page-1 universitas indonesia agenda k3 industri kimia 5-4-11 silabus, pembagian tugas, intro safety...

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UNIVERSITAS INDONESIA

AGENDA

K3 Industri KimiaK3 Industri Kimia

5-4-11 silabus, pembagian tugas, Intro safety

12-4-11 Safety at BP Tangguh (guest lecture, HSE engineer)

19-4-11 Chemical Process Safety

26-4-11 Safety Analysis

3-5-11 Ujian

Reference:

1.Safety Analysis: Principles and Practice in occupational safety, Lars Harms-Ringdahl

2.Chemical Process Safety: Fundamentals with Applications

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TUGASTUGAS

1. Buat file pptx

No absen 1-13 masing2 bab 1-13 buku chemical process safety

Misal no absen 1: bab 1

No absen 14-20: bab 1-14 buku safety analysis (per dua bab)

Misal no absen 14: bab 1-2, no absen 15: bab 3-4

No absen 21: bab 15

Dikumpulkan dengan nama file :

No absen-nama-bab.pptx, Contoh: 1-heri-bab1.pptx

Kirim ke [email protected], paling lambat hari minggu jam 16 by email

PIN: 233FAA46

• PenilaianTugas: 20%

Absensi: 10%

Ujian: 20%

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AGENDA

INTRODUCTIONINTRODUCTION

•Safety Philosophy•Personal Protective Equipment•Safety Manner (safety induction dll)•Accident, Incident (fire, explosion, third party)•Emergency response (procedure)•Investigation (internal, external, forensik, analysis)•Safety Awareness (training, manner, SOP)

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SAFETY HEALTH AND ENVIRONMENTALPOLICY STATEMENT

Kangean Energy Indonesia Limited is committed to manage the Safety, Health and Environmental (SHE). Effective SHE performance is crucial to the success of the business.

The Company goal is to avoid any accident by improving personnel behavior.

Prevention of pollution, management of natural resources for sustainability and continual improvement are vital components and key to our success.

In fulfilling this commitment, the Management will:

• Develop SHE Performance Management Standards and ensure its compliance with all relevant laws and regulations and other requirements to which oil and gas business subscribes.

• Foster open communication with employees, contractors, neighbors, public interest group and those who work with us.

• Openly and periodically report SHE performance, good and bad, evaluate and review it and promptly take necessary corrective actions accordingly.

• Recognize those who contribute to improve SHE performance

This SHE policy is in effect and become the responsibility of everyone who works for Kangean Energy Indonesia Limited to Adhere.

Keisuke InouePresident & General ManagerAugust 2008

Kangean Energy Indonesia

Kangean Energy Indonesia

Ltd.

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PPEPPE

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P&ID IFA

How to Develop/Finalize

Process Verification Proj.Spec Discipline Comments

P&ID IFH

P&ID IFC

P&IDAs Built

Company Comments

HAZOPSIL Study, etc.

Detail Design Feedback

Vendor Data Input

Field Change Feedback

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AGENDA

HAZOP (Hazard and Operability Studies)HAZOP (Hazard and Operability Studies)

HAZOP is a systematic and highly structured study with a critical approach to examine the process and engineering intentions of the process design.

HAZOP is used to identify all possible causes of deviation from normal safe operation that could lead to any safety and fire hazard, environmental risk or operability problems.

Some of the causes may be unrealistic and so they will be rejected as not meaningful. Some of the consequences may be trivial and would be considered no further. However there may be some deviations with both causes that are conceivable and consequences that are potentially hazardous. These potential hazards are then noted for recommendations/ action.

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The important terms used in the HAZOP studyThe important terms used in the HAZOP study

Intention: The intention defines, how the selected section/ unit is designed or expected to operate.

Guide words: These are simple words, which are used to qualify the intention in order to guide and stimulate the thinking process and so discover deviations. A list of guide words, along with the likely causes, is given below.

Deviation: These are departures from the intention, which are discovered by systematically applying the guidewords.

Causes: These are the reasons why deviations might occur. Once a deviation has been shown to have a conceivable or realistic cause, it can be treated as meaningful.

Consequences: They are results of deviations, should they occur.Hazards: The consequences, which can cause damage, injury or

loss.

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AGENDA

The primary aims of HAZOPThe primary aims of HAZOP

• To identify the cause of all deviations or changes from the design intent;

• To determine all major hazard and operability problems associated with these deviations;

• To decide whether action is required to control the hazard or operability problem; and,

• To ensure that the actions decided upon are implemented and documented.

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HAZOP GUIDE WORDS & EXAMPLE CAUSESHAZOP GUIDE WORDS & EXAMPLE CAUSES

GUIDE WORDS

PARAMETERS

PROBABLE CAUSES

NOWrong routing – blockage – incorrect slip plate – incorrectly fitted check valve – burst pipe – large leak – equipment failure (isolation valve, pump vessel, etc.) – incorrect pressure differential – isolation in error – etc.

REVERSE

Defective check valve – siphon effect – incorrect pressure differential – two way flow – emergency venting – incorrect operation – in line spare equipment – etc.

MOREIncreased pumping capacity – increased suction pressure – reduced delivery head – greater fluid density – exchanger tube leaks – restriction orifice plates deleted – cross connection of systems – control faults – control valve trim changed – running two pumps – etc.

LESSLine restrictions – filter blockage – defective pumps – fouling of vessels, valves, orifice plates – density or viscosity changes – etc.

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HAZOP StepsHAZOP Steps

• Select and confirm the scope of a node.• Explain the general design intentions and operating conditions of the node.• Specify process parameters for node.• Select a process parameter (Flow, Pressure, etc.) and specify the design intention

relating to this parameter.• Apply a deviation (more, less, etc.) to the parameter and develop a meaningful

causes/ hazards of the deviation from the intention.• Identify all scenarios causes / hazards of the deviation from the intention.• Identify all major consequences associated with each cause without regards to

safeguards.• Specify predominate safeguards against each consequence.• Identify existing level of risk by selecting severity and probability in agreed risk

matrix (attachment-1)• Make recommendations to mitigate the consequences if the severity is

unacceptable.• Identify risk level if recommendations have been implemented, again by selecting

severity and probability in agreed risk matrix.• Repeat above steps for other guide words.• Repeat above steps for other process parameters.• Repeat above steps for all other nodes in review.• Document all recommendations agreed by the HAZOP team.








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HAZOP StepsHAZOP Steps















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P&ID No : BB-GS01-PGER-PI-0001 Deviation : No FlowPossible Cause : Both 2 gate valves 150# at 16” Incoming line of Gas Boot is closed. No flow to Gas Boot

Closed

Existing safeguards : PSH installed at every prod well

! Effect: No

production

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P&ID No : BB-GS01-PGER-PI-0001 Deviation : No FlowPossible Cause : Both 2 gate valves 150# at Gas Boots’ 16” liquid outgoing line are unintentionally closed. No Flow to Wash Tank

Closed

Existing safeguard

s

! Effect : Liquid level

increase

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P&ID No : BB-GS01-PGER-PI-0001 Deviation : No FlowPossible Cause : Production Fluid’s incoming header ruptures due to corrosion or hit by car. No flow to Gas Boot

Incoming header rupture

! Effect : No production & Oil spill

Existing safeguards : Operator regular check

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P&ID No : BB-GS01-PGER-PI-0001 Deviation : No FlowPossible Cause : Two 12” gate valves at Gas Boots outgoing lines are unintentionally closed. No flow to scrubber.

Closed

Existing safeguards:

PSV installed

! Effect : Pressure in the Gas Boot increase,

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P&ID No : BB-GS01-PGER-PI-0002 Deviation : No FlowPossible Cause : Any of 12” gate valve on gas line to PCV V51 is unintentionally closed and at the same time the Gas Plant Compressor is down. No Flow to Flare.

Closed

Existing safeguard

s

! Effect : Pressure in Gas Boot increase

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P&ID No : BB-GS01-PGER-PI-0001 Deviation : No FlowPossible Cause : Black out which makes all producer wells down.

Black Out

There is no fluid enters the gas boot & no production to Shipping Tank

Existing safeguards : LSL installed at all tanks, LSL and PSL are installed at Transfer Pump & Shipping Pumpand by-pass valve should not be opened

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P&ID No : BB-GS01-PGER-PI-0001 Deviation : Less FlowPossible Cause : Scale at incoming line to Gas Boot.

Scale

No consequences to Pager GS. Flow bottlenecks at off-plot line.

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P&ID No : BB-GS01-PGER-PI-0001 Deviation : More FlowPossible Cause : More well POP or New Fields going in

More well pop

* Capacity of GS is 180,000 BPD, higher than peak forecast production

at 125,000 BPD.

Consequences : Overflow in the surge Tank. Water quality decrease.

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P&ID No : BB-GS01-PGER-PI-0001 Deviation : More FlowPossible Cause : If one of incoming valve to Gas Boot accidentally shut-in, more fluid will be flowed to second boot.

! Effects : One Gas Boot will handle more liquid. More gas would be carried under to wash tank and gas blanket scrubber. Wash Tank

pressure will increase and separation efficiency would be lowered. May blow-up the tank’s roof.

Existing safeguards : PSV installed at tank &

scrubber

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P&ID No : BB-GS01-PGER-PI-0001 Deviation : More PressurePossible Cause : Gas Plant Down.

! Effects : Pressure at Gas Boot increase. Liquid level decreases. Gas may blow under

PCV V51 will set pressure at 10 psig

and let excess pressure to flare.

LCV V1/2 will regulate to set

liquid level at set point

PSV at Gas Boot.

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EMERGENCY RESPONSE PROCEDURE

Proposed ERP outlineEMERGENCY RESPONSE

PROCEDURE (ERP)

EMERGENCY SITUATION1. Definition2. Infrastructure3. Organization4. Action5. Identification of

Hazard

EMERGENCY RESPONSE PROCEDURE1. ERP for Gas

Leakage2. ERP for Fire/

Explosion

INVESTIGATIONPROCEDURE1. Preparation2. Report and

Recommendation3. Analysis4. Data Collection

EMERGENCYRESPONSE AWARENESS1. Training2. Simulation3. Hazard Control

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EMERGENCY SITUATION

Definition

An unexpected or undesired extraordinary event that might endanger human being, environment and the company business.

Minor Emergency Major Emergency

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EMERGENCY SITUATION

Emergencies situation based on type of

accident

Gas leakage EmergencyGas Leakage Emergency is an emergency that threatens

human safety and or property.

Fire or explosion EmergencyFire or Explosion Emergency is a fire explosion incident that

threatens the personnel safety and/or results in the loss of properties

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Infrastructure

Emergency Control Centre (ECC) Equipment

•ECC•Accident Investigation

•Coordination and responsibility•Information Receiving and Follow Up •Communication for Emergency Control Centre

•Maintaining Liaison •Public Education•Hospitals

EMERGENCY SITUATION

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Emergency Control Centre (ECC)

A place in company, usually in the control room, where reports and commands are centred to take control

EMERGENCY SITUATION

INFRASTRUCTURE

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Authority that should be

appointed to control operation:

Coordination and Responsibility

Fire Chief

Support Controller Head Office

Fire Marshall on Site

Responsibilities of the highest authorities:

• Appointing official of related function to handle such accident and/or supervise operations on site.

• Ensuring that all necessary action is taken without neglecting the safety of life and property.

• Ensuring that appropriate resource are available and adequate to deal with the accident.

• Ensuring that communication is maintained properly between the area office and emergency scene, including the completion of the accident report as soon as possible.

EMERGENCY SITUATION

INFRASTRUCTURE

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Information Receiving and Follow Up

Communication for Emergency Control Centre

Information • Name, address number of reporter• Time and date

• Reported location• Action taken

Receiver• Give immediate response• Report to the Fire Chief

Equipment in ECC :• Telephone • Facsimile machine.• Radio call signs and pager numbers for operational staff.

EMERGENCY SITUATION

INFRASTRUCTURE

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Maintaining Liaison

Public Education

Each SBU/District office must establish and maintain liaison with Fire Department, Police, and other public service officials

Each SBU/District must establish an education program for customers, the public, appropriate government organization etc about the manner they are expected to respond to a gas pipeline emergency situation.

Hospitals

Each SBU/District must prepare a list of hospitals or other medical facilities in its area

EMERGENCY SITUATION

INFRASTRUCTURE

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Equipment

• A whiteboard;• A telephone or cellular;• Communication radios;• A computer and e-mail

account;• Printer;• A camera and Handy cam

Digital;• Facsimile;• Megaphones;• Gas proof flash lights;• Tables and chairs• Fire Extinguisher.

• A wall clock;• A calendar;• Complete network

maps • A Tape recorder;• First aid boxes;• An Overhead Projector;• A typewriter;• A filling cabinet;• Administration

facilities;• A waste basket;• ECC Mobile.

In ECC

EMERGENCY SITUATION

INFRASTRUCTURE

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In Accident Investigation

• Phone list• Area and city maps• Note book• Measuring tape• Tape recorder and cassette• Report form• Investigation checklist• Gas Detector• Tool kit• Preliminary witness form• Clip board with plastic cover

• Pencils and pens• Compass• Camera and its apparatus• Label• Sealable plastic bags• Small bottles, boxes• Perimeter marking tape• Danger and caution tag• Company work order• List of expert for assistance• Magnifying glass

EMERGENCY SITUATION

INFRASTRUCTURE

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Organization

objective scopeAuthorities in

ChargeTasks and Authorities

Procedure

EMERGENCY SITUATION

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Objective

• Give guidelines to personnel involved in the Emergency Organization about their functions and duties.

• Give guidelines to every authority in the Emergency Organization about his responsibilities and authorities.

• Give guidelines to the personnel involved in the Emergency Organization about the positions or locations where they should gather upon receipt emergency news or information.

EMERGENCY SITUATION

ORGANIZATION

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Procedure

Emergency pickets

Emergencysituation

some of the team members

identify the incident

ECC

report

If major emergency

Emergency OrganizationRelated centres

Emergency Response Procedure

EMERGENCY SITUATION

ORGANIZATION

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ECC

FIRE CHIEF

DEPUTY FIRECHIEF FOR

OPERATION

EHC


MARKETING


ENGINEERING

DEPUTY FIRECHIEF FORFINANCE


ADMIN.

DEPUTY FIRECHIEF FORSECURITY


PUBLICRELATION

FIRE MARSHALL

MEDICAL TEAM• DOCTORS/NURESES• AMBULANCE/HOSPITAL• ENVT. PROT. STAFF

FIRE OFFICER• FIRE FIGHTER• NETWORK RECOVERY• SALVAGE

FIRE STATION• SUPPORTING• DOCUMENTATOR• OSH OFFICERS

SECURITY• POLICE• COMPANY/OTHER

INSTITUTION SECURITY

Organization of Emergency

EMERGENCY SITUATION

ORGANIZATION

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Identification of hazard

Identification Classification variety of Hazard

High Pressure

Load Shedding

Emergencies andPressure Reduction

Escaped Gasinside Structure

Leakage outsideStructure

Fire and

Explosion

EMERGENCY SITUATION

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Identification

Dangerous situation or

not?

Incident

Requires immediate

action or not?

Emergency procedures including the plan to control emergency situations and

the action to be taken by the employee

EMERGENCY SITUATION

IDENTIFICATION OF HAZARD

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Classification

Major emergencies associated with the low pressure system caused by loss of gas supplies affecting a number of customers

Class I Emergency

An interruption or decrease in gas supply at one or more off-take stations, resulting in a serious reduction of the availability of gas to be supplied at one or more sectors.

Class II Emergency

A failure of the high-pressure system or any incident requiring an immediate interruption of a sector of the system, which may have a serious effect on gas supplies in the area

Class III Emergency

EMERGENCY SITUATION

IDENTIFICATION OF HAZARD

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ACTION

Action

Repair &Restore

Evacuation

Repair:• Repairing affected facilities• Not to damage other facilities. • Make temporary or permanent repair

Restore:• Restore any service outage• Check service leakage• Carry out a final site check .• Perform the inspection in person.

• Turn off the main electrical switch • Evacuated Structure which could be effected by an explosion.• ECC must be informed • Made an arrangements for the welfare of evacuees.• Traffic and pedestrians must be kept well clear of the site.• Evacuated property must not be reoccupied until safe.

EMERGENCY SITUATION

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Emergency Response Procedure

ERP for Gas Leakage

Minor Gas Leakage

Emergency

ERP for Fire or Explosion

Major Fire or Explosion

Minor Fire or Explosion

Major Gas Leakage

Emergency


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ERP for Gas Leakage

To effectively control a gas leakage so that it can be immediately localized or controlled, so that the lost of life, property and serious damages can be minimized.


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Major Gas Leakage Emergency

Picket at ECC

Emergency news

Reporter Some of membersPickets unit in

district

Fire chief

Fire marshall

Picket at station

Emergency organization

set into operation

If gas leakage can’tbe controlled

Deputy Fire chiefOther related

officer

Security Head Officer in charge

Handling thegas leakage

Ensure the safety of personnel, materials, equipments and emergency evidence

Deputy Fire chief

Minor Gas Leakage Emergency


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ERP for Fire and Explosion

To effectively extinguish, localize, and control a fire or explosion so that it does not seriously affect the company’s operations.


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Major Fire/ExplosionEmergency

Picket at ECC

Emergency news

Reporter Some of membersPickets unit in

district

Fire chief

Fire marshall

Picket at station

Emergency organization

set into operation

If Fire/Explosion can’tbe controlled

Deputy Fire chiefOther related

officer

Security Head Officer in charge

Handling theFire/Explosion

Ensure the safety of personnel, materials, equipments and emergency evidence

Deputy Fire chief

Minor Fire/Explosion Emergency

Outside a Station


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SECURITY TEAM

FIRE OFFICE• FIRE FIGHTING TEAM• RESCUE & SALVAGE TEAM

• REPAIR TEAM

RING – 0EMERGENCY SCENE

DOCUMENTATION OFFICER

SAFETY STAFF

EMERGECY AUX TEAM

TRANSPORTATION (POOL)

AMBULANCE

ENVIRONMENT PROTECTION STAFF

DOCTORS ORURSES

RING – 2FIRE STATION

RESERVE TEAM

2

2

2

1

1

1

1

1

1

1

1

RING – 1EMERGENCY HANDLING

CENTERClose To Emergency Scene

FIRE MARSHALL

RADIO

RING – 2EMERGENCY CONTROL CENTER

(ECC)Control Room

FIRE CHIEFOFFICER IN CHARGE

PGN STATION OR CUSTOMERS

BRANCH OFFICE

RADIOTelephone

FIRE FIGHTING TEAM

RESCUE SALVAGE TEAM

REPAIR &SERVICE TEAM

FIRE MARSHALL

RADIOBRANCH OR UNIT HEAD

OPERATION COORDINATORS OFTECHNICAL, FINANCE, ADM

SALES OFFICERS OR STAFF

FINANCE AND ADMINISTRATION OFFICERS

DISTRIBUTION COORDINATORSOF SALES & PUBLIC RELATION

1

1

1

1

1

1

1

1

1

2

Emergency Handling Operating Procedure


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INVESTIGATION PROCEDURE

Preparation Data CollectionReport and

RecommendationAnalysis

. Make investigation team. Make hypothesis

. Records

. Supporting Document

. Witness

. Picture

. Laboratory test

. Testing

Investigation Report


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Preparation

Investigation Team

Investigation Team consist of:•Safety experts•Supervisors or Direct superiors•Related experts (operation and engineering)

Principal responsibilities of investigation team:• Conducting investigation to determine causes of accidents.• Preparing report and giving recommendation for future action.

Hypothesis: Accident Cause Analysis

• What happen ?•. What should happen?•. Is there a lack of knowledge and skills?•. Is there ay motivation disharmony?•.are there physical and mental problem?

• does the work have a procedure?•. Is there routine plan and maintenance?•. Do the existing maintenance procedures

correct?•. Is there an improper use of devices and

tools?•.is there a habit of using wrong articles or

devices?


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Data Collection

1. RecordsDescribing the employees,equipment, materials and

work environment condition

6. TestingGas pipeline network system

And facility having the incident, the meter and regulator

must be tested

5. Laboratory Test To obtain the accurate dataAbout the cause of incident,establish test to the material

used for the facilities

3. WitnessThe investigators interview

the witnesses to collectdata of the accidents

2. Supporting Documents All documents including location

Map, engineering document,Operating data and all procedure

In emergency

4. PictureThe investigator must takeas many pictures as soon

as possible after the accident


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Analysis

The steps of a Fault Tree Analysis:• Determining the topic of accident• Determining the factors contributing to the accident• Breaking down or tracing the factors into the basic causes of the accident.• Drawing the conclusion on the basis of the basic causes of the accident combined with the facts and data got from the fields.• Determining the follow up actions including the preventive measures and recurrence prevention.


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FLOW CHART

BURN INJURY

FIRE

FUEL OXYGEN HEAT

LEAKINGFLANGES

EXTERNAL INTERNAL

MATCHESSTRIKE

AGAINTSMETAL

UNSUITABLEKEYS

STOVES MATCHESVEHICLES

The conclusion is drawn after analyzing the possible basic causes of the accident, and considering the facts and data collected from the field


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Report and Recommendation

General Manager of SBU/District

Related Director Highest Authority

in the Area

Investigator

Report Report

RecommendationSection

Conclusion Section


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EMERGENCY RESPONSE AWARENESS

Training Hazard ControlSimulation

SHE TrainingLearning

Organization


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Training

• SHE Training

Emergency training is necessary to identify problem areas, develop personal skills and maintain awareness.

• LEARNING ORGANIZATION

Organizational learning involves all the problems and challenges of individual learning, since individuals are agents of the organization.

Five stages in Audit Learning model:1. Awareness2. Understanding3. Demonstration4. Implementation5. Transfer


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Simulation

Emergency Response Simulation standard aims to develop personal skills and maintain awareness of all parties involve in emergency situation so that the lost of life, property and serious damages can be minimized.


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Hazard Control

Hazard control includes recognizing, evaluating, and eliminating (or mitigating) hazards that occur because of human errors and physical deficiencies within the workplace

Two system control measures:1. Administration control measures2. Engineering control measures

Additional helpful clarification:• Inspection• Training• Education• Housekeeping• Preventive maintenance • Warning equipment


page-1 universitas indonesia agenda k3 industri kimia 5-4-11 silabus, pembagian tugas, intro safety...

Documents

security team

topic of accident

accident cause analysis

possible basic causes

emergency handlingcenterclose

causes of accidents

laboratory test

cause of incident