(41i) Criticality of Credible PHA Studies

Fatima Fertilizer Company Limited (FFL) is one of Pakistan’s largest fertilizers manufacturing complexes that process natural resources like natural gas, rock phosphate, limestone and water into vital products for farmers and industrial customers. FFL site comprise of complex & hazardous manufacturing facilities Ammonia, Urea, Nitric acid, Calcium Ammonium Nitrate (CAN) and Nitro Phosphate (NP), Off-site and Utilities, Product Handling and bagging plants.

The parent unit of the complex is a 1700 MTPD ammonia plant which was relocated from Rozenburg, Netherlands to Pakistan in year 2007. The plant was originally designed by CF, Braun in 1968 with name plate capacity of 1350 MTPD. Prior to relocation of ammonia plant from Kemira, Rozenburg to Pakistan; it has gone several revamps and energy conversation projects resulting in increase in production capacity from 1350 MTPD to 1700 MTPD.

During the external assessment on Process Safety Management System of FFL by Dupont in 2021, Risk Assessment & PHA studies of the site plants were highlighted as one of the key concerning areas and PHA quality observations were identified. Process Safety Information and Quality Process Hazards Analysis are cornerstones for an effective PSM program and Good Quality PHA studies are critical to Risk Based PSM Program.

FFL aims to shift its paradigm from conventional Process Safety Management to Risk Based Process Safety Management model to ensure sustainability. The three year road map is developed for migration program to Risk Based Process Safety. The first and foremost important aspect of this program is to improve the quality of existing PHA studies of all operating units. Following are the key highlights of the PHA improvement program at FFL.

• Identification of Right persons for training & capability development on PHA as leaders/facilitators.
• Expert Resource/Consultant was engaged who developed a customized training as per FFL requirements and two week practical workshop was planned along with practical exercise of PHA in which participants participated as member, scribe & leaders in different exercises.
• Revalidation of Base line PHAs on revised risk based approach.
• Development of PHA Leaders/Facilitators Pool after capacity building on PHA & risk assessments by Expert Consultants.
• A standardized Risk Framework, Risk Matrix and Level-II guideline of PHA was developed after capturing all the learnings.
• Training of whole team is planned on whole program in phased approach.
• One unit detailed PHA study is planned to be conducted by PHA Expert consultant with the team of FFL employees. In this way, members will get hands on practical training in detail sessions.
• FFL identified potential leaders were also trained & certified on TUV Rheinland - Risktec (UK) for HAZOP leader certification.

The paper will explain the details of improving PHA leadership and study outcomes.