The Gresik Gas Distribution Station (GDS) is a critical natural gas facility operating under high-pressure conditions, where process failures may lead to Major Accident Hazards (MAHs). Therefore, systematic hazard identification is essential to ensure process safety and operational reliability. This study aims to identify potential MAHs and determine the Safety Critical Elements (SCEs) required to prevent and manage these hazards. The study employed the Hazard and Operability Study (HAZOP) method to evaluate three key process nodes: the metering and regulating system, odorant injection system, and instrument air system. Process deviations were analyzed using guide words, followed by risk assessment to identify MAHs. Safety Critical Elements were subsequently identified based on their safety functions, including the prevention, detection, control, mitigation, and recovery of MAH events. The analysis identified 17 potential causes classified as Major Accident Hazards and 76 Safety Critical Elements, grouped into 26 SCE types. Based on the criticality assessment, 4 SCEs were classified as high criticality, 9 as medium criticality, and 13 as low criticality. The most critical SCEs were HC Pipework, Level Indicator, Fixed Point Flammable Gas Detectors, and Flame Detectors. These findings demonstrate that the HAZOP-based approach effectively identifies Major Accident Hazards and establishes priorities for Safety Critical Element management, providing a practical basis for improving process safety and operational reliability in natural gas distribution facilities.
A generator set (genset) is an essential supporting facility that ensures the continuity of electrical power supply in manufacturing companies during failures of the main power source. Generator failures may interrupt production activities, increase maintenance costs, and reduce overall operational effectiveness. This study aims to identify potential risks of generator set failures using the Hazard and Operability Study (HAZOP) method, analyze the root causes of failures using Fault Tree Analysis (FTA), and propose appropriate risk control recommendations. The research data were collected through observations, interviews, documentation, and historical maintenance records from the Facility Department. The HAZOP analysis revealed that radiator overheating had the highest Risk Score of 20, categorized as an extreme risk, while battery drop and fuel filter blockage each obtained a Risk Score of 16, categorized as high risk. Furthermore, the FTA results indicated that generator failure was caused by several basic events, including battery drop, fuel filter blockage, radiator overheating, alternator failure, starter motor failure, and oil leakage, with a calculated top event probability of 67.2%. The proposed recommendations include implementing preventive maintenance, conducting routine inspections, replacing components based on service life, and improving generator condition monitoring to enhance equipment reliability and minimize operational failure risks.
Boas Ginting, H. Irwan· International Journal of Sci...· 0 citations
A preventive approach in identifying potential hazards in satiun presses in palm oil mills is very important to prevent work accidents. This study aims to analyze potential hazards at press stations in palm oil mills using the Hazard and Operability Study (HAZOP) method, identify the causes and impacts of each potential hazard found, determine the level of risk based on the results of risk assessments, and prepare appropriate control recommendations as an effort to improve occupational safety and health in the mill environment. The results of the study showed that the level of risk at the press station varied from the Medium category (exposure to hot steam/oil and scratches on the work tools), High (slipping on the floor/slippery stairs and electric shock), to the Extreme category which is very critical in the form of the potential for workers' hands to be pinched on the screw press machineduring cleaning (possibility: 3, severity: 5). As an effort to improve work safety, integrated control recommendations were formulated which include the implementation of strict cleaning SOPs, the implementation of the Lockout/Tagout (LOTO) system on machines and electrical panels, housekeeping improvements with the installation of anti-slip step nosing materials, and the obligation to use standard PPE in a disciplined manner.
Azhar Basyir Rantawi, A. L. Siregar, Hendra Saputra et al.· Jurnal Inotera· 0 citations
The relentless expansion of the Chemical Process Industry (CPI) necessitates the implementation of rigorous and comprehensive safety evaluations. This research manuscript presents an extensive Quantitative Risk Assessment (QRA) conducted on a major petrochemical refinery, specifically targeting the hazards associated with the storage and processing of highly volatile and toxic substances. Integrating Hazard Identification and Risk Assessment (HIRA), Failure Mode and Effects Analysis (FMEA), and Fault Tree Analysis (FTA), this study establishes a robust methodological framework for assessing industrial risk. A systematic screening process utilizing IPO (Inter Provinciaal Overleg) A-factor and S-factor metrics was deployed to isolate the most severe major accident hazard (MAH) installations, culminating in the selection of pressurized Liquefied Petroleum Gas (LPG) and Propylene Horton spheres, large-scale Naphtha storage tanks, and Hydrogen Sulphide (H2S) transfer pipelines. Advanced mathematical consequence modeling was executed, comprising TNT equivalency methods for Vapour Cloud Explosions (VCE), semi-empirical thermodynamic models for Boiling Liquid Expanding Vapour Explosions (BLEVE), and the Pasquill-Gifford dispersion model for toxic gas plumes. The consequence analysis revealed that a catastrophic failure of a 1,200 MT LPG Horton sphere generates a fireball 616.3 meters in diameter, emitting lethal horizontal thermal radiation fluxes (109 kW/m²) that extensively impinge upon vulnerable off-site residential boundaries. Furthermore, the synthesis of FTA-derived failure frequencies (3.6E-7 per year for Horton spheres) with local demographic data demonstrated that the societal risk (F-N curve) breaches the universally accepted ALARP (As Low As Reasonably Practicable) thresholds. The findings underscore the acute vulnerability of densely populated regions adjacent to legacy pressurized storage facilities. The manuscript concludes by presenting concrete, inherently safer design recommendations, advocating strongly for the phase-out of above-ground spheres in favor of mounded bullet technology, alongside the enhancement of Safety Instrumented Systems (SIS) and stringent land-use zoning.
Devesh Dixit and Dr Neeta Banger· International Journal of Adv...· 0 citations
Natural gas has emerged as one of the major energy sources supporting India's petrochemical, power generation, fertilizer, refinery, and manufacturing sectors. The continuous expansion of cross-country gas pipeline networks under the national energy infrastructure has significantly increased the demand for safe and reliable pipeline installation practices. However, gas pipeline construction involves several high-risk activities, including excavation, trenching, Horizontal Directional Drilling (HDD), pipe lifting, welding, hydrostatic testing, and confined space operations, which expose workers to multiple occupational hazards and increase the likelihood of accidents if appropriate safety measures are not implemented.
The present study aims to develop an integrated safety assessment framework for hazard identification, risk assessment, and risk control during gas pipeline installation works. The research focuses on identifying hazards associated with various construction activities, evaluating their risk levels, and recommending appropriate control measures to improve occupational safety and reduce accident potential. The study adopts a comprehensive methodology comprising questionnaire-based survey analysis involving 127 professionals associated with gas pipeline construction, systematic site observation of actual construction practices, Fault Tree Analysis (FTA) for determining root causes of critical accident scenarios, and Hazard Identification, Risk Assessment and Risk Control (HIRARC) for qualitative risk evaluation and prioritization. The integration of these techniques provides a systematic approach for identifying unsafe acts, unsafe conditions, human factors, equipment failures, and management deficiencies contributing to construction-related incidents.
The findings indicate that unsafe worker behaviour, inadequate supervision, poor safety compliance, ineffective communication, and deficiencies in risk control measures are among the major contributors to occupational accidents during gas pipeline installation. Fault Tree Analysis revealed that seemingly minor unsafe conditions and procedural deviations can combine to produce catastrophic events, while HIRARC effectively prioritizes hazards according to their likelihood and severity, enabling the implementation of suitable engineering, administrative, and personal protective control measures. The study further emphasizes that active management commitment, competent safety professionals, regular site inspections, safety induction programmes, toolbox talks, and continuous monitoring significantly enhance workplace safety performance.
The proposed integrated safety assessment framework offers a practical and systematic approach for strengthening safety management in gas pipeline construction projects in India. The outcomes of this research can assist project owners, contractors, safety professionals, and regulatory agencies in improving hazard identification, minimizing occupational risks, enhancing safety compliance, and promoting a proactive safety culture throughout the lifecycle of gas pipeline installation projects.
Ajay Kumar Singh, Mohsin Khan and Dr. Neeta Banger· International Journal of Adv...· 0 citations
The chemical process industry is indispensable to modern society but involves inherent risks associated with toxic,
flammable, reactive and corrosive substances, high pressures and temperatures, complex process interactions and large
inventories. Although major accidents are relatively infrequent, their consequences may extend beyond the plant boundary
and affect workers, emergency responders, communities, infrastructure and the environment. This review re-examines
chemical-industry safety and security from an integrated process-safety and disaster-risk-management perspective, using
the author's earlier article as its foundation while substantially rewriting and expanding its content. The review covers
hazard identification, HAZOP, What-If analysis, FMEA, fault-tree analysis, Layer of Protection Analysis, quantitative risk
assessment, inherently safer design, management of change, safety instrumented systems, mechanical integrity, human
factors, emergency planning and community preparedness. It also considers natural-hazard-triggered technological
accidents, the Indian regulatory framework and international approaches including OSHA Process Safety Management and
ISO 45001. Recent developments in digitalization, sensors, predictive analytics, digital twins and artificial intelligence are
examined as opportunities for early warning and decision support, together with their cybersecurity and human-factor
implications. The review concludes that effective chemical safety cannot depend on a single safeguard. It requires a
continuously verified system integrating safer design, reliable equipment, competent people, strong safety culture,
emergency preparedness, physical and cyber security, and organizational learning.
Ashok Agarwal· International Journal of Inn...· 0 citations
This study aims to identify potential hazards, assess occupational safety risks, and develop safety improvement recommendations for mechanical work at PT Arasindo Bina Bersama using the Job Safety Analysis (JSA) and Hazard Identification, Risk Assessment, and Risk Control (HIRARC) methods. This study employed qualitative and quantitative approaches through field observations, interviews, and documentation. JSA was used to identify potential hazards at each stage of the work process, while HIRARC was applied to assess risk levels and determine appropriate control measures based on the hierarchy of controls. The results identified three critical mechanical activities, namely hydraulic hose and pipe installation, axle component dismantling and installation, and hydraulic pipe and hose assembly, with a total of 26 identified hazards. The HIRARC risk assessment classified the hazards into 1 Very High Risk, 4 High Risk, 18 Medium Risk, and 3 Low Risk categories. Hazards classified as Very High Risk and High Risk were prioritized for immediate implementation of control measures. Meanwhile, Medium Risk hazards required additional controls to reduce the level of risk, whereas Low Risk hazards only required periodic monitoring. Safety improvement recommendations were developed based on the hierarchy of controls, including elimination, substitution, engineering controls, administrative controls, and personal protective equipment. This study demonstrates that the integration of JSA and HIRARC provides a systematic approach to hazard identification, risk prioritization, and the development of effective control strategies to improve occupational safety and promote a sustainable occupational health and safety culture.
Fannisha Aura Rifqo, B. Kusuma, Muhammad Ali Akbar· Heuristic· 0 citations
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