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MAJOR HAZARDS CONTROL

Learn about major hazards, incidents like Bhopal & Piper Alpha, factors contributing to accidents, control measures, and accident models.

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MAJOR HAZARDS CONTROL

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  1. MAJOR HAZARDS CONTROL Direktorat Pengawasan Norma K3 Kemenakertrans

  2. 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

  3. 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)

  4. HARMFUL EFFECT ARISING FROM MAJOR CHEMICAL HAZARDS • DEATHS – immediate and delayed • PHYSICAL INJURIES – disabling and non disabling • MENTAL INJURIES – short term or long term • SOCIAL TRAUMA – short term or long term • DISRUPTION OF PEOPLE’S WAY OF LIFE – short term or long term • ENVIRONMENT DAMAGE – short term or long term • FINANCIAL LOSS; property damage; consequential loss

  5. 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

  6. 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

  7. 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

  8. 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

  9. 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

  10. MAJOR HAZARD CONTROL is Prevention of Major Accidents

  11. Factors Influencing Major Incidents

  12. MAJOR ACCIDENTS OCCUR ALWAYS UNEXPECTED • At night • During the weekend • When the factory is stopped • During a power failure • In very bad weather

  13. CONTROL MEASURES • Avoidance of Risks • Prevention of Accidents • Mitigation of Consequences • Operation • Maintenance • Repair • Modification • Decommissioning • Sitting of the plant • Lay out • Design • Construction • Start up

  14. AVOIDANCE OF RISKS • Small Inventories • Safer Substances • Lower Pressure • Lower Temperature • Etc REDUCE POTENTIAL

  15. PREVENTION OF ACCIDENTS • Ensure adequate control • instrumentation • Reduce Failures • Improve Detection • Improve Shutdown • Improve Relief • Site Layout • Operator training • Operation Maintenance • Work permit system • Inspection, testing • Accident - investigation • Etc REDUCE PROBABILITY

  16. MITIGATION OF CONSEQUENCES • Detection systems • Emergency action on site • Choice of site • Firefighting system • First aid kit • Personal service/ambulance • Control development nearby • Etc REDUCE IMPACT

  17. ACCIDENT MODEL HUMAN FAILURE Unsafe acts INCIDENT Latent Errors Unsafe Plant/ Condition PERFORMANCE INFLUENCING FACTORS Fail to recover situation ORGANISATION PERSON JOB ACCIDENT Failure of mitigation

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

  19. HUMAN FACTOR • 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) INDIVIDUAL ORGANIZATION HUMAN FACTOR (Health & Safety Executive -1999) JOB

  20. EXAMPLES OF MAJOR HAZARD WORKS • Petrochemical Works • Chemical Works • LPG Storage • Fertilizer Works • Explosives Manufacture • Bulk Use of Chlorine • Pesticide factories • Etc

  21. CONTOHINDUSTRIAL MAJOR ACCIDENT • PELEDAKAN (Explosions) • Cyxlohexane (Mati : 28; Cidera : 89) Flixborough –UK, 1974 • Propylene (Mati : 14; Cidera :107) Beek, Netherland, 1975 • KEBAKARAN (Major Fires) • LPG (Mati : 650; Cidera : 2500) Mexico City, 1985 • TOKSIK (Toxic Release) • Methyl Isocyanate (MIC) (Mati :2000;Cidera :20000 Bhopal, India, 1984

  22. 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

  23. DESIGNATION OF MAJOR HAZARD PLANT • List of Substances considered to be dangerous • Threshold Quantities for each of substances on the list

  24. 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

  25. KEWAJIBAN PENGUSAHA ATAU PENGURUSPersh. 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)

  26. KEWAJIBAN PENGUSAHA ATAU PENGURUSPersh. 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

  27. KEWAJIBAN PENGUSAHA ATAU PENGURUSPersh. 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)

  28. KEWAJIBAN PENGUSAHA ATAU PENGURUSPersh. 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

  29. DOKUMEN PENGENDALIAN POTENSI BAHAYA BESARBerisikan : • 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

  30. DOKUMEN PENGENDALIAN POTENSI BAHAYA MENENGAHBerisikan : • 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

  31. Faktor2 yg dipertimbangkan dlm memilih lokasi MH Instalasi : • Proximity to populated areas; • Proximity to public ways; • Risk from adjacent facilities; • Storage quantities; • Present and predicted development of adjacent properties; • Topography of the site, including elevation and slope;

  32. Faktor2 yg dipertimbangkan dlm memilih lokasi MH Instalasi : • Access for emergency response; • Availability of needed utility; • Requirement for the receipt and shipment of products; • Local codes and regulation; • Prevailing wind condition;

  33. IDENTIFICATION AND PRIOTISATION OF MAJOR HAZARD CONTROL • Factories • Installation • Plant Unit

  34. PRIORITISATION OF MAJOR HAZARDFACTORIES IDENTIFIED FACTORY RANKING FACTOR (FRF) : Consist of 5 rating factors : • Hazard Rating (HR) • Capacity Rating (CR) • Population Rating (PR) • Domino Effect Rating (DER) • Special Object Rating (SOR) FRF = HR + CR +PR + DER + SOR

  35. HAZARD RATING (HR) • The chemical & physical properties • The hazardous substances

  36. CAPACITY RATING (CR) • Max. quantity • Threshold quantity CR = Max. Capacity ILO Threshold Quantity

  37. POPULATION RATING (PR) • Population in within a circle of 1 km

  38. DOMINO EFFECT RATING (DER) • Major Hazard Installation

  39. SPECIAL OBJECTS RATING (SOR) • Object such as : schools, hospitals, cinemas, markets, supermarkets etc • Within a circle of 1 km

  40. FACTORY RANKING FACTOR (FRF)

  41. 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)

  42. 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)

  43. 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

  44. CONDTIONS FACTOR (CF) • A measure for the conditions under which a Major Hazard Substances is present in the installation • Condition deviations and corrections

  45. CONDITIONS FACTOR (CF) CF = a x b x (c + d)

  46. 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 : • Flammable Substances :10.000 kg • Extremely Toxic Substances : 1 kg (based on LC < 20 mg/kg) • Toxic Substances; reference = 300 kg Chlorine • Explosive Substances; reference = 1000 kg TNT • See list of Dangerous substances and Threshold Quantities

  47. CORRECTION FACTOR c FOR LIQUIDS (I) Table 1 :

  48. CORRECTION FACTOR c FOR LIQUIDS (II)

  49. 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

  50. MH INSTALLATION CATEGORIES Designation Factor ( DF)

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