(187c) Lesson Learnt and Process Safety of Ammonia Urea Plant

Engro Fertilizers is second largest Urea Producer in Pakistan. Engro is operating 02 Ammonia, 03 Urea and 03 Utilities plants near a rich natural gas facility known as Mari Gas field in district Ghokti. Engro has achieved excellence in process safety and is striving for world class safety performer. In 2014 Engro achieved land mark 4.3 DuPont ranking in process safety. High standards of process safety has been achieved through management commitment and developing a marvelous system of integrated safety management. Engro commissioned new Ammonia Urea complex in 2010 based on Snamprogetti technology having capacity of 2194 MeT/day Liquid Ammonia and 3835 MeT/day Urea. During commissioning number of process related incidents were recorded. A dedicated resource was deputed to record these happenings and circulate this data with in operations department. Lesson learnt helped in minimizing serious process incidents during commissioning as well during normal plant operation. On monthly basis a circular is being shared among operations team based on lesson learnt, effective planning based on key findings eradicated serious risk of process upset through procedural coverage and technical trainings. Hardware modifications were also incorporated along with soft skills improvement which significantly reduced incident rate. Reduced process incidents improved service factor and energy index of Ammonia Urea complex.