Chemical Reactivity Hazard Risk Assessment and Management System Development for Downstream Chemical Industry

Chemical Reactivity Hazard Risk Assessment and  Management System Development for Downstream  Chemical Industry

The potential of Chemical Reactivity Hazards (CRH) for downstream chemical industry (DCI) in Indonesia is still considerably high. In general, DCI in Indonesia still uses conventional technology with limited human resources capability, while have to handle numerous types of chemicals. The aim of this research is to conduct chemical reactivity hazard (CRH) risk assessments and develop CRH control systems for DCI.

This research was done using modified SREST-Layer Assessment (Shah et al 2005) by addition of workforce factor into the assessment. There are five steps in this method: (1) assessment of chemical hazards based on NFPA 704, (2) study of CRH using CRW 2 software programs from NOAA, (3) identification of potential CRH in production processes, (4) develop a CRH worst-case scenarios, (5) assessment of CRH worst-case scenario with the KJ Analysis and develop CRH quantitative causation model through questioners result and processed using LISREL 8.50.

From the results of the CRH study at three downstream chemical industries could be proved that the Safety Management System Factor (SMSF), Workers Factor (WF) and Safety Technology Factor (STF) decreased Hazards Index (HI) and Risk Index (RI) of CRH in DCI higher than Shah et al model (2005) which only includes STF. WF provides the greatest contribution (44.6%) compared SMSF (32.5%) and STF (22.9%).

From the CRH causation model developed found seven variables were the cause of the CRH trigger, namely; Management and Workforce Commitment, Hazard and Risk Analysis, CRH Training, Competency, Workforce Factor, Standard Operating Procedure and Working Environment. Only two variables were directly associated with CRH trigger, namely: Workforce Factors that affect directly to the occurrence of Mixing and Process Parameter Error and Working Environment affecting occurrence of Storage Error. The CRH management system was developed based on CRH causation model that contains five elements; Management and Workforce Commitment, Hazard and Risk Analysis, CRH Training Program, Standard Operating Procedure, and Safe Working Environment. This system can be integrated with standard management system ISO 9001, ISO 14001 and OHSAS 18001 or SMK3. This system is very appropriate to be applied in downstream chemical industries that use many different chemicals with conventional technology and limited human resources.

Key words:

Downstream Chemical Industry, Chemical Reactivity Hazards, Hazards Index, Management System, CRH Causation Model

References: 81 (1980 - 2010)