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)
2)
3)
4)
5)

6)
7)

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 PEOPLES WAY OF LIFE short
term or long term
ENVIRONMENT DAMAGE short term or long term
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 peoples 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 peoples 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 peoples 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

Lay out
Design
Construction
Start up

Operation
Maintenance
Repair
Modification
Decommissioning

AVOIDANCE OF RISKS
Small Inventories
Safer Substances
Lower Pressure
Lower Temperature
Etc

REDUCE
POTENTIAL

PREVENTION OF ACCIDENTS

Ensure adequate control

Site Layout
Operator training
Operation Maintenance

instrumentation
Reduce Failures
Improve Detection
Improve Shutdown
Improve Relief

Work permit system

Inspection, testing
Accident - investigation
Etc

REDUCE
PROBABILITY

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

ACCIDENT MODEL
HUMAN
FAILURE

Unsafe acts
INCIDENT
Latent
Errors

Unsafe Plant/
Condition

PERFORMANCE
INFLUENCING FACTORS

Fail to
recover situation

ORGANISATION

PERSON

JOB

Failure of
mitigation

ACCIDENT
ACCIDENT

ACCIDENT MODEL

ORGANISATION

PERSON

JOB

ORGANISATION :
kharakteristik perusahaan
sistem manajemen
diklat
pengawasan/supervisi
pengupahan
lingkungan sosial
dll

PERSON :
aptitude
sifat
sistem nilai
kharakteristik
minat
motivasi
usia
jenis kelamin
pendidikan
pengalaman dll
JOB :
mesin
peralatan kerja
bahan
lingkungan fisik
metode kerja
dll

GA

HUMAN
FACTOR

N
TIO
ZA
NI

IND
IVI

OR

DU
AL

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
PELEDAKAN (Explosions)

I.

Cyxlohexane (Mati : 28; Cidera : 89) Flixborough UK, 1974

Propylene (Mati : 14; Cidera :107) Beek, Netherland, 1975

KEBAKARAN (Major Fires)

II.

LPG (Mati : 650; Cidera : 2500) Mexico City, 1985

TOKSIK (Toxic Release)

III.

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

modification

a poorly designated

DESIGNATION OF MAJOR
HAZARD PLANT
List

of Substances considered to be
dangerous

Threshold

on the list

Quantities for each of substances

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.
2.
3.
4.
5.

6.

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;

Faktor2 yg dipertimbangkan dlm

memilih lokasi MH Instalasi :
7.
8.
9.

10.
11.

Access for emergency response;

Availability of needed utility;
Requirement for the receipt and shipment
of products;
Local codes and regulation;
Prevailing wind condition;

IDENTIFICATION AND PRIOTISATION OF MAJOR

HAZARD CONTROL

1.
2.
3.

Factories
Installation
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)

No.

The chemical & physical properties

The hazardous substances
Group of Hazardous Substances

Penalty
Point

1.

Extremely Toxic and Toxic Substances gases (Cl2, NH3,

Phosgene)

25

2.

Flammable Substances (LPG, Butane, Propane, Propylene,

Hydrogen)

20

3.

Highly Reactive and Explosive Substances (NH4NO3,TNT)

15

4.

Extremely Toxic and Toxic Substances powder/solid

(Parathion Methyl)

10

5.

Liquid Flammable Substances solvent (Toluen, naphta)

CAPACITY RATING (CR)

Max. quantity
Threshold quantity
No.

Capacity ratio

Penalty Points

1.

CR < 10

2.

10 < CR < 50

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

2.

1000 < PR < 5000

3.

PR > 5000

DOMINO EFFECT RATING (DER)

Major Hazard Installation

No.

Domino Effect Rating

Penalty Points

1.

1 MH Installation

2.

2 MH Installation

3.

> 3 MH Installation

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

2.

1 Special objects

3.

> 2 Special objects

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

Installation for Processing

Installation for storage

1
0.1

Installation out of doors

Installation in enclosure

1
2

Substance is in the gaseous phase

Substance is in the liquid phase (see table 1)

10
0.1 -10
0.1

Substance is in the solid phase (respirable powder only)

If the process temperature is equal or higher than ambient

If the process temperature is lower than ambient (see table 2)

0
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 :

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

a.
b.
c.
d.

See list of Dangerous substances and Threshold Quantities

CORRECTION FACTOR c FOR LIQUIDS (I)

Table 1 :
No Process Temperature (Tp Tbp)
1.

Tp>90c below the boiling point

80-90
below the boiling point
70-80
below the boiling point
60-70
below the boiling point
50-60
below the boiling point
40-50
below the boiling point
30-40
below the boiling point
20-30
below the boiling point
10-20
below the boiling point
<10 below or above boiling point

Correction
Factors
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1

CORRECTION FACTOR c FOR LIQUIDS (II)

No Process Temperature (Tp Tbp)

10 - 20c above the boiling point

20 - 30 above the boiling point
30 - 40 above the boiling point
40 - 50 above the boiling point
50 - 60 above the boiling point
60 - 70 above the boiling point
70 - 80 above the boiling point
80 - 90 above the boiling point
Tp> 90 above the boiling point

Correction
Factors
2
3
4
5
6
7
8
9
10

CORRECTION FACTOR d
Tabel 2 :
- 25C < boiling point < ambient C : 0
- 75C < boiling point < - 25C
:1
- 125C < 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 35C
Boiling Point Cl2 : - 34C
Threshold Quantity Cl2 : 300 kg. DF = ?
DF= (Q x CF)/DQ
CF = 1 (processing)x2(enclosed)x7(69C 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 : - 2C; Tbp propane : - 45C
Storage & ambient temp. (max. 35C)
T proses antara 30 40C diatas utk Tbp butane dan 70
- 80C 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

Index

Category I

F < 65

Category II

65 < F < 95

Category III

F > 95

Toxicity Index

T<6
6 < T < 10

T > 10

SURVEY SAFETY STUDIES

Category
Checklist 1

II

Checklist 2

III

Hazard and Operability Study (HAZOPS)

Accident Data

Emission of Safety Devices

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

Failure 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

Explosion and/or fire in

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

Corrosion (internal)
Corrosion (external)
Erosion
Mechanical stress,
fatigue
Fouling and clogging
Failure of seals

Thermal expansion
Contraction
Decomposition
Incorrect sampling
Stratification
Control errors
Fire in the observed
plant element

SEKIAN