Risk management framework and practices for boiler operations in Malaysia

Boiler operations had a reputation for being one of the most hazardous work environments. Workers in the boiler plant face many safety risks due to the nature of the job. The work environment is often hot and noisy, consisting of several major equipment and operations involved in its process, and there is always a risk for crushing injuries, electrical shocks and burns, boiler fires and explosions, and contact with hazardous chemicals. Numerous activities performed in boiler operations are complex; these operations are hazardous and can cause accidents. This study aims to develop and propose risk management frameworks for working in a hazardous working environment at the boiler plant in Malaysia to prevent and control accidents and implement adequate safety and health management. Next, to analyze the risk factors and hazards for boiler operations based on the nature of work at the boilers in Malaysia using several methods: Bowtie Risk Assessment, Hazard and Operability Study (HAZOP), Failure Mode and Effect Analysis (FMEA). The result showed that the rate based on hazard sources in the boiler division has Extreme Risk levels (8%), High (14%), Medium (35%), and Low (43%). Risk assessment based on the type of hazard in the boiler division has risk levels ranging from high to the lowest score is the danger of Mechanical (25%), Electrical hazard (10%), chemical hazards (6%), and physical hazards (59%). The developed risk management framework with enhanced risk assessment techniques may solve the integration of sustainability aspects in boiler operations safety and risk management.