HAZID is a sheet-form whose contents analyzes about the preventions of
hazards in a factory or plant; in accordance to its overall aspects. As it is mentioned in the previous chapter, that the aspects in the making and running of a factory is numerous, such as; The location of the plant, the transportation infrastructure (such as streets, bridges, etc), the piping of the plant and also the power lines of the plant. The risks that might happen in the installation and operation of the factory; which will impact to the workforces, environment, and assets. The data of the process running in the factory (Process Flow Diagram), the Process & Instruments Diagram, plant layout and other datas that might support the analysis of HAZID. The factors that has been researched from records and history which have high possibilities to trigger hazards and accidents in more or less the same way, and also the data of impacts of the hazards themselves. It can be seen clearly that HAZID is very essential to be conducted to prevent any kind of accidents, from small to large-scale of accidents, to occur. HAZID uses datas mentioned above to determine the best prevention act that can be done so that the factory can be installed and operating safely; both healthily, securely and economically. The following table will show the parameters used in this HAZID analysis to determine the hazard occurence frequency and their impacts to the plant. Table 1 - The parameters to determine Hazard Frequency in HAZID analysis. Hazards Frequency VERY FREQUENT FREQUENT SELDOM More than 10 times in 10 years about 1 s/d 10 times in 10 years Less than 1 times in 10 years
Table 2 - The parameters to determine Hazard Effect in HAZID analysis. Parameter Minor Major Severe Human Resources No Accident No fatal accident Fatal accident Asset Loss less than US$ 100.000 Loss US$ 100.000 s/d 1.000.000 Loss more than US$ 1.000.000 Environment No environmental damage Little damage to environment Great damage to environment
And the full form-sheet of HAZID analysis can be seen in the next page. We tried to analyze all prevention acts as much and as feasible as possible. Basically, in the operation of manufacturing for KEINSTROM itself can be considered not too hazardous. Based on the HAZID analysis we found that the possibility of severe hazard effect is higher in doing maintenance than in the operation and inventories. Thus, by knowing so from the HAZID analysis; we will pay more attention to the safety aspect of the equipment maintenance in our factory to prevent any severe hazard effects from happening.
Table 3 - HAZID Analysis for Keinstrom manufacturing. Location Description Cause Hazard Potency Hazard effect Hazard Frequency Prevention Human resources Assets Environment Raw Material Storage Room Room to store raw materials of KEINSTROM Clothe Dryer Overload capacity Damaged to the raw material storage room Minor Major Major Likely Good scheduling in ordering and storing the raw material, good scheduling in production time
Fluctuation in storing conditions Damaged to raw material stored inside storage room Minor Severe Minor Unlikely Provide devices to control the temperature, pressure, humidity of the room conditions; inspection before raw material transferred to production room to check whether it is still in good condition or not. Production Room Room where the main processes of manufacturing KEINSTROM clothe dryer Spill of raw materials when they are put into unit operations Workers slipped and injured, lower the production capacity than expected capacity Major Major Major Most Workers use personal protective equipment, good and frequent equipment maintenance Source: Author Documentation Table 3 - HAZID Analysis for Keinstrom manufacturing. (continiues) Location Description Cause Hazard Potency Hazard effect Hazard Frequency Prevention Human resources Assets Environment
Heavy wind exposure particulate raw material are blown away, exposure in production area and may be environment Major Major Major Unlikely Close the door and windows of production room; regulate the entry and exit time frequency of workers towards and from production room;
Dirty equipment or materials interact with sterile equipment or material corrosion Minor Severe Minor Unlikely Use coating in place equipment; Ideally, materials should move through the facility in a unidirectional fashion, with no crossover of any kind
Collapse of equipment or pipes Workers can be injured, raw material can be spilled Severe Major Minor Unlikely Good support to the equipment or pipes to make sure they are in the stabile position. Source: Author Documentation
Table 3 - HAZID Analysis for Keinstrom manufacturing. (continiues) Location Description Cause Hazard Potency Hazard effect Hazard Frequency Prevention Human resources Assets Environment
Fluctuation in Production conditions Damaged to raw material stored inside storage room Minor Severe Minor Unlikely Provide devices to control the temperature, pressure, humidity of the room conditions. Product Storage Room Room to store products before distribution Overload capacity Damaged to the storage room Minor Major Minor Unlikely Good scheduling in distribution time, good scheduling in production time
Collapse of packages arrangement Workers injured Major minor minor likely Good storing and arrangement of packages, workers use personal protective equipment
Animal (includes mouse, cockroach) invasion to storage room Damage to the products boxes stored inside storage room Minor Major Minor Unlikely Frequent control and inspection Source: Author Documentation Table 3 - HAZID Analysis for Keinstrom manufacturing. (continiues) Location Description Cause Hazard Potency Hazard effect Hazard Frequency Prevention Human resources Assets Environment
Fluctuation in storing conditions Damaged to products stored inside storage room Minor Severe Minor Unlikely Provide devices to control the temperature, pressure, humidity of the room conditions; inspection before products transferred to distribution section to check whether it is still in good condition or not.
Induction of fire to flammable material Fire Severe Severe Severe Unlikely Frequent control and inspection, provide fire detector facility, fire alarm and fire extinguisher, regulation that prohibit workers to bring cigarettes and fire inside the storage room Packaging Room Place to put the cap and the bottle. Then packed in a carton. Accumulation of card box or products inside packaging room Damage to the packaging room; higher the risk of damage Minor Major Minor Unlikely Good scheduling in transferring in and out material to and from packaging room Table 3 - HAZID Analysis for Keinstrom manufacturing. (continiues) Location Description Cause Hazard Potency Hazard effect Hazard Frequency Prevention Human resources Assets Environment
Carton packing damaged and many defects such as folded, piece of sloppy, too thin materials Packaging is not neat, defects in the packaging, reducing packaging aesthetic Minor Major Minor Unlikely Inspection and quality control and packaging cartons
Incompatibility between the size of a cloth dryer and boxes Cause packaging to not be closed completely Minor Major Minor Unlikely Inspection and quality control clothes dryer Empty Package Storage Room Room to store cardboard and tubes for KEINSTROM clothe dryer Overload capacity Damaged to the storage room Minor Minor Minor Unlikely Good scheduling in ordering and storing the empty packages, good scheduling in packaging time Source: Author Documentation
Table 3 - HAZID Analysis for Keinstrom manufacturing. (continiues) Location Description Cause Hazard Potency Hazard effect Hazard Frequency Prevention Human resources Assets Environment
Animal (includes mouse, cockroach) invasion to storage room Contamination to the packages stored inside storage room Minor Major Minor Unlikely Frequent control and inspection, frequent sterilization
Collapse of empty packages arrangement Workers injured Major Minor Minor Likely Good storing and arrangement of empty packages, workers use personal protective equipment
Induction of fire to flammable material Fire or explosion Severe Severe Severe Unlikely Frequent control and inspection, provide fire detector facility, fire alarm and fire extinguisher, regulation that prohibit workers to bring cigarettes and fire inside the storage room Source: Author Documentation
Table 3 - HAZID Analysis for Keinstrom manufacturing. (continiues) Location Description Cause Hazard Potency Hazard effect Hazard Frequency Prevention Human resources Assets Environment Waste Treatment Area Area to process waste produced in production of KEINSTROM clothe dryer Volume of paint is too high in painting room flooding Major Major Major Unlikely Frequent control and inspection, provide painting facility
Leakage in unit operations and pipelines Environmental pollution Major Severe Severe Unlikely Frequent control and inspection Warehouse products are ready to ship Storage products ready to be delivered to the wholesalers warehouse Short circuiting of electrification systems are not insulated or well controlled Create a fire hazard until no remaining products Severe Severe Severe Unlikely Ensuring and checking periodically electrification system Source: Author Documentation