HAZOP Method Research Articles

Quantitative Risk Assessment of Hydrotreated Vegetable Oil at an Oil and Gas Company

Introduction: An oil and gas refinery operates various equipment with specific functions for different processes. Each piece of equipment has potential hazards that can damage the equipment and injure or kill workers. This study focuses on the hydrotreated vegetable oil (HVO) export facility from the jetty loading area at an oil and gas company that processes flammable liquid using various equipment. Methods: The HAZOP method determined the hazardous spots, and the probability of each equipment failure corresponding to the system was also determined using fault tree analysis (FTA). Furthermore, every event tree analysis (ETA) output probability was also determined. The probability and radius of pool fire varied for different leak hole scenarios. The final steps are individual risk per annum and potential loss of life to measure the risk level of the system. Results: Based on HAZOP deviation scenarios, every operating equipment can potentially cause a pool fire. In FTA, scenarios were developed based on different leakage hole sizes, ranging from 1-3 mm, 3-10 mm, 10-50 mm, 150 mm, and >150 mm. The results indicated that leakage could occur across all operating equipment. Similarly, the ETA applied the same bore size scenarios. The consequence analysis yielded a worst-case outcome of pool fire and a best-case outcome of un-ignited fluid release. Subsequently, the pool fire output was modeled using ALOHA, which resulted in three heat flux zones: the red zone (10 kW/m²), the orange zone (5 kW/m²), and the yellow zone (2 kW/m²). Smaller leak holes had a higher probability but smaller pool fire radius. The initial risk of the export facility was unacceptable. Furthermore, insufficient safeguards contribute significantly to the resulting high-risk level. Two mitigations were implemented: adding safeguards and reducing worker hours. Conclusion: The final results showed that for every piece of equipment, the overall risk of the export facility became acceptable after mitigation..

Penerapan Program Kesehatan dan Keselamatan Kerja dalam Aktivitas Kerja Coal Hauling di PT. XYZ

The implementation of an occupational health and safety (K3) program can be an effort for mining companies to make efforts to prevent accidents in mining work activities such as coal hauling. Based on this, the purpose of this study was to analyze the implementation of K3 (occupational health and safety) on coal hauling activities by PT. XYZ with HAZOP and HIRARC methods. The research was carried out using data collection methods such as interviews, observations, and document studies. Furthermore, the data were analyzed using the HAZOP and HIRARC methods, which are data analysis methods that aim to determine the potential hazards that exist in mining work activities. The results showed that through the HAZOP analysis showed that there were 12 sources of danger in 5 work activities in the Coal hauling section. These 12 hazard sources are divided into 4 hazard categories with 56% high risk, 24% moderate risk, 15% extreme conditions, and 5% low risk. Based on this, it can be seen that the potential hazard by causing work accidents is quite significant. Meanwhile, the HIRARC analysis shows that there are 6 sources of danger with 9 potential work accidents which are divided into 4 categories of hazards as much as 51% high risk 4 potential risks, 21% extreme risk with 1 high value potential risk, 18% low risk with 3 potential risks, and 10% medium risk with 1 potential hazard. This potential and source of danger has and will continue to allow for the occurrence of losses, both material and physical injury to employees.

Perancangan Sistem Pengendalian Risiko Menggunakan Simplified Bowtie Analysis pada Fasilitas FSO Federal II di PT XYZ

The oil and gas industry in Indonesia, including PT XYZ which manages domestic oil and gas, faces high complexity and risk. PT XYZ's operations are supported by several offshore platforms and facilities which have various potential risks. Process safety is a top priority to prevent major incidents or major accidents. PT XYZ uses Process Hazard Analysis (PHA) which needs to be revalidated every five years to ensure procedures comply with current conditions. This research focuses on the FSO Federal II facility owned by PT XYZ, a 200 thousand barrel capacity crude oil storage vessel with a high potential risk of major incidents. PT XYZ uses the HAZOP and HAZID methods in PHA to identify risks. However, PT XYZ does not yet have a direct control system for workers. This research aims to create a risk control system that can be used by Federal II FSO workers as a work guide. This work guide will help in handling undesirable events that have the potential to cause major incidents. Proposed improvements include creating a work guidance document based on risk identification using Bowtie Analysis, which produces a mapping diagram of causes, peak events, hazards and consequences. The bowtie diagram will be simplified to make things easier for workers, considering the large number of processes in FSO Federal II. This guideline will help workers prevent major incidents from occurring.

Proposed Improvements to Reduce the Risk Work Accidents on CV HB with FMEA and HAZOP Method

A company called CV HB makes socks based on what its customers want. Bandung is home to CV HB. Several machines, including Santoni, Dakong, Obrass, Stock Steam, and others, are employed in CV HB's sock production process. Numerous personnel who are in charge of running the machinery and performing other production tasks are also a part of the production process. The execution of health and safety protocols has yet to be well-executed in the production sector. The organization saw 24 workplace accidents between 2019 and 2023, including injuries from needles and blades, hands stuck in machinery, brain injuries from machines, slipping down stairs, and many more incidents. In order to address health and safety concerns at CV HB, the research attempts to pinpoint the root causes of workplace mishaps and offer suggestions for enhancement. Hazard and Operability Review (HAZOP) and Failure Mode and Effects Analysis (FMEA) were the methodologies used in the investigation. A few suggestions for improvement for the chosen departments are using material handling tools during the material retrieval process, posting warnings about machines with sharp parts, requiring protective gear like masks and gloves, designing foam padding for sharp machine parts, and installing fans.

ANALYSIS OF OCCUPATIONAL SAFETY AND HEALTH (K3) RISK IN THE CONSTRUCTION OF SAMPANG SOUTH RING ROAD (JLS) USING HAZID HIRA AND HAZOP METHODS

Occupational Health and Safety (K3) is all engineering activities to support construction work in realizing the fulfillment of security, safety, health and sustainability standards that ensure construction engineering safety, workforce safety and health, public safety and environmental safety. The method used is HIRA, HAZID and HAZOP. In HIRA, there are 4 dominant risk variables that may occur during the construction of the South Ring Road (JLS) Sampang, namely: (X4.4), (X5.3), (X6.1), and (X6.2). To determine whether or not the variable data used using the HAZID method is to use a preliminary questionnaire which is distributed before the main questionnaire. the correlation value of each variable is obtained or it is called r count, then the r count can be compared with r table. To determine the risk response and recommendations that may occur using the HAZOP method is to use literature studies from previous journals as well as occupational safety and health standards. Thus, 19 recommendations for controlling the 4 dominant risks that may occur in the South Ring Road (JLS) Sampang project are obtained.

Risk Assessment of Solid Propellant Rocket Motor using a Combination of HAZOP and FMEA Methods

The development of rockets in Indonesia has long been carried out by the National Aeronautics and Space Agency (LAPAN), which has now been integrated into the National Research and Innovation Agency (BRIN). The Research Centre for Rocket Technology, which is one of the centres within BRIN, has been developing solid propellant-based rockets with a various sizes and types. Solid-propellant rocket technology is commonly used because of their reliability, cost-effectiveness, and simple design. However, this technology is one of the high-risk technologies, whose failure can harm humans, damage the environment and cause huge losses to assets. As a high-risk technology, risk assessment activities must be carried out, starting from the design, manufacturing, testing and up to the launching stage. In this paper, we studied a risk assessment for general Solid-propellant Rocket Motor (SRM). SRM is basically a device that processes chemical energy in solid propellant into thrust (kinetic energy) in a container that functions as a pressure vessel. The risk assessment methods commonly used in this technology are the HAZOP or FMEA methods. The HAZOP is excellent in identifying failure modes systematically through identifying the deviation of physical process parameters but has difficulties in prioritizing the risk. The FMEA has effectiveness in understanding failure mechanisms and establishing necessary countermeasures, but for a product with a lot of components, the worksheet is also complex. By combining these two methods, integrating the superiority of each method, this research can identify modes, causes and effects of failure that may occur in SRM effective and accurately. In addition, this research also proposes corrective or preventive actions for each failure mode. As the objective of the risk assessment, results of the research can be used as input for the designers to improve their design and as inspection and surveillance objects for QC officers.

ANALISIS RISIKO DAN FAKTOR PENYEBAB TABRAKAN KAPAL KM. ARMADA SEJATI DI PELABUHAN SURABAYA DALAM KAITANNYA HUKUM MARITIM

Abstract; This research aims to find out about the risk of danger from ship collisions and to find out the factors that influence the risk of KM ship collisions. True Fleet at PT. Greetings Pacific Indonesia Lines. The type of research in this research is Normative Juridical research. The research approaches in this research are the statutory approach and the case approach. Sources of legal materials in this research are primary legal materials, secondary legal materials and tertiary legal materials. Data collection in this research used library research. Analysis will also be carried out using qualitative methods. The research results show that risk identification mapping of hazards that occur in activities on Armada Sejati ships can be carried out using the HAZOP or hazard method and the results show that the most dominant hazards are risks identified from several hazard sources such as ship accidents, painting, welding, mooring/unmooring, to loading and unloading goods. The occurrence of ship collision accidents can be caused by several factors, namely technical factors related to monitoring the ship's seaworthiness, natural factors related to weather and currents, human factors related to the human resources of the crew and also the company, as well as other factors.

Safety, health, and environmental risk assessment of the aromatic outlet of Imam Khomeini Petrochemical Company using LOPA and fuzzy-LOPA and pollutants and control actions using the Bow-tie method.

Today, with the development of the industry, the occurrence of accidents caused by the release and explosion of chemical and toxic substances in industrial units has increased, and these accidents sometimes cause irreparable damage to human life and the environment. According to a study by the American Petroleum Institute, of the recent major accidents in the last 30 years, 44% are related to machinery failure and 12% are caused by unknown factors and lack of information. Therefore, equipment risk control is aimed at preventing large and dangerous accident. The present study, the performance of LOPA and fuzzy-LOPA methods was compared toward the risk assessment of Imam Khomeini Petrochemical Company under certainty and uncertainty of data. This comparison was done in order to a conceptual method with high certainty to assess high-level hazards leading to health and safety risks and environmental pollution. First, the health, safety hazards and environmental aspects were identified via the HAZOP method. Then, a risk assessment was performed using the LOPA method. The fuzzification, severity, and likelihood of each risk were considered as an input variable and risk probability as an output variable. Finally, was the methods used in our analysis were compared and the Bow-tie software was used to draw a Bow-tie diagram to control and reduce the risks. As a result, a total of 50 safety and health hazards and 37 environmental aspects were identified in the aromatic outlet of the studied company using the HAZOP method. The most critical risks identified were operational activities in feed and product tanks; flammable materials pumping; blocking the flare path; and releasing H2S gas. The results showed that the production of air pollutants in the power supply unit, disposal of waste from reactor tanks, disposal of waste from condensate tanks, and fire and explosion of the reactor are high-level environmental risks. In the conditions of uncertainty or the absence of information related to the probability and severity of the risk scenario, among the mentioned methods. The result showed that errors in the risk assessment were reduced to an acceptable extent by using Fuzzy LOPA method.

Analisis Keselamatan Dan Kesehatan Kerja Dengan Menggunakan Metode Hazop Pada Proses Pan Oil Di PT. X

PT. X works in the automotive manufacturing industry. There are various departments in the corporate structure, one of which is K3 (Occupational Health and Safety). This department is an important part of a company. Bearing in mind that all machines and equipment used have potential hazards. Therefore, the purpose of this research is to examine the risk of work accidents that endanger the safety and health of employees. To control the potential for work accidents, the HAZOP method was chosen. The HAZOP approach was used to conduct this research. Hazard and Operability Studies (HAZOP) was founded by ICI, a British chemical company. As a result, HAZOPs are increasingly being used in the chemical sector where they will be used in dealing with accidents that occur due to negligence of workers. The results obtained when conducting research using the hazop method obtained 3 levels of hazard risk and showing the percentage of each level of risk, including 50% low risk, 25% high risk, and 25% extreme risk. Low risk is the process of using manual equipment and forklifts, high level of risk in the machining process, and extreme level of risk in the casting process. Keywords: Accident, hazop, health, safety, work

Hazard Analysis of an Autonomous Container Handling System – a Comparison of STPA and HAZOP Methods

Increasing automation is a major trend in container terminals. In automated container handling systems, safety has been previously ensured by segregating the automated machinery from other traffic and workers moving on foot. Currently, further increases in flexibility are sought by developing autonomous systems that are capable of mixed-traffic operations without the need for separate operating areas. This increases the complexity of the systems and introduces new safety hazards. In addition to traditional hazard analysis methods, new approaches are needed to address the emergent risks related to autonomous operations. This paper studies the applicability of the STPA (system-theoretic process analysis) method in hazard analysis of an autonomous machine system. To support the evaluation, we define evaluation categories for comparison of the analysis methods. We also compare STPA with an established method, HAZOP (hazard and operability study). To perform the comparison, both STPA and HAZOP are applied to an autonomous container handling system concept. The study suggests that both STPA and HAZOP are well suited to support the development of autonomous machinery. However, we also highlight some notable differences in the methods, mostly related to the different underlying accident models that they utilise. HAZOP is an established method with tools and standards available. STPA, on the other hand, provides a well-defined syntax to ensure the analysis quality and a system modelling approach that supports the system development.

Hazard and Risk Analysis Using Hirarc and Hazop Methods on Erection Girder Work

Superstructure work of the toll flyover construction is one of the works that have a high level of risk, especially when the erection girder work passes over the existing toll road. This study aims to identify hazards on erection girder work using the HIRARC and HAZOP methods. Using these two methods requires the implementation of questionnaire and surveying, using at least 30 respondents with 34 respondents is successfully gathered. The results showed that there were 36 possible hazards where 11 hazards were identified as moderate risk and 25 hazards identified as low risk. Then an interview was conducted with occupational health and safety (OHS) experts on site to validate the results of this research. Efforts are being made to carry out inspections of heavy equipment before use, only operators who have SIO that are appropriate and competent to do, conduct toolbox meetings, install warning signs, use PPE, and coordinate and cooperate with existing toll owners.

Study of the Effectiveness of Implementing Occupational Safety and Health with the Hazop Method in the Cikarang Industrial Center

The brick industry center in Cikarang has not implemented Occupational Safety and Health (K3). This is due to the lack of understanding of industrial owners and workers regarding the importance of implementing OSH in the workplace. Therefore, the application of OSH in IKM, especially in the Cikarang industrial center, must be effective and optimal to increase the productivity and competitiveness of the industrial center. The purpose of this study was to assess the application of occupational safety and health with the HAZOP method in the Cikarang Brick Industry Center. This research is a quantitative research with a descriptive analytic design. The research objects are four brick industries in the Cikarang brick industry center. The stages in this research are hazard identification and risk assessment in industrial centers using the HAZOP method for potential work accident hazards. The results of this study obtained the findings of several risks with an extreme risk level of 17% with 3 very risky sources of danger, for high risk of 66% with 14 sources of high hazard, and a moderate risk of 17% with 3 sources of low hazard. The conclusion of this study is that there are 20 potential hazards that can occur with high risk potential or high risk which has the most potential with a total of 14 sources of danger.

Application of Hazard and Operability Analysis (HAZOP) Method for Risk Analysis in CGS Station

Background: The hazard and operability study (HAZOP) method is a risk assessment method based on engineering systems used for qualitative analysis or quantitative evaluation. It is mainly used to discover potential hazards and operational difficulties in the design and qualitative stages of chemical systems. The study aims to apply the HAZOP method in process and safety operations at gas depressurization station.
 Methods: This descriptive study was performed at CGS station. The station was divided into four principal nodes including: filter, heater, regulator, and odorize part. Required information for HAZOP worksheets were gathered by operational procedures, daily reports and interviews with engineers and operators working at the station. To determine the severity of consequences and probability of occurrence of scenarios that were predicted based on the risk matrix, the amount of risk was specified and the necessary suggestions were made in this regard.
 Results: According to this study, the operational indicators in the pressure reducing station process included pressure, flow, level and temperature. 22 main deviations and 50 causes of failures were identified. 5 deviations (23%) were in the low risk range (green area) and 17 (77%) were in the medium risk range (yellow area).
 Conclusions: Causes and effects of deviations in operational parameters at four nodes in gas depressurization station were identified by HAZOP. Preventive actions were emphasized, such as consistent inspection of pipelines, preventive and timely maintenance and preparing a well-scheduled plan for inspecting the equipment in terms of corrosion, inspection, and design revision.

Hazard Identification in Coal Boiler with HAZOP Method at Pt. Charoen Pokphand Indonesia

Hazard Identification in Coal Boiler with HAZOP Method at Pt. Charoen Pokphand Indonesia

SAFETY EVALUATION OF PETROLEUM TANK FARM: AN ANALYTICAL STUDY OF NNPCL MAIDUGURI DEPOT PLANT

A petroleum tank farm, usually known as an oil terminal is a common facility that stores flammable liquid. Tank farm has possible hazards to the people, environment and asset. Some of the hazards such as fire, static electricity, transportation etc. are accidents which occur at the oil terminals. Many industries are using different risk assessment methods to priorities hazards linked to their work activities. In this study, a new risk and safety analysis model, known as quantitative risk assessment (QRA) for tank farm was applied. QRA is an effective planning tool used in chemical processing plant, to help at forecasting the potential major accident occurrences, so that suitable mitigating and preventive measures can be implemented. QRA was conducted on a selected NNPCL Maiduguri depot tank farm with specified objectives. The three main objectives for this study are hazard identification, risk evaluation using qualitative and quantitative risk assessment by using the hazard and operability analysis, HAZOP and failure mode effect analysis (FMEA) methods. It was found that hazard occurrences were from various categories namely general management, hazardous chemical exposure and fire safety etc. In this research work, two scenarios was established and the estimated risks are associated to the petroleum tank farm activity such as leakage at dispenser area due to poor safeguarding systems, underground fuel leakage during unloading due to fittings failure and storage tank explosion due to high pressure. However, in summary, complete planning which combines all aspects are deemed necessary so that the impact of the associated risk from the operational, storage and maintenance of petroleum tank farm can be identified and minimized during the activities by working out the FMEA method sheet.

Minimizing Work Accidents in the Shipyarding Industry Using JSA and HAZOP Methods

PT. Cahaya Baru Shipyard is a company engaged in ship repair. Activities in shipyards have various risks, one of which is work accidents. The research aims to determine the risk of work accidents from shipbuilding activities, risk control and suggestions for improvement. This study identifies risks using the Job Safety Analysis (JSA) method and assisted by the Hazard And Operability Study (HAZOP) method to control potential hazards and recommendations for new safety systems to minimize work accidents. The research method used is qualitative. The results of the study show that most work accidents occur in welding and cutting activities with a percentage of 23.3%. Providing personal protective equipment and workers reminding each other to use safety equipment and to remain careful in doing their work, implementing standard operating procedures (SOPs) and existing work instructions can be a way that can be done to minimize work accidents.

A Quantitative HAZOP Risk Analysis Under Extended CREAM Approach for Maritime Autonomous Surface Ship (MASS) Operation

Abstract Globally, there has been a substantial growth in interest in autonomous surface ships. This new domain presents numerous concerns for enhanced reader comprehension. The most crucial topic to consider is the safety of autonomous ships and the risks they present. To enable the use of autonomous ships, they must be as safe for the environment and for people as manned surface ships. However, as it has not yet been widely implemented, acquiring real-time data restricts the scope of the study. The objective of this paper is to conduct a comprehensive quantitative risk analysis for maritime autonomous surface ships (MASS). Therefore, it focuses on the operations to be performed by MASS and the factors that may pose a risk. In this context, Hazard and Operability Analysis (HAZOP) and Cognitive Reliability and Error Analysis Method (CREAM) approaches will be used in risk analysis assessment. While the HAZOP method will be used to determine the deviations, causes, possible consequences, and measurements that autonomous surface ships will be exposed to, the extended CREAM will be used to determine the likelihood of occurrence and risk levels of the MASS operation. The outcomes of the paper are anticipated to enhance the safety operational safety level of autonomous ships as well as mitigate risks.

Analysis of Accident and Occupational Diseases with HAZOP Method and The Risk Control of Batik Papringan Workers, Banyumas

An industry that has danger is Batik Papringan, Banyumas. Workers have not implemented Occupational Safety and Health (OSH) at work. It can be seen from the physical environment with poor lighting, workplaces that do not apply Ringkas, Rapi, Resik, Rawat, Rajin (5R), not using Personal Protective Equipment, unergonomic position, and feeling anxious due to decreased demand. Therefore, it is necessary to analyze occupational accidents and diseases and their control. The study took time in August 2020. The population was 200 people. The sample was obtained with the inclusion criteria, namely all Batik workers who were actively working until August 2020, while the exclusion criteria were workers who changed professions so that 190 people were obtained. The research design was cross-sectional with mixed-method analysis. The research was conducted using the HAZOP (Hazards and Operability Studies) sheet instrument. HAZOP sheet consists of job observation, hazard identification, Likelihood, and Consequences scoring, risk categorization, and control. The calculation results show that there is an extreme risk of three hazards (exposure to chemicals from wax, cloth dye, wood dust; bending attitude, static position; not applying 5R). The three extreme risks are respiratory disorders, dermatitis, fatigue, low back pain, Carpal Tunnel Syndrome (CTS), effectiveness, and efficiency of work decrease. The conclusion is that workers are at extreme risk. Employees need to be committed to risk management through disciplined risk control.

ANALISIS RISIKO KESELAMATAN DAN KESEHATAN KERJA PADA PROYEK KONSTRUKSI GEDUNG PAMJAYA MENGGUNAKAN METODE HAZARD OF OPERABILITY STUDY (HAZOP)

Over the past five years, work accident cases in Indonesia have continued to increase and reached the highest point in 2020 of 177,000 cases. This proves that steps are needed to reduce the number of work accidents by conducting a risk assessment in accordance with the main objective of K3, namely creating a safe work environment by conducting qualitative and quantitative assessments. This study aims to design a proposed improvement in the PAM JAYA building construction project by identifying the existing hazards and determining the level of risk using the Hazard of Operability Study method. The HAZOP method was chosen because its work is systematic, structured, thorough, and very suitable to be applied to the system newly implemented, in this study the PAM JAYA building construction project which has only been running for several months. This study finds 5 findings of extreme risk level hazards, 12 findings of highrisk level hazards, 2 findings of medium risk level hazards, and 1 finding of low risk level hazardsin the PAM JAYA building construction project. The suggestions for improvement given in this study are based on five hierarchies of risk control, such as Elimination, Substitution, Engineering, Administrative Control, and Use of PPE

A New Semi-Quantitative Process Safety Assessment Method and Its Application for Fluorochemical Industry

Traditional hazard and operability analysis (HAZOP) is one of the most widely applied methods for process safety management in process enterprises. Due to its principles based on the conservative and qualitative judgment, it often leads to too conservative risk identification results for the fluorine chemical industry usually with high-risk processes to keep the continuity of production. Most of improved quantitative and semi-quantitative methods are based on the layer of protection analysis (LOPA) to resolve the over-conservative problem of traditional HAZOP with the database of LOPA. However, the improved model, taking LOPA as the main line and HAZOP only as the provider of scenarios and influencing factors, is limited to the fact that LOPA can only analyze complete and independent protection layers (IPLs). Therefore, in order to realize the quantitative or semi-quantitative analysis of disaster causes and consequences, a new semi-quantitative HAZOP method takes HAZOP as the main line to integrate LOPA, F&EI (fire and explosion index) for quantitatively calculating the reduction factors, probability on failure demand (PFD) of general protection layers (GPLs) and PFD of IPLs. With the case comparison of fluorine chemical industry, it is proved that this new method can effectively improve the problem that traditional HAZOP are too conservative in complex scenarios.