Application of failure mode effect analysis ohazard identification and risk control

Abstract

Introduction: PT. X is a chemical industry with high hazards, especially those related to hazardous and toxic materials; the company also uses equipment and machines with fire or explosion hazards. Component’s failure to operate is a major problem in PT. X. The specific objective of this study was to evaluate hazards and control the risks to prevent accidents and protect company assets, especially for employee safety. Methods: The data collected is Process Flow Diagram (PFD), Material Safety Data Sheet (MSDS), and component failure data. The risk assessment for the components of Sodium Silicate Production is carried out by multiplying the occurrence measurement scale and severity measurement scale. The risk value for the unacceptable risk category is between 12 and 25, where the risk must be controlled first. Results: This study found that the highest risk value is dissolver tank leaks, the production pump not working, and the ball valve stuck. An example of structural mitigation in the dissolver tank is to carry out routine maintenance once a month to know the material’s condition and to immediately make repairs if there are signs of tank damage to prevent leakage in the tank. Conclusions: This research proves that some hazards have not been evaluated and controlled, so there are still some failures in the production process of Sodium Silicate.