DEVELOPMENT OF A PROCESS SAFETY EVALUATION TOOL FOR DUST EXPLOSION IN PHARMACEUTICAL INDUSTRY
By
Aliya Dharaningtyas 11304004
BACHELOR’S DEGREE in
CHEMICAL ENGINEERING – PHARMACEUTICAL ENGINEERING FACULTY OF LIFE SCIENCES AND TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
Revision After Thesis Defense on 19th July 2017
Aliya Dharaningtyas STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Aliya Dharaningtyas
_____________________________________________
Student Date
Approved by:
Ir. Paulus Gunawan, MM.
_____________________________________________
Thesis Advisor Date
Dr.-Ing. Diah Indriani Widiputri
_____________________________________________
Thesis Co-Advisor Date
Dr. Dipl.-Ing. Samuel P. Kusumocahyo
_____________________________________________
Dean Date
Aliya Dharaningtyas ABSTRACT
DEVELOPMENT OF A PROCESS SAFETY EVALUATION TOOL FOR DUST EXPLOSION IN PHARMACEUTICAL INDUSTRY
By
Aliya Dharaningtyas
Ir. Paulus Gunawan, MM., Advisor Dr.-Ing. Diah Indriani Widiputri, Co-Advisor
SWISS GERMAN UNIVERSITY
Dust explosion considered as dangerous accident in process industry. However, in industry, safety while processing combustible dust is sometimes underestimated. In order to know how hazardous dust explosion might occur in a process, risk assessment needs to be conducted. Risk assessment is a combination of likelihood and severity level of the hazard. In the industry, conducting risk assessment is sometime inefficient and takes a lot of time and effort. Therefore, a semi-quantitative safety evaluation tool that estimate severity level of dust explosion is developed in this work.
The safety evaluation tool consists of series of questions regarding material used, operating condition and environment of the process. By using the tool, severity level of dust explosion in a process can be estimated. After the evaluation tool has been developed, validation was done to ensure the tool acceptable and applicable in pharmaceutical industry. In order to complete risk assessment process, the validation was continued to combine the estimated severity level and the likelihood of a dust explosion occurrence that has been developed by previous study.
Keywords: Dust Explosion, risk assessment, severity, safety.
Aliya Dharaningtyas
© Copyright 2017 by Aliya Dharaningtyas
All rights reserved
Aliya Dharaningtyas DEDICATION
I dedicate this works to God and my family.
Aliya Dharaningtyas ACKNOWLEDGEMENTS
During the development of this thesis, I would like to thank God for giving me strength, guidance, patience and blessing so this thesis to do and finalize this thesis work. Then, I would like to thank to:
Ir. Paulus Gunawan, MM. as my thesis advisor and Dr.-Ing. Diah Indriani Widiputri as my thesis co-advisor, for giving me their knowledge, suggestion, ideas and support during my thesis period.
Adi Wibowo, Haryo Wijaya, Edi Purnomo, Yodi Fitrio, Imam Muhammad Sulaiman Hakim, Slamet Budi Harto and Afina Laras Smaranesha from PT. DEF for welcoming me and giving me their valuable advices and sharing their broader knowledge about pharmaceutical industry.
All my questionnaires participants for giving their valuable time to answer my questionnaires.
Ivan Kevianto for the advices and support throughout the making of the thesis.
Budi Setyono for giving me a helping hand to complete this thesis.
My parents and my brother, for giving me never-ending support and pray.
To my beloved friends Jessica Putri, Livia Serafin, Putri Astari Dewi, Chicha Guyanto, Cynthia and Jesslyn Nastasja for the never ending laugh and support.
Pharmaceutical engineering student 2013 and all life sciences and technology students for sharing this 4 years of university life.
And the rest of people who helped me during my thesis who I cannot mention one by one.
Aliya Dharaningtyas TABLE OF CONTENTS
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 9
LIST OF TABLES ... 10
CHAPTER 1 – INTRODUCTION ... 12
1.1. Background ... 12
1.2. Research Problem ... 13
1.3. Research Objective ... 13
1.4. Significance of Study ... 14
1.5. Research Question ... 14
CHAPTER 2 - LITERATURE REVIEW ... 15
2.1. Why Dust Can Explode ... 15
2.1.1. Definition of Dust Explosion ... 15
2.1.2. Mechanism of Dust Explosion ... 16
2.1.3. Primary and Secondary Explosion ... 17
2.2. Case of Past Dust Explosion ... 18
2.3. Factors Causing Dust Explosion ... 19
2.3.1. Combustible Dust ... 20
2.3.2. Oxidant ... 20
2.3.3. Ignition Source ... 21
2.3.4. Dispersion of Dust ... 23
2.3.5. Confinement ... 24
2.4. Explosible Dusts Classification ... 24
Aliya Dharaningtyas
2.5. Risk Assessment ... 25
2.6. Dust Explosion Evaluation Tool ... 29
2.7. Multi Criteria Decision Making ... 30
CHAPTER 3 – RESEARCH METHODS ... 34
3.1. Time Frame of Study ... 34
3.2. Research Framework ... 34
3.3. Population and Sampling Method ... 36
3.4. Data Sources and Collection ... 37
CHAPTER 4 – RESULTS AND DISCUSSIONS ... 38
4.1. Industrial Observation ... 38
4.2. Assessment Tool Development ... 38
4.2.1. Identification of Factors and Factor Grouping ... 40
4.2.2. Weight Elicitation ... 44
4.2.3. Development of Dust Explosion Evaluation Tool ... 46
4.2.4. Severity Categorization ... 54
4.2.5. Suggestion for Groups in Need of Attention ... 56
CHAPTER 5 – TOOL VALIDATION ... 62
5.1. Drying Process ... 63
5.2. Blending Process ... 71
5.3. Result of Validation ... 77
CHAPTER 6 – CONCLUSIONS AND RECCOMENDATIONS ... 78
6.1. Conclusions ... 78
6.2. Recommendations ... 78
GLOSSARY ... 79
REFERENCES ... 80
APPENDICES ... 83
CURRICULUM VITAE ... 97
