MAJOR HAZARDS

CONTROL
Direktorat Pengawasan Norma K3
Kemenakertrans
 MAJOR HAZARD
Danger of large accidents, with consequences not only on the
plant site, but also in the surroundings :
 Many dead or wounded
 Heavy damage to buildings
 Wide and unfavorable publicity: press, radio,TV
 Emotional public reactions
 Serious consequences for the company involved :
 Production loss
 Investigation
 Insurance procedures
 Additional safety requirements
 Shutdown, perhaps : PERMANENT
 MAJOR ACCIDENT
A major accident is defined in the regulation as :
“A sudden occurrence at facility causing
serious danger or harm to :
- a relevant person or
- an at risk community or
- property or
- the environment
whether the danger or harm occurs immediately
or at a later time”.
(Australian Government – Comcare)
 HARMFUL EFFECT ARISING FROM
MAJOR CHEMICAL HAZARDS

1) DEATHS – immediate and delayed

2) PHYSICAL INJURIES – disabling and non disabling
3) MENTAL INJURIES – short term or long term
4) SOCIAL TRAUMA – short term or long term
5) DISRUPTION OF PEOPLE’S WAY OF LIFE – short
term or long term
6) ENVIRONMENT DAMAGE – short term or long term
7) FINANCIAL LOSS; property damage; consequential
loss
 INCIDENT BHOPAL,INDIA (3/12/84)
 Nature of occurrence : runaway reaction in
storage tank released ca. 30 tons of MIC
 Fatalities : Immediate : > 2000; delayed : ??
 Physical injuries : + 200.000; disabled : ??
 Mental injuries : extreme shock & panic,
prolonged & extreme anxiety
 Disruption of people’s way of live : ??
 Environmental damage : ??
 Financial loss : property damage £ 100 millions
 INCIDENT MEXICO CITY (19/11/84)
 Nature of occurrence : 18 hours conflagration of
ca.6000 tons of LPG
 Fatalities : Immediate : > 500; delayed : ??
 Physical injuries : 7097; disabled : 100
 Mental injuries : severe shock & panic
 Disruption of people’s way of live : 39.000
homeless or evacuated; hundreds of houses up
to 300 meters destroyed
 Environmental damage : ??
 Financial loss : property damage >£ 13 millions
 INCIDENT PIPER ALPHA OIL PLATFORM,
NORTH SEA (6/7/88)

 Nature of occurrence : explosion destroyed oil

production platform
 Fatalities : Immediate : 167; delayed : nil
 Physical injuries : 20; disabled : 7
 Mental injuries : loss of public confidence; loss of
morale in workforce
 Disruption of people’s way of live : relief fund £
millions
 Environmental damage : 5 km oil slick formed
 Financial loss : property damage + £ 500
millions
 SPECIFIC FACTORS CONTRIBUTING TO
MAJOR ACCIDENT (1)

 Poor management practices; e.g : inadequate

supervision
 Pressure to meet production target
 Inadequate Safety Management System
 Failure to learn lessons from previous accident
 Communication issues; e.g : between shifts, between
personnel and management
 Inadequate reporting system
 Complacency
 Violation / non compliance behavior
 SPECIFIC FACTORS CONTRIBUTING TO
MAJOR ACCIDENT (2)
 Inadequate training, e.g : emergency response, fire
and safety
 Lack of competency
 Excessive working hours resulting in mental fatigue
 Inadequate procedures
 Modification /up date to equipment without operator
knowledge and/ or revised risk assessment
 Inadequate /insufficient maintenance
 Maintenance error
MAJOR HAZARD CONTROL
is
Prevention of Major Accidents
Factors Influencing Major Incidents
MAJOR ACCIDENTS OCCUR ALWAYS
UNEXPECTED

 At night
 During the weekend
 When the factory is stopped
 During a power failure
 In very bad weather
CONTROL MEASURES

Avoidance of Risks
 Prevention of Accidents

 Mitigation of Consequences

Sitting of the plant Operation

Lay out Maintenance
Design Repair
Construction Modification
Start up Decommissioning
AVOIDANCE OF RISKS

 Small Inventories
 Safer Substances

 Lower Pressure REDUCE

 Lower Temperature POTENTIAL
 Etc
PREVENTION OF ACCIDENTS
 Ensure adequate control
 instrumentation
 Reduce Failures
 Improve Detection
 Improve Shutdown
 Improve Relief
 Site Layout REDUCE


Operator training
Operation Maintenance
PROBABILITY
 Work permit system
 Inspection, testing
 Accident - investigation
 Etc
MITIGATION OF CONSEQUENCES

 Detection systems
 Emergency action on site
 Choice of site
 Firefighting system
REDUCE
 First aid kit
IMPACT
 Personal service/ambulance
 Control development nearby
 Etc
 ACCIDENT MODEL
HUMAN
FAILURE Unsafe acts

INCIDENT

Latent Unsafe Plant/

Errors Condition

PERFORMANCE
INFLUENCING FACTORS Fail to
recover situation

ORGANISATION

PERSON JOB
Failure of ACCIDENT
mitigation
 ACCIDENT MODEL
PERSON :
• aptitude
• sifat
ORGANISATION • sistem nilai
• kharakteristik
• minat
• motivasi
PERSON JOB
• usia
• jenis kelamin
• pendidikan
• pengalaman dll
ORGANISATION :
• kharakteristik perusahaan JOB :
• sistem manajemen • mesin
• diklat • peralatan kerja
• pengawasan/supervisi • bahan
• pengupahan • lingkungan fisik
• lingkungan sosial • metode kerja
• dll • dll
HUMAN FACTOR

HUMAN
FACTOR
(Health & Safety Executive -1999)

JOB

 The JOB – what people are ask to do

(task/workload/procedures/environment/equipment)
 The INDIVUAL – who is doing it (competence/attitude/capability/risk
perception)
 ORGANIZATION – how is the work organized
(leadership/resources/culture/communication)
EXAMPLES OF MAJOR HAZARD
WORKS

 Petrochemical Works
 Chemical Works
 LPG Storage
 Fertilizer Works
 Explosives Manufacture
 Bulk Use of Chlorine
 Pesticide factories
 Etc
 CONTOH
INDUSTRIAL MAJOR ACCIDENT
I. PELEDAKAN (Explosions)
 Cyxlohexane (Mati : 28; Cidera : 89) Flixborough –UK, 1974
 Propylene (Mati : 14; Cidera :107) Beek, Netherland, 1975
II. KEBAKARAN (Major Fires)
 LPG (Mati : 650; Cidera : 2500) Mexico City, 1985
III. TOKSIK (Toxic Release)
 Methyl Isocyanate (MIC) (Mati :2000;Cidera :20000 Bhopal,
India, 1984
 MAJOR ACCIDENT

 BHOPAL – absence of system maintenance

 PIPER ALPHA – an error in work organization
and transmission of instruction
 CHERNOBYL – breach of safety regulation
 FLIXBOROUGH – a poorly designated
modification
DESIGNATION OF MAJOR
HAZARD PLANT

 List of Substances considered to be

dangerous

 Threshold Quantities for each of substances

on the list
PENETAPAN POTENSI BAHAYA
INSTALASI
 POTENSI BAHAYA BESAR :
Kuantitas Bahan yang Digunakan melebihi
Nilai Ambang Kuantitas (NAK)
Qs > TQ
 POTENSI BAHAYA MENENGAH : Kuantitas
Bahan yang Digunakan sama atau lebih kecil Nilai
Ambang Kuantitas (NAK)
Qs = TQ atau Qs < TQ
 KEWAJIBAN PENGUSAHA ATAU PENGURUS
Persh. Potensi Bahaya Besar (I)

 Mempekerjakan Petugas K3 Kimia :

 Sistem Kerja Non Shift min. 2 orang
 Sistem Kerja Shift min. 5 orang
 Mempekerjakan Ahli K3 Kimia min. 1 orang
 Membuat Dokumen Pengendalian Potensi
Bahaya Besar
 Melaporkan Setiap Perubahan (bahan, kuantitas,
proses dan modifikasi instalasi)
KEWAJIBAN PENGUSAHA ATAU PENGURUS
Persh. Potensi Bahaya Besar (II)

 Melakukan Pemeriksaan dan Pengujian

Faktor Kimia min. 6 bulan sekali
 Melakukan Pemeriksaan dan Pengujian
Instalasi min. 2 tahun sekali
 Melakukan Pemeriksaan Kesehatan Tenaga
Kerja min. 1 tahun sekali
KEWAJIBAN PENGUSAHA ATAU PENGURUS
Persh. Potensi Bahaya Menengah (I)

 Mempekerjakan Petugas K3 Kimia :

 Sistem Kerja Non Shift min. 1 orang
 Sistem Kerja Shift min. 3 orang
 Membuat Dokumen Pengendalian Potensi
Bahaya Menengah
 Melaporkan Setiap Perubahan (bahan,
kuantitas, proses dan modifikasi instalasi)
KEWAJIBAN PENGUSAHA ATAU PENGURUS
Persh. Potensi Bahaya Menengah (II)

 Melakukan Pemeriksaan dan Pengujian

Faktor Kimia min. 1 tahun sekali
 Melakukan Pemeriksaan dan Pengujian
Instalasi min. 3 tahun sekali
 Melakukan Pemeriksaan Kesehatan Tenaga
Kerja min. 1 tahun sekali
DOKUMEN PENGENDALIAN POTENSI BAHAYA BESAR
Berisikan :
 Identifikasi Bahaya, Penilaian dan
Pengendalian Risiko
 Kegiatan Tehnis, Rancang Bangun,
Konstruksi, Pemilihan Bahan Kimia,
Pengoperasian dan Pemeliharaan Instalasi
 Kegiatan Pembinaan Tenaga Kerja
 Rencana dan Prosedur Penanggulangan
Keadaan Darurat
 Prosedur Kerja Aman
 DOKUMEN PENGENDALIAN POTENSI BAHAYA
MENENGAH
Berisikan :

 Identifikasi Bahaya, Penilaian dan

Pengendalian Risiko
 Kegiatan Tehnis, Rancang Bangun,
Konstruksi, Pemilihan Bahan Kimia,
Pengoperasian dan Pemeliharaan Instalasi
 Kegiatan Pembinaan Tenaga Kerja
 Prosedur Kerja Aman
Faktor2 yg dipertimbangkan dlm
memilih lokasi MH Instalasi :
1. Proximity to populated areas;
2. Proximity to public ways;
3. Risk from adjacent facilities;
4. Storage quantities;
5. Present and predicted development of
adjacent properties;
6. Topography of the site, including elevation
and slope;
Faktor2 yg dipertimbangkan dlm
memilih lokasi MH Instalasi :

7. Access for emergency response;

8. Availability of needed utility;
9. Requirement for the receipt and shipment
of products;
10. Local codes and regulation;
11. Prevailing wind condition;
IDENTIFICATION AND PRIOTISATION OF MAJOR
HAZARD CONTROL

1. Factories
2. Installation
3. Plant Unit
PRIORITISATION OF MAJOR HAZARD
FACTORIES IDENTIFIED
FACTORY RANKING FACTOR (FRF) :
Consist of 5 rating factors :
1) Hazard Rating (HR)
2) Capacity Rating (CR)
3) Population Rating (PR)
4) Domino Effect Rating (DER)
5) Special Object Rating (SOR)

FRF = HR + CR +PR + DER + SOR

 HAZARD RATING (HR)
 The chemical & physical properties
 The hazardous substances

No. Group of Hazardous Substances Penalty

Point
1. Extremely Toxic and Toxic Substances – gases (Cl2, NH3, 25
Phosgene)

2. Flammable Substances (LPG, Butane, Propane, Propylene, 20

Hydrogen)
3. Highly Reactive and Explosive Substances (NH4NO3,TNT) 15

4. Extremely Toxic and Toxic Substances – powder/solid 10

(Parathion Methyl)
5. Liquid Flammable Substances – solvent (Toluen, naphta) 5
 CAPACITY RATING (CR)
 Max. quantity
 Threshold quantity

No. Capacity ratio Penalty Points

1. CR < 10 4
2. 10 < CR < 50 8
3. 50 < CR < 100 12
4. CR > 100 16

CR = Max. Capacity
ILO Threshold Quantity
 POPULATION RATING (PR)
 Population in within a circle of 1 km

No. Number of People Penalty Points

1. PR < 1000 3
2. 1000 < PR < 5000 6
3. PR > 5000 9
 DOMINO EFFECT RATING (DER)
 Major Hazard Installation

No. Domino Effect Rating Penalty Points

1. 1 MH Installation 0
2. 2 MH Installation 2
3. > 3 MH Installation 4
 SPECIAL OBJECTS RATING
(SOR)
 Object such as : schools, hospitals, cinemas, markets,
supermarkets etc
 Within a circle of 1 km

No. Categories SOR points

1. No special objects 0
2. 1 Special objects 1
3. > 2 Special objects 2
FACTORY RANKING FACTOR
(FRF)

No. Factories Categories FRF

I. Important MH Factories 12 < FRF < 27
II. More Important MH Factories 27 < FRF < 41
III. Most Important MH Factories 41 < FRF < 56
 CONTOH 1
PT. X Jakarta, Informasi :
LPG : 37.000 tons
Penduduk lebih dari 10.000 orang, tidak
terdapat MH instalasi lainnya dan tidak ada
spesial objek
Jawaban : HR = 20; CR = 37.000 : 25 = 1480 =>
CR > 100, CRp = 16; PR = 9; DER = 0 dan
SOR = 0
Jadi FRF = 20+16+9+0+0 = 45 (Category III)
 CONTOH 2
PT. X Cikampek, Informasi :
Chlorine : 113 tons
Penduduk lebih dari 1000 orang, tidak
terdapat MH instalasi lainnya dan spesial objek
sekolah dan rumah sakit
Jawaban : HR = 25; CR = 113 : 10 = 11
=> CRp = 8; PR = 6; DER = 0 dan SOR = 2
Jadi FRF = 25+8+6+0+2 = 41 (Category II)
IDENTIFICATION AND PRIORITISATION OF
MAJOR HAZARD INSTALATION

Calculation of Designation Factor (DF) of a

Major Hazard Installation :

DF = Q x CF/DQ
DF = Designation Factor of Major
Hazard Installation.
Q = Max. Quantity of Major Hazard
Substance in kg
CF = Condition Factor
DQ = Designation Quantity of Major Hazard
Substance in kg
 CONDTIONS FACTOR (CF)
 A measure for the conditions under which a Major Hazard Substances
is present in the installation
 Condition deviations and corrections
No. Condition Correction
Factor
a Installation for Processing 1
Installation for storage 0.1
b Installation out of doors 1
Installation in enclosure 2
c Substance is in the gaseous phase 10
Substance is in the liquid phase (see table 1) 0.1 -10
Substance is in the solid phase (respirable powder only)
0.1
d If the process temperature is equal or higher than ambient 0
If the process temperature is lower than ambient (see table 2)
0-3
CONDITIONS FACTOR
(CF)

CF = a x b x (c + d)
DESIGNATION QUANTITY (DQ)
 Quantity of hazardous substance when released suddenly,
can result in extreme danger for a worker within a radius of
100 m from the point of emission

 The designation Quantity :

a. Flammable Substances :10.000 kg
b. Extremely Toxic Substances : 1 kg (based on LC < 20
mg/kg)
c. Toxic Substances; reference = 300 kg Chlorine
d. Explosive Substances; reference = 1000 kg TNT

 See list of Dangerous substances and Threshold Quantities

CORRECTION FACTOR c FOR LIQUIDS (I)
Table 1 :
No Process Temperature (Tp – Tbp) Correction
Factors
1. Tp>90˚c below the boiling point 0.1
80-90 below the boiling point 0.2
70-80 below the boiling point 0.3
60-70 below the boiling point 0.4
50-60 below the boiling point 0.5
40-50 below the boiling point 0.6
30-40 below the boiling point 0.7
20-30 below the boiling point 0.8
10-20 below the boiling point 0.9
<10 below or above boiling point 1
CORRECTION FACTOR c FOR LIQUIDS (II)
No Process Temperature (Tp – Tbp) Correction
Factors

10 - 20˚c above the boiling point 2

20 - 30 above the boiling point 3
30 - 40 above the boiling point 4
40 - 50 above the boiling point 5
50 - 60 above the boiling point 6
60 - 70 above the boiling point 7
70 - 80 above the boiling point 8
80 - 90 above the boiling point 9
Tp> 90 above the boiling point 10
CORRECTION FACTOR d
Tabel 2 :
- 25˚C < boiling point < ambient ˚C : 0
- 75˚C < boiling point < - 25˚C :1
- 125˚C < boiling point < - 75 ˚C :2
boiling point < -125 ˚C :3
 MH INSTALLATION CATEGORIES
Designation Factor ( DF)

No. MH Installation Categories DF

I. Important MH Installation 0 < DF < 100
II. More Important MH Installation 100 < DF < 500
III. Most Important MH Installation DF > 500
CONTOH 1
Instalasi produksi yang tertutup, berisikan 2.100
kg bahan kimia beracun Chlorine dalam bentuk
cair pada temperatur proses 35˚C
Boiling Point Cl2 : - 34˚C
Threshold Quantity Cl2 : 300 kg. DF = ?
DF= (Q x CF)/DQ
CF = 1 (processing)x2(enclosed)x7(69˚C above
atm bp) = 14
DF = (2100 x 14)/300 kg = 98 (Category I.
Important MH Instalation )
CONTOH 2
PT.X Jawa Barat – LPG Instalasi penyimpanan yang di
lapangan terbuka, berisikan 37000 ton;
DQ = 10 ton
LPG mixture : 80% butane; 20% propane
Tbp butane : - 2˚C; Tbp propane : - 45˚C
Storage & ambient temp. (max. 35˚C)
T proses antara 30 – 40˚C diatas utk Tbp butane dan 70
- 80˚C utk propane. DF = ?
DF= (Q x CF)/DQ
DF = 80%x37000x0.1(4+0) + 20%x37000x0.1(8+0)/10
DF = 1776 (Category III. Most Important MH Instalation )
CLASSIFICATION OF PLANT
ELEMENT

 DOW INDEX
 FIRE, EXPLOSION & TOXICITY INDEX
(FE&T INDEX)
CLASSIFICATION OF PLANT
ELEMENT
Category Fire and Explosion Toxicity Index
Index

Category I F < 65 T<6

Category II 65 < F < 95 6 < T < 10

Category III F > 95 T > 10

SURVEY SAFETY STUDIES
Category I II III

Checklist 1 x x

Checklist 2 x

Hazard and Operability Study (HAZOPS) x

Accident Data x x x

Emission of Safety Devices x x x

CHECKLIST 1
Causes (internal and external) that may lead to loss of
containment of a hazardous material in the installation

 Failure in  Explosion and/or fire in

 The supply/discharge of
process substances
 The electric power
supply
 The cooling water supply
 The process water or
common water supply
 Air supply
 Steam supply
 Inert gas supply
 Fuel supply
the area
 Extreme high open air
temperature
 Extreme low open air
temperature
 Flood
 Soil subsidence
 Stroke of lightning
 Mechanical impact
CHECKLIST 2
Causes that may lead to loss of containment of
the hazardous substances from the installation

 Exceeding safe limits  Thermal expansion

 Corrosion (internal)  Contraction
 Corrosion (external)  Decomposition
 Erosion  Incorrect sampling
 Mechanical stress,  Stratification
fatigue  Control errors
 Fouling and clogging  Fire in the observed
 Failure of seals plant element
SEKIAN