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CHAPTER 1
facilities, throughout their life cycle, to make certain that risks to employees, the
public, or the environment are consistently controlled within the organizations
risk tolerance. It is a process of defining and describing hazards by characterizing
including potential loses and injuries. HIRA is based on routine activities such as
daily, weekly, or monthly. The activities include the poduction process or
determination of risk related to sequences of actvities. The value of risk itself can
be calculated by multiplying the quantitative value of hazard severity with the
amount of its probability within certain amount of time. The equation to calculate
risk (R) is provided below.
Risk = Hazard Severity x Hazard Probability
Based on calculation above, we must know the value of each variables to
get the R value. To calculate the hazard probability, we will write down the
parameter and the estimated occurance per periode to specify the level of
probability to high, medium, or low.
Table X.X Hazard Probability
Parameter
Unllikely (1)
Likely (2)
Hazard
probability
Human
Resources
Productivity
Environment
Low (1)
Medium (2)
No injuries
Minor injury,
still able to do
work after
Production still
on schedule
(losses under
25%)
No significant
damage, can be
removed/cleaned
in less than a
month
Production
reduces
significantly
(loses 25-50%)
Minor damage.
Requires 1-6
months to fully
remove the
pollutant.
High (3)
Fatal injury
(involves
bleeding,
fracture, fainting
and other body
malfunction, and
death)
Production stops
(loses 50-100%)
Fatal damage.
Requires more
than 6 months to
fully remove the
pollutant.
Low (1)
1
2
3
Medium (2)
2
4
6
High (3)
3
6
9
Type
Safe
Specification
The process will continue even after the risk
Moderate
happened
We have to pay attention to the variable to
High
So, after we identify the hazard effect, the hazard probability, and the
metric of risk, we can make the HIRA analysis. Below is the HIRA specification.
Raw materials
storing
Raw materials
mobilization
Operating storage
vessels
Hazard
Potency
Hazard Effect
Severity
Level
Probability
Level
Risk
Expiration
Loss of raw
materials
Medium
(2)
Likely (2)
Moderate
(4)
Air
contamination
Raw materials
contamination
High (3)
Most Likely
(3)
High (9)
Spilled or
scattered
Loss of raw
materials
Medium
(2)
Likely (2)
Moderate
(4)
Exposure to
laborer
Minor injuries
Medium
(2)
High (6)
Spilled or
scattered when
charging
Loss of raw
materials
Low (1)
Moderate
(3)
Overload
Loss of raw
materials
Medium
(2)
Likely (2)
Moderate
(4)
Leakage
Loss of raw
Medium
Likely (2)
Moderate
Action
(Prevention or
Countermeasures)
Neat organization of the
inflow and usage of raw
materials (raw material
scheduling)
Final Risk
(After
action)
High (6)
Professional laborer,
bigger capacity of loading
cart, locked cart, addition
of Standard Operational
Procedure, Hire
Supervisor
Usage of PPE, addition of
Standard Operational
Procedure
Professional laborer,
addition of Standard
Operational Procedure
Professional laborer,
addition of Standard
Operational Procedure,
Hire Supervisor
Routine checking and
Safe (2)
Safe (2)
Safe (2)
Safe (2)
Safe (2)
Safe (2)
Operating
electrical related
equipments
Operating filling
equipment
materials
(2)
(4)
Labor contact
Minor injuries
Medium
(2)
Likely (2)
Moderate
(4)
Short circuit
Fire
High (3)
Unikely (1)
Moderate
(3)
Leakage
Loss of raw
materials
Medium
(2)
Likely (2)
Moderate
(4)
Overpressure
Damaged
Equipment
High (3)
Unlikely (1)
Moderate
(3)
Overheating
Damaged
Equipment
High (3)
Unlikely (1)
Moderate
(3)
Labor contact
Major injuries
High (3)
Unlikely (1)
Moderate
(3)
Unstacked
bottle assembly
Unfilled bottles
Low (1)
Likely (2)
Moderate
(3)
Underfilling
Products
Low (1)
Likely (2)
Safe (2)
maintenance, Hire
Supervisor
Usage of PPE, addition of
Standard Operational
Procedure
Usage of certified and
good quality wires,
addition of fire
extinguisher
Routine checking and
maintenance, Hire
Supervisor
Better equipment material
and automated control
system
Better equipment material
and automated control
system
Usage of PPE, addition of
Standard Operational
Procedure, available
emergency services in
plant
Automated bottle
assembling system
addition
Hire product quaity
Safe (2)
Safe (2)
Safe (2)
Safe (2)
Safe (2)
Safe (2)
Safe (1)
Safe (1)
Overfilling
Operating
capping
equipment
Monitoring and
operating the
equipment
system control
cannot be sold
Products
cannot be
capped
assessor
Low (1)
Likely (2)
Safe (2)
Unlikely (1)
Safe (2)
Labor contact
Minor injuries
Medium
(2)
Unstacked
bottle assembly
Uncapped
bottles
Low (1)
Likely (2)
Safe (2)
Broken button
Production is
not optimal
Medium
(2)
Unlikely (1)
Safe (2)
Broken wires
Production is
not optimal
Medium
(2)
Unlikely (1)
Safe (2)
Pipe leak
Loss of
products
Medium
(2)
Likely (2)
Moderate
(4)
Pipe corrosion
Contamination
of products
High (3)
High (9)
Medium
(2)
Likely (2)
Moderate
(4)
Monitoring the
pipeline
Product
mobilization to
Slipped and
Fall
Minor injuries
Safe (1)
Safe (1)
Safe (1)
Safe (1)
Safe (1)
Safe (2)
Moderate
(4)
Safe (2)
truck
Scattered
products
Product
distribution
Loss of
products
Medium
(2)
Likely (2)
Moderate
(4)
Major Injuries
Medium
(2)
High (6)
Delayed
product
distribution
High (3)
High (9)
Loss of
products
Medium
(2)
High (6)
Fall
Major Injuries
Medium
(2)
Likely (2)
Moderate
(4)
Equipment not
Contamination
Medium
High (6)
Accident
Cleaning the
equipment
Procedure, available
emergency services in
plant
Professional laborer,
addition of Standard
Operational Procedure,
Bigger trasnsporting cart,
Hire Supervisor
Not only one chaffeur,
organize shift the
distribution schedule is
not too packed, distribute
in working hours
Better organization in
distribution schedule, not
only one truck, determine
alternative distribution
scenarion
Prepare excess number of
products to replace the
damaged ones
Usage of PPE, addition of
Standard Operational
Procedure, available
emergency services in
plant
Professional laborer,
Safe (2)
Moderate
(4)
Moderate
(4)
Moderate
(4)
Safe (2)
Moderate
Cleaning the
office
Waste treatment
cleaned
thoroughly
of materials
(2)
Minor Injuries
Medium
(2)
Likely (2)
Moderate
(4)
Broken system
Contamination
of the
environment
High (3)
Unlikely (1)
Moderate
(3)
Leakage
Contamination
of the
environment
High (3)
High (9)
Labor contact
Major injuries
High (3)
Likely (2)
High (6)
addition of Standard
Operational Procedure,,
Hire Supervisor, Periodic
quality assurance
Usage of PPE, addition of
Standard Operational
Procedure, available
emergency services in
plant
Professional laborer,
addition of Standard
Operational Procedure,,
Hire Supervisor, Routine
checking and maintenance
Better piping materials,
alternative scenario of
waste treatment, CSR,
addition of Standard
Operational Procedure,,
Hire Supervisor, Routine
checking and maintenance
Professional laborer,
addition of Standard
Operational Procedure,
Usage of PPE
(4)
Safe (2)
Safe (2)
Moderate
(4)
Safe (2)
Center for Chemical Process Safety (CCPS), AIChE. 2008. Guidelines for Hazard
Evaluation Procedures, 3rd Edition. Wiley-American Institute of Chemical
Engineers.
Laird Wilson and Doug McCutcheon. 2000. Industrial Safety and Risk Management,
1st Edition. Canada: University of Alberta Press.
Trevor Kletz. 2006. Hazop and Hazan, 4th Edition. Institution of Chemical
Engineers.
US Department Labour. Global Harmonized System. www.osha.org. Accessed on
May, 12th 2013.