CF Industries, headquartered in Deerfield, Illinois has a plant site in Courtright, Ontario, close to the St. Clair River. CF Industries manufactures fertilizer and distributes its product globally. It is the second largest nitrogen fertilizer producer in the world. CF Industries implements Process Safety Management (PSM), see Figure below. This is a comprehensive system used in many industries that is part of due diligence in plant operations intended to keep employees and the community safe. Process Hazard Analysis (PHA) is a key element of any PSM program and must be completed for any changes to operating units. The purpose of the analysis is to determine potential consequences (impacts) to people, environment, the community, and the business. All efforts must be made to reduce the potential impact of the change to a reasonable level. CF Industries would like to relocate two natural gas regulators upstream of a filter to increase performance. A process hazard review must be completed in order to determine if the safeguards are adequate for the equipment relocation.
Luke Kittmer, a Process Safety Engineer at CF Industries, facilitated the PHA for the regulator relocation at the CF Industries plant in Courtright, Ontario.
The teaching objective of this case is to introduce process safety to undergraduate students and provide a situational example that allows students to complete the steps required for Hazard Identification and Risk Assessment (HIRA). This case study is suggested for any course that benefits from adding a process safety application to the curriculum. At the end of this case study, the student(s) will be able to:
- Determine what information is needed for a Process Hazard Analysis
- Analyze process flow sheets and Process and Information Diagrams
- Apply inherently safer design principles
- Use principles of process safety management