11/06/2025

Rencana Pembelajaran Semester

Keselamatan Pabrik Kimia

(Chemical Factory Safety)
• Chapter 1
• Introduction

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Bahasan Pustaka
Minggu Bab
1 Introduction
2 Safety Process Legal • Utama :
3 Process Safety Management • 1. Crowl and Louvar (1999), “Chemical Process Safety”,
4 Industrial Hygiene 2nd ed, Prentice Hall.
5 Quiz 1 • 2. Ketentuan Keselamatan Kerja dan Perundang-
6 Source Models undangan RI.
7 Toxic Release and Dispersion Model
• Pendukung :
8 Fire and Explosion
9 Designs to Prevent Fires and Explosions • 1. Goetsch DL (2005),”Occupational Safety and Health for
10 Relief System Technologists Engineers, and Managers, 5th ed, Prentice
Hall
11 Quiz 2
12 Hazard Identification • 2. Keltz T(1999), “What When Wrong?”, 4t ed, Gulf
13 Risk Assesment Publishing
14 Presentasi Case Studies HAZOP • 3. King, Ralp & Magid,John ( 1982 ),”Industrial hazard and
15 EAS Safety Handbook”, Butterworth Scientific, London.
16 Remidial EAS

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Examples of the technology of safety include

- hydrodynamic models representing two-phase
flow through a vessel relief,
- dispersion models representing the spread of
“To know is to survive and to
toxic vapor through a plant after a release,
ignore fundamentals is to
and Safety Moment
court disaster”
- H.H Fawcett
- mathematical techniques to determine the • https://www.youtube.com/wat
various ways that processes can fail and the ch?v=Jg7mLSG-Yws
probability of failure. • Imperial Sugar Blast

Increase Economics More Complex Technology

More Complex Technology  More Safety Consideration

More Safety Consideration  More Fundamentals Theory Need to be Considered

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1-1 Safety Program

1-2 Engineering Ethics

Kep.Men. Tenaga Kerja No.

KEP.187/MEN/1999

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1-3 Accident and Loss Statistics 1-3 Accident and

Loss Statistics

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1-4 Acceptable
Risk

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1-5 Public Perceptions

1-6 The Nature

of the Accident
Process

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Nature of Accident Process

1-6 The Nature of the Accident Process - Most of accident follow a three-step-sequence

Initiation
[the event that starts the accident]
Most accidents follow a three-step sequence:
1. initiation (the event that starts the accident),
2. propagation (the event or events that maintain or expand the Propagation
accident), and
3. termination (the event or events that stop the accident or [the event that maintain or expand the accident]
diminish it in size).

Termination
[the event that stop the accident or diminish it in size]

An effective approach is to ensure that accident, once initiated, do not

propagate and will terminate as quickly as possible…

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PHILOSOPHY OF ACCIDENT PREVENTION PHILOSOPHY OF ACCIDENT PREVENTION

Domino Theory Loss Causation Theory

Permit the Permit the Permit the Permit the

existence of existence of existence of existence of

Use of PPE
Safe work
Reporting
Selection

condition

practices
Attitude

First aid
unsafe
Proper

Proper

H.W Heinrich Prof. F.E Bird & Loftus

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1-7 Inherent Safety

In general, the safety of a process relies on multiple layers of

The major approach to inherently safer process
protection. The first layer of protection is the process design
designs is divided into the following
features. Subsequent layers include control systems, interlocks,
categories:
safety shutdown systems, protective systems, alarms, and
1. intensification
emergency response plans. Inherent safety is a part of all
2. substitution
layers of protection; however, it is especially directed toward
3. attenuation
process design features. The best approach to prevent
4. limitation of effects
accidents is to add process design features to prevent hazardous
5. simplification/error tolerance
situations. An inherently safer plant is more tolerant of operator
errors and abnormal conditions.

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1-8 Four Significant Disasters Assignment - 1

Flixborough, England
Bhopal, India
• Please divide class into 4 group
Seveso, Italy
• Make a simple report (in ppt file or presentation file) about one of major incidents below
Pasadena, Texas • Flixborough, England
• Bhopal, India
• Seveso, Italy
• Pasadena, Texas
• Deepwater Horizon oil spill
• Tambang Sawalunto explosion
• Kilang Balongan 2021 incident
• PT Indonesia Huabao Industrial Park (IHIP) incident
• Petrowidada explosion

• Simple Report Point:

• Overview Production Process
• How Incident can be happen
• Losses caused by the incident
• Aftermath Solution
• What can be done to avoid the same disaster from happening? (recommendations)

• Please submit in myITSclassroom not later than February 28th 2025 23:59

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Safety & health program

Topic Outline
It is a measure of effectiveness of safety programs

System Introduction

Importance of safety & health in Chemical industries

YOU Attitude
Definitions

Successful Safety
Program Accidents & loss statistics

Time Fundamentals Responsible Care

Case Studies

Experience

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REMINDER !!!....
Fundamental principles
At the end of this topic, it is expected that students will be able to:
Using knowledge & skill for enhancement of human welfare
Honest and impartial and serving with fidelity the public, their employers and clients
•Identify the importance of safety programs Striving to increase the competence and prestige of the engineering profession

•Explain the terms used in OSH e.g. hazards, accident, risk etc. Fundamental canons (for engineer)

 Engineers shall hold paramount the safety, health and welfare of the public in the
•Explain the importance of accident and loss statistics and performance of their professional duties
calculate the number of accidents and/or fatalities using OSHA
incidence rate, FAR and fatality rate.  Engineers shall perform services only in areas of their competence
 Engineer shall issues public statement only in an objective and truthful manner
•Explain the definition and importance of responsible care  Engineers shall act in professional matters for each employer or client as faithful agents or
trustees, and shall avoid conflict of interest
 Engineer shall build their professional reputations on the merits of their services
•Describe the four most cited disasters and identify its impact to Engineers shall act in such a manner as to uphold and enhance the honor, integrity, and
the standard in the practice of safety 
dignity of the engineering profession
 Engineers shall continue their professional development throughout their careers and shall
provide opportunities for the professional development of those engineers under their
supervision.

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Introduction-general Introduction-general

 Economic growth = technological advance THEN…

 Change the molecular structure or create new products from chemicals, the
possibility exists for fires, explosions or releases of flammable or toxic liquids, Accident prevention
vapors, gases or process chemicals. Emphasis on worker’s safety – hard
 Today, safety = technological advances; becoming a scientific discipline hats, safety shoes, rules and
regulations.

• Chemical industry is entering an era of more complex processes thus more NOW…
complex safety and health technology
= Loss prevention
• Example of technology of safety:
• Hydrodynamic models representing two-phase flow through a vessel relief. Includes hazard identification, technical
• Dispersion models representing the spread of toxic vapor through a plant after evaluation & design of new engineering
a release. features to prevent loss
• Mathematical techniques to determine the various ways that processes can
fail and the probability of failure.

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Introduction-general Safety & health program

The importance of safety & health are:

• Prevents the valuable equipments from totally damaged and losing
a large amount of investment.
• Assures the prolonged human resource contribution to profit the
chemical plant.
• To avoid other indirect cost

• Safety deals with acute effects of hazards,

whereas health deals with chronic effects of
hazards.

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Safety & health program inherent safety

• Good safety & health program identifies and eliminates existing hazards. Excellent
one has management system to prevent existence of hazards Inherent safety is to select a process or equipment which
is by
nature a safer process by applying;-
Safety
Safety
management
support
knowledge
Minimize (intensification) Substitution
-reduce inventories of hazardous - avoid using hazardous materials,
Safety
experience commitmen
materials in process and storage but instead, use a safer one
t

Technical
INHERENT
SAFETY
competence

Simplification and error Moderate (attenuation and

tolerance limitation of effects)
Ingredient of successful - Provide process or condition that - use of hazardous material under
safety & health program has fewer opportunities for error the least hazardous condition

“The essence of the inherently safer approach to plant design is the avoidance of hazards rather than their control by added-on
protective equipment” [T. A. Kletz, Plant Design for Safety: A User-Friendly Approach, 1991]

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Definitions Nature of Accident Process

• the prevention of accidents through the use of appropriate technologies

Safety & loss prevention to identify the hazards of a chemical plant and eliminate them before an
accident occurs.

• a chemical or physical condition that has the potential to cause

Hazard damage to people, property, or the environment

• An undesirable event which has a potential to cause a serious accident.

Near misses

• a measure of human injury, environmental damage, or economic loss in

Risk terms of both the incident likelihood and the magnitude of the loss or
injury.

• unexpected and unplanned incident or sequential incident that causes

Accident injury and illness, material damage or process loss.

• is arisen when one is exposed with the hazard.

Danger

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Nature of Accident Process Nature of Accident Process

Type of loss [Hydrocarbon Chemical Plant Accidents]

Probability of Potential of Potential for

occurence fatalities economic loss

•Fire • HIGH • Low • Intermediate

•Explosions • Intermediate • Intermediate • HIGH
•Toxic release • Low • HIGH • Low Piping system failure represents the
bulk of accident, followed by storage
tank and reactor

Most complicated mechanical

Three type of chemical plants accident components are minimally
responsible for large losses

Chemical plant accidents follow typical pattern. Fires are the most common, followed
by explosion and toxic release
Vapor cloud explosion account for
the largest percentage of these large
With respect to fatalities, the order reverses, with toxic release having the greatest losses

potential of fatalities Toxic release typically result in little

damage to equipment
Hardware associated with largest losses
Economic loss is consistently high for accident involving explosions

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Accidents & Loss Statistics Accidents & Loss Statistics

Occupational Safety and Health Administration (OSHA) incidence rate

Accidents & Loss Statistics • Based on cases per 100 worker per year
• A worker year is assumed to contain 2,000 hours
• There are 3 systems considered: • The OSHA incidence rate is therefore based on 200,000 hours of
• Occupational Safety and Health Administration (OSHA) worker exposure to a hazard
incidence rate • Two types of calculations (1) based on injuries and illness (2) based
• Fatal accident rate (FAR) on lost workdays

• Fatality rate or deaths per person per year (Fatal Accident Rate) FAR
• Based on 1000 employees working their lifetime
• The employees are assumed to work a total of 50 years
• These methods report the number of accidents and/or
• Used mostly by British chemical industry
fatalities for a fixed number of workers during a specific
period Fatality Rate
• Independent of the number of hours.
• Based on the number of fatalities per year and total number of
people in applicable population

azizanramli2010fkksa

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Responsible Care Responsible Care

Responsible Care
• Why RC?
• To respond to public concerns about manufacture,
transport, use and disposal of chemicals
• Community awareness and involvement are key
features to initiative
Responsible Care • Aim of RC;
• It is an initiative of the chemical industry and adopted • Improve chemical industry performance in HSE
by chemical companies to improve continuous HSE • Improve public perception in the chemical industry
performance of their operations and products in
manner responsible to the concern of the public • What does it mean?

• Started in Canada in 1985, and 1994 in Malaysia by

Chemical Industries Council of Malaysia (CICM)

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Responsible Care Responsible Care

Codes of Management Practices
Codes of Management Practices;

• Distribution Code [adopted in 1995]

• Focuses on reducing the potential for harm posed by the distribution of
Product Pollution
Stewardship Prevention chemicals to the general public, employees and environment.
Code Code
• Community Awareness and Emergency Response Code [adopted in 1996]
• Promotes emergency response planning and encourages dialogues with
Community nearby communities to understand their concerns.
Process Safety Awareness and
Code Emergency
Response Code
• Pollution Prevention Code [adopted in 1997]
• Commits industry to the save management and reduction in the amount of all
pollutants released into the environment.
Security code
Distribution
code [adopted in • Process Safety Code [adopted in 1999]
2002]
• To prevent fires, explosion and accidental chemical releases at the plant sites.
Employee
Health and
Safety Code

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Responsible Care AssignmENT

Codes of Management Practices; Below are some of the most cited industrial disasters to be read ahead and
discussed in the group.;
 Flixborough, England, 1974 [caprolactam, raw material for the
• Employee Health and Safety Code [adopted in 1999] production of nylon]
 Bhopal, India, 1984 [ production of pesticides- methyl isocyanate or
• Protects and promotes the health and safety of employees and visitors at MIC]
plant site.  Seveso, Italy, 1976 [production of hexachlorophene, a bactericide]
• Product Stewardship Code [adopted in 1999]  Pasadena, Texas, 1989 [polyethylene plant]
 PEMEX LPG Terminal explosion and fire, Mexico City, Mexico, 1984
• To make health, safety and environment protection a priority in all stages of a
 BP Texas City Refinery explosion and fire, 2005
chemical product’s life, from design to disposal.
 Bright Sparkler Fireworks explosion and fire, Sg. Buloh, Malaysia,1991
• Security Code [adopted in 2002 by ACC] [explosion]
• which addresses facility, cyber and transportation security - requires
Prepare a presentation of any of above chemical plant disasters. [MAX: 6
companies to conduct comprehensive security vulnerability assessments presentation slides inclusive of presentation title]
(SVAs) of their facilities, and implement security enhancements
• The Code also requires companies to create security management systems,  The presentation should include
which are documented to provide quality control and assurances.  How did it happened? (story-telling time)
 Why did it happened? (errors/mistakes)
 What were the consequences? (fatalities/injuries)
 What can be done to avoid the same disaster from happening?
(recommendations)

A series of questions will be asked and points will be awarded accordingly.

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