Process Safety Management (PSM) in a Solvent Extraction Plant

Operator Training Module (Based on Process Safety Principles and Industry Good Practice)

1. What is Process Safety?

Process Safety is the disciplined management of hazards associated with chemicals, energy, and industrial processes to prevent major incidents such as:

• Fires

• Explosions

• Toxic releases

• Environmental contamination

• Equipment failures

In process safety framework, the goal is:

"Prevent loss of containment of hazardous materials and energy."

For operators, process safety means:

• Operating equipment within safe limits.

• Following approved procedures.

• Identifying abnormal situations early.

• Preventing incidents before they occur.

---

2. Why Process Safety is Critical in Solvent Extraction Plants

A solvent extraction plant typically handles:

• Flammable organic solvents (e.g., hexane, kerosene, diluents)

• Corrosive chemicals

• Pressurized systems

• Rotating equipment

• Heated process streams

Potential major hazards include:

Hazard	Consequence
Solvent leak	Fire or explosion
Tank overfill	Spill and environmental damage
Static electricity	Ignition source
Pump seal failure	Loss of containment
Process upset	Fire, release, equipment damage
Confined space hazards	Injury or fatality

---

3. Shell's Process Safety Fundamentals

Industry promotes several key barriers to prevent major incidents.

Hazard

Something with potential to cause harm.

Example:

• Hexane storage tank

• Solvent transfer pipeline

• Extraction vessel

Threat

Something that can cause the hazard to be released.

Examples:

• Corrosion

• Human error

• Overpressure

• Mechanical failure

Consequence

What happens if control is lost.

Examples:

• Fire

• Explosion

• Injury

• Environmental pollution

Barrier

A measure that prevents or mitigates an incident.

Examples:

• Relief valve

• Gas detector

• Emergency shutdown (ESD)

• Operating procedure

• Trained operator

---

4. The Swiss Cheese Model

Industry training often uses the concept that multiple protection layers are needed.

Example:

Hazard:
Storage tank containing solvent

Protection layers:

1. Proper operating procedures

2. Level alarm

3. High-high level trip

4. Overflow containment

5. Emergency response

An incident usually occurs when several barriers fail at the same time.

---

5. Process Safety Critical Elements for Operators

A. Operating Procedures

Operators must:

✓ Follow approved SOPs

✓ Never bypass procedures

✓ Know:

• Start-up procedures

• Normal operation

• Shutdown procedures

• Emergency shutdown

Before operating, verify:

• Correct valve positions

• Tank levels

• Pump status

• Instrument readings

---

B. Operating Envelope

Every process has safe limits.

Examples:

Parameter	Safe Limit
Temperature	40–60°C
Pressure	0–2 barg
Tank level	20–85%
Flow rate	Design range

Operators must:

• Monitor limits continuously.

• Report deviations immediately.

• Take corrective action according to procedures.

---

C. Alarm Management

Alarms are warning signs.

Operators should:

When alarm occurs:

1. Acknowledge alarm.

2. Identify cause.

3. Verify field condition.

4. Take corrective action.

5. Monitor results.

Never:

✗ Ignore alarms

✗ Continuously silence alarms without investigation

---

D. Management of Change (MOC)

Any change can introduce new risks.

Examples:

• New pump installed

• New solvent introduced

• Control logic modified

• Temporary bypass installed

Operators should never make unauthorized changes.

Always ensure:

• MOC approval completed

• Training provided

• Procedures updated

---

6. Loss of Containment (LOC)

Industry identifies Loss of Containment as a major process safety event.

Examples:

• Solvent leak from flange

• Pump seal leakage

• Hose rupture

• Tank overflow

Operator Responsibilities

Conduct routine inspections for:

• Leaks

• Unusual odors

• Vibrations

• Corrosion

• Damaged insulation

• Abnormal noise

Report immediately using site reporting systems.

---

7. Permit to Work (PTW)

PTW controls hazardous work.

Typical permits:

Hot Work

Examples:

• Welding

• Grinding

• Cutting

Additional requirements:

• Gas testing

• Fire watch

• Area isolation

---

Cold Work

Examples:

• Mechanical maintenance

• Instrument servicing

---

Confined Space Entry

Examples:

• Tanks

• Columns

• Vessels

Requirements:

• Atmospheric testing

• Rescue plan

• Entry permit

• Standby person

---

Electrical Work

Only authorized personnel may perform electrical tasks.

---

8. Isolation and Lock Out Tag Out (LOTO)

Before maintenance:

Energy sources must be isolated.

Examples:

• Electrical energy

• Hydraulic pressure

• Pneumatic pressure

• Chemical energy

Operator verification:

1. Shut down equipment.

2. Apply lock.

3. Apply tag.

4. Verify zero energy.

5. Confirm isolation.

Never remove another person's lock.

---

9. Solvent Handling Safety

Because solvents are highly flammable:

Prevent Ignition Sources

No:

• Smoking

• Open flames

• Unauthorized electrical equipment

Control:

• Static electricity

• Hot surfaces

• Sparks

---

Grounding and Bonding

Required during:

• Tank filling

• Tanker unloading

• Solvent transfer

Purpose:

Prevent static discharge ignition.

---

Ventilation

Maintain adequate ventilation to prevent accumulation of flammable vapors.

---

10. Process Safety Critical Equipment (PSCE)

Industry emphasizes maintaining critical barriers.

Examples in solvent extraction plants:

Hardware

• Relief valves

• ESD valves

• Firewater systems

• Gas detectors

• Flame detectors

• Emergency shutdown systems

• Level trips

Operator Actions

Never:

• Bypass protection systems without approval

• Disable alarms

• Block relief devices

Report immediately if any PSCE is unavailable.

---

11. Emergency Response

Operators must know:

Fire Response

1. Raise alarm.

2. Inform control room.

3. Stop operation if required.

4. Follow emergency procedures.

5. Proceed to muster point.

---

Solvent Spill Response

1. Eliminate ignition sources.

2. Stop leak if safe.

3. Notify supervisor.

4. Contain spill.

5. Follow spill response plan.

---

Gas Release Response

1. Evacuate if required.

2. Raise alarm.

3. Follow wind direction guidance.

4. Proceed to assembly point.

---

12. Human Factors and Safety Culture

Many major incidents involve human factors.

Common errors:

• Rushing work

• Assumptions

• Poor communication

• Procedure violations

• Fatigue

Industry promotes:

STOP and THINK

Before every task:

• What can go wrong?

• What barriers are in place?

• What is the worst credible consequence?

---

13. Learning from Major Industry Incidents

Operators should understand lessons from major process safety incidents such as:

• Piper Alpha Disaster

• Texas City Refinery Explosion

• Buncefield Fire

Common causes:

• Loss of containment

• Alarm failures

• Poor communication

• Inadequate procedures

• Weak management of change

---

14. Operator Golden Rules

Always

✓ Follow procedures

✓ Verify before acting

✓ Report abnormalities

✓ Challenge unsafe conditions

✓ Respect operating limits

✓ Maintain housekeeping

✓ Participate in safety meetings

✓ Stop work if conditions become unsafe

---

Never

✗ Bypass safety systems

✗ Ignore alarms

✗ Operate outside limits without authorization

✗ Use unauthorized tools in hazardous areas

✗ Take shortcuts

✗ Restart equipment after a trip without investigation

---

Key Training Message

For a solvent extraction plant operator, process safety is not just preventing personal injury—it is preventing fires, explosions, and major chemical releases. Every operator is a safety barrier. By following procedures, respecting operating limits, maintaining vigilance for leaks and abnormal conditions, and protecting critical safeguards, operators help ensure safe, reliable, and environmentally responsible operation of the plant.

Simple Process Safety Formula

Hazard + Loss of Control = Major Incident

Hazard + Effective Barriers = Safe Operation

This principle aligns closely with industry's process safety philosophy: maintain barriers, prevent loss of containment, and operate within the defined safe operating envelope at all times.

Terjemahan bahasa Indonesia

Process Safety Management (PSM) dalam Solvent Extraction Plant menurut Praktik Industri

Process Safety Management (PSM) adalah sistem pengelolaan risiko yang bertujuan mencegah kejadian besar (Major Accident Events) seperti kebakaran, ledakan, pelepasan bahan kimia berbahaya, kerusakan aset, dan dampak terhadap lingkungan yang dapat terjadi dalam operasi pabrik solvent extraction.

Berbeda dengan keselamatan kerja (Occupational Safety) yang berfokus pada cedera individu, Process Safety berfokus pada pengendalian bahaya yang berasal dari proses, peralatan, energi, dan bahan kimia dalam jumlah besar.

---

1. Tujuan PSM dalam Solvent Extraction Plant

Tujuan utama PSM adalah memastikan bahwa:

• Fasilitas dirancang secara aman.

• Peralatan beroperasi dalam batas yang ditetapkan.

• Integritas peralatan tetap terjaga sepanjang umur operasi.

• Risiko proses diidentifikasi dan dikendalikan.

• Terdapat sistem perlindungan untuk mencegah serta mengurangi dampak kecelakaan besar.

Dalam solvent extraction plant, fokus utama biasanya meliputi:

• Pencegahan kebakaran akibat pelarut organik yang mudah terbakar.

• Pencegahan ledakan akibat akumulasi uap mudah terbakar.

• Pencegahan tumpahan (spill) bahan kimia.

• Pencegahan kehilangan containment (Loss of Containment).

• Perlindungan pekerja, aset, dan lingkungan.

---

2. Bahaya Utama dalam Solvent Extraction Plant

Beberapa potensi bahaya yang umum ditemukan adalah:

Bahaya	Potensi Dampak
Kebocoran solvent	Kebakaran, ledakan
Overfilling tangki	Tumpahan dan kebakaran
Listrik statis	Sumber penyalaan (ignition source)
Kerusakan seal pompa	Kehilangan containment
Korosi pipa	Kebocoran atau pecah pipa
Kesalahan operator	Gangguan proses atau kecelakaan
Kegagalan utilitas	Ketidakstabilan operasi

Karena sebagian besar solvent bersifat mudah terbakar, pengendalian sumber penyalaan menjadi aspek yang sangat penting.

---

3. Konsep Barrier (Lapisan Perlindungan)

Dalam praktik industri, risiko dikendalikan menggunakan beberapa lapisan perlindungan yang independen.

Contoh Kasus: Tangki Penyimpanan Solvent

Ancaman (Threat):
Pengisian berlebih (overfilling).

Barrier Pencegahan

1. Level transmitter.

2. Alarm level tinggi.

3. Sistem shutdown level tinggi-tinggi (High High Level Shutdown).

4. Pemantauan operator.

Barrier Mitigasi

1. Bundwall atau tanggul penahan tumpahan.

2. Sistem foam pemadam kebakaran.

3. Fire water system.

4. Tim tanggap darurat.

Prinsipnya adalah satu kegagalan tidak boleh menyebabkan seluruh sistem perlindungan gagal.

---

4. Process Safety Fundamentals

Beberapa prinsip dasar process safety yang diterapkan di berbagai industri proses adalah:

a. Tidak melakukan perubahan tanpa persetujuan resmi

Setiap perubahan harus melalui proses Management of Change (MOC).

b. Memastikan isolasi aman sebelum pekerjaan perawatan

Peralatan harus diisolasi, dikosongkan, dan diverifikasi aman sebelum maintenance.

c. Mematuhi batas operasi

Operasi harus dijalankan sesuai parameter yang telah ditentukan.

d. Menangani alarm dengan benar

Alarm proses harus segera ditindaklanjuti dan tidak boleh diabaikan.

e. Memastikan peralatan kembali aman setelah maintenance

Dilakukan inspeksi dan pengujian sebelum startup kembali.

---

5. Management of Change (MOC)

MOC merupakan proses formal untuk mengelola setiap perubahan yang dapat memengaruhi keselamatan proses.

Contoh perubahan yang memerlukan MOC:

• Penggantian jenis solvent.

• Perubahan kapasitas pompa.

• Modifikasi pipa dan valve.

• Perubahan logika kontrol PLC atau DCS.

• Perubahan prosedur operasi.

Evaluasi MOC biasanya mencakup:

• Risiko baru yang muncul.

• Dampak terhadap keselamatan proses.

• Dampak terhadap sistem proteksi kebakaran.

• Kebutuhan revisi prosedur.

• Kebutuhan pelatihan operator.

---

6. Operating Envelope (Batas Operasi Aman)

Setiap parameter proses harus memiliki batas operasi yang jelas.

Contoh:

Parameter	Normal	Alarm	Shutdown
Level Tangki	30–80%	90%	95%
Temperatur	25–40°C	45°C	50°C
Tekanan	0,2 bar	0,4 bar	0,5 bar

Operator wajib mengambil tindakan korektif sebelum mencapai batas shutdown.

---

7. Asset Integrity dan Mechanical Integrity

Keamanan proses sangat bergantung pada kondisi fisik peralatan.

Program yang umum dilakukan meliputi:

Mechanical Integrity

• Inspeksi pipa.

• Monitoring korosi.

• Pengukuran ketebalan pipa.

• Pemeriksaan pressure relief valve (PRV/PSV).

• Inspeksi tangki penyimpanan.

Instrument Integrity

• Kalibrasi instrumen.

• Pengujian alarm.

• Pengujian shutdown system.

• Verifikasi Safety Instrumented System (SIS).

Fire Protection Integrity

• Pengujian pompa kebakaran.

• Pengujian sistem foam.

• Pemeriksaan hydrant.

• Pemeriksaan fire detector dan gas detector.

---

8. Hazard Identification dan Risk Assessment

Sebelum fasilitas beroperasi maupun saat modifikasi dilakukan, berbagai studi risiko perlu dilaksanakan.

Metode yang umum digunakan:

• HAZID (Hazard Identification)

• HAZOP (Hazard and Operability Study)

• LOPA (Layer of Protection Analysis)

• Bow Tie Analysis

• Quantitative Risk Assessment (QRA)

Contoh HAZOP pada Mixer-Settler

Deviasi	Penyebab	Konsekuensi
High Level	Valve gagal menutup	Overflow
Low Flow	Pompa trip	Gangguan proses
High Temperature	Pendingin gagal	Penguapan solvent

---

9. Emergency Response

Skenario darurat yang harus dipersiapkan antara lain:

Kebocoran solvent

• Isolasi area.

• Hentikan sumber kebocoran.

• Eliminasi sumber penyalaan.

Kebakaran pompa

• Aktivasi ESD.

• Aktifkan sistem pemadam.

• Evakuasi area jika diperlukan.

Kebakaran tangki

• Aktivasi foam system.

• Pendinginan tangki sekitar dengan fire water.

• Koordinasi dengan tim tanggap darurat.

Fasilitas biasanya dilengkapi dengan:

• Emergency Shutdown System (ESD)

• Fire and Gas Detection System

• Alarm darurat

• Muster Point

• Emergency Response Plan

---

10. Indikator Kinerja Process Safety (PS KPI)

Kinerja process safety dipantau menggunakan indikator utama.

Lagging Indicators

Mengukur kejadian yang telah terjadi:

• Loss of Containment (LoC)

• Kebakaran proses

• Ledakan

• Pelepasan bahan berbahaya

Leading Indicators

Mengukur efektivitas pencegahan:

• Kepatuhan inspeksi.

• Penyelesaian tindakan HAZOP.

• Jumlah MOC yang tertunda.

• Ketersediaan Safety Critical Equipment.

• Kepatuhan pengujian sistem proteksi.

---

Kesimpulan

Dalam solvent extraction plant, Process Safety Management merupakan sistem yang memastikan bahwa bahan kimia berbahaya tetap terkendali di dalam peralatan proses melalui:

1. Identifikasi bahaya dan penilaian risiko.

2. Pengendalian melalui beberapa lapisan perlindungan (barrier).

3. Pengelolaan perubahan (MOC) yang disiplin.

4. Pemeliharaan integritas peralatan.

5. Pengoperasian dalam batas aman.

6. Kesiapsiagaan keadaan darurat.

7. Pemantauan berkelanjutan terhadap kinerja keselamatan proses.

Prinsip utamanya adalah mencegah kehilangan containment (Loss of Containment) sehingga solvent, energi, dan bahan berbahaya tetap berada di dalam sistem proses yang dirancang untuk menampungnya.