Register of Operation on Process

Dept./Section: FL
Plant/Line: FL-1 Date:
No Operation No. Description Job Title Process Flow Chart
1 PUP-FL-01-01 Impin Operator A
2 PUP-FL-01-02 Digester Operator A
3 PUP-FL-01-03 Blow Tank Operator A Chip Digester Blow Tank
4 PUP-FL-01-04 Knotter Screen Operator A
5 PUP-FL-01-05 Pre-MCO2 Operator A
Wash Press
Knotter Pre-MCO2 MCO2
6 PUP-FL-01-06 MCO2 Reactor Operator A Screen Wash Press Reactor
7 PUP-FL-01-07 Post-MCO2 Operator A
Wash Press
8 PUP-FL-01-08 Unbleach Operator A
Tower Post-MCO2 Unbleach Pre Bleach
Wash Press Tower Wash Press

Division/Depart. Head: Section Head: Prepared:

Register of Operation on Process

Dept./Section: FL
Plant/Line: FL-1 Date:
No Operation No. Description Job Title Process Flow Chart
9 PUP-FL-01-09 Pre Bleach Operator B
Wash Press
10 PUP-FL-01-10 Dhot Tower Operator B Unbleach Pre Bleach
Tower Wash Press Dhot Tank
11 PUP-FL-01-11 Dhot Wash Operator B
Press
12 PUP-FL-01-12 EOP Reator Operator B
13 PUP-FL-01-13 EOP Wash Operator B Dhot Wash EOP Wash
Press Press EOP Reator Press
14 PUP-FL-01-14 D1 Tower Operator B
15 PUP-FL-01-15 D1 Wash Press Operator B
16 PUP-FL-01-16 HT Tower Operator B D1 Wash
D1 Tower Press HD Tower

Division/Depart. Head: Section Head: Prepared:

Evaluation of Hazard Identification, Risk Assessment

Dept./Section: FL-1 Date:

Operation Recent Risk
Risk Assessment
Condition Control Method

Risk Scale
Area /

Consequenc
Non-routine

EffectC
Hazardous

Emergency

Probability

=SFC )
No Equipment / Procedure Hazard Category Remark

Routine

Control
Factor Hardw Softwar

(R
e (S)
Operation

(F)
are e

Risk
PUP-FL- Digester Chip Feeding Operation Touch with high/low
V - - [PH11] HW02 8 4 0.4 12.8 S2
01-02 control temperature
White Liquor Chemical Chemicals leakage
V - - [CH04] HW52 SW01 16 2 0.2 6.4 S1
Feeding (include waste liquor)
Steam Feeding Operation Touch with high/low
V - - [PH11] HW52 8 6 0.8 38.4 S2
control temperature
Stock Blowing Operation
V - - [PH11] Touch with high/low HW52 16 10 0.4 64.0 S3
control temperature
Maintenance Mechanic Fall
- V - [PH04] SW01 8 4 0.4 12.8 S2

Black Liquor Chemical Chemicals leakage

- - V [CH04] 16 10 1 160.0 S4
Spillage (include waste liquor)

Safety Dept. Head: Safety Staff: Dept. Head: Section Head: Prepared:
Register of High & Unacceptable Risk and Determining Controls

Dept./Section: FL-1 Date:

Operation Control of Unacceptable
Condition Risk
Area /

Non-routine

Emergency
Hazardous Risk
No Equipment Procedure Hazard Category Improve & Control Action

Routine
Factor Scale
/ Operation A B C D E

PUP-FL- Digester Black Liquor Chemicals leakage

- - V Chemical [CH04] S4 V
01-02 Spillage (include waste liquor)

M.R.(s): Safety Dept. Head: Safety Staff: Dept. Head: Section Head:

Control of unacceptable risk, using Vto select:

[A] Elimination, [B] Substitution, [C] Engineering controls, [D] Signage/warnings and/or administrative controls, [E] Personal protective equipment
Select Hazardous Factor Hazard Category
V Chemical [BI01] Pathogenic bacteria propagate
- Electrical [BI02] Food poison
Radiation energy [BI03] Pathogenic bacteria infect
Operation control [BI04] Moldy, corrupt
Mechanic [CH01] Fire accident
Working environment [CH02] Explosion
Human factor [CH03] Touch with hazardous substance
Biologic [CH04] Chemicals leakage (include waste liquor)
Others [CH05] Hazardous gas leakage
[CH06] Odor
[CH07] Smoking
[CH08] Lacking oxygen, suffocation
[HE01] Bad design cause human mistake
[HE02] Height & space not enough, cause injure/harm
[HE03] Carry overweight, cause injure/harm
[HE04] Bad posture, cause injure/harm
[HE05] Repeat work, cause injure/harm
[HE06] Improper motion
[OT01] Traffic accident - public road
[OT02] Traffic accident - mill site road
[OT03] Traffic accident - shipping, air transportation
[OT04] Working pressure
[OT05] Others
[PH01] Substance fall down
[PH02] Collapse, topple down
[PH03] Substance break down
[PH04] Fall
[PH05] Tumble, slip
[PH06] Collide,
[PH07] Clip, draw into, crush
[PH08] Cut, bruise
[PH09] Tread,
[PH10] Drown
[PH11] Touch with high/low temperature
[PH12] High noise
[PH13] Lighting not enough
[PH14] Poor ventilation
[PH15] Dust expose
[PH16] Ionizing radiation expose
[PH17] Non-ionizing radiation expose
[PH18] Vibration
[PH19] Electric shock, burns
[PH20] Low voltage, electric trip
[PH21] Water leakage
[PH22] Explosion(dust)
[PH23] Pressure abnormal
 Consequence(S) Probability(P) Control effect(C) Risk Score Risk Grade
1 1 0.2 >=250 S5 Unacceptable
4 2 0.4 >=150 S4 High
8 4 0.6 >=50 S3 Medium
16 6 0.8 >=10 S2 Low
32 10 1.0 <10 S1 Acceptable

e injure/harm
Unacceptable

Acceptable
Consequence(S)
Legal and other Production/Equipm
Score Injuries and deaths
requirement ent/ Finance loss
1 Uncontrolled Not obvious injuries Not obvious loss

4 Legal uncontrolled Medical injuries Production loss:

Other controlled Finance loss(USD):

Injuries of
8 Legal controlled temporary lose all Production loss:
function
Finance loss(USD):
Injuries of
Specified inspect
16 permanent lose Production loss:
items by government
partial function
Legal request for
Finance loss(USD):
continual monitoring
Punished by One death or three
32 Production loss:
government above injuries
Not complied legal
Finance loss(USD):
requirement
 Probability(P)
Hazardous Properties Description

Immediately, Physical, Never happened

and Others
Happened one time: >= 10
< one day. years
Happened one time: >= 5 years,
< 3,000
< 10 years
Happened one time: >= 3 years,
>= 1, < 3 days.
< 5 years
Happened one time: < 3 years
>= 3,000, < 20,000

Slowly, Chemical, and Exposed time < working time

>= 3, < 7 days.
Others 10%
(exposed time under Working time: >= 10%, < 35%
>= 20,000, < 200,000 working environment)
Working time: >= 35%, < 60%
>= 7 days.
Working time: >= 60%, < 80%
>= 200,000
Working time: >= 80%
 Control effect(C)
Score Score Description

1 0.2 Having more than two hardware protect

actions, and good operation control
2 0.4 Having one hardware protect action, and
good operation control
4 0.6 Having hardware protect action, but no
operation control
6 0.8 No hardware protect action, but having
good operation control
10 1 No hardware protect action, and no
operation control
1

10
 Risk grade
Risk Score Risk Grade
256-320 S5 unacceptable
>250

153.6-192 S4 high
150-250
51.2-128 S3 medium
50-150
10-48 S2 low
10-50

0.2-9.6 S1 acceptable
<10
 Improving Action
Stop operation, and review recent protect action
immediately.
Issue/implement the improve programme or
enhance the adaptability of operation.
Review recent protect action, and priority to
evaluate, improve, to reduce the risk scale
Acceptable temporally, but need to monitor the
operation condition, consider to issue improving
action
Acceptable, monitoring by recent protect action

Acceptable, dont need to change

Operation Condition Description
Routine 1. Normal operation
- Process operation
2. Periodic operation
- Maintenance & cleaning during operation
Non-routine 1. Non-periodic operation
- Plant or equipment start-up/shut-downs
- Facilities or equipment cleaning
- Schedule maintenance
- Process change (furnishing, grade, or line/equipment
change)
2. Occasional condition
- Temporary process modifications
- Non-schedule maintenance
- Field trip
- Temporary plant or equipment shut-downs
- Temporary arrange
- Other abnormal condition
Emergency 1. Natural disasters:
- Earthquake
- Extreme weather condition(flooring, forest fires, etc.)
2. Serious condition:
- Utility (electric power, steam, water, gas etc.) disruption
- Fire accident, explosion,
- Equipment damage, storage tank leakage or overflow
- Process abnormal discharge, hazard chemical spillage
3. Others:
- Interested parties serious responded
 Control Method
Hardware Auto operation HW01

HW02

HW03

HW04

Manual HW51
operation HW52

HW53
Software SW01
SW02
SW03
SW04
SW05
SW06
SW07
SW08
 Description
Detection, Alarm, and control equipment:
- leakage, level, temperature, pressure, flow
Protect device
- safety protective device
- interlock system
- photo-electric detect device
- noise/vibration protect device
- cooling system
Fire protect system
- auto fire fighting device
- smoking detect device
Auxiliary device
- emergency discharge system
- emergency power off system, power supply system
- emergency light device
Manual emergency device
Manual detect device
- leakage, temperature,
Remote control device
Personal protect device
Emergency preparedness response
Working permits
Preventive maintenance & lubrication
Training
Contractor management
Managing change
Trouble shooting
N Hazardous Factor Description
o
1 Chemical 1. Material properties( according MSDS):
Toxic gases, chocking gases, flammable
gases/liquid/solid, prohibit water substance, oxidize
substance, toxic substance, corrosive substance.
2. Waste materials
Waste acid/alkali/solvent, waste
gas/powder/sludge/solid
3. Odour
4. Other hazardous substance
2 Electrical High voltage, high electric current
3 Radiation energy 1. Ionizing radiation(X-ray)
2. Electromagnetic wave(RF, micro wave, UV, IR)
3. Laser
4 Operation control 1. Temperature: High temperature(>45 C), low
temperature(<0 C)
2. Pressure: High pressure(>1 atm), vacuum(<1 atm)
5 Mechanic 1. Machine/equipment
2. Tools/parts
3. Heavy equipment/forklift/vehicle
6 Working 1. Infrastructure
environment 2. Noise(average >= 85 dB, moment >= 140 dB)
3. Vibration
4. others
7 Human factor 1. Posture
2. Design
3. Space
4. Light
8 Biologic Pathogenic bacteria
9 Others