control ignition sources –
Housekeeping •Control combustible materials •Post exit signs
•Keep exits unlocked or equipped with panic bars •Detection &
Mitigation Equipment –Alarms, smoke and heat detectors,
sprinklers, emergency lighting and fire extinguishers need to be
properly located, maintained, and serviced regularly Response
Equipment •Initial hazard assessment •Place in accessible
locations –Fire extinguishers –Spill control kits –PPE –
Respirators –DECON showers (decontamination) •Schedule
routine maintenance and inspection of all response equipment
American Industrial Hygiene Association Emergency Response
Planning Guidelines •ERPG-1 –The maximum airborne
concentration below which it is believed that nearly all
individuals could be exposed for up to one hour without
experiencing other than mild, transient adverse health effects or
without perceiving a clearly defined objectionable odor.
•ERPG-2 –The maximum airborne concentration below which
it is believed that nearly all individuals could be exposed for up
to one hour without experiencing or developing irreversible or
other serious health effects or symptoms which could impair an
individual's ability to take protective action.
•ERPG-3 –The maximum airborne concentration below which
it is believed that nearly all individuals could be exposed for up
to one hour without experiencing or developing life-threatening
health effects
Software •Software Applications •Assist first responders with
accessible and accurate response information –Interactive
Cameo software modules –Cameo Data Management •Location
of chemicals
•Chemical quantities •Storage conditions •Cameo Chemicals
•Mapping applications •Atmospheric dispersion models •Aloha
software •Estimates threat zones associated with chemical
releases, including toxic gas clouds, fires, and explosions Unity
of Effort: •Success in managing an emergency depends on clear
roles and responsibilities and a clear chain of command. •Use of
an Incident Command System (ICS) allows coordination among
different jurisdictions and functional responsibilities to interact
effectively on the scene. Incident Command System: –
Developed to resolve: •Ineffective communication •Lack of
common command structure •Lack of accountability •Inability
to coordinate resources –Based on basic business management
•Plan •Direct •Organize •Communicate •Delegate •Evaluate
Incident Management System
Community Involvement
–Prepare for emergencies involving local communities
•Communicate! •Develop an emergency planning committee
•Select notification method to community •Inform community
of hazardous materials at your plant –Safety data sheets –
TOXNET
EMERGENCY RESPONSE
Response to HAZMAT Incidents•What makes hazardous
materials incidents so dangerous?
–Material characteristics may be unknown –Chemical, physical
hazards, biological (?) hazards •Toxic •Corrosive •Flammable
•Reactive –Conditions may be confusing –Limited time to
respond to the incident
Who Will Response?
–Employees? –Local police and fire department? –Local
ambulance, hospital? –Military? –Local HAZMAT team? –
Plant HAZMAT team?
Emergency Response Decision Making•DECIDE Process
–Detect hazmat presence –Estimate likely harm •Material
properties •Containment •Weather •Modeling data –
Decide on objectives –Identify action options –Do best option –
Evaluate progress
Emergency Response Decide on Objectives
•Priorities
1.Persons (Responders ; Workers ; Community )
2.Property (At the site; Protecting community )
3.Environment (Air, ground and surface water, soil, wildlife )
Emergency Response
•Initiate the Incident Command System: –Incident Commander
1.Establishes the strategy and tactics 2.Has ultimate
responsibility for incident outcome 3.The position is established
for every incident 4.May establish a command post –Command
Staff positions
1.Safety officer 2.Liaison officer 3.Information officer
4.Identify options: Size of spill may determine response
Identify Action Options
•Large Catastrophic Incidents
–Perform a risk analysis of response options •Should be a
continuous process during an event –Response options are
dependent on plant capabilities and approach –Mode of
response-defensive or offensive? (1)Training levels of
responders (HAZMAT trained?)(2)Technical
resources(3)External support available? –Local fire department
or HAZMAT –Military •Defensive of Offensive
Approach?
Defensive Options Large Event
•Persons
–Evacuate if possible –Shut off air intakes –Shelter-in
place/safe rooms •Property/Equipment –Emergency shut offs –
Emergency ventilation –Purging hazardous gas systems
•Environment –Diking water sources
Offensive Options Large Event•Written Standard Operating
Procedures
–For each hazardous material or process on-site •Select action
from alternative strategies •Select PPE/equipment for
responders –Ensure compatibility of PPE with hazards •Safe
approach is to select the highest PPE level
•Then, reduce the level when sufficient information on the
hazard
Restoring Processes •Backup power –Does power switch-over
automatically?
–How long will it run? –How much fuel do you have? –What
areas will it support? –How often is it tested and maintained?
Post-incident Follow-up •Debriefing
•Post-incident investigation
–Prepare a report of the incident –Revise response plans/lessons
learned –Share lessons learned –Keep all records –Correct
response deficiencies –Mitigate identified hazards
Identifikasi Hazard dan Dampaknya
PHA the Big Picture•A Process Hazard Analysis (PHA) is a
structured team review of an operation involving hazardous
materials/energies, to:
1.identify previously unrecognized hazards,
2.identify opportunities to make the operation inherently safer,
3.identify loss event scenarios, 4.evaluate the scenario risks to
identify where existing safeguards may not be adequate, and
5.document team findings and recommendations.
Definisi•Presence of a stored or connected material or energy
with inherent characteristics having the potential for causing
loss or harm Jenis Hazards
•Jenis hazards
1.Toksisitas dan korosivitas 2.Asphyxia – kondisi kekurangan
oksigen untuk bernafas 3.Pembakaran (pembakaran) 4.Detonasi
– pembakaran suatu zat diawali dan mengalami perambatan
sangat cepat sehingga mengakibatkan gelombang goncangan
5.Reaktivitas kimiawi 6.Perubahan fasa dengan sangat cepat
(BLEVEs - Boiling Liquid Expanding-Vapor Explosion)
7.Pecahnya bejana 8.Bahaya fisik lainnya
•Jenis/ sifat tersebut tidak saling berhubungan (not mutually
exclusive)
Bahaya Toksisitas dan Korosivitas•Terjadi bila
–Ada kemungkinan terpapar
–Ada atau kemungkinan timbul suatu material dan mekanisme
terjadinya kontak •Contoh: gas khlor untuk pengolahan air
•Toksisitas dapat mengakibatkan berbagai efek kesehatan
tergantung pada sifat, konsentrasi material, jalannya pemaparan
dan lamanya kontak
Asphyxia •Asphyxia (asphyxiation) adalah kondisi di mana
tubuh tidak memperoleh cukup oksigen untuk menyuplai
seluruh tubuh •Asphyxian ialah gas yang dapat mengakibatkan
ketidak sadaran atau kematian yang diakibatkan terganggunya
pernapasan (suffocation) –Asphyxian fisika diakibatkan
adanya gas yang mengusir/mengurangi konsentrasi normal O2
di udara –Asphyxian kimia mengakibatkan gangguan tubuh
dalam memasukkan oksigen kedalam tubuh
•Kebanyakan asphyxian tidak berbau dan tidak berwarna (N2,
CO2, H2, Argon, gas hidrokarbon dsb) Bahaya Pembakaran
(combustion hazard) •Hakekat pembakaran dan kebakaran:
Potensi terlepasnya energi secara tidak terkendali akibat
peristiwa oksidasi bahan yang dapat terbakar •Tiga syarat
terjadi pembakaran –Bahan yang dapat terbakar –Oksidator
–Penyalaan (ignition), kecuali untuk bahan piroforik
Dampak •Dampak yang mungkin terjadi akibat pembakaran –
Flash fire, pool fire and/or jet fire –Confined vapor explosion –
Vapor cloud explosion –Dust or mist explosion –Toxic
combustion products •Dampak dari kebakaaran tergantung dari
besarnya energi yang dihasilkan
Berbagai Definisi Pembakaran
•Ada berbagai peristiwa terkait dengn oksidasi dan pembakaran
1.Pembakaran 2.Oksidasi 3.Oksidator 4.Ledakan 5.Pembakaran
(terbakar) spontan 6.Piroforik
Flamabilitas
•Flamabilitas (Flammability) ialah kemudahan suatu bahan
dapat menyala/ terbakar) ditentukan oleh parameter berikut : 1.
Titik nyala (flash point) 2. Autoignition temperature 3. Rentang
flammabilitas (LFL/UFL)
•Fire Point adalah suhu terendah dimana suatu zat (bahan
bakar) cukup mengeluarkan uap dan terbakar secara terus
menerus bila diberi sumber penyalaan yang cukup. •Titik bakar
suatu zat beberapa derajat lebih tinggi dari titik nyalanya (flash
point).
Titik Nyala (flash point)
•Flash Point adalah suhu terendah dimana senyawa/bahan
mengeluarkan uap yang cukup untuk membentuk campuran
dengan udara yang dapat terbakar.
•Apabila campuran uap dengan udara pada temperatur tertentu
dapat terbakar tanpa adanya sumber api maka kondisi ini
disebut ignition mixture dan auto ignition temperature
Rentang Flamabilitas•Campuran uap bahan bakar dan udara
yang mengandung oksigen pada konsentrasi tertentu dapat
terbakar bila ada sumber api.
•Daerah konsentrasi campuran uap dengan udara dibatasi oleh
konsentrasi terendah dan konsentrasi tertinggi yang dikenal
sebagai Lower Flammability Limits (LFL) dan Upper
Flammability Limits (UFL)
•Kedua definisi ini dimaksudkan untuk campuran gas,
dinyatakan dalam % bahan mudah terbakar di udara
•Campuran gas tidak akan terbakar bila lebih kecil dari LFL,
karena terlalu encer.
•Campuran gas tidak akan terbakar bila lebih besar dari UFL,
karena terlalu pekat.
Limiting oxygen concentration (LOC): •Limiting oxygen
concentration (LOC): Konsentrasi oksigen, dinyatakan dalam
%, dimana tidak akan terjadi pembakaran bila suatu zat yang
dapat terbakar oksigennya dibawah angka tersebut. •Contoh –
LOC CH4 ialah 12% (volume % oxygen)
Kriteria Desain 1.Hindari campuran yang dapat terbakar
2.Hilangkan sumber penyalaan api
Diagram Flamabilitas
Sumber Penyalaan
1.Sumber yang terlihat, misalnya api las 2.Penyalaan spontan
pada temperatur tertentu 3.Bersumber dari listrik 4.Bersumber
dari bahan kimia
Pengendalian Sumber Penyalaan •Dengan mengenali
sumbernya –Terus menerus, misalnya nyala api –Munculnya
potensi/ kadang-kadang misalnya dari knalpot mobil yang lewat
•Mengenali apa atau kejadian apa yang berpotensi menyala,
misalnya kebocoran •Menyediakan pengendalian yang
memadai
Bahaya Detonasi•Hakekat detonasi: berpotensi menimbulkan
gelombang ledakan (blast wawe) yang merusak karena terjadi
reaksi kimia sangat cepat
•Dua jenis mekanisme
–Diawali oleh bahan peledak padat atau cair, contoh TNT,
peroksida yang tidak stabil
–Menjalarnya reaksi campuran pada fasa gas dengan kecepatan
sangat tinggi mencapai kecepatan detonasi, contoh ledakan
vapor cloud
Beberapa Definisi
Beberapa definisi terkait detonasi 1.Deflagration: Penjalaran
kecepatan reaksi lebih kecil daripada kecepatan suara
dibandingkan dengan kecepatan material didepannya yang tidak
bereaksi 2.Detonation: Penjalaran kecepatan reaksi lebih besar
daripada kecepatan suara dibandingkan dengan kecepatan
material didepannya yang tidak bereaksi
Reaktivitas Kimia (Chemical Reactivity) •Hakekat bahaya
reaktivitas ialah reaksi kimia yang tidak terkendali dan
mengakibatkan kehilangan atau kerugian •Peristiwa itu terjadi
karena energi atau produk yang dihasilkan oleh reaksi tersebut
tidak mampu diserap oleh lingkungannya secara aman •Contoh
yang umum terjadi –Hilangnya kendali terhadap reaksi yang
diinginkan (intended) –Terjadinya reaksi yang tidak diinginkan
•Dampak: kebakaran, ledakan, terlepasnya gas beracun dan/atau
panas dsb
Jenis Bahaya Reaktivitas Kimia •Reaktif dengan air
•Peristiwa oksidasi •Pembakaran spontan/ piroforic
•Pembentukan peroksida •Polimerisasi •Dekomposisi
•Pengaturan reaksi atau Rearranging •Interaksi, mis. karena
tidak kompatibel
BLEVES •Hakekat bahaya ialah terjadinya transisi fasa
dengan sangat cepat atau seketika (instant) disertai dengan
pertambahan volume yang sangat besar •Kondisi yang
menyebabkan BLEVE: gas pada kondisi cair bertekanan berada
diatas titik didihnya •Contoh: bejana penyimpan gas propana
berada ditengah kebakaran dan terkena semburan pada ruang
uap sehingga kekuatan logam melemah mencapai batas
kegagalan metal tsb •Energi ledakan yang diakibatkan oleh
perubahan fasa dan pecahnya bejana; bejana akan hancur
berantakan dan diikuti dengan bola api
Bahaya Bejana Pecah •Hakekat bursting vessel explosion:
Terlepasnya energi uap atau gas yang disimpan yang terjadi
hampir seketika, juga disebut –Penyimpanan dengan tekanan
berlebih –Ledakan karena bejana pecah •Contoh –Kebakaran
didalam bejana –Tidak ada peralatan pengaman (relieve)
•Dampak –Energi yang diakibatkan oleh bejana yang meledak –
Kerusakan karena hantaman puing-puing bejana
Bahaya Fisik Lannya •Tekanan hidrolik: semburan cairan
media sistem hidrolik •Kerusakan karena terjadi peristiwa
vakum •Bocoran gas, cairan atau benda panas •Temperatur
cryogenic: luka bakar cryogenic •Penampungan cairan yang
sangat besar, termasuk bendungan •Awan gelap karena bahan
kimia, mis. salmiak
Hasil Identifikasi•Biasanya identifikasi bahaya menghasilkan
1.Dafter bahan ang mudah terbakar 2.Daftar bahan toksik/
korosif dan hasil sampingnya 3.Daftar material ber-energi dan
peledak 4.Daftar debu yang dapat meledak 5.Daftar reaksi
berbahaya; matriks interaksi kimia 6.Sifat berbahaya yang
penting: flash point, toksisitas 7.Daftar asphysian dan oksidator
8.Jumlah simpanan material berbahaya 9.Daftar bahan kimia
dan jumlah yang harus dilaporkan bila lepas ke lingkungan
10.Daftar bahaya fisik 11.Daftar kontaminan dan kondisi
proses yang menyebabkan reaksi runaway.
Data Bahaya Kimia
•Sumber data bahaya kimia
–Safety Data Sheets dari supplier –Sumber spesifik (e.g.,
Chlorine Institute) –Buku dan handbooks (e.g., Sax, Bretherick
Process Safety Management Process Safety Overview
is Process Safety? ◦has been defined in a number of ways
Safety Management
Process Safety Management Systems from around the world –
The PSM Models ◦American Occupational Health and Safety
Administration Process Safety Management Rule enacted in
1994 ◦12 Elements – OSHA – US Occupational Health and
Safety Administration PSM Rule 1910.119 ◦CCPS, Guidelines
for Technical Management of Chemical Process Safety ◦14
Elements - CSChE – The Canadian Society for Chemical
Engineering ◦API RP 750 ◦20 Elements - AIChE CCPS – The
American Institute for Chemical Engineers Center for Chemical
Process Safety ◦20 Elements – EU Energy Institute ◦Some large
corporations may also sell their custom systems or services for
implementing PSM 12 Elements – OSHA – US Occupational
Health and Safety Administration PSM Rule 1910.119 What is
OSHA PSM? The proactive and systematic identification,
evaluation, and mitigation or prevention of chemical releases
that could occur as a result of failures in process, procedures, or
equipment. OSHA Process Safety Guidance and Information 29
CFR 1910.119 Requirement 1.Process Safety Information
2.Employee Involvement 3.Process Hazard Analysis
4.Operating Procedures 5.Training 6.Contractors 7.Pre-startup
Safety Review 8.Mechanical Integrity 9.Hot Work
10.Management of Change 11.Incident Investigation
12.Emergency Planning and Response 13.Compliance Audits
14.Trade Secrets Elements of Chemical PSM – CCPS
1.Accountability 2.Process knowledge and documentation
3.Capital project review and design procedures (new,
expansion, acquired plants) 4.Process risk management
5.Management of change 6.Process and equipment integrity
7.Human factors 8.Training and performance 9.Incident
investigation 10.Standards, codes and law 11.Audit and
corrective actions 12.Enhancement of process safety knowledge
OSHA Process Safety Guidance and Information
1.Process Safety Information 2.Employee Involvement
3.Process Hazard Analysis 4.Operating Procedures 5.Training
6.Contractors 7.Pre-startup Safety Review 8.Mechanical
Integrity 9.Hot Work 10.Management of Change 11.Incident
Investigation 12.Emergency Planning and Response
Introduction
1910.119 is intended to prevent or minimize the consequences
of a catastrophic release of toxic, reactive, flammable or
combination of activities including any use, storage,
manufacturing, handling or the on-site movement of HHC's.
up of vessels which are
interconnected and separate vessels which are located such that
intends to accomplish its goal by requiring a comprehensive
management program integrating technologies, procedures, and
management practices. The OSHA Process Safety Management
(PSM) standard (29 CFR 1910.119) was published in the
Federal Register on Monday, February 24, 1992. The
compliance dates for Process Safety Information and Process
Hazards Analysis is as follows: At least 25% must be finished
by May 26, 1994. At least 50% must be finished by May 26,
1995. At least 75% must be finished by May 26, 1996. All must
be finished by May 26, 1997. OSHA has added two more
elements to the final rule in addition to the twelve elements
contained in the proposed standard: employee participation and
trade secret protection. Applicability
process which contains a threshold quantity or greater amount
of a toxic or reactive HHC as specified in Ap
it applies to 10,000 pounds or greater amounts of flammable
liquids and gases and to the process activity of manufacturing
explosives and pyrotechnics. Exceptions The standard does not
apply to A.Retail facilities, B.Normally unoccupied remote
facilities and oil or gas well drilling or servicing activities.
C.Hydrocarbon fuels used solely for work place consumption as
a fuel are not covered, if such fuels are not part of a process
containing another HHC covered by the standard.
D.Atmospheric tank storage and associated transfer of
flammable liquids which are kept below their normal boiling
point without benefit of chilling or refrigeration are not covered
by the PSM standard unless the atmospheric tank is connected
to a process or is sited in close proximity to a covered process
such that an incident in a covered process could involve the
atmospheric tank. Scope and Application
involves a chemical at or above the specified threshold
quantities (TQ) listed in Appendix A of the Rule. (TQ amounts
liquid or gas on site in one location, in a quantity of 10,000
pounds (4535.9 kg) or more ◦e.g., 10,000 lbs. of Methane =
223,714 ft3 at STP Methane produced in a large wastewater
treatment plant is covered if the total amount of methane in the
process exceeds 10,000 pounds. CCPS, Guidelines for
Technical Management of Chemical Process Safety Elements
of Chemical Process Safety Mgt of CCPS 1.Accountability
2.Process knowledge and documentation 3.Capital project
review and design procedures (new, expansion, acquired plants)
4.Process risk management 5.Management of change 6.Process
and equipment integrity 7.Human factors 8.Training and
performance 9.Incident investigation 10.Standards, codes and
law 11.Audit and corrective actions 12.Enhancement of process
safety knowledge Process and Equipment Integrity
handle all anticipated conditions, not just ideal or typical ones
tion,
automatic safeguards API RP 750 Management Of Process
Hazard API RP 750 APPLICATIONS
practice is intended for facilities that use, produce, process, or
store the following substances: 1.Flammable or explosive
substances that are present in such quantity and condition that a
sudden, catastrophic release of more than 5 tons of gas or vapor
can occur over a matter of minutes, based on credible failure
scenarios and the properties of the materials involved (see
Appendixes A and B). 2.Toxic substances that have a substance
hazard index (SHI) greater than 5000 (see Appendix C) and that
are present in amounts above a threshold quantity. 3.Toxic
substances commonly handled by the petroleum industry that
meet the SHI criteria include hydrogen sulfide (H2S), chlorine
(CI2), hydrogen fluoride (HF), and ammonia (NH3). The
following facilities are examples of those to which this
recommended practice may be applicable, based on the criteria
of 1.3.1.1, Item b: 4.Hydrogen sulfide and sulfur recovery
facilities. 5.Chlorine handling and storage facilities. 6.Hydrogen
fluoride alkylation and storage facilities. 7.Ammonia storage
and refrigeration facilities. API RP 750 Applicability Of RP
petrochemical operations, and major processing facilities.
troleum gases, including
surface facilities for underground storage caverns, are within
the scope of this recommended practice, unless specifically
accordance with this recommended practice, such measures
should conform to the most current provisions of any
applicable, federal, state, or local regulations. Operations Not
Within The Scope Of API RP 750
within the scope of this RP: 1.Distribution, retail, and jobber
operations. 2.Liquefied natural gas (LNG) facilities and
pipeline and transportation operations regulated by the U.S.
DOT. 3.Oil and gas well drilling, service, and production
facilities and operations covered by the U.S. Minerals
Management Service. 4.Natural gas processing facilities
excluded by Appendix B. 5.Storage of hydrocarbon fuels solely
for on-site consumption. 6.Storage of flammable or combustible
nonreactive, bulk liquid materials at atmospheric pressure
without benefit of chilling or refrigeration, and the transfer of
those materials. API RP 750 Purpose
practice is intended ◦to assist in the management of process
hazards. ◦to help prevent the occurrence of, or minimize the
consequences of, catastrophic releases of toxic or explosive
material
management of process hazards in design, construction, start-
up, operation, inspection, maintenance, and modification of
with a potential for catastrophic release, as defined herein. API
750 Introduction
Safety Information 2.Operating Procedures 3.Mechanical
Integrity 4.Process Hazards Analysis 5.Safe Work Practices
6.Training 7.Management of Change 8.Pre-Start-up Safety
Review 9.Emergency Response 10.Incident Investigation
11.Audit There are three criteria for establishing whether API
750 is necessary.
contains 5 tons of material that could be released quickly, API
750 may be necessary. There is an example of an LPG tank
measuring 6' x 10' as an example. This is a very small
(SHI). If the SHI>5000, then API 750 is necessary. ◦SHI =
EVC@20o / ATC ◦The EVC is the equilibrium vapor
composition at 20oC and is therefore related to the vapor
pressure. The ATC is the Acute Toxicity Concentration. This is
The last criterion is an evaluation of whether an accident could
cause injury to the public or could cause damage to the
environment. In other words, is the plant located near a
population center or near an environmentally safe area? ◦An
example, is NH3 has an SHI of 1000.
Risk-Based Process Safety Risk-Based
untuk menggambarkan atribut-atribut risiko dari proses,
lebih dari Tiga Atribut Risiko: ◦Hazard based ◦Consequence
sederhanakan
menjadi Risk-Based
system approach that uses risk-based strategies and
implementation tactics that are commensurate with the risk-
based need for process safety activities, availability of
resources, and existing process safety culture to design, correct,
and improve PSM activities Mengapa? Tantangan PSM
sebelumnya ◦Kinerja belum memuaskan ◦Tekanan keterbatasan
sumber daya ◦Stagnasi PSM, tidak ada kemajuan
Evolusi Pendekatan Strategik – Apa
yang sebaiknya saya lakukan? (ASME, ANSI, API, NFPA)
– Apa yang harus saya lakukan?
berdasar CONTINUOUS IMPROVEMENT – Bagaimana
dasarkan
RISIKO – Bagaimana saya dapat mengelola risiko dengan lebih
baik? Apa itu RBPS? RBPS Risk-Based Process Safety =
seluruh daur hidup proses/ operasi •Tujuan Pedoman
(Guidelines) RBPS
membantu para profesional PS : membangun &
mengoperasikan sistem PSM yang efektif (dan efisien) Apa
Yang Dapat Dilakukan RBPS? Pedomand RBPS memberi
petujuk bagaimana ◦Merancang sistem PSM ◦Memperbaiki
sistem yang kurang sempurna ◦Menyempurnakan praktek- Implementasi considered, their location, and the potentially affected
praktek PSM •Paling efektif bila di-integrasikan dengan sistem k memperbaiki/ menambah kekurangan PSM population. •A technology may be inherently safer than another
manajemen lainnya (Operasi, HSE, security, lainnya teknik/ with respect to some hazards but inherently less safe with
bisnis - Kualitas, Keandalan) Merupakan Pedoman Pedoman ada Prinsip Preventif dan Elemen RBPS respect to others, and may not be safe enough to meet societal
RBPS ◦Sifatnya tidak wajib (non-compliance) ◦Bukan satu- expectations. IST are based on an •Because an option may be
satunya untuk mencapai Kesesuaian dengan peraturan inherently safer with regard to some hazards and inherently less
perundangan ◦Tetapi, dapat menciptakan harapan untuk PS safe with regard to others, decisions about the optimum strategy
for managing risks from all hazards are required. •The decision
setempat yang spesifik dapat menyebabkan kegiatan RBPS process must consider the entire life cycle, the full spectrum of
yang berbeda karena adanya perbedaan kebutuhan, sumber daya hazards and risks, and the potential for transfer of risk from one
dan budaya safety yang ada Pendekatan Yang Digunakan impacted population to another. •Technical and economic
Pendekatan RBPS ◦Memahami bahwa tidak semua bahaya feasibility of options must also be considered. •―The essence of
dan risiko yang diakibatkan sama ◦Fokus pada bahaya dan the inherently safer approach to plant design is the avoidance of
risiko yang lebih besar ◦Menyediakan energi seperlunya untuk hazards rather than their control by added-on protective
setiap aktifitas ◦Sumber daya dapat dimanfaatkan dengan equipment.‖
semestinya untuk meningkatkan kinerja safety pabrik dan
kinerja bisnis perusahaan ybs Kriteria RBPS Usaha efektif
untuk peningkatan safety harus didasari ◦Pemahaman bahaya
dan risiko (hazards and risk) ◦Memahami kebutuhan dan
penggunaan sumber daya yang digunakan ◦Memahami bahwa
harus dipahami baik-baik agar dapat dibuat keputusan-
anya tidak
bersifat kuantitatif Ukuran Keberhasilan •Ukuran efektif:
Perusahaan harus menemukan cara untuk mengukur kinerja dan
efisiensi sehingga dapat memanfaatkan sumber daya yang
terbatas untuk hal-hal yang prioritasnya lebih tinggi Empat Pilar
RBPS Perlunya penerapan empat pilar menghindari kecelakaan
dengan tingkat keras tidaknya yang sesuai dengan risiko
1.Commit to process safety (cornerstone RBPS): Perusahaan
yang mendukung penuh safety sebagai nilai utama akan
melakukan the right things, in the rights ways, at the right times
2.Memahami risiko (fondasi RBPS): Dengan informasi ini
perusahaan meng-alokasikan sumber daya yang terbatas secara
efektif 3.Mengelola risiko ( eksekusi masalah RBPS terus
menerus) – Perusahaan harus i.Mengoperasikan dan
mempertahankan proses yang ber-resiko ii.Melakukan
perubahan hanya dalam batas toleransi iii.Bersiap, responsif
dan mengelola insiden bila ternyata terjadi 4.Belajar dari
pengalaman (Peluang improvement). Menggunakan
pengalaman sendiri dan orang lain untuk perbaikan
i.Menggunakan pengukuran yang tepat untuk feedback
Daur Hidup Fasilitas 1.Conceptual Design 2.PFD 3.Detailed
ii.Menggunakan leading indicator Manfaat Manfaat Fokus pada
Design 4.Construction 5.Post-startup 6.Decommissioning
Empat Pilar ◦Meningkatkan efektifitas PS ◦Mengurangi
Permasalahan pada Fasa pada Daur Hidup
frekuensi dan tingkat serius insiden ◦Meningkatkan HSE jangka
panjang dan kinerja bisnis ◦Menghindari pemisah (gaps), tidak
konsisten, pengerjaan berlebihan, pengerjaan tidak sempurna
yang dapat mengakibatkan kegagalan RBPS Elements 20
Elemen RBPS, perluasan CCPS PSM Elements ◦Dapat
dirancang dan diterapkan di berbagai tingkatan keras/ tidaknya
untuk optimasi kinerja PSM, Efisiensi dan Efektifitas
◦Membantu menghilangkap pemisah dan ke-tidak konsisten-an •Inherently safer designs permanently and inseparably reduce or
hal- Commit eliminate process hazards that must be contained and controlled
to Process Safety 1.Process Safety Culture 2.Compliance with to avoid loss events Importance of IS •Trevor Kletz: ―What you
Standards 3.Process Safety Competency 4.Workforce don‘t have, can‘t leak‖ •Similarly: What you don‘t have can‘t
Understanding Hazard be stolen, ignited or intentionally released •Those hazards that
& Risk 6.Process Knowledge Management 7.Hazard are not eliminated or reduced to insignificance must be
Manage Risk 8.Operating managed throughout the lifetime of the facility, to avoid process
Procedures 9.Safe Work Practices 10.Asset Integrity and incidents that can result in loss and harm. ―Layers of
Reliability 11.Contractor Management 12.Training and Protection‖ are needed to protect against hazards that are not
Performance Assurance 13.Management of Change eliminated
14.Operational Readiness 15.Conduct of Operations
Learn From Experience
17.Incident Investigations 18.Measurement and Metrics
19.Auditing 20.Management Review and Continuous
Improvement Pemakaian Pedoman RBPS
(issues) safety untuk semua operasi yang melibatkan: produksi,
penggunaan, penyimpanan, penanganan bahan berbahaya atau
ana dalam
daur hidup yang dibahas berdasar pertimbangan toleransi
Yang IS Benefits •Reduce the need for engineered controls and safety
systems (including initial and ongoing costs) •Reduce labor
Termasuk/ Tidak dalam cakupan ◦Termasuk seluruh daur hidup
proses ◦Fasilitas yang tetap/ diam, bukan transportasi: meskipun costs and potential liabilities associated with ongoing regulatory
relevan tetapi tidak dipertimbangkan sewaktu penyusunan Inherently Safer Design Definition •Inherently Safer compliance •Eliminate the need for personal protective
Pedoman RBPS ◦Proses, bukan produk Technology (IST), also known as Inherently Safer Design equipment associated with particular hazards •Reduce
◦Area teknis yang berhubungan: Pedoman RBPS ini ditulis (ISD), permanently eliminates or reduces hazards to avoid or emergency preparedness and response requirements •Improve
reduce the consequences of incidents •IST is a philosophy, neighborhood/ community relations Process Safety Strategy •
untuk tujuan PS yang berdiri sendiri, dan tidak secara ekplisit
applied to the design and operation life cycle, including Inherent - Hazard reduction • Passive - Process or equipment
mencakup:: OHS, Environmental Protection, Product
manufacture, transport, storage, use, and disposal. •IST is an
Stewardship, Product distribution, Security, Quality Kerangka design features that reduce risk without active functioning of
Sistem Manajemen 1.Penjelasan Garis Besar (Element iterative process that considers such options, including any device • Active - Engineering controls • Procedural –
Overview) 2.Prinsip dan sifat penting (Key principles and eliminating a hazard, reducing a hazard, substituting a less Administrative controls Inherent Safety Strategies
hazardous material, using less hazardous process conditions,
essential features) 3.Kegiatan dan pilihan pelakasanaan
(Possible Work activities and implementation option) 4.Contoh and designing a process to reduce the potential for, or
peningkatan kinerja (Performance and efficiency improvement consequences of, human error, equipment failure, or intentional
examples) 5.Pengukuran (Possible Metrics) 6.Evaluasi IST are relative •A technology can only be described as
Manajemen (Management review topics) Petunjuk inherently safer when compared to a different technology,
including a description of the hazard or set of hazards being
Definition •IST is an iterative process that considers such
options, including eliminating a hazard, reducing a hazard,
substituting a less hazardous material, using less hazardous
process conditions, and designing a process to reduce the
potential for, or consequences of, human error, equipment
failure, or intentional harm. Minimize •To minimize is to
reduce the amount of potential energy present (i.e., get the
system closer to a zero energy state), thus reducing the potential
impacts if containment or control of the hazard is lost Some
Minimize Strategies •Some strategies for making a process
inherently safer by minimization : •Inventory reduction; e.g., –
–fewer
tanks; just-in-time delivery –less vapor volume –generate on
demand (chlorine, MIC, ammonia, hydrogen...) –receive by
pipeline instead of by truck or rail •Process intensification
•Process operation closer to ambient conditions Ultimate Case
Ultimate case of minimization: •Elimination of the hazard; e.g.,
–Eliminating use of a particular hazardous material –Operating
the system at a zero energy state with respect to a particular
hazard –Shutting down the process –Using a toll manufacturer
(risk transfer ) Substitute • To substitute is to replace with a less
hazardous material or condition Some strategies for making a
process inherently safer by substitution : •Commercially
available alternatives •Alternative raw material or intermediate
that can be transported and stored more safely •Alternative
chemistry –Propylene oxidation process instead of Reppe
process for manufacture of acrylic esters –Biosynthesis routes
Substitute - Chlorine example •Chlorine Substite –Sodium
hypochlorite –Calcium hypochlorite –Hydrogen peroxide –
Chlorine dioxide –Bromine –Mixed oxidants Substitute –
Solvent Example •Solvent substitutes: –Water-based paints,
adhesives –Aqueous cleaning systems –Less volatile solvents;
higher flash point –Dibasic esters for paint stripping Attenuate
•To attenuate (or moderate) is to handle a material under less
hazardous process conditions. •Note: Available energy may be
the same, but potential loss event impacts can be reduced Some
strategies for making a process inherently safer by attenuation :
•Dilution ◦ E.g., using in aqueous instead of anhydrous form –
Using in solution such that the solute would boil off before a
runaway reaction temperature was achieved –Lower
concentration of benzoyl peroxide in paste –Mixing coal dust
with rock dust •Refrigeration –E.g. storing anhydrous ammonia
as a refrigerated liquid instead of as a liquefied gas Simplify
•To simplify is to eliminate unnecessary complexity. •Some
simplification strategies: –Use simpler equipment arrangement
•E.g., gravity flow •Natural convection –Eliminate
interconnections to reduce the likelihood of inadvertent mixing
–Minimize number of flanges, connections, and other potential
leak locations Limit Effects •The greatest opportunity to limit
effects is generally by increasing the distance between the
potential loss event location and the people, property and
environment that could be affected. Implementation in the Life
Cycle •IST is a philosophy, applied to the design and operation
life cycle, including manufacture, transport, storage, use, and
disposal. • IST is an iterative process that considers such
options, including eliminating a hazard, reducing a hazard,
substituting a less hazardous material, using less hazardous
process conditions, and designing a process to reduce the
potential for, or consequences of, human error, equipment
failure, or intentional harm. Two Basic IS Activities 1.Design
and build inherent safety into a process. 2.Continually look for
ways to reduce or eliminate hazards throughout the process life
cycle. Most effective life cycle phases to review a process for
opportunities to make it inherently safer –R&D –Conceptual
design –Detailed engineering –Routine operation Inherently
Safety Review Typical inherent safety review steps: 1.Collect
and review background information 2.Identify / define
/document the major hazards 3.Review the process flow
schematic –Look at each process step and hazardous material –
Identify creative ways to improve the process by applying
inherently safer principles to reduce or eliminate hazards
4.Document the review and follow-up actions Limitation of IS
Inherently Safer does not necessarily mean lower risk! •Process
change may introduce new hazards –E.g., hydrogen gas
generated by hydrolysis •Loss event likelihood may be affected
–E.g., Supplying from many small cylinders instead of one
large cylinder increases frequency of connecting and
disconnecting cylinders •Loss event severity can also be
affected
–E.g., total containment increases burst pressure
PROCESS SAFETY OVERVIEW
Process Safety Overview 1. What is Process Safety ?- has been
defined in a number of ways 2. Opposite of Process Safety:
Major Incidents
3. The Anatomy of Process Safety Incidents4. Overview of
Process Safety Strategies 5. Taking advantage of past
experience6. Defense in depth/ layers of protection 7. Elements
of process Safety Management
Background
*Within the past ten or fifteen years the chemical and petroleum
industries have undergone considerable changes
– Process conditions: more severe P, T
– Stored material concentration has increased
with Special Reference to Plant Design
– Plant Size and single stream
– Interlinking storage
– Faster proces respons
– Very large items of equipment
– Growing of the scale of possible fire, explosion and toxic
releases and growing of the might be affected area
*Greatly increased the potential for loss both in human and in
economic terms, increasing concern forindustry, insurance and
historical loss statistics
*Relatively good attention on safety has been no longer
sufficient with the growing scale and complexity in modern
plants increasing concern and adequacy of existing procedures.
*During that period there has been growing public concern
about the various forms of pollution, including gaseous and
liquid effluents and solid wastes and noise
*an engineering approach is therefore adoptec and as far as
possible both the hazards and the protection are evaluated
quantitatively.
DEFINISI PROCESS SAFETY : ketiadaan akan kehilangan
atau bahaya dari api, ledakan, dan pelepasan materi berbahaya
pada fasilitas proses (event-focused definition); ketiadaan tsb
dicapai dengan: *identifikasi bahaya proses *bahaya tsb
dibatasi & dikontrol *menangani situasi abnormal dgn
pengamanan yg efektif.
Proses safety: operasi/fasilitas yg menangani, memakai,
memproses/menyimpan materi berbahaya dan terbebas dari
insiden yg tidak disengaja/berbahaya (fokus di safety
&environment ; probability rendah tapi konsekuensi tinggi ;
perlu ahli teknik terkait proses dan material ; tanggung jwb oleh
senior management & engineer). Tujuan : melindungi aset dan
lingkungan.
Personal safety :lebih fokus ke safety & health ; probability
tinggi tapi konsekuensi umumnya rendah ; tanggung jwb oleh
frontline worker & supervisor. Tujuan : melindungi dari cedera
dan sakit (perlu peralatan pelindung, operational integrity dan
lower incident cost)
Proses safety management (PSM): aplikasi dr sist manajemen
u/ identifikasi, mengerti, dan mengontrol bhaya proses u/
menghindari kecelakaan/luka.
CCPS (Center for Chemical Process Safety,): guideline u/
technical management proses safety kimia.
“Proses”:aktivitas yg melibatkan bhn kimia yg sangat bbahaya
termasuk penggunaan, penyimpanan, pembuatan, penanganan /
pemindahan on-site, atau kombinasi dr aktivitas tsb.
Major Process Incident 1)Flixborough,UK(Juni‘74):
*oksidasi parsial sikloheksan *kegagalan dlm temporary piping
*dlm 30s, 30 ton siklo terlepas *ledakan vapor cloud *28 fatal,
53 luka, 1800+ *muncul di UK ―Health & Safety at Work Act‖
2) Seveso, Italy (july‘76):terlepasnya dioxin, 80000binatang
mati /dibunuh, plant dihancurkan. EU ―Seveso Directive‖
3)Mexico-nov‘84 ledakan, boiling- liquid-expanding-vapor
explosions (BLEVEs), tanki meroket 1200m 4) Bhopal,India-
dec‘84: MIC toxic vapor terlepas. Seveso II, EPA Risk
Management Program. 5)Pasedena,texas okt‘89: hidrokarbon
terlepas 6)Toulouse,Prancis-sept‘01: ledakan tangki
ammonium nitrat. 7)Texas BP America Refinery Explosion-
mar‘05 *One valve not opened during unit re-start*Release of
hot flammable material from blowdown*Ignition and vapor
cloud explosion*. 8)Buncefield,UK-dec‘05:tangki
penyimpanan overflow, meledak
Sejarah dan Evolusi Safety
-Sudah sejak awal peradabannya manusia berkepentingan
dengan Safety
-Ada berbagai perspektif perkembangan Safety yang signifikan
(manajemen, hukum dsb) , diawali dari era Revolusi Industri
yang ditandai ketidak siapan semua pihak (―Sweat Shops‖)
-Sampai dengan pertengahan abad 20 bertahap muncul
kesadaran global dari berbagai pihak dan memikirkan upaya
untuk menghindari kecelakaan dan mencari penyebabnya
(Occupational Safety and Health Act 1970, OSHA, UK –
Health & Safety at Work Act 1974, UU no 1/1970
Keselamatan dan Kesehatan Kerja)
-Pertengahan abad 20 Dimulainya konsepsi Safety Manajemen
K3 (SMS)
-Tahun 1990-an Sistem Manajemen K3 (OHSAS 18001 dsb)
dan sertifikasinya
-Tahun 1980-an Mulai muncul pemikiran Process Safety dan
PSM, didorong oleh insiden besar pabrik Kimia di Eropa dan
USA dan terus berkembang
-2007 Muncul konsep Risk Based Process Safety
The development of loss prevention can be clearly traced
through the literature
-1960 the first of a periodic series of symposia on Chemical
Process Hazards
-1964The Dow Chemical Company published its Process
Safety Manual
-1967 The AIChE started an annual series of Loss Prevention
symposia .
-1971 The European Federation of Chemical Engineers‘
symposium on Major Engineers‘ symposium on Major Loss
Prevention in the Process Industries at Newcastle
-1973 the creation of Engineering Practice Committee of a
Loss Prevention Panel by the Institution of Chemical Engineers
-1974 the Federation‘s symposium on Loss Prevention and
Safety Promotion in the Process Industries at Delft
-In the United Kingdom the Health and Safety at Work etc. Act
1974 has given further impetus to loss prevention (embodied in
the Act, is that of self- regulation by industry)
-1974 Flixborough disaster
Penyebab kecelakaan dan kerugian fasilitas kimia
– Kerusakan mekanikal 41 %
– Kesalahan operasi 19 %
– Gangguan proses 10 %
– Bencana alam dan yang sejenis 5 %
– Laing-lain 25%
Kerusakan mekanikal
– Perpipaan (31%); - Tangki penyimpan 17 %; -Reaktor
13%; -Bejana proses 7%; -Peralatan laut 6 %; -Lain-lain
26 %
ALASAN PENERAPAN PSM
Menghidari bencana terlepasnya bahaN kimia yang sangat
berbahaya KARENA :
– Temperatur dan tekanan lebih tinggi
– Lebih banyak energi tersimpan didalamproses
– Pabrik lebih terintegrasi
– Masyarakat menuntut pengoperasian
– Kegagalan manajeen merupakan akar masalah dari
sebagian besar (90%) insiden
– Perlu adanyapendekatan terpadu dalam mengendalikan
bahaya kimia
– OSHA PSM terdiri dari 14 elemen
Proses Hazard, DEFINISI :adanya hubungan antara material
yg disimpan dan energi (energy hazard) yang terkait dengan
inherrent characteristic(material hazard) dan memiliki
potensi untuk menyebabkan kerugian atau kerusakan
(chemical interaction hazard)
3 Tipe process hazard :1.material hazard (terkaitnya suatu
proses material dgn 1/lebih bahaya) ; 2.energy hazard (suatu
bentuk energi fisik yang terkndung/ terhubung dgn proses yg
punya potensi kerugian atau kerusakan); 3.chemical
interaction hazard (adanya bahan yg saling brinteraksi dengan
potensi kerugian/kerusakan, dgn cara yang ga disengaja/ga
terkontrol).
Material hazard  Inherent characteristic (flammability,
toxicity, instability, corrosivity).Flammability (flash point; heat
of combustion; sesuatu yg mudah menyala).Safety Data
Sheet(SDSs)—Berisi ringkasan lgkp dr hazard; d‘perlukn untuk
d akses d t4 krja; berisi smua bhan brbahya d t4 krja; tersedia
smua dr pemasok(internet); hanya mmberikan informasi dasar
reaktivitas kimia; biasa ga konsisten dr sumber ke sumber
Keterbatasan : NFPA704 dan SDSs hanya mmberikan properti
untuk material bahaya yg individu (energi pd bahaya gada;
interaksi kimia gada; apabila hazard brinteraksi dgn yg lain jg
gada)
Derajat bahaya : energi makin jauh dr 0  bahaya >>
ANATOMI PROSES SAFETY INCIDENTS (DEFINISI).
Insiden: peristiwa yg ga direncanakan/mengakibatkan/punya
potensi merugikan.
Process Inds. Incidents:Api, Ledakan, pelepasan bhn kimia
(33nya=loss event) menyebabkan dampak: fatalitas,
luka/penyakit, lingk rusak, evakuasi property yg rusak,
kerugian, plant tutup, denda, perkara hukum.
KEY DEFINITION.Loss event: Suatu waktu dlm situasi
abnormal dimana tindakan nonfisik yang terjadi memiliki
dampak bahaya maupun kehilangan (loss). Cth: terlpeasnya bhn
kimia bbahaya;EX: terbakarnya flammable vapor/dust cloud;
tekanan dlm tangki tllu tinggi.
Why do loss event happen? *kita menangani materi & energy
proses yg berbahaya u/ cari uang & menyediakan masy.Produk
yg mereka butuhkan.*selama kita menangani hal tsb, maka ada
potensi terjadinya loss event (namun ada cara2yg dpt dilakukan
u/ mengurangi kemungkinan / konsekuensi terjadinya loss event
hingga tngkat yg bisa ditoleransi.
How Do Loss Events Happen?  melalui ANATOMY OF
AN INCIDENT dan karena UNSAFE ACT & CONDITION
PRECURSOR
Analogi:kita handle harimau di zoo u/ cari uang&kasih tunjuk
masy.
Process Safety menghindari kerugian atau kerusakan pada
fasilitas proses dengan :a.) mengidentifikasi bahaya proses, b.)
Mengendalikannya dan c.)Melawan situasi yang tidak biasa/
abnormal dengan perlindungan yang efektif.
How do loss events happen? Anatomy of an incident, Unsafe
act & condition precursors
Anatomy of an incident : normal operation : During normal
operation, all hazards are contained and controlled… initiating
cause : • Every incident starts with an initiating cause initiating
cause (also called an initiating event or just a ―cause‖ Example
initiating causes (– Feed pump fails off -Procedural step
omitted -Truck runs into process piping – Wrong raw material
is received –Extreme low ambient temperature) • Once an
initiating cause occurs, normal operation cannot continue
without a process or operational response
Anatomy of an incident – deviation : The immediate result of
an initiating cause is a
deviation. Deviation : - No Flow -Low Temperature -High
Pressure -Less Material Added -Excess Impurities -Transfer to
Wrong Tank -Loss of Containment
Anatomy of an incident – abnormal situation: normal
situation (Most engineering focuses on designing t ka process to
work); abnormal situation (We must also consider how a
process can fail, starting with abnormal situation)
Incident sequence without safeguards: cause deviation  lost
event  impacts. How do loss event occur? 1 Anatomy of an
incident 2 Unsafe act and condition percursors
What Must Be Done?
Alternatives to be done:
1. Overview of Process Strategies
2. Taking advantage of past experience
3. Defense in depth/ Layers of Protections
4. Elements of Process Safety Management
Taking Advantage of the Past Experience : Using Past
Experience
Regulations, Codes, Industry standards, Company standards,
―Best practices‖ Handbooks, Guidelines, Procedures,
Checklists, Supplier, Recommendations
• One term commonly used for non iregulatory codes and
standards is ― RAGAGEPs‖
• From U.S. OSHA‘s Process Safety Management Standard
(Process Safety Information element):
29 CFR 1910.119(d)(3)(ii) The employer shall document that
equipment complies with recognized and generally accepted
good engineering practices.
Overview of Process Strategies
RAGAGEPs
Recognized and Generally Accepted Good Engineering
Practices
◦Take advantage of wealth of experience
◦Pass on accumulated knowledge
◦Reduce recurrence of past incidents
◦Enable uniformity of expectations
◦Reduce liabilities when followed Definisi kunci : safeguard adalah device, sistem, atau aksi yang
Example: Anhydrous Ammonia cenderung mengganggu rantai peristiwa yang mengikuti
Regulatory requirements: penyebab awal atau yang dapat memitigasi dampak
E.g., U.S. OSHA Standard 29 CFR 1910.111,E.g., U.S. OSHA kehilangan. Dua tipe safeguard :
Standard 29 CFR 1910.111, ―Storage and Handling of
Anhydrous Ammonia‖
Industry standards
◦CGA G-2, ―Anhydrous Ammonia‖
◦ANSI/CGA K61.1, ―American National Standard Safety
Requirements for the Storage and Handling Safety
Requirements for the Storage and Handling of Anhydrous
Ammonia‖
Other standards apply to specific applications, e.g., EN 378 for
ammonia refrigeration Prventive safeguards: Operational mode: operasi abnormal;
RAGAGEPs Alphabet Soup : IEC, NFPA, ASME, ISA, UL, tujuan: untuk mendapatkan kembali kontrol atau shutdown,
FM, CGA, BS, DIN, ASHRAE, IIAR, ASTM, API, mencegah terjadinya loss. Contoh preventive safeguards:
AIChE/CCPS, IRI, Chlorine Institute, SOCMA, etc.
operator merespon alarm, sistem instrument safety, hardwired
Layers of Protection
interlock, quench, blowdown, last resort dump, emergency
• Also called ―Safety layers‖
relief system
• Multiple layers may be needed, since no protection is 100%
reliable
• Each layer must be designed to be effective
• Each layer must be maintained to be effective
• Some layers of protection are contain and control measures
• Other layers of protection are safeguards
Layer dari proteksi : disebut juga “layers keamanan”, beberapa
layer bisa dibutuhkan krn tdk ada 100% layer yg bs diandalkan,
setiap layer harus didesain u/ efektif dan dijaga u/ slalu efektif,
beberapa lapisan proteksi mengandung mengontrol langkah-
langkah, layer lainnya adalah pelindung
“Lapisan proteksi” dianatara bahaya dan penerima bahaya
pertahanan mendalam Mitigasi: operational mode: emergency; tujuan: meminimalisir
Contain&control : operational mode  normal operation, dampak, contoh mitigative safeguards: sprinkler, monitor,
objektifmengendalikan normal operation, menjaga bahaya
deluge, emergency warning system, emergency response,
slalu terlindungi dan terkendali, contoh dari langkah-langkah
―contain and control‖sistem kontrol proses yg secondary containment, discharge scrubbing, flaring, treatment,
basic/mendasar, inspeksi-pengujian-perawatan, pelatihan etc
operator (bagaimana mengoperasikan system scara benar dan
konsisten, bagaimana menjaga proses dlm batas yg ditetapkan),
pelindung u/ melindungi dari bahaya luar (manajemen
perubahan)
Elemen program PSM komprehensif: sistem mgt, partisipasi
pekerja, informasi process safety, process hazard analysis,
prosedur operasi, training, safety kontraktor, pre-startup safety
reviews, mechanical integrity, safe work practives, mgt of
change, emergency planning and response, investigasi insiden,
audit yang sesuai. CCPS Process safety mgt:cakupan (elemen2
PSM): 1. Akuntabilitas 2. Pengetahuan tentang proses dan
dokumentasi 3. Capital project review dan desain prosedur 4.
Process risk mgt 5.Mgt of change 6.Process and human
integrity 7.Factor manusia 8.Training dan performance
9.Investigasi insiden 10.Standar perusahaan, kode, regulasi
11.Audit dan langkah2 perbaikan 12. Pengembangan process
safety knowledge Elemen2 OSHA 29 CFR 1910.119: 1.
Process safety information 2.Keterlibatan pekerja 3.Process
hazard analysis 4.Prosedur operasi 5.Training 6.Kontraktor 7.
Pre-startup safety review 8. Mechanical integrity 9. Hot work
10. Mgt of change 11.Investigasi insiden 12.Emergency
planning dan response 13. Kesesuaian audit 14.
Trade‖perdagangan?‖ rahasia
API RP 750: 1. Process safety information 2.Prosedur operasi
3.Mechanical integrity 4.Process hazard analysis 5.Praktek2
bekerja aman 6.Training 7.Mgt of change 8. Pre-startup safety
review 9. Emergency review 10.Investigasi insiden 11. Audit
The Four Pillars of RBPS •Commitment to process safety is the
cornerstone of process safety
excellence. (strong leadership and solid management
commitment) • Understand hazards and risk experience has
demonstrated that businesses using hazard and risk information
to plan, develop, and deploy stable, lower-risk operations are
much more likely to enjoy long-term success. •Managing risk
focuses on four issues: (1) prudently operating and maintaining
processes (2) managing changes, (3) maintaining the integrity
of equipment and assuring quality of materials, fabrications,
and repairs, (4) preparing for, responding to, and managing
incidents that do occur. •Learning from experience involves
monitoring, and acting on, internal and external sources of
information. Despite a company‘s best efforts, operations do
not always proceed as planned, accidents and near misses occur
The twenty elements are described in more detail in the
following sections. Comparison of RBPS elements to OSHA
PSM elements
Personal Protective Equipment
Things to do to have effective safe dress & PPE
• Be familiar with the required standards and regulatory
requirements
• Be able to recognize hazards
• Be familiar with the best safety equipment available
• Know the procedures
• Know how to maintain and clean the equipment
• Develop an effective method for persuading employees to
dress safely and to wear proper PPE
Protections : • Eyes • Face • Feet and Legs • Head • Ear •
Fingers, palms, and hands • Respiratory • Safety belts and
harnesses • Life lines (Manila rope) • Ionizing radiation •
Hair style
Causes of eye injury : •Flying objects e.g. from hand tools
•Abrasive wheel (small flying particles) •Corrosive substances
•Injurious light or heat rays •Splashing metal •Poisonous gas or
fumes
Eye protective equipment :
• Cover goggles (protect both the eyes and corrective lenses) •
Protective spectacles (without side shields) • Spectacles with
side shields • Cup goggles • Splash resistant goggles • Dust
goggles • Miners‘ goggles ( for fogging problem with corrosion
resistance wire screen) • Melters‘ goggles (with Cobalt blue
glass) • Welders‘ goggles (with filter lenses)
Face protection : • Face shields • Babbitting helmets
(protect against splashes of hot metal) • Welding helmets
(protect against molten metal & radiation) • Hand held shield
(used where the conevience of a helmet is not needed • Hoods
with air supply (worn for work around toxic fumes, dusts,
mists, or gases)
Feet protection : • metal free shoes for electrical hazard •
‗congress‘ or gaiter type shoes for molten metal protection •
reinforced soles (protruding nail hazards) • shoes for wet work
conditions • shoes with metatarsal guards for operation with
heavy materials)
Leg Protection : • legging • knee pads
Fingers, palms, hands protection:
• asbestos glove – burn protection
• metal mesh glove – protect against cut & blows • rubber glove
– for electrician
• rubber, neoprene, vinyl – for handling chemicals • leather
gloves • chrome tanned cowhide leather gloves – used in
foundries and steel mill • cotton gloves – against dirt or
abrasion • coated fabric gloves – protect against chemical
Ear protection : • Insert type • Muff type – acoustic barrier
Respiratory protection:
• air purifying devices – remove contaminant from air
• mechanical filter – protect against dust • chemical cartridge
respirator
• gas mask (mouth/ face piece and canister) : black – organic
vapor ; white – acid gases ; yellow – organic vapor & acid
gases ; green – ammonia etc
• hose masks with or without blower
• supplied air devices
• abrasive blasting helmet
• self contained breathing apparatus - portable air supply
Safe work clothing
- Safe :
• clean, good repair and suited for the job • good fit • no specific
hazard: nectie, loose sleeves • jewelry • cap to protect hair from
oil etc
- Material for protective clothing :
• aluminized and reflective clothing – radiant heat • asbestos –
intense conducted heat • flame resistant cotton fabric • flame
resistance duck – lightweight and strong • glass fiber – for
construction, etc
Why PPE is Important
•Personal protective equipment (PPE) is designed to prevent or
lessen the severity of injuries to workers.
•The employer must assess the workplace and determine what
hazards may necessitate the use of PPE before assigning PPE to
workers.
How Hard Hats Protect You
•A rigid shell that resists and deflects blows to the head;
•Suspension system inside acts as a shock absorber •Some hats
serve as an insulator against electrical shocks •Shields your
scalp, face, neck, and shoulders against splashes, spills, and
drips •Some can be modified so you can add face shields,
goggles, hoods or hearing protection
Hardhat Inspection
•Shells should be inspected for dents, cracks, gouges & any
damage from impact, penetration, abrasions, rough treatment or
wear.
•Degradation of thermoplastic material may be apparent when
the shell becomes stiff, brittle, faded, dull in color or chalky in
appearance.
•Replace at the first sign of any of these conditions
 Eye & Face Protection
PPE for Impact Hazards
•Safety Glasses: Primary protectors intended to shield the eyes
from a variety of impact hazards
•Goggles: Primary protectors intended to shield the eyes against
flying fragments, objects, large chips, and particles.
•Face Shields: Secondary protectors intended to protect the
entire face against exposure to impact hazards
Ventilated Goggles
Ventilated goggles allow air circulation while providing
protection against airborne particles, dust, liquids or light.
Available with either Direct or Indirect ventilation
•Direct ventilation goggles: Where strenuous work is done in
hot conditions, 'direct ventilation' goggles may be more
suitable. However these are unsuitable for protection against
chemicals, gases and dust
•Indirect ventilation Goggles: 'Indirect ventilation' goggles are
not perforated, but are fitted with baffled ventilators to prevent
liquids and dust from entering. Indirect ventilation goggles will
not protect against gas or vapor.
Non-Ventilated Goggles
Do not allow the passage of air into the goggle ; Prevent splash
entry; May fog and require frequent lens cleaning
Faceshields
• DO NOT use any faceshield unless you also wear suitable
primary eye protection devices (spectacles or goggles).
• Faceshields are heavier & bulkier than other types of eye
protector but are comfortable if fitted with an adjustable head
harness.
• Faceshields protect the face but do not fully enclose the eyes
and therefore do not protect against dusts, mist or gases
–Transparent face shields must be replaced when warped,
scratched or brittle with age
 Hearing Protection
EPA and ANSI
•EPA is responsible for determining adequacy of hearing
protector attenuation (NRR).
•EPA adopts ANSI‘s protocol for making the determination
•ANSI has issued a new protocol for the labeling regulation for
hearing protectors that has yet to be adopted by EPA
•EPA is collecting information on revising their labeling
regulation
Hearing Protection : •Ear plugs •Ear muffs •Audiometric
testing •More information provided in training on hearing
conservation
 Respiratory Protection
Respirators
• A hazardous task assessment may be done to determine if you
need to wear a respirator
•If you are required to wear a respirator you will be included in
our respiratory protection program
•You must be medically cleared to wear a respirator
•In addition to the initial fit-test, wearers must check the seal of
their respirators every time they put them on
•User seal checks are necessary to ensure that the respirator has
been put on correctly
Dust Masks
•Only suitable for non-hazardous, non-respirable nuisance
dusts.
•If your employer provides respirators for your voluntary use,
or if you provide your own respirator, you need to take certain
precautions to be sure that the respirator itself does not present
a hazard.
Respirator Ratings
•―N‖ if they are not resistant to oil
•―R‖ if somewhat resistant to oil, and
•―P‖ if strongly resistant (oil proof).
Hood Respirators : Helmet or hood respirators can be
effective in protecting workers with facial hair, or in other
applications where conventional respirators do not provide
adequate fit, comfort or protection
 Hand Protection
Why It’s Important
•It has been estimated that almost 20% of all disabling accidents
on the job involve the hands
•Some examples of traumatic injuries to your hands:
–Cuts: Tools and machines with a sharp edges
–Punctures: Staples, screwdrivers, nails, chisels and stiff wire
–Sprains, Crushing Injuries: Getting your hands caught in
machinery
Hand Protection
•Gloves: Cotton, Leather, Latex, Viton, Butyl, Neoprene, PVC,
Nitrile, Other
Disposable Vinyl
•Deliver comfort, flexibility, sensitivity
•Translucent white, 5-mil vinyl
•Non-allergenic alternative to latex
•Lightly-powdered or powder-free
Coated Gloves
•Provide cut, puncture and abrasion-resistancene •Latex coating
on palm, fingertips and thumb •Crinkle finish for superior grip
in wet and dry applications •Tacky nitrile coating for sure grip
•Light nylon shell for dexterity
•Offers better fit and grip than uncoated cotton or string knit
gloves
Reusable Latex
•Versatile, reusable Latex
•18-mil, 100% natural latex – excellent tensile strength and
sensitivity; good grip
•Resists detergents, acids, salts, caustics, fats and alcohol
•Cotton lining for ease of donning
•12‖ length protects wrists and forearm
Disposable Latex
•Strong, comfortable and economical
•Textured fingertips for secure grip
•Available lightly powdered or powder-free
Latex + Neoprene
•Comfort of latex plus the chemical protection of neoprene
•Provides excellent chemical resistance against acids, oils,
grease, salts, animal fats and battery acid
•Resist puncture, tears and abrasion
•Ideal for auto and battery manufacturing, chemical plants,
cleaning printing presses and wiping down machinery
Butyl
•Offers greater resistance to gas and water vapors than
Neoprene
•Provides greater safety when handling toxic substances like
ketones, esters, etc
PVC/Nitrile Gloves
•Gloves are PVC with nitrile-reinforced coating
•Textured to improve wet grip
•Cotton interlock liner for comfort
Reusable Nitrile
•Excellent resistance to a variety of solvents and petroleum
products
•Resist most liquids
•Resist cuts, snags, punctures, swelling and degradation by
organic solvents and hydrocarbons
 Foot Protection
Why It’s Important
•Compression Injuries Heavy machinery, equipment, and other
objects can roll over your feet. The result of these types of
accidents is often broken or crushed bones.
•Injuries from Spills and Splashes Liquids such as acids,
caustics, and molten metals can spill into your shoes and boots.
These hazardous materials can cause chemical and heat burns.
What kind of shoe should electricians wear? Shoes with non-
conductive soles meeting the requirements of ANSI Z41 PT9l
(M/F) I-75 C-75 EH. "EH" represents the "electrical hazard"
designation
Types of Foot Protection: •Work shoes •Boots •Steel-toed
shoes & boots
Protective Clothing and Vests : •Uniforms •Disposable
clothing •Vests (Cooling, Visibility) •Cold weather protection
General Welding Safety: Personal Protective Equipment
(PPE); Welder is properly grounded; Adequate ventilation;
Work in a Firesafe zone; First-Aid Kit
Analisa Bahaya dan risiko
Ada beberapa defisini hazard (lihat sebelumnya) dan risiko,
antara lain
•Bahaya (hazard): Adanya material atau suatu kondisi yang
berpotensi mengakibatkan kehilangan atau kerugian
•Risiko: gabungan besar kecilnya dampak dari suatu kejadian
yang tidak diinginkan dengan kemungkinan terjadinya kejadian
tsb., atau
Risiko = besarnya dampak x kemungkinan terjadi
Process hazard analysis.
•A hazard evaluation of broad scope that identifies and
qualitatively analyzes the significance of hazardous situations
associated with a process or activity (CCPS)
•The process hazard analysis is a thorough, orderly, systematic
approach for identifying, evaluating, and controlling the
hazards of processes involving highly hazardous chemicals.
(OSHA)
•A Process Hazard Analysis (PHA) is a structured team review
of an operation involving hazardous materials/energies, to
–identify previously unrecognized hazards (dibahas di bab lain)
–identify opportunities to make the operation inherently safer
(dibahas di bab lain)
–identify loss event scenarios,
–evaluate the scenario risks to identify where existing
safeguards may not be adequate
–document team findings and recommendations
Experienced Bases PHA
•Menentukan pelindung (safeguards) tanpa mengkaji skenario
•Menggunakan pengalaman kolektif
•Metoda ini membandingkan dengan RAGAGEPs (recognized
and generally accepted good engineering practices )
Ciri Pendekatan Pengalaman
•Efektif untuk memanfaatkan pengalaman •Dapat diterapkan
sepanjang daur hidup fasilitas •Tidak ditujukan untuk
melakukan analisa terhadap yang rendah kemungkinan
terjadinya dan dampak yang besar •Tidak sesuai untuk proses
yang kompleks dan unik •Contoh metoda yang digunakan:
Tinjauan safety; Bagaimana seandainya (What-if)
Check-list
•Membuat daftar yang menyatakan status suatu sistem •Dapat
digunakan untuk analisa bahan, alat dan prosedur •Dilakukan
kelompok •Membuat daftar pertanyaan untuk suatu obyek dan
memilih jawabnya ya/tidak, misalnya cara penyimpanan
material, ada tidaknya pengaman dsb •Identifikasi bahaya LESS OF : Drop below intended lower limit
proses dan peralatan biasanya menggunakan PFD dan P&ID PART OF: Achieve part of intent
Metoda Prediktif AS WELL AS : Something in addition to intent
•Kualitatif atau kuantitatif REVERSE : Logical opposite of intent occurs
•Semua metoda prediktif didasarkan pada skenario (scenario OTHER THAN : Something different from inten
based) Bagaimana menerapkan Intent dan Deviasi
•Mampu digunakan untuk melakukan analisa pembuatan •Jangan memunculkan deviasi sebelum keingingan (intent)
proteksi (safeguard) untuk proses yang kompleks, yaitu dijelaskan, didokumentasi dan disepakati
berdampak besar dan kecil kemungkinan terjadinya •Daftar deviasi dapat dimulai setelah intent dinyatakan
Analisa Sebab (Initiating Cause)
Identifikasi penyebab: •Lihat urutan sebelumnya (hanya untuk
node ybs saja) •Umumnya ada beberapa penyebab yang
mungkin
Tujuan Analisa Prediktif Analisa Kejadian Kehilangan (Loss Events)
Sasaran scenario based ialah mengidentifikasi dan menganalisa •Tentukan dampak dari sebab dan deviasi •Andaikan terjadi
semua skenario kegagalan skenario terjadi kehilangan •Penyebab sifatnya lokal sedangkan
–Biasanya tidak mungkin dilakukan hanya dengan inspeksi, dampak dapat terjadi dimana saja dan kapan saja
diperlukan metoda yang lebih sistematik
–Dalam praktek ada cukup banyak skenario dapat tergantikan
dengan logika dan pengalaman, yaitu bila: Kemungkinan
terjadinya dapat diabaikan; Konsekuensinya sangat kecil
Contoh Pendekatan Prediktif
1. What-If Analysis 2. What-If/ Checklist Analysis 3. Hazard
and Operability (HAZOP) Study 4. Failure Modes and Effects HAZOPs Procedure
Analysis (FMEA) 5. Fault Tree Analysis (FTA) 6. Event Tree 1.Awali dengan diagram alir rinci, mis P&ID
Analysis (ETA) 2.Pilih titik atau node yang akan dievaluasi (bejana, pipa,
Metoda Kualitatif – What If? instruksi kerja)
•Konsep: Melakukan pengamatan sistematik dengan 3.Jelaskan kondisi yang diinginkan (design intent) pada titik tsb
memunculkan pertanyaan dimulai dengan ―Bagaimana 4.Pilih paramater proses: flow, level, tekanan, etc
seandainya …….?‖ 5.Terapkan kata pemandu (guide word) pada parameter proses
•Dilakukan oleh kelompok +/- 5 orang, yang tugasnya untuk memperkirakan deviasi yang mungkin terjadi to the
memunculkan dan mencari solusi atas berbagai pertanyaan process parameter to suggest possible deviations.
yang relevan 6.Kalau deviasi sesuai (applicable), tentukan penyebabnya dan
•Analisa dilakukan per segmen, dimulai dari awal proses pelindungnya
sampai akhir 7.Perkirakaan konsekuensi dari deviasi tsb., kalau ada
•Biasanya pertanyaan terletak pada ―sebab‖ (initiating cause), 8.Sarankan tindak lanjutnya (Apa? Oleh siapa? Kapan?)
dan jawabannya mengikuti skenario atau anatomi insiden 9.Catat semua informasi
Panduan Jawab atas What if…? 10.Ulangi langkah 5 s/d 9 hingga semua guide words yang
•Terapkan pada setiap segmen: sesuai sudah dipilih
1.Jelaskan potensi konsekuensi dan dampaknya 11.Ulangi langkah 4 s/d 10 sampai semua parameter proses
2.Bila konsekuensi tsb relevan, lakukan probabilitasnya yang dapat diterapkan sudah dipertimbangkan untuk suatu node
3.Cari dan kaji pelindung (safeguards) yang dapat diterapkan 12.Ulangi langkah 2 s/d 11 sampai semua node sudah
4.Tentukan jenis pelindung yang memadai dipertimbangkan untuk suatu seksi, dan teruskan ke section
5.Kembangkan semua temuan dan saran-saran seperlunya berikutnya pada P&ID tsb
6.Munculkan pertanyaan lain
•Bila tidak ada pertanyaan tersisa, lanjutkan dengan analisa
segmen berikutnya
Pelindung
•Memadai tidaknya pelindung (safeguards) ditentukan
menggunakan skenario
–Apakah pelindung tsb independen?
–Apakah kecepatannya memadai?
•Skenario tergantung tiga hal: sebab (initiating cause), kejadian
kerugian (loss event) dan pelindung
•Kalau risiko terlalu besar pelindung tidak akan memadai
•Risiko dapat ditentukan dengan: pertimbangan kualitatif,
matriks risiko dan besarnya risiko
Hazard and Operability Study
•Definisi Hazard and Operability Study (HAZOP)
–HAZOP ialah sebuah teknik untuk identifikasi bahaya proses
dan potensi masalah operasional dengan menggunakan
beberapa guide words untuk mempelajari deviasi proses
•Dilakukan secara kelompok
•Parameter analisa harus jelas (temperatur, flow, prosedur dsb)
HAZOP
•Analisis dilakukan pada sebuah titik/fokus, disebut Node, yang
harus dipilih
•Node dapat berupa:
–Bejana proses; –Transfer line [•Asalkan pada sebuah titik
dimana terjadi perubahan parameter proses; •Di ujung
perpipaan, mis pada antarmuka bejana (vessel interface); Implementasi temuan-temuan dan Rekomendasi
•Perpipaan dapat juga termasuk pompa, kerangan, filter dsb.]; Apa yang penting dari PHA?
–Suatu langkah dalam sebuah prosedur 1. Laporan PHA 2. Pemahaman lbh mendalam ttg sistem ybs 3.
Guide Words Temuan-temuan dan rekomendasi 4. Langkah-langkah yang
•Guide Words diterapkan pada keinginan yang direncanakan harus diambil
(design intent), dengan tujuan melakukan identifikasi deviasi Failure Modes and Effect Analysis (FMEA)
dari operasi normal •Fokus pada kegagalan peralatan yang tidak saling tergantung
•Guide Words dan artinya (independent equipment) dan efeknya pada sistem yang lebih
NONE: Negation of intent besar •Tingkatan sistem dan sub-system: Pabrik, subsistem,
MORE OF:Exceed intended upper limit
peralatan, komponen •Good for systems with little human
interaction
Contoh Failure Mode
(gmbr lnjut bawah-nya)
SOAL UTS TAHUN LALU
1. Dlm melakukan analisa resiko pd process safety
management mmbuat model disperse gas beracun trmasuk
dlm analisa konsekuensi (B)
2. Metode proses hazard analysis yg dmulai dg mrumuskan
suatu akibat lalu mnelusuri rngkaian pnyebab2nya dsbt event
tree analysis (S)
3. Prubahan standard operation procedure merupakan cakupan
management of change (B)
4. Dlm defense in depth, keandalan salah satu proteksi suatu
fasilitas trgantung keandalan proteksi lain pd LOPA ybs. (S)
5. Di dlm instrumentasi pabrik yg lazim dsbt push button, ialah
suatu instrument yg dgunakan utk camp tgn operator
mngambil alih kendali dlm kondisi darurat (B)
6. Pljaran paling berharga dr strategi Bhopal ialah krn padatnya
pemukiman pnduduk di skitar pabrik (B)
7. Mrancang & mmbuat bejana mngikuti ASME code brarti
mngikuti prinsip RAGAGEP (B)
8. Mnyimpan ammonia pd kondisi tkanan atmosfir dg
mnggunakan unit refrigerasi mrupakan cara yg plg aman &
efisien (B)
9. Memilih suatu titik pd diagram PI&D dan mmbuat evaluasi
hazard pd ttik tsb dg mnggunakan scenario dan guide words
adalah slah satu metode process hazard analysis yg dsbt fault
tree analysis (S)
10. Suatu operasi pabrik kimia yg mngalami deviasi dr kondisi
aman akan brada dalam keadaan tdk aman bila dimatikan
(B)
Jlaskan mngama process safety dan psm sngat penting utk industry proses
dan me miliki prbedaan yg cukup signifikan dbandingkan dg occupational
safety / K3?
Process safety penting untuk industri proses karena dengan adanya process
safety, industri dapat terhindar dari kerugian atau kerusakan pada fasilitas
proses dengan cara: a.) mengidentifikasi bahaya proses, b.) Mengendalikannya
dan c.) Melawan situasi yang tidak biasa/ abnormal dengan perlindungan yang
efektif. Selain PS, PSM juga penting untuk industri proses karena PSM (dari
bahan kimia yang sangat berbahaya) memiliki tujuan utama untuk mencegah
pelepasan bahan kimia berbahaya yang tidak diinginkan terutama ke lokasi
yang dapat mengekspos karyawan dan orang lain untuk bahaya serius. Suatu
program manajemen keselamatan proses yang efektif memerlukan pendekatan
sistematis untuk mengevaluasi keseluruhan proses kimia. Dengan menggunakan
pendekatan ini, desain proses, teknologi proses, perubahan proses, kegiatan dan
prosedur operasi dan pemeliharaan, aktivitas dan prosedur non-rutin, rencana
dan prosedur kesiapsiagaan darurat, program pelatihan, dan elemen lain yang
mempengaruhi proses semuanya dipertimbangkan dalam evaluasi.
Perbedaan PS dan Occupational Safety
-Siapa yang dipertimbangkan?
lingkungan dan bisnis
-Insiden
Pengeluaran (biaya)
- kejadian.
besar (pembeliann alat proses baru, pemeliharaan peralatan yang ada, sampai
desain ulang proses)
SLIDE PPT PROCESS SAFETY CULTURE
Process safety cultire adalah Kombinasi dari nilai-nilai dan
perilaku kelompok yang menentukan cara di mana keselamatan
proses dikelola
Mengapa penting? Seperti fasilitas dalam industri dan shift
kerja yang baik berperan penting dalam menentukan perilaku
individu yang disiplin. Budaya yang sehat akan -membuat
anggotanya memahami mengapa kepatuhan yang ketat terhadap
prosedur dan kedisiplinan sangat penting.
Siapa saja yang berkepentingan dan bertanggung jawab me ngenai safety
culture ini
Pada dasarnya setiaporang di lingkungan perusahaan memiliki peran dan
tanggung jawab dalam safety culture sesuai dengan fungsi dan tugasnya
masing-masing
Direktur Utama
· Bertanggung jawab untuk memastikan bahwa sistem manajemen K3 telah
berjalan dengan baik dengan memberikan komitmen dan menetapkan kebijakan
termasuk memberikan sumber daya yang diperlukan.;· Melakukan tinjauan
manajemen secara berkala untuk melihat kinerja pelaksanaan SMK3 serta
memberikan arahan dan peningkatan yang diperlukan secara berkesinambungan
Board of Directors
· Memastikan proses yang diperlukan untuk Sistem Manajemen K3 ditetapkan,
diterapkan dan dipelihara.;· Melaporkan kepada Direktur Utama mengenai
kinerja Sistem Manajemen K3 dan peluang untuk perbaikan.;· Memastikan
kesadaran dari seluruh karyawan mengenai pentingnya memenuhi persyaratan
pelanggan.;· Bertanggung jawab terhadap pemecahan masalah / kendala dalam
pembangunan dan penerapan Sistem Manajemen K3 di semua unit kerja.;·
Memastikan penggunaan Standar Kerja/ Acuan Kerja terkini untuk masing-
masing unit kerja.;· Mewakili perusahaan untuk masalah Sistem Manajemen K3
terutama kepada Pihak Luar.;· Merencanakan dan melaksanakan serta
memantau Program Audit Internal serta Tinjauan Manajemen.;· Mengontrol
dokumen, seperti menerbitkan, perubahan, distribusi, penomoran dan
pemusnahan.;· Memelihara dokumen, seperti master dokumen Manual K3,
Prosedur, K3 Plan, Form, Catatan K3, Laporan Audit dan hasil Rapat Sistem
Manajemen K3; · Sebagai penghubung perusahaan dengan pihak luar yang
berhubungan dengan Sistem Manajemen K3.
Manager Proyek
· Bertanggung jawab terhadap keselamatan dan kesehatan dari seluruh pekerja,
kontraktor, tamu dan masyarakat ketika berada di bidang kerjanya.;·
Bertanggung jawab menyediakan sumber daya untuk penerapan sistem
manajemen K3 di lingkungannya masing-masing;· Bertanggung jawab untuk
memastikan bahwa peraturan perundangan dibidang K3 yang berlaku bagi
perusahaan telah dipenuhi;· Berwenang untuk menentukan suatu kegiatan dapat
diteruskan atau harus dihentikan berdasarkan penilaian resiko;· Berwenang
untuk mengeluarkan Laporan ketidak sesuaian;· Berwenang untuk mengambil
tindakan tegas terhadap tindakan-tindakan yang dapat membahayakan K3;·
Berwenang untuk memberlakukan keadaan dalam darurat ( emergency )
Manager HSE :
· Bertanggung jawab terjaganya dokumentasi sistem manajemen K3;·
Menerima tanggung jawab untuk memastikan sistem diterapkan diseluruh
bagian/fungsi;· Bertanggung jawab untuk memastikan sistem berjalan efektif
dan tetap sesuai dengan sasaran yang telah ditetapkan;· Bertanggung jawab
mendapatkan informasi peraturan yang terbaru;· Bertanggung jawab untuk
mengaudit sistem dan melaporkan kepada Board of Directors;· Bertanggung
jawab untuk melaksanakan komunikasi dengan eksternal;· Bertanggung jawab
mengevaluasi bahaya-bahaya dari proses yang ada atau yang baru dan untuk
menekan resiko-resikonya;· Bertanggung jawab menetapkan dan
mengembangkan rencana tanggap darurat; · Berwenang untuk mengeluarkan
laporan kecelakaan, laporan ketidak sesuaian dan tindakan perbaikan
Seluruh Manager :
· Bertanggung jawab untuk memastikan penerapan sistem manajemen K3 di
tempat kerjanya dan memastikan bahwa seluruh resiko yang ada di areanya
telah diidentifikasi, terdokumentasi, direkam dan dikendalikan;· Memastikan
bahwa program peningkatan K3 di area kerja mereka telah dijalankan dengan
baik;· Membina dan memastikan bahwa pekerja bawahannya termasuk pihak
ketiga telah memahami dan mematuhi semua ketentuan keselamatan kerja yang
berlaku.
Seluruh pekerja :
· Bertanggung jawab untuk memenuhi persyaratan sistem manajemen K3 setiap
saat di dalam menjalankan pekerjaannya masing-masing.;· Bertanggung jawab
melaporkan kecelakaan atau insiden atau tindakan yang dapat mengarah pada
insiden (unsafe condition) kepada atasannya dan merekamnya dalam buku
kecelakaan dan insiden;· Melaksanakan pekerjaan sesuai dengan ketentuan
keselamatan dan cara kerja aman yang berlaku untuk pekerjaannya masing-
masing, termasuk penggunaan alat keselamatan yang sesuai.
Budaya positif Budaya positif (safety culture) merupakan
―produk utama‖ dari process safety culture. Intinya, budaya
positif adalah kumpulan sikap, pandangan, serta perilaku yang
seharusnya dimiliki, baik secara individual maupun secara
keseluruhan organisasi, untuk membuat keselamatan (safety)
menjadi sebuah prioritas. Budaya positif seringkali dianggap
sepele, sehingga sering dikesampingkan oleh banyak
perusahaan
Contoh budaya positif : 1 Mengintegrasikan suatu keharusan,
2 Berfokus pada potensi kegagalan, 3 Menyediakan sumber
daya, 4 Menekankan untuk belajar dari pengalaman masa lalu,
5 Berusaha untuk terus meningkatkan kinerja, 6 Keterlibatan
dalam mengidentifikasi bahaya
Budaya safety negative pabrik gula madukismo :
1 Kebocoran Pipa air kondensat (65⁰ C) bocor dan
menyebabkan korosi pada fondasi tangki netralisasi nira (900
m³) tidak pernah dibiarkan karena dianggap hal yang sepele,
padahal lama kelamaan fondasi tangki tersebut bisa rusak dan
menyebabkan tangki terjatuh.
2 Steam yang bocor ke lingkungan sekitar membuat lingkungan
menjadi lembab dan alat – alat sekitar mudah terkorosi
(misalnya penampungan sulfur dioksida yang sangat
berbahaya bila terjadi kebocoran)
3 Apabila suatu saat terjadi deviasi tekanan evaporator dan
tidak terdeteksi pada pembacaan, dapat menyebabkan
kecelakaan proses (tangki meledak).
4 Minimnya kontroller temperatur/tekanan pada alat proses
(hanya ada pada boiler), sedangkan di alat pemanasan lain
seperti evaporator dan crystalizer tidak ada controller. Tanpa
kontroller, deviasi yang terjadi pada tekanan/temperatur
menjadi tidak terkontrol dan bisa menyebabkan kecelakaan
(padahal temperatur cukup tinggi, sekitar 120C)
5 Ampas tebu digunakan sebagai bahan bakar boiler. Ampas
tebu tersebut dimasukkan oleh tenaga manusia, namun ketika
dimasukkan ke bagian bahan bakar, ada ampas menyala yang
keluar dari boiler tersebut, dan berpotensi untuk
menyebabkan kebakaran. Hal ini menadakan masih ada
prosedur kerja yang kurang mementingkan safety.
Budaya safety positif yg sharusnya madukismo :
1 Dilakukan pemeriksaan dan pelaporan secara lebih detail, meskipun terhadap
penyimpangan terkecil (seperti kebocoran pipa air); 2 Dilakukan penggantian
indikator tekanan/temperatur yang telah usang pada alat – alat proses; 3
Meningkatkan jumlah controller untuk memperbaiki seandainya terdapat
deviasi proses; 4 Adanya evaluasi berkelanjutan terhadap prosedur kerja yang
dianggap masih memiliki potensi bahaya proses yang tinggi
Tahapan mencapai budaya safety positif :
1. Komitmen Manajemen Terhadap Keselamatan Kerja
Komitmen manajemen dapat diwujudkan dalam bentuk kebijakan yang tertulis,
jelas, mudah dimengerti dan diketahui oleh seluruh pekerja. Tidak hanya itu,
dukungan dan upaya nyata dari pihak manajemen atau pimpinan juga
dibutuhkan untuk membuktikan bahwa perusahaan benar-benar berkomitmen
terhadap keselamatan kerja.
Upaya nyata tersebut dapat ditunjukkan dengan sikap dan segala tindakan yang
berhubungan dengan keselamatan kerja. Contohnya, penerapan peraturan dan
prosedur, tersedianya fasilitas keselamatan kerja yang memadai dan sumber
daya yang mumpuni.
2. Peraturan dan Prosedur Keselamatan Kerja
Manajemen bertanggung jawab untuk menetapkan dan menerapkan peraturan
dan prosedur keselamatan kerja. Peraturan dan prosedur keselamatan kerja yang
dibuat harus mudah dimengerti, dikomunikasikan dan disosialisasikan kepada
pekerja.
Peraturan merupakan suatu hal yang mengikat dan disepakati.
Prosedur merupakan rangkaian dari suatu tata kerja yang berurutan, tahap demi
tahap serta jelas menunjukkan jalan atau arus (flow).
Tujuan dibentuknya atau diterapkannya peraturan dan prosedur ini, yaitu untuk
mengendalikan bahaya yang ada di tempat kerja, melindungi pekerja dari
kemungkinan terjadi kecelakaan dan untuk mengatur perilaku pekerja sehingga
nantinya tercipta budaya keselamatan yang baik.
Bentuk dari peraturan dan prosedur K3 di antaranya program komunikasi
bahaya, alat pelindung diri (APD), prosedur izin kerja khusus (work permit),
prosedur praktek kerja aman, prosedur tanggap darurat, dll.
3. Komunikasi
Komunikasi akan menghasilkan persepsi yang nantinya diinterpretasikan secara
berbeda oleh tiap individu. Persepsi sendiri berasal dari berbagai stimulus yang
diberikan oleh organisasi ketika berkomunikasi dengan pekerja.
Menjalin komunikasi dua arah antara manajer dengan pekerja, pekerja dengan
pekerja, manajer dengan manajer atau departemen dengan departemen menjadi
poin penting dalam menciptakan budaya keselamatan yang baik.
Ciptakan komunikasi secara terbuka (transparan) dan jangan ragu meminta
pendapat kepada pekerja. Sediakan wadah komunikasi antara pemimpin/
manajemen puncak dengan pekerja. Tersedianya wadah komunikasi ini dapat
mendukung seluruh pekerja untuk memberikan masukan tentang peningkatan
keselamatan di perusahaan. Jangan pernah mengabaikan berbagai masukan dari
pekerja karena akan membuat mereka cenderung bersikap acuh terhadap semua
program yang dijalankan perusahaan.
4. Keterlibatan Pekerja dalam Keselamatan Kerja
Berhentilah berpikir bahwa membangun budaya keselamatan kerja adalah
tanggung jawab departemen K3. Budaya keselamatan akan menjadi lebih
efektif apabila komitmen manajemen dilaksanakan secara nyata dan terdapat
keterlibatan langsung dari pekerja dalam keselamatan kerja. Keterlibatan
pekerja dalam keselamatan kerja dapat dilakukan dengan berbagai cara, di
antaranya: Keaktifan pekerja dalam kegiatan K3; Memberi masukan mengenai
adanya kondisi berbahaya di lingkungan kerja; Menjalankan dan melaksanakan
kegiatan dengan cara yang aman; Memberi masukan dalam penyusunan
prosedur dan cara kerja aman; Mengingatkan pekerja lain mengenai bahaya K3.
Dengan melibatkan, memberdayakan dan mendorong pekerja dalam penerapan
K3 ternyata dapat menimbulkan rasa tanggung jawab mereka untuk selalu
mengutamakan K3 dalam pekerjaannya. Para pekerja akan merasa dihargai
dengan keterlibatan mereka dalam membangun budaya keselamatan di
perusahaan.
5. Lingkungan Sosial Pekerja
Budaya keselamatan merupakan kombinasi antara sikap, norma dan persepsi
pekerja terhadap keselamatan kerja. Salah satu cara untuk melihat lingkungan
sosial pekerja sebagai faktor pembentuk budaya keselamatan, yaitu dengan
melihat persepsi pekerja terhadap lingkungan sosialnya.
Ahli K3 mengemukakan, sebisa mungkin perusahaan membentuk suatu
lingkungan kerja yang kondusif, salah satunya budaya tidak saling menyalahkan
bila terjadi kecelakaan pada pekerja. Budaya keselamatan di perusahaan dapat
dikatakan baik jika tidak ada budaya saling menyalahkan di antara pekerja
dengan pekerja maupun pekerja dengan manajer ketika terjadi kecelakaan kerja.
Dengan adanya lingkungan sosial pekerja yang baik, dampak positif yang dapat
timbul, yaitu terbentuknya kesadaran akan keselamatan di antara pekerja.
6. Perilaku Keselamatan Kerja
Dalam K3, perilaku lebih difokuskan pada perilaku tidak aman (unsafe act). Hal
ini dikarenakan penyebab dasar terjadinya kecelakaan kerja salah satunya
dikarenakan perilaku tidak aman yang berupa kesalahan atau kelalaian yang
dibuat oleh manusia.
Perilaku keselamatan kerja merupakan hasil dari persepsi pekerja terhadap K3.
Persepsi pekerja yang menekankan pentingnya K3, mereka tentu akan
menggunakan APD dan mematuhi semua prosedur keselamatan bahkan tanpa
harus selalu ada yang mengawasi. Persepsi yang baik terhadap keselamatan
kerja dapat dijadikan landasan untuk membentuk perilaku keselamatan yang
baik dengan didukung komitmen manajemen yang aktif. Dampak positif
terbentuknya perilaku keselamatan yang baik, yakni dapat mengurangi
kecelakaan kerja yang disebabkan oleh tindakan tidak aman dan menjadi faktor
penting dalam membangun budaya keselamatan di tempat kerja.
7. Kepemimpinan Keselamatan (Safety Leadership)
Motivasi pekerja dibangun berdasarkan pada contoh suri teladan. Motivasi
pekerja biasanya akan muncul setelah ia melihat adanya contoh keteladanan
yang baik dari seorang atasan. Keteladanan meliputi keteladanan sikap, moral,
kinerja, kecerdasan, dan sebagainya. Jenis keteladanan inilah sangat diutamakan
dalam penerapan K3 dan membangun budaya keselamatan dalam suatu
organisasi.
Pemimpin keselamatan harus menjadi role model bagi para pekerja. Pemimpin
memiliki pengaruh dalam mengubah persepsi pekerja, bagaimana cara mereka
berpikir, bersikap dan berperilaku untuk membangun budaya keselamatan.
Faktor keteladanan dalam safety leadership sangat diutamakan dalam
membangun budaya keselamatan dalam suatu organisasi. Pimpinan dan manajer
dapat memberi contoh nilai-nilai keselamatan yang ditunjukkan dalam perilaku
dan tindakan serta etika kerja untuk meningkatkan keselamatan. Pemimpin
keselamatan harus menunjukkan kepedulian dan keteladanan yang tinggi
melalui keterlibatan langsung dalam program keselamatan yang ditetapkan.
Perlu disadari bahwa unsur utama dalam membangun budaya keselamatan
adalah pembentukan sikap dan perilaku selamat yang dibangun dari nilai-nilai
keselamatan yang ditanamkan dalam budaya organisasi.
SOAL UAS 2017
1) Jelaskan mengapa PS dan PSM sangat penting untuk industri
proses dan memiliki perbedaan yang cukup signifikan
dibandingkan dengan Occupational Safety atau Keselamatan
dan Kesehatan Kerja
Jwb : PS dan PSM dinilai lebih penting daripada K3 akibat
adanya perkembangan jaman. Sebuah industri kimia dari tahun
ke tahun mengalami perubahan, di mana pada saat ini banyak
sekali industri yang menggunakan kondisi-kondisi operasi
ekstrem (P & T tinggi), menggunakan bahan-bahan yang
cenderung lebih berbahaya, ukuran peralatan yang lebih besar,
dll. Hal-hal demikian semakin meningkatkan kemungkinan
terjadinya kecelakaan pada aspek manusia dan fasilitas. Aspek
keselamatan pada manusia sudah dibahas di K3. Seiring
semakin kompleksnya industri-industri kimia, hal ini membuat
perhatian akan safety tidak bisa hanya berfokus pada aspek
manusianya saja. K3 dalam hal ini dinilai sudah tidak
mencukupi untuk membahas safety pada suatu industri kimia.
Seperti yang dijelaskan di atas, perkembangan jaman
membuat banyak industri kimia menghasilkan polutan dan
limbah-limbah yang cenderung lebih berbahaya. Hal ini
menimbulkan kegerahan pada masyarakat, di mana
masyarakat menuntut akan adanya aspek keamanan pada
suatu pabrik kimia. Dengan demikian diperlukan adanya
pengendalian akan bahaya dalam suatu pabrik kimia. Pabrik
kimia itu sendiri merupakan hazard, dan akan selalu ada
hazard, maka sering disebut pula residual risk. Dalam hal K3,
safety dikendalikan berdasarkan eliminasi/substitusi risiko
serendah-rendahnya sampai ke tingkat acceptable limit.
Namun, seringkali K3 hanya berakhir menjadi administratif
semata (peringatan2). Hal ini semakin menonjolkan betapa
pentingnya PS, di mana pada PS dibutuhkan engineering
control dalam menciptakan keadaan ALARP (as low as
reasonably practicable). Dari segi manajemen, keduanya
penting karena manajemen merupakan root of cause. Namun,
hal utama yang membedakan ialah bahwa PSM muncul akibat
adanya kejadian katastropik (cth: Bhopal, Fixedborough)
sedangkan SMK3 mencakup aturan-aturan atau undang-
undang yang ditetapkan yang berisi standar-standar
manajemen K3. Hal ini berbeda jauh karena pada PSM elemen-
elemen yang dibahas tidak hanya mencakup peralatan atau
proses di pabrik, tetapi juga terhadap komunitas. Oleh sebab
itulah, PS dan PSM muncul dan terus berkembang seiring
dengan adanya kemajuan teknologi serta kejadian-kejadian
yang dapat dipelajari, dibandingkan SMK3 dan K3 yang
cenderung tetap.
2) Case Study : Ledakan Gas Ethylene
Kebakaran disebabkan karena kebocoran gas ethylene pd
sebuah tubing yg menghubungkan pipa keluaran kompresor
dgn alat penunjuk tekanan (Pressure drop). Kebocoran tsb
terjadi krn fatigue (kelelahan alat). Diperkirakan sumber
pantikan api berasal dari elektrostatik. Kompresor tdk dijaga
trs menerus olh operator tetapi dilengkapi dgn alat pendeteksi
gas yg dpt terbakar tapi sistem ini tdk memberi suara alarm ke
ruang pengendali krn relay nya gagal berfungsi. Peristiwa ini
dpt berhenti setelah gas terlanjur terlepas kira-kira 11000 lbs
ke atmsfer berkat keberhasilan menutupnya kerangan yg
dirancang fail to close. Buatkan saran agar insiden ini tdk
terulang lagi.
Jwb : Upaya prefentif yang dapat dilakukan untuk mencegah
terjadinya kebakaran akibat bocornya gas etilen adalah dengan
melakukan pergantian tube secara berkala agar tidak
mengalami fatigue yang disebabkan oleh getaran pada
kompresor dan melakukan pengaturan ulang pada valve yang
dirancang fail to close untuk menurunkan batas minimumnya,
agar responnya tidak lambat karena pada kasus ini sebanyak
11000 lb gas etilen sudah terlanjur terlepas ke atmosfer.
Sedangkan, upaya mitigatif yang dapat dilakukan untuk
menanggulangi atau meminimalisir dampak yang terjadi akibat
kebocoran gas etilen adalah dengan membuat suatu kolam
penampungan gas etilen di sekitar kompressor, dmn kolam tsb
dikondisikan berada pada kondisi di bawah titik didih etilen,
shg gas etilen yg menguap saat terjadi kebocoran tidak
menyebar dan dpt terkondens menjadi etilen cair yg akan
tertampung pada kolam tsb. Perlu juga disediakan fire
extinguisher dan sprinkler untuk memadamkan kebakaran
yang terjadi agar tidak cepat meluas atau bila perlu dibuat
kolam air yang dapat digunakan jika terjadi kebakaran akibat
kebocoran gas etilen tsb.
3) CCPS risk based process safety
a) Jelaskan scr singkat apa yg dimaksud dengan Hazard
Identification and Risk Analysis pada RPBS elemen 7
Jwb : Hazard Identification and Risk Analysis (HIRA) merupakan
istilah yang menggambarkan segala aktivitas yang berkaitan
dengan identifikasi bahaya dan evaluasi risiko sepanjang daur
hidup/umur pabrik (mulai dari dirancang sampai dirobohkan),
sehingga risiko-risiko yang ada dapat di-contain and control
sehingga mencapai titik risiko yang dapat diterima. Kunci dari
HIRA ini berbasis pada 3 unsur penting: What can go wrong?
How often? What is the consequences?
b) Jelaskan scr singkat tetapi komprehensif hal-hal yg spesifik
dan khas elemen ini dari perspektif RBPS
Jwb : Secara garis besar, HIRA terbagi atas 2 elemen, yaitu
qualitative risk analysis dan quantitative risk analysis.
Qualitative risk analysis mencakup HAZOP, FMEA, What-if,
checklist, LOPA. Sementara quantitative risk analysis mencakup fault tree,
event tree.
1.Process Hazard identification didalam industri kimia dapat
dikelompokkan menjadi dua yaitu kualitatif dan kuantitatif.
a.Sebutkan apa saja metodanya dan jelaskan secara singkat saja.
Jelaskan juga penggunaannya. B.Jelaskan dengan lebih detail dan
bandingkan fault tree dan even tree.
Jawab:
a.Kualitatif:
-HAZOP merupakan upaya identifikasi bahaya terhadap pekerja maupun
alat proses yang dilakukan secara terstruktur dan sistematis dari sebuah
proses, sehingga proses dapat berjalan aman dan efisien. HAZOP biasanya
didiskusikan dalam suatu tim yang terdiri dari individu-individu multi-
disiplin. HAZOP sendiri menggunakan parameter, yaitu deviasi pada proses
(jika terjadi deviasi maka proses menjadi tidak normal). HAZOP dilakukan
dengan menyediakan node, dimana pada node deviasi dapat diukur.
HAZOP sebaiknya mulai dilakukan saat desain proses awal (misalnya
melalui PFD, P&ID), dan saat proses sudah berlangsung.
-What-if/checklist Merupakan process hazard identification dimana tim
berdiskusi dalam mengidentifikasi hazard dengan mempertanyakan
“bagaimana jika” dan kemudian mencari solusinya. Diskusi dilakukan
dengan menggunakan sebuah daftar/list/checklist yang berisikan kategori-
kategori yang hendak dibahas. What-if/checklist biasa dilakukan saat
proses baru akan dimulai dan untuk memitigasi terjadinya accident.
-FMEA merupakan process hazard identification yang berdasarkan sistem
proses yang detil, yakni dalam menganalisa kemungkinan terjadinya
kesalahan atau kegagalan dalam suatu komponen sistem, baik kesalahan
dari segi alat atau sistem tersebut sendiri. FMEA dilakukan secara
bertahap, yakni dalam mengidentifikasi kegagalan/kesalahan dalam suatu
proses. FMEA biasanya dilakukan dalam suatu proses baru atau proses
yang baru diimprovisasi.
Kuantitatif:
-Fault tree digunakan sebagai metode deduktif dalam mengidentifikasi
bagaimana hazard dapat menimbulkan accident. Accident yang
didefinisikan (top event) kemudian dianalisa kembali untuk mengetahui
semua kemungkinan scenario yang dapat menyebabkan terjadinya
accident tersebut. Kesalahan-kesalahan yang dapat terjadi yang
menyebabkan terjadinya accident dapat dikarenakan human error,
software, maupun factor lingkungan. Fault tree merupakan salah satu
tindakan preventif dalam mencegah accident/hazard.
-Event tree digunakan sebagai metode induktif untuk mengidentifikasi
hazard dengan mula-mula mendefinisikan event/work (initiating event)
yang akan dilakukan dan kemudian menganalisa kontrol/safety yang
digunakan dalam event/work. Identifikasi hazard kemudian dilakukan
dengan mengasumsikan kontrol/safety tidak berjalan dengan baik,
sehingga urutan-urutan dari accident kemudian dapat dideskripsikan.
Initiating event yang dilakukan merupakan serangkaian proses menuju top
event. Event tree merupakan salah satu cara yang digunakan untuk
memitigasi loss.
a.Fault tree merupakan metode identifikasi hazard dimana accident
didefinisikan terlebih dahulu, dan kemudian dianalisa kembali semua
hazard yang dapat menyebabkan terjadinya accident. Maka fault tree biasa
digunakan dalam mencegah terjadinya hazard/accident.
Event tree adalah metode identifikasi dimana suatu event/work (initiating
event) yang memiliki potensi hazard/accident dianalisa untuk mengetahui
kemungkinan hasil-hasil dari event/work tersebut. Seluruh kemungkinan
terjadinya hazard akan dianalisa sehingga seluruh kemungkinan dari hasil
work/event juga akan dapat diketahui. Maka event tree lebih difokuskan
dalam memitigasi loss.
Maka perbedaan dari fault tree dan event tree yaitu:
-Fault tree mengidentifikasi hazard secara deduktif yakni berdasarkan
accident (top event), dan kemudian seluruh hazard yang dapat
menimbulkan accident dianalisa secara backward, sehingga
hazard/accident dapat dicegah
-Sedangkan pada event tree setiap kemungkinan terjadinya hazard pada
suatu event/work (initiating event) dianalisa secara induktif untuk
mengetahui semua kemungkinan hazard dan semua kemungkinan hasil
dari work/event (top event), sehingga loss dari work/event dapat
dimitigasi
2. Emergency Response
a.Apa yang dimaksud dengan tanggap darurat (emergency response)?
b.Apa saja yang harus aspek-aspek penting dipertimbangkan dalam
membuat prosedur tanggap darurat untuk industri kimia? Jawablah
secara berurutan langkah-langkahnya
Jawab :
a.Aspek-aspek yang harus diperhatikan dalam prosedur tanggap darurat
untuk industri kimia adalah:
-Mempelajari MSDS dan seluruh data yang ada untuk seluruh bahan kimia
yang digunakan yang setidaknya meliputi: toksisitas, Permissible exposure
limits, data fisik, data reaktivitas, data korosivitas, Thermal and chemical
stability data, dan bahaya-bahaya yang terjadi apabila bahan kimia
tersebut tercampur / terkena dengan material lain.
-Mengetahui sifat fisika dan kimia dari proses maupun bahan yang
digunakan.
-Mengetahui lingkungan sekitar pabrik secara terperinci dari kondisi
warga sekitar hingga kondisi cuaca / alam.
-Membuat risk assessment untuk semua proses yang digunakan agar dapat
mengetahui berbagai kemungkinan kecelakaan yang dapat terjadi.
b.Menurut OSHA, hal –hal penting yang perlu diperhatikan dalam membuat
suatu prosedur tanggap darurat yaitu:
-Mengetahui / mengenal dengan baik kondisi lingkungan tempat
kecelakaan maupun evakuasi.
-Langkah-langkah evakuasi yang jelas untuk evakuasi maupun shut down
darurat.
-Aksi yang jelas untuk setiap elemen karyawan apabila suatu kecelakaan
terjadi agar tidak terjadi kepanikan / kebingungan yang tidak perlu saat
-Prosedur evakuasi yang spesifik / detail termasuk rute evakuasi dan letak
pintu keluar darurat. Prosedur ini harus ditampilkan ditempat yang mudah
dibaca.
-Prosedur untuk membantu evakuasi orang cacat maupun orang yang
berbahasa asing.
-Penjelasan yang jelas mengenai aksi yang harus dilakukan dalam pilihan
untuk melanjutkan operasi, shut down operasi yang penting, dan memilih
meninggalkan operasi untuk mengevakuasi diri sendiri.
-Sistem transportasi yang terstruktur untuk mengevakuasi orang dalam
jumlah banyak.
Apabila kecelakaan terjadi, perusahaan juga harus memiliki sistem
pemberitahuan kecelakaan yang baik termasuk untuk karyawan yang
cacat. Sistem tersebut harus meliputi:
Alarm yang jelas terdengar maupun terlihat dan disadari oleh semua
karyawan di seluruh lingkungan kerja sebagai sinyal melakukan aksi sesuai
prosedur yang sesuai.
-Memiliki jaringan komunikasi yang baik untuk mengabarkan kecelakaan
kepada departemen keamanan maupun warga sekitar.
4.Human error sering diartikan sebatas kejadian yang diakibatkan
oleh perilaku operatornya saja misalnya pilot pesawat, sopir
kendaraan umum, operator pabrik dsb. Bagaimana pendapat
saudara? Jelaskan bahwa human error terjadi di setiap tahapan(life
cycle) kegiatan industri kimia. Berilah contohnya
Jawab :
Human error secara merupakan seluruh penyebebab terjadinya sebuah
insiden akibat kesalahan / kelalaian manusia. Kesalahan operator
merupakan salah satu human error, tetapi kesalahan pada proses
perancangan, pembangunan dan persiapan juga merupakan human error.
Human factor juga dapat terjadi pada tahap life cycle lain.
Misalnya:
-Pada tahap analisis  Human error pada tahapan ini umumnya mencakup
kurangnya pengetahuan process engineer tentang proses yang akan
dirancang sehingga menimbulkan kesalahan- kesalahan pada proses atau
menggunakan proses yang kurang aman. Contoh nyatanya adalah
peristiwa windscale fire di Inggris yang salah satu penyebabnya adalah
kurangnya pengetahuan tentang proses dari operator .
-Pada tahap realisasi  Kejadian-kejadian yang tidak terpikirikan
sebelumnya terjadi sehingga menimbulkan human error, seperti pada
tahap operasi & pemeliharaan, validasi dab tahap pelaksanaan ; kurangnya
sistem pengamanan dan external relief facilities.
-Pada tahap operasi  Umumnya kesalahan kesalahan terjadi diakibatkan
oleh operator, baik akibat kelalaian operator ataupun operator merubah
kondisi kondisi proses yang berlangsung di pabrik tanpa pengetahuan yang
memadai sehingga dapat menyebabkan kecelakaan. Contohnya pada
kecelakaan Chernobyl, dimana kecelakaan terjadi akibat operator
mematikan perangkat keamanan dan kesalahan operator yang
memindahkan inti / core dari reaktor.
5. Process Safety Management
a.Apa yang dimaksud dengan Process Safety Management?
b.Apa yang dimaksud Elemen dan Komponen menurut “CCPS, Plant
Guidelines for Technical Management of Chemical Process Safety”?
c.Jelaskan dengan singkat elemen 4 “Management of Change”
Jawab :
a.Apa yang dimaksud dengan Process Safety Management?
Merupakan suatu regulasi yang dikeluarkan oleh U. S. Occupational Safety
and Health Administration (OSHA) yang bertujuan untuk mencegah
terjadinya kecelakaan atau kejadian yang tidak diinginkan dalam bekerja.
Hal ini dilakukan dengan cara identifikasi secara proaktif dan sistematis;
evaluasi; mitigasi atau pencegahan lepasnya bahan kimia yang dapat
menyebabkan kegagalan proses, prosedur, maupun peralatan pada pabrik.
b.Apa yang dimaksud Elemen dan Komponen menurut “CCPS, Plant
Guidelines for Technical Management of Chemical Process Safety”?
Merupakan bagian dari Process Safety Management (PSM) yng masing-
masing mengatur tentang hal yang harus diperhatikan supaya PSM dapat
berjalan dengan baik. Elemen-elemen ini dimaksudkan untuk dijalankan
selaras dengan program safety dan peraturan regional. Kerangka lengkap
dari elemen PSM ini direkomendasikan untuk tiap bagian, walaupun
beberapa elemen/komponen kurang dapat diterapkan pada bagian
tertentu daripada elemen yang lain, tergantung dari derajat potential
hazard pada CSChE Process Safety Management Guide. Suatu bagian harus
mengevaluasi secara berhati-hati terhadap tiap elemen sebelum
memutuskan bahwa elemen itu tidak dapat diterapkan.
c.Jelaskan dengan singkat elemen 4 “Management of Change”
Merupakan elemen yang mengatur tentang managemen apabila ada
perubahan. Elemen ini mengharuskan para pegawai untuk
mengembangkan dan mengimplemetasikan prosedur apabila terjadi
perubahan pada proses kimia, peralatan proses, dan prosedur operasi.
Sebelum perubahan terjadi (kecuali untuk pergantian peralatan dan
sejenisnya), perubahan tersebut harus dikaji terlebih dahulu untuk
memastikan perubahan tersebut tidak mengganggu keamanan operasi.
Setelah perubahan telah terjadi, semua pekerja yang bekerja pada sector
tersebut harus dilatih, dan perlu diadakan review pre-startup.
6.Jenis-jenis kebakaran/API
a.Apa yang dimaksud dengan BLEVE? Bagaimana karakteristiknya
b.Sebutkan jenis-jenis kebakaran selain BLEVE
Jawab :
a.BLEVE (Boiling-Liquid-Expanding-Vapour-Explosion) merupakan
salah satu jenis ledakan yang terjadi pada tangki (seperti konteiner),
dimana diluarnya terdapat tekanan tinggi dengan temperatur diatas boiling
point sehingga cairan yang terdapat didalamnya secara cepat menguap
dan terbakar yang disertai dengan bola api dan ledakan yang kuat. Hal ini
biasa terjadi karena adanya api dari luar yang membakar material tersebut,
sehingga tekanan dalam tangki meningkat dan cairan dalam tangki mulai
berkurang akibat pemanasan, dan disaat cairan mulai habis, wadah cairan
tersebut mulai pecah dan menyebabkan ledakan gas yang kuat.:
b.Jenis-jenis api :
-Flash fire  api yang diakibatkan adanya lepasan gas yang mudah
terbakar ke lingkungan, sehingga membentuk bola api dan ledakan yang
kuat.
-Jet fire  api yang terjadi akibat kebocoran gas bertekanan tinggi yang
berasal dari cairan yang mudah terbakar dalam wadah. Kecepatan api pada
jenis kebakaran ini sangat tinggi karena tekanan tinggi sehingga
menghasilkan kecepatan gas yang tinggi.
-Running liquid fire  api yang menyerupai jenis pool fire namun tidak
hanya diam diatas permukaan tanah tetapi ikut mengalir diatas
permukaannya.
-Pool fire  api yang terjadi karena adanya cairan yang mudah terbakar
tumpah ke permukaan tanah.
Macam-macam ledakan:
-Vapor Cloud  ledakan yang paling berbahaya pada industri proses kimia,
terjadi karena adanya gas yang mudah terbakar, saat terdapat panas dan
berkontak dengan udara maka terjadilah vapor cloud.
-Confined explosion  Jenis ledakan yang terjadi di suatu ruang tertutup
seperti dalam vessel atau suatu bangunan. Ledakan ini paling sering terjadi
pada ledakan gas dan ledakan dust. Ledakan ini tergantung pada
kemudahan terbakarnya material tersebut, oleh sebab itu perlu diketahui
konsentrasi dan tekanan yang optimum saat kondisi operasi.
-Energy of Chemical explosion jenis ledakan akibat bahan kimia hasil
ekspansi gas. Ledakan ini dapat terjadi karena adanya pemanasan termal
akibat proses reaksi reaktan menjadi produk dan perubahan jumlah mol
oleh reaksi.
-Mechanical Explosion  Reaksi tidak memperngaruhi terjadinya ledakan
ini, biasa terjadi karena adanya energi yang terkandung dalam material
dan dilepas dengan cepat sehingga terjadi ledakan.
Nuclear explosion  Ledakan yang terjadi karena adanya reaksi fusi dan
fisi yang dapat digunakan pada bom.