hazop work sheet zaltoprofen

8/16/2019 HAZOP Work Sheet Zaltoprofen

1/26

IPCA

IPCA LABORATORIES-Ankleshwar JOGI

HAZOP STUDY

REPORT NO.:- ZaltoProfen

Work Sheet No. !"#

Work Sheet No. "

Sta$e No- " !S%nthes&s of ZaltoProfen Cr'(e#

Pro)ess ste* No

!+es&$n Intent#

Rea)t&on

Pro)ess s', ste*

No-

1. Charging of poly-phosphori ai!". Charging of D# $a%&r'. S%irring(. Cooling). Charging of Di-ai!*. Charging of #&%hyl yloh&+an&,. H&a%ing. Dis%illa%ion. Cooling1/. Charging Of Tol0&n&11. Charging Of D# a%&r 21". 3ay&r S&para%ion

No(e No. "."." to "."."

Ref. P+ ZaltoProfen Cr'(e

". Char$&n$ of *ol%-*hos*hor&) a)&(.

+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons

Low Te1*erat're • H04an &rror-

5&&ping %h& 6rin&

7al7& Op&n8 6rin&

7al7& passing.

• Poly-phosphori

ai! Soli!ifying

in %h& r&a%or

• Agi%a%or

9a44ing

• Pro!0%ion

No%hing 2 T&4p&ra%0r&

n!ia%or is pro7i!&! 60%

sa4& is no% r&or!ing

6&for& an! !0ring Poly-

phosphori ai!

1; ----Pro&!0ral on%rol--

op&ra%or %o log %h& r&a%or

%&4p&ra%0r& 6&for& harging

%h& Poly-phosphori ai! in

%h& r&a%or.

"; A%ion %a5&n 6& on lo$

'


2/26

IPCA


HAZOP STUDY


!&lay

• Prop&r%y!a4ag& 2 4o%or

!a4ag&<

agi%a%or shaf%

Da4ag&

%&4p&ra%0r& 6y op&ra%or

sho0l! 6& !o04&n%&! an!op&ra%ors %o 6& %rain&!

7ali!a%&!.

'; 3o$ %&4p&ra%0r& s&nsor

$i%h a0%o4a%ion %o sh0% of

6rin& inl&% on

pr&!&%&r4in&! lo$

%&4p&ra%0r& %o 6& pro7i!&!

Conta1&nat&on • H04an &rror.

• rong 4a%&rial 0s&!

for $ashing

• 3&a5ag& in r&a%or

• #a%&rial =0ali%y

!&gra!a%ion.

• 3oss of

pro!0%ion.

• >0ali%y h&5<

pro&!0ral

on%rol &+is%s forall ra$ 4a%&rials

R&a%or %hi5n&ss

s0r7&y is arri&! o0%

on& in " y&ars.

9a5&% pr&ss0r& %&s%

is !on& on& in "

y&ars.

.

S*&lla$e. • #a%&rial loss . • SOPs ar& a7aila6l&.

• Training is i4par%&!

%o op&ra%ional s%a?.

• P&rsonn&l 7igilan&.

• PPEs ar& pro7i!&!.

• SC@A s&% is a7aila6l&

in plan% 60il!ing.

(/


3/26

IPCA


HAZOP STUDY


-Char$&n$ of +2 water

3&$h 0'ant&t%. • H04an &rror. • >0ali%y !&gra!a%ion.

• 3&an sl0rry for4a%ion.

• @#R pro&!0r&s ar&

follo$&!.

• a%&r 4&%&r8

#&as0r&! =0an%i%y

harging.

Low 0'ant&t% • H04an &rror. • R&a%ion 4ay 6&

a?&%&!.


follo$&!.

• Dips%i5 is a7aila6l& %o

4&as0r& l&7&l in

!r04s.

A$&tator sto**e(. • Po$&r fail0r&.

• Agi%a%or a44&!.

• 4prop&r !issol0%ion. • DB s&% is a7aila6l&.

• P# of agi%a%or 4o%or

arri&! o0% p&rio!ially.

Less t&1e allowe(

for A$&tat&on.

• H04an &rror. • >0ali%y !&gra!a%ion. • SOP is a7aila6l&.

No Cool&n$ water

a/a&la,le

• Po$&r fail0r&

• S%&a4 lin&! 0p %o

r&a%or a5&% 6y

4is%a5&.

• E+o%h&r4i

r&a%ion.

• D&lay&! 6a%h %i4&

• D&gra!&! =0ali%y

•

T&4p&ra%0r& inr&as&s.

• SOPs ar& a7aila6l&.

• P&rsonal 7igilan&.

• #&hanial lo5 %o 6&

pro7i!&! s0h %ha% only on&

0%ili%y an 6& lin&! 0p a% a

%i4&.

4-St&rr&n$

A$&tator sto**e(.

Po$&r fail0r&.

Agi%a%or a44&!.

Thi5 sl0rry for4a%ion.

4prop&r 4i+ing.

#an0al 7igilan&.

DB s&% is a7aila6l&.

(1


4/26

IPCA


HAZOP STUDY


P# of agi%a%or 4o%or

arri&! o0% p&rio!ially.Less t&1e allowe(

for st&rr&n$.

H04an &rror.

Po$&r ail0r&.

#o%or ail0r&.

Agi%a%or a44&!.

4prop&r !issol0%ion.

SOP is a7aila6l&.




3&$h

te1*erat're.

Po$&r fail0r&.

No ooling $a%&r

a7aila6l&.

a0l%y

%&4p&ra%0r&

in!ia%ion.

Un!&sir&! r&a%ion.

>0ali%y !&gra!&!.


P# ali6ra%ion of

%&4p&ra%0r&

in!ia%or is !on&p&rio!ially.

@#R pro&!0r&s ar&

follo$&!.

PPEs shall 6& $orn

6y op&ra%ional s%a?.

R&!0n!an% %&4p&ra%0r&

in!ia%ion $i%h alar4 %o

6& pro7i!&!.

Low te1*erat're H04an &rror.

Chilling or 6rin&

lin&! 0p %o

r&a%or a5&% 6y4is%a5&

a0l%y

%&4p&ra%0r&

in!ia%ion.

>0ali%y !&gra!a%ion. P# ali6ra%ion of

%&4p&ra%0r&

in!ia%or is !on&

p&rio!ially.

R&!0n!an% %&4p&ra%0r&

in!ia%ion $i%h lo$

%&4p&ra%0r& alar4 %o 6&

pro7i!&!.

5-Cool&n$

("


5/26

IPCA


HAZOP STUDY


3&$h te1*erat're • S%&a4 lin&! 0p

%o r&a%or a5&%6y 4is%a5&

• No ooling $a%&r

a7aila6l&.

• D&lay&! 6a%h %i4&. • SOPs ar& a7aila6l&.



pro7i!&! s0h %ha% onlyon& 0%ili%y an 6& lin&!

0p a% a %i4&.

Low te1*erat're • No assigna6l&

a0s&.

6- Char$&n$ of +&a)&(

3&$h 0'ant&t% • H04an &rror • #a%&rial loss.

• Un!&sir&! =0ali%y.

• SOP is a7aila6l&.

S*&lla$e !+'r&n$

)har$&n$ of (r'1s #

• No assigna6l&

a0s&

• • •

7-Char$&n$ of 2eth%l)%)lohe8ane




S*&lla$e !+'r&n$

)har$&n$ of (r'1s #

• No assigna6l&

a0s&

9-3eat&n$

3&$h te1*erat're • S%&a4 lin&! 0p %o • D&lay&! 6a%h %i4&. • SOPs ar& a7aila6l&. • #&hanial lo5 %o 6&

('


6/26

IPCA


HAZOP STUDY


r&a%or a5&% 6y

4is%a5&

• No ooling $a%&r

a7aila6l&.

• P&rsonal 7igilan&. pro7i!&! s0h %ha% only on&


%i4&.

.


a0s&.

:-+&st&llat&on

3&$h Te1*erat're • High s%&a4 loa! in

r&a%or a5&%.

• High ra%& of

&7apora%ion..

• R&a%or o7&r-pr&ss0ria%ion.


• T&4p&ra%0r& in!ia%ion

is a7aila6l&.


• T&4p&ra%0r& on%rol 7al7&

in s%&a4 s0pply %o 6&

pro7i!&!.

Low Te1*erat're • Po$&r fail0r&.

• H04an &rror.

• H&a%ing s%&a4 no%

a7aila6l&.

• @a%h %i4& inr&as&s.

3&$h *ress're • High s%&a4 loa! in

r&a%or a5&%

• #a%&rial l&a5 an!

froa%hing

• T&4p&ra%0r&8Fo$ on%rol

7al7& in s%&a4 s0pply %o 6&pro7i!&!.

.

;- Cool&n$

3&$h te1*erat're • S%&a4 lin&! 0p

%o r&a%or a5&%

6y 4is%a5&




pro7i!&! s0h %ha% only

on& 0%ili%y an 6& lin&!

((


7/26

IPCA


HAZOP STUDY


• No ooling $a%&r

a7aila6l&.

0p a% a %i4&.

.

Low Te1*erat're No assigna6l&

a0s&8 no haar!

•

"0ali%y !&gra!a%ion.


follo$&!.

.


a?&%&!.


follo$&!.

.

S*&lla$e. H04an &rror in

4an0al han!ling of

%h& on%ain&rs.

• ir&

• P&rsonn&l in0ry.

• S0?oa%ion.


• Training is i4par%&! %o

op&ra%ional s%a?.


• PPEs ar& pro7i!&!.

• SC@A s&% is a7aila6l& in

plan% 60il!ing.

.

""- Char$&n$ Of +2 Water

()


8/26

IPCA


HAZOP STUDY


3&$h 0'ant&t%. • H04an &rror. • Sol7&n% loss.

• >0ali%y !&gra!a%ion.

• @#R pro&!0r&s ar&follo$&!.

.


a?&%&!.


follo$&!.

• Dips%i5 is a7aila6l& %o

4&as0r& l&7&l in

!r04s.

A$&tator sto**e(. • Po$&r fail0r&.

•

Agi%a%or a44&!.

• 4prop&r !issol0%ion. • DB s&% is a7aila6l&.

•

P# of agi%a%or 4o%orarri&! o0% p&rio!ially.

Less t&1e allowe(

for A$&tat&on.

• H04an &rror. • >0ali%y !&gra!a%ion. • SOP is a7aila6l&.

No Cool&n$ water

a/a&la,le

• Po$&r fail0r&

• S%&a4 lin&! 0p %o

r&a%or a5&% 6y

4is%a5&.

• E+o%h&r4i

r&a%ion.

• D&lay&! 6a%h %i4&

• D&gra!&! =0ali%y

• T&4p&ra%0r& inr&as&s.




pro7i!&! s0h %ha% only on&


%i4&.

"- La%er Se*arat&on

Conta1&nat&on • 3&ss s&%%ling %i4&

• #ishan!ling

• H04an &rror

• Pro!0% loss

• >0ali%y !&gra!a%ion.

• P&rsonn&l 7igilan&

• Sa4pl& is h&5&! in

>C 3a6.

(*


9/26

IPCA


HAZOP STUDY


Work Sheet No. !#

Work Sheet No.

Sta$e No- " !S%nthes&s of ZaltoProfen Cr'(e

Pro)ess ste* No

!+es&$n Intent#

!Centr&f'$&n$ an( /a)''1 (r%&n$ #

Pro)ess s', ste*

No-

". Char$&n$ = s*&nn&n$.

. Tol'ene Wash

4. Cake >nloa(&n$

5. ?a)''1 (r%&n$

No(e No.

(,


10/26

IPCA


HAZOP STUDY


Ref. P+ ZaltoProfen Cr'(e

". Char$&n$ = s*&nn&n$.


3&$h Press're • 4prop&r

harging.

• C&n%rif0g& o7&r

pr&ss0ri&!.

• C&n%rif0g& 60rs%.

• Prop&r%y !a4ag&.

• Da4ag& %o lo%h.

• Prop&r lin&0p is

&ns0r&! 6&for&

spinning.

3&$h @'ant&t% •

#is-o440nia%ion

• High pr&ss0r& in

r&a%or.

• R&a%or 7al7&

passing.

• H04an &rror.

•

#a%&rial loss.• E+pos0r& of sol7&n% %o

op&ra%ional s%a?.

• or4a%ion of Fa44a6l&

7apors in plan% 60il!ing.

• Da4ag& %o &n%rif0g&.

• P&rsonn&l in0ry.

• Spillag&.

#an0al op&ra%ion


11/26

IPCA


HAZOP STUDY


2ore T&1e • H04an &rror. • D&lay&! 6a%h %i4&. • @#R pro&!0r& in

pla&.

• Co4pl&%ion of l%ra%ion

is &ns0r&! fro4 sigh%

glass in 4o%h&r li=0or

lin&.

+r&/e a&l'reSto* • Po$&r fail0r&. • D&lay&! 6a%h %i4&. • DB s&% is a7aila6l&.

Also !Centr&f'$e

)o/er o*en ('r&n$

)har$&n$.#

• #an0al harging

fro4 &n%rif0g& %op

o7&r.

• Sol7&n% 7apor &+pos& %o

op&ra%ional s%a?.


7apor.

• ir&.

• PPEs ar& pro7i!&! %o

op&ra%ional s%a?.

• 3i4i% s$i%h %o s%op

spinning in as& of %op

o7&r op&n %o 6&

inorpora%&! in all

&n%rif0g&s.

Also !Centr&f'$e

)o/er o*en ('r&n$

s*&nn&n$#.

• H04an &rror.

• ail0r& of la%h.

• ail0r& of l i4i%

s$i%h.


op&ra%ional s%a?.


7apor.

• ir&.

• 3i4i% s$i%h s%ops


o7&r is op&n IN&$

&n%rif0g&s;.



o7&r op&n %o 6&

inorpora%&! in all

&n%rif0g&s.

Low s*ee( • 3oos& 6&l%. • n&Gi&n% l%ra%ion.

• D&lay&! 6a%h %i4&.

• &% a5& for4a%ion.

• Sp&&! in!ia%ion %o 6&

pro7i!&!.

3&$h Sol&(s !&n

1other l&0'or#

• il%&r 6ag l&a5ag&.

• il%&r 6ag passing.

• >0ali%y !&gra!a%ion. • SOPs ar& a7aila6l&.

• il%&r 6ags ar&

r&pla&! af%&r &7&ry

&igh% 6a%h&s.

Wet )ake. • il%&r 6ag ho5ing.

• #o%h&r li=0or lin&

ho5ing.

• D&lay&! 6a%h %i4&.

• #a%&rial loss.

• SOP is a7aila6l& for

0sag& of &n%rif0g&

6ag.

(


12/26

IPCA


HAZOP STUDY


• 3o$ &n%rif0g&

sp&&!.

BeforeAfter

!)har$&n$ (one

,efore start&n$

s*&nn&n$#.

• H04an &rror. • High 7i6ra%ion.

• n&Gi&n% l%ra%ion.

• C&n%rif0g& i46alan&!.

• Di?&r&n% sp&&! s&l&%ion %o

6& pro7i!&! !0ring

harging spinning.

• A0%o4a%ion Iharging 6lo5

7al7& shall op&n only $h&n

&n%rif0g& is a% appropria%&

RP#;.

3&$h /&,rat&on • 4prop&r harging.

• Charging !on&

$i%ho0% s%ar%ingspinning.

• C&n%rif0g&

o7&rloa!.


ho5&!.

• Spar5.

• ir&.

• Da4ag& %o &=0ip4&n%.

• A0%o4a%ion I&n%rif0g&

4o%or shall s%op a% high

7i6ra%ion;.

S*&lla$e !2other

l&0'or#

• #3 a%h po% I#3

%an5; o7&r Fo$.

• #3 %ransf&r p04p

no% $or5ing.

• ir&.

• Sol7&n% loss.

• #a%&rial loss.

•

To+i &?&%.

• SOP is a7aila6l&. • #3 a%h po% apai%y %o 6&

r&7i&$&!.

• 3&7&l ga0g& %o 6& pro7i!&!

%o #3 %an5.

• D04p %an5 %o 6& pro7i!&!

%o s%or& #3 !0ring

&n%rif0ging in as& of #3

p04p fail0r&.

. Tol'ene Wash


• rong 4a%&rial

0s&! for $ashing


!&gra!a%ion. No saf&%y

iss0&

.

)/


13/26

IPCA


HAZOP STUDY


S*&lla$e E8*os're • #an0al a%i7i%y. • #a%&rial loss.

• ir&.

• n&Gi&n% $ashing.

• H&al%h haar!.

• PPEs ar& $orn 6yop&ra%ional s%a?.

• SOP on%rol

• Train&! p&rsons

• ir& &+%ing0ish&rs ar&

pro7i!&!.

+r&/e sto* • Po$&r fail0r& • D&lay&! 6a%h %i4&. • DB s&% is a7aila6l&.

4.Cake >nloa(&n$

S*&lla$e • H04an &rror

• #ishan!ling.

• To+i 7apor &+pos0r&. • PPEs IOrgani 7apor

4as5; ar& pro7i!&! %o

op&ra%ional p&rsonn&l.

Also !+a1a$e to

lter )loth#

• Us& of har! %ools

%o srap o0% har!

a5&.

• Clo%h !a4ag&. • @#R pro&!0r& is

a7aila6l&.

• #an0al 7igilan&.

4. /a)''1 (r%&n$

S*&lla$e H04an &rror.

4prop&r

han!ling.

Japor &+pos0r&.

#a%&rial loss.

S0?oa%ion.

PPEs ar& a7aila6l&

%o op&ra%ional

s%a?.

3&$h

Te1*erat're

T&4p&ra%0r&

on%rol sys%&4

fail0r&.

#a%&rial =0ali%y

!&gra!&!.

#a%&rial loss.

ir&.

T&4p&ra%0r&

in!ia%ion is

a7aila6l&.

Low

Te1*erat're

T&4p&ra%0r&

on%rol sys%&4

#a%&rial =0ali%y

!&gra!&!.

T&4p&ra%0r&

in!ia%ion is

)1


14/26

IPCA


HAZOP STUDY


fail0r&. a7aila6l&.

#an0al sa4plingis !on& for

&ns0ring 4ois%0r&

on%&n%.

3&$h low

!(r%&n$ a&r#

No assigna6l&

a0s&.

Po$!&r arry o7&r

$i%h !rying air

LowNo low

!(r%&n$ a&r#

Cho5ing of air

l%&r.

Po$&r fail0r&.

@lo$&r fail0r&.

D&lay&! 6a%h %i4&. #an0al sa4pling

is !on& for

&ns0ring 4ois%0r&

on%&n%.

Less T&1e H04an &rror. High 4ois%0r&

on%&n%.

#an0al sa4pling

is !on& for

&ns0ring 4ois%0r&

on%&n%.

2ore T&1e H04an &rror. D&lay&! 6a%h %i4&. @#R pro&!0r& in-

lin&.

S*&lla$e+'st&n

$.

#an0al a%i7i%y

Poor

ho0s&5&&ping

E+pos0r& %o %o+i

!0s%

PPEs ar& a7aila6l&

%o op&ra%ional

s%a?.

)"


15/26

IPCA


HAZOP STUDY


Work Sheet No. !4#

Work Sheet No. 4

Sta$e No- !BZB-B# P'r&)at&on of Zalto*ren )r'(e

Pro)ess ste* No

!+es&$n Intent#

Rea)t&on

Pro)ess s', ste*

No-

". Char$&n$ of Zalto*ren )r'(e

. Char$&n$ of A)etone

4. Char$&n$ of Car,on sl'rr%

5. 3eat&n$ an( st&rr&n$

No(e No. ".4." to ".4.6

Ref. P+ P'r&)at&on of Zalto*ren )r'(e

"-Char$&n$ of Zalto*ren )r'(e


Conta1&nat&on • H04an &rror. • #a%&rial =0ali%y

!&gra!a%ion.

• 3oss of pro!0%ion.

>0ali%y h&5<

pro&!0ral on%rol

&+is%s for all ra$

4a%&rials

SOP on%rol.

S&0ri%y 6y !&7i&

on%rol.

No 0na0%hori&!

&n%ry.

)'


16/26

IPCA


HAZOP STUDY


@&s% Ho0s&5&&ping

pra%i&s

-Char$&n$ of A)etone





S*&lla$e No assigna6l&

a0s&< only &rror

!0ring 4an0al

han!ling

• Japor &+pos0r& • SOP< PPE

4-Char$&n$ of Car,on Sl'rr% 3eat&n$ an( st&rr&n$





S*&lla$e No assigna6l&

a0s&<

• No onsi!&ra6l&

haar!

5- 3eat&n$ an( st&rr&n$


A$&tator sto**e(. Po$&r fail0r&.

Agi%a%or a44&!.

Thi5 sl0rry for4a%ion.

4prop&r 4i+ing.

#an0al 7igilan&.




Less t&1e allowe(

for st&rr&n$.

H04an &rror.

Po$&r ail0r&.

4prop&r !issol0%ion. SOP is a7aila6l&.


)(


17/26

IPCA


HAZOP STUDY


#o%or ail0r&.

Agi%a%or a44&!.



3&$h te1*erat're • S%&a4 lin&! 0p %o

r&a%or a5&% 6y

4is%a5&

• No ooling $a%&r

a7aila6l&.



#&hanial lo5 %o 6& pro7i!&!

s0h %ha% only on& 0%ili%y an 6&

lin&! 0p a% a %i4&.

.


a0s&.

Work Sheet No. 5

Sta$e No- !BZB-B# P'r&)at&on of Zalto*ren )r'(e

Pro)ess ste* No Press're lter&n$ (&st&ll&n$ an( see(&n$ of the 1ass

))


18/26

IPCA


HAZOP STUDY


!+es&$n Intent#

Pro)ess s', ste*No-

"- Press're lter&n$- +&st&ll&n$

4-See(&n$

No(e No. ".4." to ".4.6

Ref. P+ P'r&)at&on of Zalto*ren )r'(e

"- Press're lter&n$


Chok&n$ of the

lter

No saf&%y Haar! Pro!0%ion !&lay • SOP on%rol

S*&lla$e 3&a5ag& in %h&

l%&r

A%4osph&r&

on%a4ina%ion< h&a%h

haar!

• SOP8 PPE

- +&st&ll&n$


3&$h Te1*erat're • High s%&a4 loa! inr&a%or a5&%.

• High ra%& of &7apora%ion..

• R&a%or o7&r-

pr&ss0ria%ion.


• T&4p&ra%0r& in!ia%ion

is a7aila6l&.


• T&4p&ra%0r& on%rol 7al7&in s%&a4 s0pply %o 6&

pro7i!&!.

Low Te1*erat're • Po$&r fail0r&.

• H04an &rror.

• @a%h %i4& inr&as&s.

)*


19/26

IPCA


HAZOP STUDY


• H&a%ing s%&a4 no%

a7aila6l&.

- See(&n$


No onsi!&ra6l&

haar! in any

!&7ia%ion only pro&ss

!&lay- No saf&%y ss0&

No onsi!&ra6l&

haar! in any

!&7ia%ion only

pro&ss !&lay- No

saf&%y ss0&

No onsi!&ra6l& haar! in

any !&7ia%ion only pro&ss

!&lay- No saf&%y ss0&

SOP on%rol for

pro&ss- %his is pro&ss

=0ali%y ri%ial a%i7i%y

$i%h no saf&%y r&la%&!

saf& g0ar!s r&=0ir&!.

•

Work Sheet No. !5#

Work Sheet No. 5

Sta$e No- P'r&)at&on of Zalto*ran )r'(e !BZB-B#

Pro)ess ste* No

!+es&$n Intent#

Centr&f'$&n$ an( /a)''1 (r%&n$

),


20/26

IPCA


HAZOP STUDY


Pro)ess s', ste*

No-

"- Char$&n$ = s*&nn&n$.

- A)etone Wash

4-Cake >nloa(&n$

5- ?a)''1 (r%&n$

No(e No. ".5." to ".5.5

Ref. P+ 2PCRBZB-B


21/26

IPCA


HAZOP STUDY


pla&.

•

Co4pl&%ion of l%ra%ionis &ns0r&! fro4 sigh%


lin&.

2ore T&1e • H04an &rror. • D&lay&! 6a%h %i4&. • @#R pro&!0r& in

pla&.

• Co4pl&%ion of l%ra%ion

is &ns0r&! fro4 sigh%


lin&.

+r&/e a&l'reSto* •Po$&r fail0r&.

•

D&lay&! 6a%h %i4&. •

DB s&% is a7aila6l&.Also !Centr&f'$e

)o/er o*en ('r&n$

)har$&n$.#

• #an0al harging

fro4 &n%rif0g& %op

o7&r.


op&ra%ional s%a?.


7apor.

• ir&.

• PPEs ar& pro7i!&! %o

op&ra%ional s%a?.



o7&r op&n %o 6&

inorpora%&! in all

&n%rif0g&s.

Also !Centr&f'$e

)o/er o*en ('r&n$

s*&nn&n$#.

• H04an &rror.

• ail0r& of la%h.

• ail0r& of l i4i%

s$i%h.


op&ra%ional s%a?.


7apor.

• ir&.

• 3i4i% s$i%h s%ops


o7&r is op&n IN&$

&n%rif0g&s;.



o7&r op&n %o 6&

inorpora%&! in all

&n%rif0g&s.

Low s*ee( • 3oos& 6&l%. • n&Gi&n% l%ra%ion.

• D&lay&! 6a%h %i4&.

• &% a5& for4a%ion.

• Sp&&! in!ia%ion %o 6&

pro7i!&!.

Wet )ake. • il%&r 6ag ho5ing.


ho5ing.

• D&lay&! 6a%h %i4&.

• #a%&rial loss.

• SOP is a7aila6l& for

0sag& of &n%rif0g&

6ag.

)


22/26

IPCA


HAZOP STUDY


• 3o$ &n%rif0g&

sp&&!.

BeforeAfter

!)har$&n$ (one

,efore start&n$

s*&nn&n$#.

• H04an &rror. • High 7i6ra%ion.

• n&Gi&n% l%ra%ion.

• C&n%rif0g& i46alan&!.

• Di?&r&n% sp&&! s&l&%ion %o

6& pro7i!&! !0ring

harging spinning.

• A0%o4a%ion Iharging 6lo5

7al7& shall op&n only $h&n

&n%rif0g& is a% appropria%&

RP#;.

3&$h /&,rat&on • 4prop&r harging.

• Charging !on&

$i%ho0% s%ar%ingspinning.

• C&n%rif0g&

o7&rloa!.


ho5&!.

• Spar5.

• ir&.

• Da4ag& %o &=0ip4&n%.

• A0%o4a%ion I&n%rif0g&

4o%or shall s%op a% high

7i6ra%ion;.

S*&lla$e !2other

l&0'or#

• #3 a%h po% I#3

%an5; o7&r Fo$.

• #3 %ransf&r p04p

no% $or5ing.

• ir&.

• Sol7&n% loss.

• #a%&rial loss.

•

To+i &?&%.

• SOP is a7aila6l&. • #3 a%h po% apai%y %o 6&

r&7i&$&!.

• 3&7&l ga0g& %o 6& pro7i!&!

%o #3 %an5.

• D04p %an5 %o 6& pro7i!&!

%o s%or& #3 !0ring

&n%rif0ging in as& of #3

p04p fail0r&.

6. A)etone Wash


• rong 4a%&rial

0s&! for $ashing


!&gra!a%ion. No saf&%y

iss0&

.

*/


23/26

IPCA


HAZOP STUDY


S*&lla$e E8*os're•

#an0al a%i7i%y. • #a%&rial loss.• ir&.

• n&Gi&n% $ashing.

• H&al%h haar!.

•PPEs ar& $orn 6yop&ra%ional s%a?.

• SOP on%rol

• Train&! p&rsons

• ir& &+%ing0ish&rs ar&

pro7i!&!.

+r&/e sto* • Po$&r fail0r& • D&lay&! 6a%h %i4&. • DB s&% is a7aila6l&.

4.Cake >nloa(&n$

S*&lla$e • H04an &rror

• #ishan!ling.

• To+i 7apor &+pos0r&. • PPEs IOrgani 7apor

4as5; ar& pro7i!&! %o

op&ra%ional p&rsonn&l.

Also !+a1a$e to

lter )loth#

• Us& of har! %ools

%o srap o0% har!

a5&.

• Clo%h !a4ag&. • @#R pro&!0r& is

a7aila6l&.

• #an0al 7igilan&.

7. /a)''1 (r%&n$

S*&lla$e H04an &rror.

4prop&r

han!ling.

Japor &+pos0r&.

#a%&rial loss.

S0?oa%ion.

PPEs ar& a7aila6l&

%o op&ra%ional

s%a?.

3&$h

Te1*erat're

T&4p&ra%0r&

on%rol sys%&4

fail0r&.

#a%&rial =0ali%y

!&gra!&!.

#a%&rial loss.

ir&.

T&4p&ra%0r&

in!ia%ion is

a7aila6l&.

Low

Te1*erat're

T&4p&ra%0r&

on%rol sys%&4

#a%&rial =0ali%y

!&gra!&!.

T&4p&ra%0r&

in!ia%ion is

*1


24/26

IPCA


HAZOP STUDY


fail0r&. a7aila6l&.

#an0al sa4plingis !on& for

&ns0ring 4ois%0r&

on%&n%.

3&$h low

!(r%&n$ a&r#

No assigna6l&

a0s&.

Po$!&r arry o7&r

$i%h !rying air

LowNo low

!(r%&n$ a&r#

Cho5ing of air

l%&r.

Po$&r fail0r&.

@lo$&r fail0r&.

D&lay&! 6a%h %i4&. #an0al sa4pling

is !on& for

&ns0ring 4ois%0r&

on%&n%.

Less T&1e H04an &rror. High 4ois%0r&

on%&n%.

#an0al sa4pling

is !on& for

&ns0ring 4ois%0r&

on%&n%.

2ore T&1e H04an &rror. D&lay&! 6a%h %i4&. @#R pro&!0r& in-

lin&.

S*&lla$e+'st&n

$.

#an0al a%i7i%y

Poor

ho0s&5&&ping

E+pos0r& %o %o+i

!0s%

PPEs ar& a7aila6l&

%o op&ra%ional

s%a?.

*"


25/26

IPCA


HAZOP STUDY


Work Sheet No. !6#

Work Sheet No. 6

Sta$e No- P'r&)at&on of Dalto*ofren )r'(e !BZB-B#

Pro)ess ste* No

!+es&$n Intent#

P'l/er&Dat&on = ,a$ ll&n$

Pro)ess s', ste*

No-

".

No(e No. ".5." to ".5.5

Ref. P+ 2PCRBZB-B


26/26

IPCA


HAZOP STUDY


S%a%i 60il! P0l7&ria%ion E+plosion in %h&

&=0ip4&n%

Ear%hing - Ni%rog&n

6lan5&%ing $i%h %rip

of p0l7&ri&r on lo$

Ni%rog&n pr&ss0r&.

D0s% oll&%ors E+plosion in %h&

&=0ip4&n%

Nil - #&%alli s%rips in

!0s% oll&%or an!

onn&%&! %o &ar%h

pi%.

@ag lling ir& An%is%a%i 6ags ar&

0s&! in op&ra%ion-

onn&%&! %o 4&%alli

h0%&.

-

-

*(

hazop work sheet zaltoprofen

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