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Abstract

The fertilizer industry is one of the chemical sectors with high-risk potential due to its operational processes involving hazardous materials as well as extreme pressure and temperature conditions. This study aims to identify and analyze hazards in the urea recovery unit using the Hazard and Operability Study (HAZOP) method, while also formulating effective risk control strategies to support the operational sustainability of the plant. The study was conducted directly at a commercial fertilizer plant in West Java using a semi-quantitative approach, which included field observations, review of technical documents such as Process Flow Diagrams (PFD), Piping and Instrumentation Diagrams (P&ID), and Material Safety Data Sheets (MSDS), as well as the implementation of structured HAZOP sessions referring to the IEC 61882:2016 standard. Risk levels were calculated using the formula R = C × S and mapped into a 5×5 risk matrix. The analysis identified eight critical deviation scenarios in the main equipment of the recovery unit, mostly related to high pressure, ammonia leakage, corrosion due to ammonium carbamate, and vacuum system failure. Based on these findings, the integration of technical and procedural controls is considered capable of reducing the dominant risk scores from the Unacceptable category to Acceptable Tolerated, thereby expected to support the achievement of the company's Zero Accident target.

Keywords: HAZOP, occupational health and safety, fertilizer industry, urea recovery, risk management, industrial safety.

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Bahasa Abstract

Industri pupuk merupakan salah satu sektor kimia yang memiliki potensi risiko tinggi karena proses operasinya melibatkan bahan berbahaya serta kondisi tekanan dan suhu yang ekstrem. Penelitian ini bertujuan untuk mengidentifikasi dan menganalisis bahaya pada unit pemulihan urea (recovery) menggunakan metode Hazard and Operability Study (HAZOP), sekaligus merumuskan strategi pengendalian risiko yang efektif untuk mendukung keberlanjutan operasional pabrik. Studi dilakukan secara langsung di salah satu pabrik pupuk komersial di Jawa Barat dengan pendekatan semi-kuantitatif, yang mencakup observasi lapangan, telaah dokumen teknis seperti Process Flow Diagram (PFD), Piping and Instrumentation Diagram (P&ID), dan Material Safety Data Sheet (MSDS), serta pelaksanaan sesi HAZOP terstruktur mengacu pada standar IEC 61882:2016. Tingkat risiko dihitung menggunakan rumus R = C × S dan dipetakan ke dalam matriks risiko 5×5. Dari hasil analisis, teridentifikasi delapan skenario deviasi kritis pada peralatan utama unit recovery, yang sebagian besar berkaitan dengan tekanan tinggi, kebocoran amonia, korosi akibat ammonium karbamat, dan kegagalan sistem vakum. Berdasarkan temuan tersebut, integrasi antara pengendalian teknis dan prosedural dinilai mampu menurunkan skor risiko dominan dari kategori Unacceptable menjadi Acceptable Tolerated, sehingga diharapkan dapat mendukung pencapaian target Zero Accident perusahaan.

Kata Kunci: HAZOP, kesehatan dan keselamatan kerja, industri pupuk, pemulihan urea, manajemen risiko, keselamatan industri.

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