Bulan K3-2024

Process Safety PSM

Management Risk Base Process Safety
20 Elements

Webinar – 12 February 2024 Process Safety Management

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Process Safety Management

16 Elements
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PENERAPAN SISTEM MANAJEMEN K3

Management
RULE BASE Commitment RISK BASE
Berdasarkan ▪ HSE Policy Berdasarkan
Undang-undang ▪ HSE Strategic Bahaya dan
dan peraturan & Planning Risiko
▪ Resources

OHS MS
(SMK3)
2/21
Safety Culture 08
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Traditional Safety (Reactive)

Pendekatan Modern (Pro-active)

Safety Culture 11
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Human-oriented risk
management /
Manajemen Risiko yang
berorientasi pada manusia
Manajemen risiko yang efektif adalah
setiap orang bertindak dengan benar
dan selamat.
Perilaku aman (Safe Behavior}
ditentukan oleh Kompetensi/
kemampuan orang me manaje Risiko.

Safety Culture 20
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Risk Perception RISK COMPETENCE

Kesadaran Individu Terhadap Risiko

Risk Acceptance
Sesuai penilaian, percaya dan menyikapi
Risiko, keputusan secara rasional

Knowledge & Skills

Penerapan Perilaku yang diharapkan.
Mengembangkan pengetahuan untuk
mengidentifikasi dan mengontrol Risiko

Commitment to
Norms & Rules
Penggabungan Perilaku yang diharapkan,
peragaan komitmen terhadap peraturan dan
prosedur dan norma-norma sosial

Safety Culture 21
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PENERAPAN SISTEM MANAJEMEN K3

6/21
Safety Culture 08
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PROCESS ▪ PO/LoI/Contract, Appendix
Legal Compliance ▪ Certificates, SIO, SILO
▪ BPJS,SKCK,MCU,KITAS
▪ Color Code & Std. of PPE
Provision & Use PPE ▪ Uniform, Company Logo
▪ Special Tool & Equipment
▪ KOM, Safety Inductions
Coord.& Communications ▪ Safety Talks, Safety Meeting
▪ Posters, Banners, Signage

▪ CW, HW, CSE, RT,

Work Permit System ▪ RA, JSA, Pre-Job Inspection
▪ Displacement, Re-new
New Entry ▪ Lifting Ops.. Erections ▪No Fatality
Critical Jobs ▪ Scaffolding, WAH

OUTPUT
▪People ▪No LTI
INPUT

▪ Flushing, HP Testing
▪Tools & Equip. GATE ▪ Off the Job Training
▪No PD
▪Material ▪No Fire
Training & Coaching ▪ On Site Training
▪ Mandatory Training ▪No Env.Impact
Displacement
▪ Incident Investigations
Reporting System ▪ Emergency Response Plan
▪ Follow Up & Recommend.
▪ MH/MP Record, W-Report
Perform, Measurement ▪ Incident Report & Record
& Monitoring (KPI) ▪ Lagging & Leading Indicator
▪ Professional HSE Team
Moral up / Campaign ▪ Safety Culture, Equal Treat
▪ Reward & Punishment

▪ MWT, Daily Patrol, Inspection

Inspections & Audit ▪ Internal & External Audit
Safety Culture 19
▪ Follow up & Recommend
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FAKTA & REALITA

 Perusahaan sudah di Sertifikasi ISO 45001
 Perusahaan sudah di Sertifikasi SMK3 PP50
 Perusahaan sudah menyediakan semua kebutuhan PPE
 Perusahaan sudah dilengkapi dengan organisasi K3
 Perusahaan sudah dilengkapi dengan Manajer K3

Kenapa masih terjadi bencana ini seperti ini?

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Process Safety Management

Major
accident

Personal
injury

Safety Culture 10
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LESSON LEARNT
Beberapa bencana industri di dunia
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FLIXBOROUGH

• Sabtu, 1 Juni 1974, Flixborough Works dari Perusahaan Nypro, Inggris

rata dengan tanah akibat ledakan hebat yang menewaskan 28 orang
serta menciderai 36 orang karyawannya,
• Terjadi kerusakan hebat di sekitar lokasi pabrik seperti gedung dan
bangunan diantaranya 1.821 rumah dan 167 toko dan bangunan
pabrik lainnya hancur total
• Kejadian ledakan dipabrik Flixborough adalah kecelakaan industri
kimia yang terparah di Inggris.
• Kejadian ini juga merupakan titik awal berkembangnya bidang Loss
Prevention di Inggris dan meningkatnya kesadaran publik terhadap
bahaya-bahaya yang dapat ditimbulkan oleh pabrik kimia.
• ACMH (Advisory Committee on Major Hazard) UK, langsung
menangani kasusini dan rekomendasi-nya diperkuat pula oleh
bencana lain yang terjadi di Seveso dua tahun kemudian.
 Flare Stack

Air N2

C 2521
Scrubber

HE

C 2522
Absorber

C 2544 R2521 R2522 R2523 R2524 R2525

Steam R2526
supply
Normal,
P=8,2 Kg/cm2
T=1550C
Cyclohexane
Storage Tank Distillation
Section
•Cyclohexanone S2539 S2538
•Cyclohexanol Separator Post-Reactor
Drum
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• Reactor bocor 6 ton DIOXIN (bahan baku

SEVESO DISASTER
pembuatan Herbisida) terlepas ke udara
Meada, Italy • Ribuan penduduk dalam radius 10 km di
10 Juli 1976 evakuasi dan ribuan ternak mati dan
penduduk mrngslsmi Chlorane.

BHOPAL DISASTER • 40 ton MIC (Methyl IsoCynate ) terlepas

ke udara dari tanki karena over pressure.
Madhya Pradesh,India 2000.
3 Desember 1984 • 2,500 orang penduduk sekitar mati
Puluhan orang seketika karena menghirup gas MIC.
meninggal &terluka
• Hydrocarbon cair meluap keliar dari
BP TEXAS DISASTER
blowdown stack karena over pressure
TEXAS CITY, USA dan uap cairan hydrocarbon menyebar
23 Maret 2005 kesekitar stack.
Puluhan orang • Uap menyambar knalpot mobil yang
meninggal &terluka terparkir hidup mesin di sekitar stack
• Chernobyl Disaster (26 April 1986) • Smelter PT.ITSS, Morowali Indonesia (24 Des. 2023)
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Process Safety Management

Process Safety Management (Background)

Manajemen Keselamatan Proses

❑ Lepasnya bahan kimia cair dan gas beracun, reaktif, mudah

terbakar yang tidak terduga dalam proses yang sangat
berbahaya di berbagai industri,
❑ Pelepasan bahan kimia berbahaya secara tidak sengaja jika
tidak dikontrol dengan baik, dapat menimbulkan kemungkinan
terjadinya bencana,
❑ Untuk membantu memastikan tempat kerja yang aman dan
sehat, CCPS & OSHA telah mengeluarkan sistem Manajemen
Keselamatan Proses (Process Safety Management),
menekankan pada pengelolaan dan program manajemen
terpadu yang mengintegrasikan teknologi, prosedur, dan
praktik sistem manajemen K3.
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Process Safety Management
Process Safety Management System
Implementation

INPUT PROCESS OUTPUT

RESOURCES CONTROLS
-Equipment -Safety
•Safe Production
PROCESS •No defect
-Infrastructure -Quality •Above Target
-Human Resource -Productivity •Enviro Friendly
-Material -Environment

•No Accident
SAFETY 20 Elements of RBPS •Low TRIR

Implement Identify the •Cont. Improvement

QHSE MS
The best problem/
MANAGEMENT solution opportunity
•Safety Culture
Study the Test
results and
feedback
potential
solution •Corporate Culture
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Process Safety Management

1950 AIChE (American Institute of Chemical Engineers)

1979 AIChE‘s Health and Safety Division.
1985 CCPS (Center for Chemical Process Safety)
Fokus pada Praktek Rekayasa dalam proses pencegahan kecelakaan
di industri kimia dan industri yang terkait lainnya.

1989 CCPS Mem-formal-kan 12 Elemen PSM

1993 OSHA Merekomendasikan 14 Elemen PSM
2001 ILO Merekomendasikan 16 Elemen PSM
2007 CCPS Merekomendasikan 4 Pilar - 20 Elemen
RBPS (Risk- Based Process Safety)
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Process Safety Management
PILAR
1. Process Safety Culture
2. Compliance with Standards
COMMIT TO
1 PROCESS SAFETY
3. Process Safety Competency
4. Workforce Involvement
5. Stakeholder Outreach
UNDERSTAND 6. Process Knowledge Management
2

ELEMENTS
HAZARDS AND RISK 7. Hazard Identification and Risk Analysis
8. Operating Procedures
9. Safe Work Practices
10. Asset Integrity and Reliability
11. Contractor Management
3 MANAGE RISK 12. Training and Performance Assurance
13. Management of Change
14. Operational Readiness
15. Conduct of Operations
16. Emergency Management
17. Incident Investigation
LEARN FROM 18. Measurement and Metrics
4 19. Auditing
EXPERIENCE
20. Management Review & Continues Improvement
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Elem CCPS OSHA

ent Risk-Based 20 PSM Elements PSM Required 14 Elements
1 Process safety culture Do not apply
2 Compliance with Standards Process safety information (PSI)
3 Process safety competency Do not apply
4 Workforce involvement Employee participation
5 Stakeholder Outreach Do not apply
6 Process knowledge management Process safety information (PSI)
7 Hazard Identification & Risk Analysis Process hazard analysis
8 Operating Procedures Operating Procedures
9 Safe Work Practices Hot work permit
10 Asset Integrity & Reliability Mechanical Integrity
11 Contractor management Contractors
12 Training & Performance Assurance Training
13 Management of Change Management of Change (MOC)
14 Operational Readiness Pre-Startup Safety review
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15 Conduct of Operations Do not apply

16 Emergency Management Emergency Planning and Response
17 Incident Investigation Incident Investigation
18 Measurements and Metrics Do not apply
19 Auditing Compliance Audits
20 Management Review and Do not apply
Continuous Improvement
Trade Secrets
1. Employee Participation
2. Process Safety Information
3. Process Hazard Analysis
4. Training
5. Contractor Safety
6. Pre-Startup Safety Review
7. Mechanical Integrity
8. Hot Work Permit
9. Management of Change
10. Operating Procedures
11. Incident Investigation
12. Emergency Planning and Response
13. Compliance Audits
RISK BASE PROCESS SAFETY 14. Trade Secrets
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Process Safety Management
4 PILAR

COMMIT TO
1 PROCESS SAFETY

UNDERSTAND
2 HAZARDS
AND RISK

3 MANAGE MOC
RISK

LEARN FROM
4 EXPERIENCE
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Process Safety Management
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Process Safety Management

INCIDENT PREVENTIONS

• Bahaya terdapat dalam berbagai cara dan hambatan-hambatan,

• Hambatan mungkin mempunyai kelemahan atau lubang,
• Jika lubang sejajar, bahaya akan lolos melalui hambatan yang
mengakibatkan potensi dampak buruk.
• Hambatan mungkin direkayasa secara fisik alat kendali atau di
kontrol oleh perilaku orang,
• Lubang bisa bersifat laten/baru jadi, atau dibuka secara aktif oleh
orang
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Process Safety Management
5 Steps to System Approach – Incident Prevention

Preventing Human Error

In Process Safety
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TERIMA KASIH zulmc0x@gmail.com

https://www.linkedin.com/in/zulkarnain-zul-4b2b97157