LECTURE 1 – TOPIC 1.

1
Part 1 – Hazard in process industry

Fukushima Daiichi: Back-up power supply dduk di ground floor… Bila tsunami berlaku, reactor tak leh shut down &
disejukkan

Bright sparkler lahirlah OSHA 1994

- DOSH diyakinkan utk buat aging plant study

SSI – SPECIAL SCHEME INSPECTION  6 YRS

Turnaround - which is sometimes referred to as a TAR – is a highly-expensive planned period of regeneration in a

plant or refinery. During this time, an entire part of the operation is offlined whilst plants are inspected and
revamped
Example of turnaround strategy – maintenance, part replacement (Tidak sama turnaround strategy)

RBI – Risk Based Inspection (mahal)

Bawah ALARP integrity level – tak approve utk run

Minit 50

Kalau tengok CIMAh, every 3 yrs plant kene buat safety report QRA.. Static QRA based on design condition. But the
truth, kadang2 plant yg umur 30 thun is better than plant 1 year..

Asset integrity level

Risk = Severity (capacity)* likelihood (Likelihood considered the same static design condition)

Likelihood utk plant lama tinggi because of deterioration of asset integrity level

Lifetime extension : Plant 25 years can be extended with some improvement

Kita xde regulation yg perlu buktikan plant tu boleh operate for how many more years

Deterioration switches, sensor boleh cover.. But major equipment tak ganti
Major equipment for turnaround strategy

Dynamic risk akan increase

QRA does not depict plant integrity.. Malaysia tidak ada database utk process plant

NADOOPOD -> Information tak cukup utk accident data

Typical industry standard : PAI, ASME, plus good project management, plant will be well delivered and constructed,
the plant is reasonably okay

Powerplant and petrochemical in MY is okay.. safety standard is ok

Worried: acid plant, pesticide, chemical

Current legislation in Malaysia is not enough to cover industry safety

TOPIC – PROBIT ANALYSIS

TNT – estimate impact of incident

Probit analysis is empirical model which is an experiment (sigmoidal)

You’ll have to learn until you capture

Drug dose vs. response and may lead to toxicity (mono equation)

P’ -> peak overpressure guna TNT equivalent model @ depend pada situation (BLEVE ke, jet fire ke)

V -> Causative variable

Ada soalan TNT explosion…

Learning thru history…. One of the incident

HAZOP – Final
HAZOP GROUP 3
LOW LEVEL & HIGH LEVEL WILL NOT CAUSE EXPLOSION

NO SEPARATION WILL NOT CAUSE EXPLOSION

NO LEVEL LEBIH KURANG SAMA DGN LOW LEVEL

LEVEL MORE TO OPERABILITY – BECAUSE LIQUID IS INCOMPRESSABLE & CAUSE BACK PRESSURE

GAS IS COMPRESSIBLE

ONCE FLOODED, NO SEPARATION SHJ

- STUDY BY PROF.  FIKIR TENTANG CRYOGENIC PROCESS (BUKAN MCM DISTILLATION BIASA)

LIQUID MASUK PRESSURE TINGGI