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Volume 6, Issue 10, October – 2021 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Analysis of Potential Risk Hazard with The HIRA


and HAZOP Approach (Case Study: Laboratory of
Engineering Faculty, Universitas Sultan Ageng
Tirtayasa)
Ade Sri Mariawati1, Lely Herlina1, Ani Umyati1
Lecture in Industrial Engineering Depatment
Engineering Faculty, Universitas Sultan Ageng Tirtayasa, Banten

Abstract:- The laboratory is a place to simulate actual with five apprenticeships; Civil Engineering has one
conditions equipped with equipment. All equipment has laboratory with three practices. And then Chemical
potential hazards: mechanical, electrical, chemical, Engineering with three laboratories, and six internships. The
physical, biological and ergonomic. This study aims to laboratory is equipped with equipment and chemicals.
determine the potential risks, assess the risks' level, and
then provide solutions for each hazard found. The method The laboratory is a small workplace which use to simulate
used in this research is HIRA and HAZOP. The results the actual work. Laboratories may contain mechanical
obtained in this study are that three laboratories have hazards, electrical hazards, chemical hazards, physical
several extreme risk values, five laboratories have a high- hazards, biological hazards, and ergonomic hazards. Table 1
risk value. Then five laboratories with medium category shows the types and forms of hazards. Work safety in the
and eight laboratories with low class. laboratory is one of the programs to protect students when
carrying out practical lectures or while at work from the risk
Keywords:- Laboratory; Risk; Hazard; HIRA; HAZOP. of work accidents and damage to machines or work tools.
Therefore, the execution of Occupational Health and Safety is
I. INTRODUCTION critical to be applied in various types of work to reduce or
even eliminate the potential risk of danger that results in
Potential hazards in a work environment can trigger work accidents. And so does the laboratory.
accidents. Potential risks can be caused by many factors,
including unsafe working conditions and unsafe activities. In Table 1. Types and forms of hazards
process risk assessment and management, hazard Type Hazard Forms of hazards
identification is the first and notable step [1][2]. And potential Mechanical hazards Clamp point, pulley or roller
hazards need to be controlled and prevented not to cause rotation
losses, accidents or damage to equipment in the work Electrical hazards Electric shock, or sparks
environment. Chemical hazards Gases, Smoke, Steam, Chemicals
Physical hazards Lighting, Vibration, Noise
The definition of the work environment, in general, is the Biological hazards Micro Biology (Virus, bacteria,
physical, social, and psychological life in one place. It affects fungi, etc.); Macro Biology
employee performance and productivity. In the work (Animals, insects, plants)
environment, everyone does their job and fulfils their duties. Ergonomic hazards Physical stress (repetitive
The work environment is not limited to the place where a movement, tight space, forcing
person works but also includes the physical and non-physical energy); Mental Stress
environment, work methods and even work arrangements both (tired/bored, overloaded)
individually and in groups.
Identification of the hazards, sources, and the effort to
One of the working environments at Sultan Ageng ensure the risk level of each hazard is the step of risk
Tirtayasa University is the Engineering Faculty. The assessment in the workplace [3]. A simple definition of hazard
Engineering Faculty, Universitas Sultan Ageng Tirtayasa, has is anything that can cause an accident. However, OHSAS
six departments and several laboratories. The laboratories are 18001: 2007 stated that hazards are all sources, situations or
in the Department of Electrical Engineering has five activities that can result in work accidents (injury) and work-
laboratories with twelve practices; Mechanical Engineering related diseases. There are many methods for conducting a
with three laboratories, and three externships; Industrial risk assessment in the workplace. This study carried out a risk
Engineering with four laboratories and fourteen practices. assessment using the Hazard Identification and Risk approach
Meanwhile, Metallurgical Engineering has two laboratories

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Volume 6, Issue 10, October – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Assessment (HIRA) and Hazard and Operability Study Table 2. The likelihood values
(HAZOP). HIRA is an approach to identify hazards and Likelihood Example Rating
evaluate risks in an activity [4]. The HIRA approach ensures (L)
that it can control existing risks within the tolerance limits of Most likely The most likely result of the 5
an organization[5]. Research on HIRA, among others, was hazard/event being realized
carried out by [5]–[11]. While HAZOP is an impersonal Possible Has a good chance of occurring 4
technique for hazard identification and risk ranking in and is not unusual
hazardous facilities[12]. Meanwhile [8], [13]–[20] solving risk Conceivable Might be occur at sometime in 3
and hazard research problems with HAZOP. future
Remote Has not been known to occur 2
This study aims to identify and classify laboratories based after many years
on the types of risks and hazards. Meanwhile, the urgency of Inconceivable Is practically impossible and has 1
this research is that it is necessary to identify potential hazard never occurred
risks in laboratories in the Engineering Faculty, Universitas (Source: DOSH 2008)
Sultan Ageng Tirtayasa. The research results are
recommendations for improvement and solutions to overcome Table 3. The severity values
potential hazards and risks in the laboratory to avoid work Severity (S) Example Rating
accidents, from near misses to fatal ones. Catastrophic Numerous fatalities, irrecoverable 5
property damage and productivity
The rest of the work is organized as follows: a brief
Fatal Approximately one single fatality 4
explanation about HIRA and HAZOP in section 2. The major property damage if hazard
methodology in section 3. Result and discussion describe in is realized
section 4. And the last is the conclusion present in section 5.
Serious Non-fatal injury, permanent 3
disability
II. HIRA AND HAZOP
Minor Disabling but not permanent 2
injury
A. Hazard and Risk
Negligble Minor abrasions, bruises, cuts, 1
Hazard and risk are different things. The following
illustration explains the two terms. (1) The live power cable is first aid type injury
open (without wrapping) located behind your house; this (Source: DOSH 2008)
condition is a hazard. However, if family members play or are
in the vicinity of the exposed power lines, it will be called Table 4. The risk values
risk. (2) Rocks hanging on the cliff road, the condition is a Risk Description Action
hazard. It will be a risk if there are road users who pass 15 - 25 High A HIGH risk requires immediate
through the area. (3) The condition of a rotating machine that action to control the hazard as
is not protected is a hazard. If mechanical workers are detailed in the hierarchy of control.
repairing the unit or close to the area, it will turn into a risk. Actions taken must be documented
So the risk is something we live with as individuals daily. on the rish assessment from
People are constantly making decisions based on risk. Simple including date dor completion.
choices in everyday life such as driving, crossing the street,
and investing money imply acceptance risk. Risk is the 5 – 12 Medium A MEDIUM risk requires a
combination of the likelihood and severity of a particular planned approach to controlling the
hazardous event occurring. Mathematically, the risk is hazard and applies temporary
calculated by the equation[21]: measure if required. Actions taken
must be documented on the risk
Risk = Likelihood (L) x Severity (S) assessment from including date for
(1) completion

The likelihood is an event that is likely to occur within a 1–4 Low A risk identified as LOW may be
certain period or under certain circumstances. Severity is the considered as acceptable and futher
result of an event such as the severity of an injury or person's reduction may not be necessary.
health, property damage, an insult to the environment, or any However, if the risk can be
combination caused by the event. Table 2 indicates the resolved quickly and efficientty,
likelihood value, and Table 3 represent severity. While Table control measures should be
4 states the risk value. The risk assessment reveals priority implemented and recorded.
actions to manage the hazard effectively. (Source: DOSH 2008)

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Volume 6, Issue 10, October – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
B. Hazard Identification and Risk approach Assessment 3) To enable employers to plan, introduce and monitor
(HIRA) preventive measures to ensure that risks care is adequately
HIRA is a process to find out the existence of a hazard, controlled at all times.
then calculate the magnitude of risk and determine whether
the risk is acceptable or not. HIRA is a technique used to C. Hazard and Operability Study (HAZOP)
recognize potential hazards of workplace accidents[8]. It’s Hazard and Operability Analysis (HAZOP) is an
systematic, comprehensive and convenient to perform approach to identify potential hazards and operational
algorithms. Based on [5][10][22], the HIRA process consists problems in a sequential manner[23]. The whole system is
of four processes, i.e. 1) Hazard identification, 2) risk assessed by asking how a part has deviation. Then decide
assessment, 3) risk analysis, 4) monitor and review. whether the deviation will pose a danger [24]. Figure 1 is an
example of a HAZOP template. states HAZOP belongs to the
The objectives of HIRA are as follows: qualitative risk analysis group. The risk index of the hazard is
1) To identify all factors that can cause harm to employees determine by multiplying the frequency (F) and the severity
and others (hazard); (S) of the effect of each hazard [12]. This step did after the
2) To consider the high probability of harm that afflicts identification of the hazard.
anyone in the circumstances of a particular case and the
severity that may arise from it (risk);

Fig 1. A HAZOP template [24]

HAZOP steps are as follows[25]: III. METHODOLOGY


1) Each HAZOP should be led by an experienced HAZOP
facilitator. HIRA and HAZOP are applied to analyze the potential
2) An essential issue for HAZOP is the definition of nodes hazard in the laboratory Engineering Faculty. Execution of
and their designation on piping and instrumentation collection data did in three ways: 1) observation, 2)
(P&ID) diagrams. interviews, and 3) measurement. We made direct observations
3) "Distortion" can be caused by various reasons, for to determine the activities in each laboratory. At the
example, human error, equipment failure, process observation stage, will carry out identification of potential
failure. hazards in the laboratory environment, activities in the
4) Causes are established at the site's perimeter, but laboratory, equipment and materials used. During the
consequences can occur during the process. observation process, documentation is also carried out to
5) Consequences can be sorted by severity using Risk support the findings of potential hazards.
Matrix Analysis.
6) All protective measures identified under HAZOP must Then undertook the interview to know a risk assessment.
be documented and implemented. While conducting a discussion on each head of the laboratory
and practicum assistant. The results obtained from the risk
assessment become a reference in risk control efforts.

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Volume 6, Issue 10, October – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Measurements made to determine the condition of the IV. RESULT AND DISCUSSION
physical environment (temperature, humidity, and wind
speed) and work posture. The laboratories observed in this study were 18
laboratories from 6 departments. The first is a laboratory in
There are three stages to apply the HIRA and the HAZOP the industrial engineering department with four laboratories,
methods in this research. The first stage is the implementation i.e the production systems laboratory. The electrical
of HIRA. Then the execution of HAZOP did in stage two. engineering department has five laboratories: electricity.
And the last is giving alternative solutions to reduce a hazard. While the chemical engineering department with three
A concise explanation for each stage is as follows. laboratories. The metallurgical engineering department
 First stage: the implementation of HIRA. consists of two laboratories, one in the civil engineering
1) Conduct visits in each laboratory. Observation aims to department. And finally, three laboratories in the mechanical
observe the conditions of the laboratory environment, engineering department. The laboratories in each department
equipment, materials, and practicum conditions. Then are as follows:
conduct interviews with laboratory assistants or 1) Industrial engineering department: production system
laboratory assistants regarding the activities carried laboratory, work system engineering and ergonomics
out in the laboratory. Then analyze activities that have laboratory, industrial & quality system optimization
the potential to have a hazard risk. Observe and laboratory, and industrial management studio.
document field conditions that can have a hazard risk 2) Electrical engineering department: computer laboratory,
and an accident. energy laboratory, control laboratory, basic electrical
2) Analyzing in more detail potential hazards and risks laboratory, telecommunications laboratory.
from observations. 3) Chemical engineering department: basic chemistry
3) After analyzing the potential hazards and risks that laboratory, chemical engineering operation laboratory,
occur, it is then assigning a value (1-5) related to the integrated computer laboratory.
severity experienced from the potential risks and 4) Metallurgical engineering department: metallurgy 1 and
hazards. Assessment can be seen from the seriousness 2 laboratory, engineering drawing and simulation
of the injury or loss that occurred. Or it can also be laboratory.
assessed from the number of lost working days. 5) Civil engineering department: civil engineering
4) Conjunction with the severity, frequency assessment laboratory.
(1-5) did. The evaluation took based on how often the 6) Mechanical engineering department: manufacturing
incident occurs or the possibility that the potential engineering laboratory, engineering measurement
hazard can occur. laboratory, drawing-design and simulation laboratory.
5) The risk value is obtained by multiplying the severity
value with the frequency of occurrence. This value Each laboratory has its practicum. The total number of
mapping is related to the risk mapping level, which is internships that have been recorded is 45 practicums. Each
low, medium, high, extreme risk. apprenticeship has its equipment, which is adjusted to the
6) After getting the risk level, the next step is to objectives to be achieved by the training. Each practicum
determine the recommended solution for each observes to carry out the potential hazards. From this manner,
laboratory. find out the risk value for each training. In this way,
suggestions for improvement will be more appropriate.
 Second stage: the execution of HAZOP
Processing using HAZOP carried out several Implementation HIRA proposed risk identification and
identification processes: hazard assessment. HIRA implementation offers risk
1) Determine the source of the hazard from the finding identification and hazard assessment. In contrast, HAZOP is
data (hazard sources such as electricity, machinery, more detailed to know the deviation which may occur in the
chemicals, biology, physics, etc.). workspace. Based on the steps in the HIRA, most of the
2) After identification based on the source of the hazard, practicum activities from laboratories in the engineering
it is necessary to find out what deviations or activities faculty are in the low-risk category. Other activities are split
can be dangerous and cause accidents. into medium, high and extreme categories. Figure 2 shows
3) Look for the cause the deviation can occur. the proportions for each group. While Table 5 is a more
4) Identify what harmful consequences will occur. detailed description of each exercise in the laboratory.
5) Determining corrective action here contains general
solutions to existing hazard sources.
 Third stage: based on HIRA and HAZOP proposed
alternative solutions that can apply to reduce or even
eliminate the potential hazards.

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Volume 6, Issue 10, October – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Extreme
7% According to Figure 2, the risk scores for the 45
practicums spread across all levels. A total of 56% or
High
15% equivalent to 25 practicums belonging to the low-risk
category. Ten practices or 22% medium risk category. High
risk as much as 7% or seven practices. And finally, a high-
risk level of 3% occurred in three internships. Practicum with
Low extreme risk belongs to Metallurgical Engineering in
56% Metallurgy 1 and 2 laboratories. Risk in extreme category
Medium should be given priority to improvement. Improvement
22% should give priority to risk in the extreme category.

Fig 2. Level of practicum risk in the laboratory, Engineering


Faculty

Tabel 5. Risk value category for each laboratory and practices


Risk catagory
Dept Laboratory Practice
L M H E
Industrial Engineering Production System Engineering drawing v
Industrial Eng Design 1 v
Industrial Eng Design 2 v
Work System Engineering Industrial Eng Design 1 v
and Ergonomic Product Design and v
Development
Industrial & Quality System Industry Statistics 1 v
Optimization Operational Research 1 v
Industry Statistics 2 v
Operational Research 2 v
Industrial Eng Design 1 v
Industrial Eng Design 2 v
Quality Control and Assurance v
Computer Simulation v
Industrial Management Studio Basic Computer Programming v
Industrial Eng Design 3 v
Electrical Engineering Computer - v
Energy Electrical Circuits v
Electric Machine v
Control Basic Control System v
Control Instrumentation v
Digital Control System v
Basic Electrical Laboratory Digital Engineering v
Electrical Measurement v
Microprocessor Basics v
Basic Electronics v
Chemical Engineering Basic Chemical Basic chemistry v
Analytical and Physical v
Chemistry
Chemical Engineering Chemical Engineering v
Operation Operation 1
Chemical Engineering v
Operation 2
Integrated Computer Engineering Drawing v
Numerical Method v
Process Simulation v
Metallurgical Engineering Metallurgy 1 and 2 Material Engineering v
Destructive Testing v
Metallurgical Lab 1 v

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Volume 6, Issue 10, October – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Metallurgical Lab 2 V
Engineering Drawing and - v
Simulation
Civil Engineering Civil Engineering Hydraulics Practicum v
Soil Surveying Prac v
Mechanical Engineering Manufacturing Engineering Manufacturing Eng 1 v
Manufacturing Eng 2 v
Engineering Measurement Metrologya and Measurement v
Techniques
Drawing Design and - v
Simulation

According to [21], hazards consist of biological hazards, Control:


chemical and dust hazards, ergonomic hazards, work Replacement of the chair to an ergonomic chair.
organization hazards, physical hazards, and safety hazards. b. Position of the practitioner when taking measurements:
Biological hazards are usually connecting with activity with When measuring the physical environment, the practitioner
animals, people, or contagious plant materials. Whereas must measure five times in a standing position at each
chemical and dust hazards are types of occupational hazards station. And the tool position is higher for a long and
caused by exposure to chemicals in the workplace. Ergonomic repeated periodically. It can cause the practitioner to
hazard happens when work, body position, and way of experience soreness in the hands.
working conditions burden your body. Work organization Control:
hazards take place when a hazard or some emphasize that Make Standard Operational Procedures practicum in detail
cause stress and pressure. Environmental or occupational and practitioners who measure alternately with each other.
hazards include physical hazards. Safety hazards are potential 2) Work System Engineering and Ergonomics Laboratory
hazards that pose a direct risk to safety/may cause natural In the industrial engineering design practicum 1, the
accidents and injuries. hazards that occur are safety hazards and ergonomic
hazards. This danger is the same as in the laboratory of
Finally in accordance with HIRA and HAZOP, the production systems. It's happening because the practicum
following potential hazard for each department are as follows: involves two laboratories.
 Industrial Engineering Department 3) Industrial & Quality System optimization Laboratory, all
potential hazards are low risk.
1) Production System Laboratory. 4) Industrial Management Studio. All potential hazards are
In technical drawing practicum activities, industrial low risk.
engineering design 1, and industrial engineering design 2,
there are potential hazards as follows  Mechanical Engineering Department
 Safety hazards 1) Manufacturing Engineering Laboratory
a. Transverse cable: When connecting the charger cable, the In manufacturing engineering practicum 1, the potential
practitioner trips over the transverse line and can cause it to hazards that occur are:
fall.  Safety hazards
Control: a. Scrap: During the turning process, scrap from the test
The cable is attached to the side of the room using cable object can hit the practitioner's eye.
clamps. Control:
b. Disconnected socket: When the practitioner wants to Make detailed Standard Operating Procedures and
connect the treadmill cable to the socket, electricity supervision by assistants during practicum.
exposed the practitioner's current due to the dire state of b. Rotating chisel: During the process of scraping the test
the socket. object, the practitioner is not careful, and his hands are hit
Control: by the operating chisel.
Fix the socket. Control:
c. Sawtooth: Practice not being careful when using the Make detailed Standard Operating Procedures and
cutting machine so that the hand hits the sawtooth and supervision by assistants during practicum.
causes injury  Physical hazards
Control: a. Sparks: During the welding process, some sparks can
Make a detailed Standard Operation Procedure practicum injure the practitioner.
and attach signs for Occupational Safety and Health using Control:
Personal Protective Equipment. Make detailed Standard Operating Procedures and
 Ergonomic hazards supervision by assistants during practicum.
a. Inadequate chair size: The chair used has a small diameter b. Welding process fumes: During the welding process, there
of the seat, and the length of the legs of the chair is high, is smoke that can be inhaled by the practitioner.
causing the practitioner to feel uncomfortable, and if not Control:
careful, he will fall from the chair.

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Volume 6, Issue 10, October – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Make detailed Standard Operating Procedures and  Civil Engineering Department
supervision by assistants during practicum. 1) Civil Engneering Laboratory
2) Engineering Measurement Laboratory. All potential The following is an exposure to potential hazards in the
hazards are low risk. hydraulics practicum and soil surveying practicum.
 Physical hazards
 Chemical Engineering Department a. Calibration machine cable: Stumbled on the machine cable
1) Basic Chemistry Laboratory while calibrating the tool.
In basic chemistry practicum activity, there are: Control:
 Safety hazards The cable is attached to the side of the room using cable
a. Furnace: When hands and other body parts hit the furnace. clamps.
Control:
Ensure that the surrounding environment is free of b. Stone/hammer: When setting a stake, the stone or hammer
flammable materials. used hits the limb.
2) Chemical Engineering Operation Laboratory Control:
In analytical and physical chemistry, chemical Wearing the Personal Protective Equipment, and create
engineering operation 1, and chemical engineering operation 2 Standard Operating Procedures for tools before use.
practicum activities, there are potential hazards as follows.  Electrical Engineering Department
 Chemical hazards 1) Computer Laboratory. There are no significant potential
a. Mercury: Mercury can come out if the compressor power hazards in all practicum.
is too high and hits the practitioner. 2) Energy Laboratory.
Control: Potential hazards in electrical circuits practicum and
Using Personal Safety Equipment (gloves, safety shoes, electric machine practicum are as follows.
goggles, etc.)  Safety hazards
 Ergonomic hazards a. Shock hazard: At the time of installation of our body parts
a. Poor posture: If the button rotates more than it should. on the chipped cable, there will be a shock hazard.
Control: Control:
Create detailed Standard Operating Procedures and Every practitioner uses safety shoes when practicum.
improve material layout for simulation practicum. b. Electric shock: When the user's hand connects the plug to
3) Integrated Computer Laboratory. All potential hazards the source contact and touches the socket in the socket. Or
are low risk for all practicum. there is a chipped cable resulting in electric shock
Control:
 Metallurgical Engineering Department Practitioners must obey the rules during the practicum and
1) Metallurgy 1 and 2 Laboratory always be guided by the Standard Operational Procedure.
Potential hazards in material engineering practicum, 3) Control Laboratory. All potential hazards in electrical
destructive testing practicum, and metallurgy 1 practicum circuits practicum and electric machine practicum state no
are: significant risks.
 Safety hazards 4) Basic Electrical Laboratory.
a. The pendulum fell: The pendulum lost control. There are no significant hazards in digital engineering
Control: practicum, microprocessor basics practicum, and basic
Standard Operating Procedures for checking tools before electronics. At the same time, safety hazards are found in
use. electrical measurement practicum.
 Ergonomic hazards
a. Pinched hands: During the separation process, hands or  Safety hazards
clothing can be carried by the conveyor and caught. a. Electric shock: Practice holding the iron on the multi-meter
Control: probe wires and jumper wires.
Availability of work display. Control:
 Physical hazards Practitioners must obey the rules during the practicum
a. Exposed to the heat of the sample container: The hot and always be guided by the Standard Operational Procedure.
container or sample is dropped and hits a member of the
body. 5) Telecommunications Laboratory. In practicum digital
Control: signal processing practicum, telecommunications basics
Addition of Personal Protective Equipment for heat/fire practicum, and signal & system practicum, no found
resistant suits potential hazards. All hazards are at a low risk level.
b. Welding beam radiation: glasses are not standard
compliant to protect eyes. V. CONCLUSION
Control:
Wearing the Personal Protective Equipment. This research aims to identify potential hazards in
2) Engineering Drawing and Simulation Laboratory. All laboratories in the Engineering Faculty, Universitas Sultan
practicum has potential hazards in low risk. Ageng Tirtayasa. This study aims to determine the potential
hazards in the laboratory of the Faculty of Engineering, Sultan

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Volume 6, Issue 10, October – 2021 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Ageng Tirtayasa University. The identified potential hazards strategies,” Environ. Impact Assess. Rev., vol. 84, no.
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