Hazard & Operability Study and Determining Safety Integrity Level on Sulfur Furnace Unit: A Case Study in Fertilizer Industry

In the process production, it is possible that some risks may be happen and potentially causing hazard. Therefore, it will lead to a failure to achieve the production target. Hazard & Operating Study (HAZOPS) of sulphur furnace are done in this research. Here, the nodes used are sulphur furnace, waste heat boiler, and steam superheater. From the analysis, it obtained 11 instruments attached on those three nodes with the highest hazard potential reaches extreme level based on AS/NZS 4360:2004 standard, while in standard of the factory it reaches a high level. Both of them are in low temperature sulphur furnace and high temperature sulphur furnace deviation. At the Safety Integrity Level (SIL) determination, it obtained 1st level of SIL on installed SIS in node sulphur furnace with a total of PFD 0,021 and RRF 48,3. Meanwhile, SIL 1 in waste heat boiler has a total value of Probability Failure of Demand (PFD) 0.0184 and Risk Reduction Factor (RRF) of 54.32. While in the last node, steam superheater, the SIS is not installed.