Keselamatan Pabrik Kimia

(/TK141283 : 2 SKS)
CHEMICAL PROCESS SAFETY
mahfud@chem-eng.its.ac.id
Mata Kuliah : KESELAMATAN PABRIK KIMIA /TK141283
Kredit : 2 sks
Semester :8

DESKRIPSI MATA KULIAH

Mata kuliah ini mempelajari tentang pemahaman konsep dasar
keselamatan proses kimia meliputi uraian tentang UU dan Peraturan K3 RI;
Accident and their Effects; Theories of Accident Causation; Falling, Impact,
Lifting, and Vision Hazards; Hazards Mata of Temperature Extreme, Pressure,
Kuliah : KESELAMATAN
PABRIK KIMIA /TK141283
Electrical, Radiation,
MATANoise
KULIAH and Vibration;
Kredit Industrial
Semester
: 2 sks
:8
Hygiene; Toxic Release
and Dispersion; Fire Explotion and Prevention Design; Relief; Hazards
Identification; Risk Assessment; Accident Investigation; Case Histories.
Adapun metode pembelajaran yang dilakukan meliputi: Kuliah pengantar;
Brainstroming; Ujian Tulis (meliputi Kuis, Tugas, ETS dan UAS), Praktek
meliputi Presentasi dan diskusi kelompok.
CAPAIAN PEMBELAJARAN MATA KULIAH
Mahasiswa mampu memahami dasar-dasar keselamatan proses kimia.
POKOK BAHASAN
UU dan Peraturan K3 RI; Accident and their Effects; Theories of Accident Causation;
Falling, Impact, Lifting, and Vision Hazards; Hazards of Temperature Extreme, Pressure,
Electrical, Radiation, Noise and Vibration; Industrial Hygiene; Toxic Release and
Dispersion; Fire Explotion and Prevention Design; Relief; Hazards Identification; Risk
Assessment; Accident Investigation; Case Histories.
PRASYARAT
-
PUSTAKA UTAMA
1. Goetsch DL (2005),”Occupational Safety and Health for Technologists Engineers, and Managers,
5th ed, Prentice Hall
2. Crowl and Louvar (1999), “Chemical Process Safety”, 2nd ed, Prentice Hall.
3. Ketentuan Keselamatan Kerja dan Perundang-undangan RI.
4. Keltz T(1999), “What When Wrong?”, 4t ed, Gulf Publishing
5. King, Ralp & Magid,John ( 1982 ),”Industrial hazard and Safety Handbook”, Butterworth
Scientific, London.
6. Wong W (2002), “How did that Happen?, Professional Eng. Publ
PUSTAKA PENDUKUNG
Marshall and Ruhermann,(2001),”Fundamentals of Process Safety”, IchenE.
Metode Pembelajaran
Teacher Centered Learning

Student Centered Learning

 Kuliah (online, offline, Hybrid)

 Diskusi Kelompok, Tugas, Latihan, Presentasi
 Evaluation by subject or by learning objective (CPL-CPMK)
Pembagian Kelompok
Ketua kelas KPK : ……..(08…)
…..@gmail.com
 Kelompok I : Accident Investigation
 Kelompok II : Hazard Identification
 Kelompok III : Theories of Accident Causation;
 Kelompok IV : Industrial Hygiene;
 Kelompok V : Fire Explotion and Prevention Design
 Kelompok VI : Safety & Relief
 Kelompok VII : Safety Management
 Kelompok VIII : JSA (Job Safety Analysis)
 Kelompok IX : HAZOP (Hazard and Operability)
 Kelompok X : FMEA (Faillure Mode Effect Analysis) & FTA (Fault Tree Anal.)
 Kelompok XI : Toxic Release and Dispersion;
What Is the Chemical Engineering ?

 To develop and apply chemical processes

 To design, construct and operate the equipment of the process
 Chemistry, physics, biology and mathematics are underlying
science
 Economics is the guide in practice

Physical Operation
Raw materials ------------------------- Products
Chemical Conversion
(low value) (high value)

Strategy of considerations
1. Technical feasibility
2. Economical feasibility
Chemical Engineering - Working with the World

Process

Product

Consumer

Raw Recycle and

Materials Remediation
About the industry…… linking with others

Automotive

Biotech

Environmental
PRODUCTS Consumer

Foods

ICT

Household Goods

Just some of the industries that make use of chemical products.

Dampak Negatip dari Industri
Kimia :
Industrial Accident :
- Fire & Explosion
- Toxic Release
 FEYZIN, 04.01.1966, FRANCE
Terletak di Selatan Lyon, kilang Feyzin,
ditoperasikan pada Juli 1964
Kebocoran uap propane yang kemudian
tersulut api, yang diikuti ledakan tangki
propane (BLEVE)

This refinery, which first began operating in 1964, was processing 1.7 million tonnes of crude oil a year. Its LPG storage zone
contained 12,850 m³ (theoretical capacity: 13,100 m³) of pressurised hydrocarbons in 10 propane or butane spherical tanks,
placed as close as 22.5 m from the A7 motorway. A technician’s assistant was extracting a sample while bleeding one of the
1,200-m³ capacity propane spheres filled to 60%. After several incidents, a strictly-controlled operating procedure had been
devised to bleed the spheres (calling for opening the upper valve, then gradually the lower valve without ever opening it
entirely). At 6:40 am, the assistant performed these steps in the wrong order, causing the valves to freeze and become locked.
A propane leak formed an inflammable cloud that slowly drifted over the motorway. Vehicles drove through the cloud without
consequence. But at 7:15 am, a car stopped 100 m from the point of the leak on the CD4 frontage road, led to the cloud’s
ignition; the driver sustained severe burns and subsequently died. An intense blowpipe flame appeared beneath the sphere 1
min later. First responders from the refinery as well as the Vienne and Lyon municipal services arrived on the scene between 7
and 8:30 am; they tried to cool the adjoining spheres and extinguish the giant flare that had grown even larger once the safety
valves on top of the sphere had been opened. The sphere suddenly exploded around 8:45 am (1st BLEVE explosion), causing
13 fatalities. The fireball rose 400 m high and reached 250 m in diameter. An adjacent propane sphere then exploded at 9:40
am (2nd BLEVE), this time resulting in no victims. The human toll was heavy: 18 deaths, including 11 fire-fighters and 84
injured among the 158 present onsite. Property damage was extensive: ignition of neighbouring tanks and the opening of
several storage spheres; projectiles blasted by the two BLEVE recovered more than 700 m away, one weighing 48 tonnes
found at 325 m; an immense crater where the 2 spheres once stood; 8,000 m³ (1,500 tonnes) of petroleum products destroyed.
The blast from the explosion could be observed as far as Vienne (16 km to the south), and 1,475 dwellings were damaged.
Criminal charges were brought against both the technician’s assistant and the safety officer for noncompliance with operating
instructions. The Site Director was also indicted. On the civil side of the suit, damages and interest were awarded. This disaster
set the stage for major reforms in regulations and in the administrative agency assigned oversight of classified facilities..
FLIXBOROUGH, 01.06.1974, ENGLAND

 Industri kimia yang memproduksi

caprolactam (70.000 ton/thn)
bahan untuk pembuatan nylon
dengan baku cyclohexane.
 Ledakan / kebakaran yang terjadi
 28 mati, 104 luka, 3000
dievakuasi
 Seveso, Italy (Juli, 1976)
❑ Plant milik Icmesa Chemical Company
yang memproduksi hexachlorophene
yang merupakan bacteriside, dengan
trichlorophenol sebagai reaksi antara
dan TCDD (2,3,7,8,-tetrachlorodibenzo
paradioxin)
❑ Bencana terjadi ketika reaktor
trichlorophenol tidak terkontrol
menyebabkan temperatur dan tekanan
naik dan meningkatkan terbentuknya
TCDD dan diperkirakan 2 kg TCDD lepas
ke udara. Hujan yang terjadi membawa
TCDD ke tanah sehingga sekitar 10 mile
kuadrat terkontaminasi. Akibatnya
banyak penduduk terdeteksi darahnya
terkontaminasi chloronce

19 F.Eff
MEXICO CITY, 19.11.1984, MEXICO
Bencana San Juanico adalah
bencana industri disebabkan oleh
serangkaian ledakan besar pada
gas petroleum cair (LPG) tangki
Pabrik di San Juanico, Meksiko (di
luar Mexico City, Meksiko) pada
tanggal 19 November 1984.

Ledakan menghabiskan 11.000 m3

gas, yang merupakan 1/3 dari
pasokan gas seluruh Mexico City.

Ledakan menghancurkan fasilitas

dan menghancurkan kota lokal San
Juan Ixhuatepec, dengan 500-600
orang tewas, dan 5000-7000
lainnya menderita luka bakar yang
parah.
 BHOPAL GAS TRAGEDY (India 2-3 Dec. 1984)

➢ Plant memproduksi pestisida dengan

bahan baku antara lain methyl iso-cyanate
(MIC). MIC bersifat sangat toxic.
Kebocoran pada tangki penyimpan terjadi
ketika terjadi kontaminasi dengan air serta
substan lainnya, reaksi yang terjadi
menimbulkan panas hingga > titik didih
MIC.
➢ Gas MIC yang lepas (diperkirakan 40
ton) menyebabkan meninggalnya sekitar
8000 orang penduduk sekitar dan yang
terluka lebih dari 500.000 orang.
➢ Worst industrial accident Cl O Cl

Cl O Cl
PASADENA, 23.10.1989, USA
Bencana Phillips mengacu
pada serangkaian ledakan
dan kebakaran yang
menghancurkan pada 23
Oktober 1989 di dekat
Houston Ship Channel di
Pasadena, Texas, USA.
Ledakan awal tercatat 3,5
pada Skala Richter, dan
kebakaran itu terjadi
kurang dari 10 jam, 23
karyawan tewas dan 314
terluka.
 Kecelakaan Luar Negeri
INSIDEN KERUGIAN
1. FLIXBOROUGH, UK - 1974 KEMATIAN : 28 ORANG (HARI LIBUR)
LEDAKAN AWAN UAP CYCLOHEXANE KERUSAKAN : US$ 232 JUTA

2. SEVESO, ITALIA - 1976 KONTAMINASI RADIUS 4 KM2

BOCORAN BAHAN BERACUN KERUSAKAN : US$ 1 JUTA

3. MEXICO CITY - 1984 KEMATIAN : 500 ORANG

LEDAKAN LPG KERUSAKAN : US$ 20 JUTA

4. BHOPAL, INDIA - 1984 KEMATIAN : 2500 ORANG

BOCORAN MIC (METHIL ISOCYANITE) KERUSAKAN : > US$ 500 JUTA

5. CHERNOBYL, EX USSR - 1986 KEMATIAN : 31 ORANG (LANGSUNG)

BOCORAN RADIASI NUKLIR/FIRE KONTAMINASI RADIOAKTIF
( > US$ 2 MILYAR )

6. PIPER ALPHA, SCOTLAND - 1988 KEMATIAN : 167 ORANG

BOCORAN MIC (METHIL ISOCYANITE) KERUSAKAN : > US$ 1 MILYAR

7. HOUSTON USA - 1989 KEMATIAN : 23 ORANG

LEDAKAN POLYETHILENE (PHILIPS 66) KERUSAKAN : > US$ 750 JUTA
 Kecelakaan dalam Negeri
INSIDEN KERUGIAN
1. LEDAKAN DI RCC UP VI, 30 DES 1994
Kebocoran Flange Rx Vapor Line 72”
KERUSAKAN : US$ 4 JUTA
2. VAPOR BLOW DI REGENERATOR UP VI
10 JAN 1995
3. KEBAKARAN 7 BUAH TANKI AREA 32 KERUSAKAN : US$ 38 JUTA
DI UP IV CILACAP, 24 OKT 1995
4. LEDAKAN BOILER DI UP VI, MEI 1996
5. KEBAKARAN PLANT 5, PLAT FORMER KERUSAKAN + US$ 37 JUTA
DI UP V BALIKPAPAN, TANGGAL
7 AGUSTUS 2000 JAM 6.4800 WIT

6. KEBAKARAN PABRIK PETRO KIMIA

DI CILEGON
7. KEBAKARAN DAN LEDAKAN DI
PT. PETROWIDADA GRESIK
8. TABRAKAN KAPAL DI SURABAYA
 Penyebab kecelakaan
19

❑ FIRE bahan bereaksi dengan oksigen sehingga pada

bidang antar-muka udara-bahan menimbulkan api.
❑ EXPLOSION Campuran udara-gas, udara-cairan atau
udara- serbuk padat akan terbakar oleh adanya nyala dan
menghasilkan panas dan tekanan.
❑ TOXIC RELEASE pelepasan bahan kimia karena
kebocoran dan atau karena adanya reaksi kimia
❑ UVCE (Unconfined Vapor Cloud Explosion) ledakan uap
yang disebabkan awan uap yang tidak terlindungi
❑ BLEVE (Boiling Liquid Expanding Vapour Explosion)
ledakan uap yang mengembang karena cairan mendidih
 Chemical Plant Accidents Typical Patterns

Fire

Other
36% 31%
Explosions
3%
30 % Vapor cloud
explosions

Sumber : Large Property Damage Losses in the

Hydrocarbon-Chemical Industries: A Thirty-Year review
(New York,1998)
17 F.Eff
 Causes of losses in the largest hydrocarbon-
chemical plant accidents
50
45 44

40
35 Mechanical
Accidents (%)

Operator error
30 Unknown
25 Process upsets
22
20 Natural hazards
Design
15 12 11 Sabotage
10
5 5
5
1
0

Sumber : Large Property Damage Losses in Hydrocarbon-Chemical

Plant Industries, A Thirty-Year Review (New York, 1998)
18 F.Eff
Sekian
Bersambung…