4th International Conference Eco-Innovation in Science, Engineering, and Technology

Volume 2023
http://dx.doi.org/10.11594/nstp.2023.3635

Conference Paper

Safety Assessment Approach of Hazard and Operability (HAZOP) In A Power Plant

Sector

Akmal Suryadi, Mega Cattleya PA Islami*, Gilang Ramadhan

Department of Industrial Engineering, Faculty of Engineering, Universitas Pembangunan Nasional

“Veteran” Jawa Timur, Surabaya 60294, Indonesia

*Corresponding author: ABSTRACT

E-mail:
[email protected] In line with the current development of society, the need for electricity can be said to
be a primary need that must be met to support community activities, both for
economic purposes and to fulfill daily household needs. The research was conducted
at one of the power generation companies. Based on the results of initial
observations and interviews with workers at the company, it was explained that the
potential danger of work accidents in the boiler machine area at the Steam-Electric
Power Station was considered high. Dangers of work accidents that can occur in the
boiler area include hot weather, noise, sparks, water vapor leaks, contact with hot
steam pipes, high pressure, slipping, and falling from heights. The danger that has
occurred in the boiler machine area is noise, noise often occurs because workers
underestimate the use of earplugs or earmuffs because they feel they often work
without using earplugs. This research aims to analyze the potential dangers of work
accidents in the PLTU boiler machine area in the company. Analysis of potential
accident hazards was carried out using the HAZOP method. It is hoped that the HAZOP
method will enable researchers to know the dangers and how to overcome them to
minimize the risk of occupational hazards. This method has the advantage that work
using this method will run systematically, the results obtained are more detailed
compared to other methods and can be used in various systems. The results of the
research show that the risk of danger in power generation companies amounts to 12
potential work accident hazards. Potential dangers of work accidents consist of
deafness (25%), burns (17%), slips (9%), shortness of breath (9%), dehydration (8%),
electric shock (8%), pinching (8%), fire (8%), and corrosion (8%).

Keywords: Potential hazards, HAZOP, Work accident

Introduction
In many countries, including Indonesia, laws and regulations have been established to protect
workers from workplace accidents. Every company or employer must maintain a safe working
environment and provide safety training to its employees. These are basic principles in the field of
occupational safety and are ethical and legal responsibilities. Violation of these obligations can result
in legal sanctions and corporate liability (Gong et al., 2021; Tamvada, 2020; López Jiménez et al., 2021).
Employees also have the right to work in a safe environment and should feel comfortable reporting
safety concerns without fear of punishment or retaliation. Workplace safety is of paramount
importance and should be a top priority for all companies for the well-being of their employees (Busch
et al., 2021; Tamers et al., 2019). In addition, workers also have a responsibility to comply with
applicable work safety guidelines. Workplace safety is a shared responsibility between the company
and employees. Employees also have an important role to play in keeping themselves and their
coworkers safe (Donoriyanto et al., 2021; Suryadi et al., 2021). Carrying out these obligations is key to
creating a safer work environment and reducing the risk of accidents and injuries (Pauliková et al.,

How to cite:
Suryadi, A., Islami, M. C. P. A, & Ramadhan, G. (2023). Safety assessment approach of Hazard and Operability (HAZOP) in a power plant
sector. 4th International Conference Eco-Innovation in Science, Engineering, and Technology. NST Proceedings. pages 245-251. doi:
10.11594/ nstp.2023.3635
 4th ICESET

2021); (Islami & Sudiarno, 2023). In addition, adherence to occupational safety guidelines by all parties
in the workplace enables companies to achieve better occupational safety targets (Provan et al., 2020;
Hu et al., 2020). Workplace accidents can occur in various types of industries, including the power
generation industry. The power generation industry involves various hazards that can cause injury or
even death if not properly managed. There are many types of potential hazards that haunt workers
such as electrical hazards, heights, hazardous chemicals, high heat and pressure, heavy equipment,
and radiation. Based on these potential hazards, work safety in the power generation industry is a top
priority. Companies in this sector must comply with safety regulations and conduct thorough safety
training for their employees. Workers must also adhere to safety guidelines, use the personal
protective equipment provided, and report incidents or safety hazards immediately. Thus, the risk of
occupational accidents in the power generation industry can be managed and reduced. One of the
companies engaged in power generation has a variety of plants such as Gas Power Plant, Steam-Electric
Power Station, and combined cycle power plant that produce electricity.
In Steam-Electric Power Station there are several important components, these machines include
boilers, turbines, generators, and condensers. Workers always face the danger of electric current
voltage, and the danger or risk faced by workers is also getting higher. A hazard itself is something that
may cause an accident or loss. Potential hazards can be defined as situations or activities that have the
potential to cause incidents or events that result in losses (Nigl et al., 2020; Falowo et al., 2022). Events
that result in this loss can be in the form of work accidents or occupational diseases. So that in the
production process of important machines electricity, it is necessary to process smoothly without any
problems. In order to achieve this smoothness, an effort is needed to minimize failures in operation.
Because failures in these operations can lead to potential work accidents, losses for the company, and
harm to workers. So, failures and accidents must be minimized so that the production system will run
properly. A work accident is an event that is not wanted or desired and usually occurs at an unexpected
time (Sultana et al., 2019). Work accidents cause many losses such as property losses and casualties.
Work accident events can be detrimental to the company both in terms of direct costs and indirect
costs. In terms of direct costs, the loss incurred is the cost of accident insurance compensation, while
in terms of indirect costs, it is the loss of working time and temporary stoppage of the production
process (Preis & Webber-Youngman, 2021). Several types of hazards may occur, including people and
property, both on and off-site. It is also important to consider the potential effects on the surrounding
environment.
Unfortunately, based on the results of observations and initial interviews with workers in the
company explained that the potential hazards of work accidents in the boiler machine area at the
Steam-Electric Power Station can be considered high. The boiler machine is a machine device that has
a function to convert water into steam. The hazards of work accidents that can occur in the boiler
machine area include hot weather, noise, sparks, water vapor leaks, contact with hot steam pipes, high
pressure, slips, and falls from height (Liu et al., 2019; Rathnayake et al., 2022). The hazards that have
occurred in the boiler machine area are noise, noise often occurs because workers underestimate using
earplugs or earmuffs because they feel they have often worked without using earplugs. If workers do
not use earplugs, it can be bad for the health of workers who are carrying out their duties in the boiler
area in the future. In addition, the boiler machine is one of the important components in the
production process. Because of these risks, efforts are needed to ensure the health and safety of
workers. Occupational Health and Safety is an effort to create a safe, comfortable working atmosphere
and achieve the goal of the highest productivity. Occupational Safety is a human effort to prevent
incidents that harm the company, workforce, community, and the natural environment. Occupational
Health and Safety is very important to be implemented in all fields of work without exception because
the application of safety can prevent and reduce the risk of accidents and diseases due to work. To
reduce or eliminate hazards that can cause accidents in the workplace, a risk management activity is

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needed which includes hazard identification, potential hazard analysis, risk assessment, risk control,
and monitoring and evaluation.
Based on the above problems, it is necessary to analyze the potential and risk of hazards for
workers. One method to be able to identify hazards and risks from work accidents is to use the Hazard
and Operability Study (HAZOP) method. The HAZOP method is a technique for identifying hazards in
construction and industrial activities. The HAZOP method can be used to identify various problems that
exist in the work process and the risk of harm to humans and the environment (Marhavilas et al., 2019;
Choi & Byeon, 2020). Another purpose of the Hazard and Operability Study (HAZOP) method is to make
an improvement or modify a work process to reduce the level of risk of work accidents and events that
can hinder the work operational process. In the process of identifying and analyzing potential
occupational safety and health hazards, the Hazard and Operability Research (HAZOP) method can be
used as one of the methods. HAZOP is a standard hazard analysis technique used in the preparation of
safety determinations in a system or modification for the presence of potential hazards or operability
problems (Medrano-González, 2019). HAZOP is a systematic hazard identification method that is
thorough and structured to identify various problems that interfere with the running of the process
and the risks contained in equipment that can pose a detrimental risk to humans/facilities in the system
(Mocellin et al., 2022; Sun et al., 2022). This method is used as a prevention effort so that the process
that takes place in a system can run smoothly and safely. HAZOP itself systematically works by looking
for various causal factors that allow accidents to occur determining adverse consequences as a result
of deviations and providing recommendations or actions that can be taken to reduce the impact of
potential risks that have been identified (Yang & Utne, 2022). Operations during repair and
maintenance can cause work accidents due to unsafe conditions by identifying hazards and risks and
controlling them through the HAZOP method. Using the HAZOP method is expected to identify various
problems that interfere with the process and the risk of harm to humans, the environment, and
facilities in the existing system in the company. Based on the description above, this research has the
aim of knowing the potential hazards of work accidents in the boiler machine area in the company. The
use of the HAZOP method aims to determine the hazards and ways of handling them to minimize the
risk of occupational hazards. This method is more systematic, the results obtained are more detailed
than other methods, and can be used in various systems.

Material and Methods

The type of research used in this research is descriptive quantitative. This research requires the
identification of research variables. The dependent variable in this study is the potential hazards and
risks of work accidents. Meanwhile, the independent variables in this study are work accident data,
use of PPE, application of standard operating procedures, types of work accidents, and human factors.
The dependent variable is the dependent variable that is influenced, or the result of the independent
variable, while the independent variable is the independent variable that affects or causes changes or
the emergence of the dependent variable. Data collection methods are ways that researchers can take
to collect data objectively. Data collection can be done in various ways depending on the research
objectives, the availability of time, energy, and costs. The end result of collecting data is generally
obtained primary data and secondary data that can help to solve problems in research. Data collection
methods in this research are primary and secondary. The data processing method used in measuring
occupational safety and health is the HAZOP method by identifies to determine the risk of work
accidents. The process of analyzing this research is in the order of identifying hazards, conducting risk
assessments by determining likelihood and severity and then determining risk levels, analyzing the
results of the causes of problems that can occur, and providing proposals or design improvements.

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Results and Discussion

The data used in this study are secondary data consisting of company profiles and work accident
data. Data collection was carried out by conducting interviews with workers in the company. According
to the company's work accident data, work accidents that often occur are near misses and minor
accidents. A near miss is an event that almost causes harm or a work accident. An example of a near
miss is a worker tripping over something that could cause a fall, but the worker does not fall. A minor
work accident is an accident such as a minor injury that only requires first aid to treat the incident.
Examples of minor work accidents are hot weather, noise, and slipping. Both near misses and minor
accidents do not cause loss of work time or company work days.
After data collection, hazard identification is the first step in solving a problem using the HAZOP
method. Hazard identification is carried out in the study in order to continue research and analysis
related to OHS in the company. After obtaining the results of hazard identification, the next step is to
conduct a risk assessment. The final result of this risk assessment will obtain a risk level, including low,
medium, high, or extreme. In classifying the risk of these hazards using the likelihood and
consequences table to determine the risk value with steps to determine the likelihood of occurrence
(likelihood), determine the severity (consequences or severity), and determine the level of risk using a
risk matrix obtained from the results of multiplying between likelihood and consequence. The
following table shows the results of calculating the risk level of each potential hazard.

Table 1. Risk level

Risk
Operation Process Risk Source L C LxC
Level
Slip Oil spills B 2 B2 Low
Firing Boiler Out of breath Boiler smoke A 2 A2 Low
Dehydration Hot weather A 1 A1 Low
Deaf Noise C 3 C3 High
Boiler operation
Burns Contact with pipe A 3 A3 Medium
Deaf Noise C 3 C3 High
Force Draft Fan Operation
Electrocution Electric current A 3 A3 Medium
Deaf Noise C 3 C3 High
Water filling process
Pinched Contact with valve A 3 A3 Medium
Burn operation Fire Sparks B 2 A2 Low
Chemical systems process Corrosion Exposure to chemical fluids B 2 B2 Low
Blow soot system Burns Water vapor leak B 3 B3 Medium
Boiler operation Deaf Noise C 3 C3 High
Force Draft Fan Operation Deaf Noise C 3 C3 High
Water filling process Deaf Noise C 3 C3 High
Boiler operation Burns Contact with pipe A 3 A3 Medium
Force Draft Fan Operation Electrocution Electric current A 3 A3 Medium
Water filling process Pinched Contact with valve A 3 A3 Medium
Blow soot system Burns Water vapor leak B 3 B3 Medium
Boiler firing Slip Oil spills B 2 B2 Low
Boiler firing Out of breath Boiler smoke A 2 A2 Low
Boiler firing Dehydration Hot weather A 1 A1 Low
Burn operation Fire Sparks B 2 A2 Low
Chemical systems process Corrosion Exposure to chemical fluids B 2 B2 Low

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Based on the results of the analysis that has been carried out, it can be described in the form of a
diagram so that it can facilitate understanding of the results of the analysis. The following is a picture
of potential hazards and their severity.

Figure 1. Potential hazards and their severity

Based on the diagram above, the results obtained are 42% for the low-risk level, 33% for the
medium-risk level, and 25% for the high-risk level. Meanwhile, the following is a diagram of the results
of identifying the potential hazards of work accidents that have been found in the boiler machine area.
There are results of 9% for slipping, 9% for asphyxiation, 8% for dehydration, 25% for deafness, 17%
for burns, 8% for electric shock, 8% for pinching, 8% for fire, and 8% for corrosion. Deafness is the
biggest potential hazard that has been identified. The following is a picture of the potential hazards of
work accidents.

Figure 2. Potential danger of work accidents

Next, risk control is carried out. Risk control is the last stage as a determinant of the overall risk
management that has been done before. Risk control is an effort made to prevent risks from occurring.
The purpose of risk control is to determine improvement suggestions to minimize the occurrence of
risky events. Risk control has a function as input to prevent and minimize the risk of work accidents. In
the process of operating the firing boiler, risk control can be done is to giving a schedule to the cleaning
service to clean in areas where oil splashes often appear, socializing to employees about K3 so that it
can be applied properly in the company and use PPE completely to reduce slipping in slippery areas,
smoke, and hot weather directly. Then in the process of operating the boiler machine, risk control can
be done by socializing with employees about the importance of wearing earplugs, supervision by SPV
to check the PPE used, and providing first aid kits in the boiler machine operation process area as the
first aid.

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Furthermore, in the process of operating the force draft fan, risk control can be done by using
earplugs or earmuffs so that the ears are protected from the noise of the boiler machine and coating
the cable with insulating material or material that cannot conduct electric current so that it cannot
injure employees who work. Then in the process of filling water, risk control can be done by using
gloves so that it can minimize the occurrence of pinching and socializing to employees about the
importance of K3 so that it can be applied properly in the work area. Pay attention to work procedures
properly. In addition, in the Burn operation process, risk control can be done is to providing fire
extinguishers in the burn operation process area, paying attention to work procedures properly, and
using wear-packs and safety shoes. Furthermore, in the chemical system operation process, risk control
can be done by providing a first aid kit in the chemical system operation process area as first aid if
injured and using PPE by the operation process. Then in the process of operating blow soot, the risk
control that can be done is to provide first aid kits in the area of the chemical system operation process
as first aid if injured and provide fire extinguishers for first aid in case of sparks or minor fires.
Based on the results of the analysis that has been carried out using the HAZOP method in the
company, there are 12 potential hazards with low, medium, and high categories. These potential
hazards include slipping, asphyxiation, dehydration, fire, and corrosion with low categories. Then the
potential hazards of burns, electric shocks, and pinching in the medium category. And the last is the
potential danger of deafness with a high category.

Conclusion
Constitution No. 31 of 1999 regarding Obliteration of Deceits of Corruption in conjunction with
Constitution No. 20 of 2001 Amendments to Constitution No. 31 of 1999 regarding Obliteration of
Deceits of Corruption through Article 17 in conjunction with 18 letter b of, which states.

Acknowledgment
This work was financially supported by the Department of Industrial Engineering, Faculty of
Engineering, Universitas Pembangunan Nasional “Veteran” Jawa Timur. Therefore, we are grateful for
the support of this research.

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