J1237 Asian Paints HAZOP WS

HAZOP WORKSHEET
Project: HAZOP Study for Asian Paints Limited Session Date: 04-12-2019
Section Section/Node
Emulsion Reactor (REA-R401) System. N1
Description: No:
To perform reaction between Pre-emulsion, solvent, catalyst, Surfactant and transfer product to Emulsion
Design
Intermediate. Revision No: 00
Intention:
OP: -, OT: -, DP: -; DT: - (Operating and Design Condition need to be provided here by Asian Paints)
Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:
Ref. Action
Parameter Guideword Deviation Cause Consequence Safeguards S F R Recommendation
No. By
N1.01 Flow Less / No 1. Less / No 1.1. 1.1.1 Delay of 1.1.1.1MES / DCS is 1 4 4

flow of DM Unavailability of reactor batch available to provide a
Preheated DM/ operation. signal for delay.
water
UV DM/ DM
water
1.2 Malfunction 1.2.1 Delay of 1.2.1.1 MES / DCS is 1 3 3
of XV- reactor batch available to provide a
R7424/23/27/26 operation. signal for delay.
closes 1.2.1.2 DCS Indication
inadvertently of XV- R7424/23/27/26
is available
2.Less / No 2.1. Malfunction 2.1.1 Delay of 2.1.1.1 MES / DCS is 1 3 3
flow of Pre- of XV- reactor batch available to provide a
R7462/22/19/20 sequence operation. signal for delay.
emulsion /
surfactant / closes
inadvertently
Description: No:
Design
Intention:
Ref. Action
No. By
catalyst / 2.1.1.2 DCS Indication
solvent of XV- R7462/22/19/20
is available
3.Less / No 3.1. 3.1.1 Delay of 3.1.1.1 MES / DCS is 1 4 4

flow of TBHP Unavailability of reactor batch available to provide a
TBHP sequence operation. signal for delay.
4.Less / No 4.1. Malfunction 4.1.1 Increase in 4.1.1.1 Rupture disc is 4 1 4 4.1.1.1.1 Provide
flow of cooling of TIC-R7401 temperature REA- available. interlock with
water loop R401 causing 4.1.1.2 PT-R7402 is flow transmitter
(Transmitter polymerisation and provided with High R7407/08 to close
malfunction) runway reaction pressure alarm. the inlet valve of Asian
which result in 4.1.1.3 Redundant feeds in case of paints
increase in pressure Temperature low flow
and possible rupture transmitter is provided
of bellows. Loss of
containment to
Description: No:
Design
Intention:
Ref. Action
No. By
environment and 4.1.1.4 Firefighting
possible fire and arrangement is
explosion. Possible available
fatality.
5.Less / No 5.1. Malfunction 5.1.1 Delay in 5.1.1.1 Redundant 2 2 4
flow of LP of TIC-R7401 operation. Temperature
steam loop transmitter is
(Transmitter provided.
malfunction) 5.1.1.2 MES / DCS is
available to provide a
signal for delay.
6.Less / No 6.1. Malfunction 6.1.1 Delay in 6.1.1.1 No flow error 1 4 4
flow from of Pump P-R404 reactor batch will get generated in
reactor REA- transfer operation. DCS.
R401 to R403
6.2. NRV stuck 6.2.1 Delay in 6.2.1.1 PSV-R7401 is 1 4 4
closed reactor batch provided.
transfer operation.
Description: No:
Design
Intention:
Ref. Action
No. By
6.2.2 Pump 6.2.1.2 PS-R7401 is
discharge piping may provided interlock to
pressurise leading to trip the pump in case
leakage from flanges of high pressure.
/ bellow. Loss of 6.2.1.3 No flow error
containment. Human will get generated in
Hazard. DCS and stop the
pump.
7.Less / No 7.1. Malfunction 7.1.1 More vapour 7.1.1.1 DCS Indication 2 3 6 7.1.1.1.1 Provide Asian
flow of cooling of XV-R7442/43 will travel to of XV-R7442/43 is flow switch in Paints
/ Chilled water close scrubber leading to available common inlet line
in HE-R401 inadvertently loss of material. of cooling/chilled
(Whichever is in 7.1.2 Load of vent water and
operation) condenser will provide low flow
increase. alarm.
7.1.1.1.2 Provide
temperature
transmitter in
outlet line of
Description: No:
Design
Intention:
Ref. Action
No. By
liquid outlet from
SEP-R401 and
provide high
temperature
alarm.
8.Less / No 8.1. Malfunction 8.1.1 Temperature in 8.1.1.1 DCS Indication 1 3 3 8.1.1.1.1 Provide Asian
flow of chilled of XV-R7435 reactor will increase. of XV-R7435 is temperature Paints
water in SEP- close Batch cycle time will available transmitter in
R401 inadvertently increase. Delay in outlet line of
operation. liquid outlet from
SEP-R401 and
provide high
temperature
alarm.
9.Tube / piping 9.1. Tubes of 9.1.1 Level will 9.1.1.1 Periodic 4 2 8 9.1.1.1.1 PT-
choked HE- condenser HE- increase in maintenance and R7402 shall be Asian
R401 R401 choked / condenser and inspection. provided with paints
liquid outlet U vapour line will interlock at high
Description: No:
Design
Intention:
Ref. Action
No. By
tube / line blocked result in 9.1.1.2 PT-R7402 is high pressure to
choked increase in reactor provided with alarm close the inlet
pressure. Possible 9.1.1.3 Rupture disc is valve of feeds.
bellow may leak available.
causing loss of 9.1.1.4 Hazardous area
containment. classification is
Possible fire and available.
explosion
N1.02 Flow More 1.More 1.1 Malfunction 1.1.1 Level will 1.1.1.1 WIT-7403 is 1 3 3 1.1.1.1.1 Consider
flow/quantity of XV- increase in reactor provided with interlock providing level
to close the all XVs in transmitter with
of DM water R7424/23/27/26 resulting in flooding
feed lines of Reactor interlock to close
open in scrubber. Loss of REA-R401 in case of the all XVs in feed Asian
inadvertently production. high high load lines of Reactor paints
1.1.1.2 DCS Indication REA-R401 in case
of XV-R7424/23/27/26 of high high level.
is available
2.More 2.1 Malfunction 2.1.1 No significate

quantity/ flow of XV- consequence
Description: No:
Design
Intention:
Ref. Action
No. By
of Pre- R7462/22/19/20 identified as quantity
emulsion / open is limited.
surfactant / inadvertently
catalyst /
solvent
3.More flow/ 3.1 Not a

quantity of credible
TBHP scenario
identified
4. More flow 4.1. Malfunction 4.1.1 Reduced 4.1.1.1 MES / DCS will 1 3 3
of cooling of TIC-R7401 temperature in monitor the
water loop reactor may lead to temperature and close
(Transmitter delay in reactor ON-OFF valve of
malfunction) batch operation. cooling and chilling per
the formulation.
5.More flow of 5.1. Malfunction 5.1.1 High 5.1.1.1 Rupture disc is 2 2 4 5.1.1.1.1 Consider
Asian
LP steam of TIC-R7401 temperature in available on reactor Providing
paints
loop reactor may lead to interlock with
Description: No:
Design
Intention:
Ref. Action
No. By
(Transmitter water vaporisation 5.1.1.2 Redundant Pressure
malfunction) increase in pressure temperature transmitter
may lead to rupture transmitter is available R7402 to close
in bellow. Human the inlet XV
hazard. valves of steam in
case of high
pressure.
6.More flow 6.1. Not a

from reactor credible
REA-R401 to scenario.
R403
7.More flow of 7.1. Not a

cooling / credible
Chilled water scenario.
in HE-R401
Description: No:
Design
Intention:
Ref. Action
No. By
8.More flow of 8.1. Not a

chilled water credible
in SEP-R401 scenario.
N1.03 Flow Reverse 1. Not a credible

Flow scenario.
N1.04 Flow Other 1.During 1.1. Malfunction 1.1.1. Product will go 1.1.1.1 Interlock is 2 2 4
than/ product of XV-R7432 to DMT-R401 (Batch provided that only one
open
misdirected transfer from waste) XV (out of XV-R7432
inadvertently
REA-R401 to and XV-R7433) will be
R403 open at a time
1.1.1.2.DCS Indication
of XV-R7432 is
available
N1.05 Pressure High 1.High 1.1 Refer

Pressure in N1.01.4 & 9 And
N1.02.5
REA-R401
Description: No:
Design
Intention:
Ref. Action
No. By
1.2 Malfunction 1.2.1 Increase in 1.2.1.1 Rupture disc is 4 2 8 1.2.1.1.1 PT- Asian
of XV-R7464 reactor pressure. available. R7402 shall be paints
closed Possible bellow may 1.2.1.2 PT-R7402 is provided with
inadvertently leak causing loss of provided with high
containment. interlock at high
pressure alarm.
Possible fire and high pressure all
1.2.1.3 DCS Indication
explosion. the inlet XV
of XV-R7464 is
available valves will close.
1.2.1.4 Hazardous area

classification is
available.
2.High 2.1. Cooling / 2.1.1 Pressure will 2.1.1.1 PSV- 1 3 3 2.1.1.1.1 Ensure Asian
pressure in chilled trap increase in cooling / R7402/03/04/05/08/09 that PSV set Paints
between chilling water line
Cooling / is available. pressure as per
isolation valve leading to leakage
chilled water through flanges and the design to
line in reactor bellows. protect the
piping.
3.High 3.1. Cooling / 3.1.1 Pressure will 3.1.1.1 PSV-R7407 is 1 3 3 3.1.1.1.1 Ensure Asian
pressure in chilled trap increase in cooling / available. that PSV set Paints
Description: No:
Design
Intention:
Ref. Action
No. By
Cooling / between chilling water line pressure as per
chilled water isolation valve leading to leakage the design to
through flanges.
line in HE- protect the
R401 piping.
4.High 4.1. Cooling trap 4.1.1 Pressure will 4.1.1.1 PSV-R7406 is 1 3 3 4.1.1.1.1 Ensure Asian
pressure in between increase in cooling available. that PSV set Paints
isolation valve water line leading to
Cooling water pressure as per
leakage through
jacket in line flanges. the design to
from reactor protect the
REA-R401 to piping.
HE-R401
N1.06 Pressure Low 1.Low 1.1 Malfunction 1.1.1 During product 1.1.1.1 Pump will start 4 2 8 1.1.1.1.1 PT-
Pressure in of XV-R7463 transfer to R403 low only if XV-R7403 is R7402 shall be
closed pressure will open. provided with
REA-R401
inadvertently. observed in reactor 1.1.1.2 Hazardous area interlock at low Asian
REA-R401 leading to classification is low-pressure to paints
damage of bellows. available. trip the pump P-
Loss of containment R404.
to environment.
Description: No:
Design
Intention:
Ref. Action
No. By
Possible fire and
explosion.
N1.07 Temperature High 1.High 1.1 Refer
Temperature N1.01.4 & 8 And
N1.02.5
in REA-R401
N1.08 Temperature Low 1.Low 1.1 Refer

Temperature N1.02.4
in REA-R401
N1.09 Level High level 1.High level in 1.1 Refer

REA-R401 N1.01.9 and
N1.02.1
N1.10 Level Low level 1.Low level in 1.1 Malfunction 1.1.1 Low low-level 2 3 6 1.1.1.1.1 Low Asian
REA-R401 of WT-R7403 lead to dry run of pressure alarm paints
(pump is pump. Pump may and Interlock
running) damage. shall be provided
on PT-R7402 to
Description: No:
Design
Intention:
Ref. Action
No. By
trip the pump P-
R404
N1.11 Composition 1.1 Not a

credible
scenario.
N1.12 Start-up / 1.1 Not a
shut down significant
hazard
N1.13 Corrosion/ 1.1 Not a
credible
Erosion
scenario.
N1.14 Drawing 1. NA
Errors
N1.15 Others Agitator 1.1 Malfunction 1.1.1 Improper 1.1.1.1 Periodic 4 2 8 1.1.1.1.1 Agitator Asian
of Agitator mixing may lead to maintenance and running feedback paints
localized reaction inspection. shall be provided
causing increase in on DCS and
temperature and interlock is
Description: No:
Design
Intention:
Ref. Action
No. By
run-away reaction 1.1.1.2 Rupture disc is provided to close
leading to pressure available. all inlet valve of
increase in reactor 1.1.1.3 Hazardous area the feeds to
resulting possible classification is Reactor REA-R401
fire and explosion. available. if agitator is not
Human hazard. running.
1.1.1.4 PT-R7402 is
provided with high 1.1.1.1.2 PT-
pressure alarm R7402 shall be
provided with
interlock at high
high pressure all
the inlet valves of
feed to reactor
REA-R401 will
close.
1.2. Agitator 1.2.1 Agitator blade 1.2.1.1 Preventive 4 2 8 1.2.1.1.1 PT-
blade loosen up may hit to wall which maintenance is in R7402 shall be
placed provided with
Description: No:
Design
Intention:
Ref. Action
No. By
may lead to fire and 1.2.1.2 Rupture disc is interlock at high
explosion. provided on reactor high pressure all
1.2.2 Improper REA-R401. the inlet valves of
mixing may lead to 1.2.1.3 PT-R7402 is feed to reactor
localized reaction provided with high REA-R401 will
causing increase in pressure alarm. close.
temperature and 1.2.1.1.2 low
run-away reaction current indication
leading to pressure and alarm shall
increase in reactor be provided on
resulting possible DCS and interlock
fire and explosion. to hold the
Human hazard. sequence
Static 2.1 Static charge 2.1.1 Static charge 2.1.1.1 Earthing and 4 2 8 2.1.1.1.1 Asian
charge generation in may lead to fire and bonding is provided. Conductive and paints
REA-R401
explosion in case of 2.1.1.2 J-bend is single-phase
flammable provided in Reactor medium
REA-R401 conductivity
Description: No:
Design
Intention:
Ref. Action
No. By
atmosphere is 2.1.1.3 Rupture disc is liquids: A
present. provided on reactor maximum flow
REA-R401. velocity of 7 m/s
2.1.1.4 Area is is recommended
classified. 2.1.1.1.2
2.1.1.5 Firefighting Contaminated or
arrangement is two-phase
available. medium or low
conductivity
liquids: A
maximum flow
velocity of 1 m/s
is recommended
Transfer Ammonia from SOV-749 and store in BT-407 N2
Description: No:
Design Transfer Ammonia from SOV-749 and store in BT-407

Revision No: 00
Intention: OP: Atmospheric, OT: Ambient, DP: ; DT: (Design Condition need to be provided here by Asian Paints)
Drawings No.: 3-APL-PSLY-18039 Rev 04 Revision Date:
Ref. Action
No. By
N2.01 Flow Less / No 1 Less or No 1.1 1.1.1. No availability of 1.1.1.1 DCS indication of 1 3 3
flow of Malfunction of Ammonia may lead to XV is available.
Ammonia from R4_XV-590261 upset in downstream. 1.1.1.2 R4_LS-590260 is
SOV-749 to BT- (Closed). available.
407.
1.2 Pump of 1.2.1. No availability of 2.1.1.1 MES/ DCS 1 4 4
SOV-749 Ammonia may lead to Control system is
malfunctioned. upset in downstream. available which will hold
the sequence in case of
no flow.
2.1.1.2 R4_LS-590260 is
available.
2 Less or No 2.1 2.1.1 Delay is 2.1.1.1 R4_LS-590260 is 1 3 3
flow of Malfunction of Operation. available.
Ammonia from R4_XV-XXXXXX 2.1.1.2 R4_WT7102
BT-407 to PET- (Closed). /WT7107 are provided
401/402. in PET 401/2.
2.1.1.3 DCS indication of
R4_XV-XXXXXX is
available.
Description: No:

Revision No: 00
Ref. Action
No. By
N2.02 Flow More 1 More Flow/ 1.1 1.1.1 Level/Pressure 1.1.1.1 R4_LS-590261 is 2 2 4
Quantity from Malfunction of will increase in Vessel available.
Ammonia to R4_XV-590261 BT-407. Possible 1.1.1.2 PPEs are
BT-407. (Open). leakage/overflow. available.
Human Health Hazard.
1.1.1.3 DCS indication of
R4_XV-590261 is
available.
1.1.1.4 Vent to scrubber
is available.
N2.03 Flow Reverse Not a Credible
Flow Scenario
N2.04 Flow Other than/ 1 Wrong 1.1 1.1.1 Deterioration of 1 4 4

misdirected Vessel (27 Lt Malfunction of Product quality.
Vessel to PET- any of R4_XV-
1/2) Line Up. XXXXX1/2.
N2.05 High 1 High 1.1 1.1.1 During Ammonia 1.1.1.1 PPEs are 3 3 6 1.1.1.1.1 Provide
Pressure
Pressure in BT- Malfunction of intake pressure will available. Pressure
Asian
407. R4_XV-590260 increase in BT-407. 1.1.1.2 DCS indication of transmitter
R4_XV-590260 is Paints
(Closed). Possible leakage /switch on BT-407
through flange. available.
and interlock in
Description: No:

Revision No: 00
Ref. Action
No. By
Human Health case of high
Hazards. pressure in BT-
407 Pump SOV-
749 will trip.
N2.06 Pressure Low 1 Low Pressure Not a Credible

in BT-407. Scenario.
N2.07 Temperature High 1 High temp in Not a Credible
BT-407. Scenario.
N2.08 Temperature Low 1 Low temp in Not a Credible
BT-407. Scenario.
N2.09 Level High level 1 High level in Refer N2.02.1
BT-407.
N2.10 Level Low level 1 Low Level in NFH

PET R-419.
N2.11 Composition 1 Off spec. Not a credible

Scenario.
Description: No:

Revision No: 00
Ref. Action
No. By
N2.12 Start-up / NFH

shut down
N2.13 Corrosion/ NFH

Erosion
N2.14 Drawing 1.1.1.1.1 Update

Errors the P&ID with
Associated Tag Asian
No’s and Paint
Equipment Tile
Block
Section
To prepare pre emulsion and transfer to the reactor (R-401) Section/Node No: N3
Description:
To prepare pre emulsion and transfer to the reactor (R-401)

Design Intention: Revision No: 00
OP: Atmospheric, OT: Ambient, DP: ; DT: (Design Condition need to be provided here by Asian Paints)
Drawings No.: 3-APL-PSLY-18039 Revision Date:
Ref. No. Parameter Guideword Deviation Cause Consequence Safeguards S F R Recommendation Action By
N3.01 Flow Less / No 1 Less or No flow 1.1 Pump 1.1.1 Product Degradation, 1.1.1.1 MES/ DCS 2 2 4
from Existing R4_PG86118 No safety concern. Control system is
GMA Tank to PET malfunctioned. available which will hold
R-419. the sequence in case of
no flow.
1.2 Strainer 1.2.1 Product Degradation, 1.2.1.1 MES/ DCS 2 3 6 1.2.1.1.1 Review Asian Paint
Chocked. Pump may run dry, seal Control system is the requirement
may leak, loss of available which will hold
of Pressure
containment may lead to the sequence in case of
human health hazard. no flow. Switch/
1.2.1.2 Flow Switch is Transmitter and
present R4_FS8618 Provide Low
which will trip the pump pressure trip of
in case of Low Flow. Pump.
1.2.1.1.2
Providing
differential
pressure
transmitter across
the strainer.
1.3 NRV Stuck 1.3.1 Product Degradation, 1.3.1.1 MES/ DCS 2 2 4
Closed. Pump may run in blocked Control system is
Section
Description:

in condition, seal may leak available which will hold
and loss of containment the sequence in case of
may lead to human health no flow.
hazard. 1.3.1.2 Flow Switch is
present R4_FS8618
which will trip the pump
in case of low Flow.
1.4 Malfunction 1.4.1 Product Degradation, 1.4.1.1 MES/ DCS 2 2 4

of R4_XV590236. Pump may run in blocked Control system is
in condition, seal may leak available which will hold
and loss of containment the sequence in case of
may lead to human health no flow.
hazard. 1.4.1.2 Flow Switch is
present R4_FS8618
which will trip the pump
in case of low Flow.
1.5 Material 1.5.1 Pump Impeller may 1.5.1.1 Thermal 2 4 8 1.5.1.1.1 Consider Asian
Freezing in line damage/ Coupling may Insulation is provided on adequacy check Paints
due to low break due to material piping.
for heat tracing
temperature (in freezing in the casing of 1.5.1.2 Heat tracing is
Winter). the pump and no flow to providing on piping.
Section
Description:

the PET R-419 will delay 1.5.1.3 Provision is and thermal
the operation. available on Existing insulation.
1.5.2 Material freezing in GMA tank to maintain
Suction line may lead to the temperature of the
pump dry run, seal may material inside the tank.
damage, loss of 1.5.1.4 Pump Overload
containment leading to protection is available.
human health hazard.
1.5.3 Material freezing in
discharge line may lead to
pump dry run, seal may
damage, loss of
containment leading to
human health hazard.
2 Less or No flow Refer 3.01,
from Existing MA Similar to Less or
Tank to PET R- No flow from
419. Existing GMA
Tank to PET R-419
Vessel.
3 Less or No flow 3.1 Pump 3.1.1 Product Degradation, 3.1.1.1 MES/ DCS 2 2 4
from Existing (R4_PG86108) No safety concern. Control system is
MMA Tank to PET malfunctioned. available which will hold
Section
Description:

R-419. the sequence in case of
no flow.
3.2 Strainer 3.2.1 Product Degradation, 3.2.1.1 MES/ DCS 4 2 8 3.2.1.1.1 Review Asian Paint
Chocked. Pump may run dry, seal Control system is the requirement
may leak, loss of available which will hold
of Pressure
containment, human the sequence in case of
health hazard, Possible no flow. Switch/
fire. 3.2.1.2 Flow Switch is Transmitter and
present R4_FS-8611 Provide Low
3.2.1.1.2
Providing
differential
pressure
transmitter across
the strainer.
3.3 NRV Stuck 3.3.1 Product Degradation, 3.3.1.1 MES/ DCS 4 2 8 3.3.1.1.1 Review Asian
Closed Pump may run in blocked Control system is the requirement Paints
in condition, seal may available which will hold
of Pressure
leak, loss of containment, the sequence in case of
human health hazard, no flow. Switch/
Section
Description:

Possible fire. 3.3.1.2 Flow Switch is Transmitter and
present R4_FS-8611 Provide High
3.4 Malfunction 3.4.1 Product Degradation, 3.4.1.1 MES/ DCS 4 2 8 3.4.1.1.1 Review Asian
of Valve Pump may run in blocked Control system is the requirement Paints
(R4_XV590237). in condition, seal may available which will hold
of Pressure
leak, loss of containment, the sequence in case of
human health hazard, no flow. Switch/
Possible fire. 3.4.1.2 Flow Switch is Transmitter and
present R4_FS-8611 Provide High
4 Less or No flow Refer 3.01,

from Existing BA Similar to Less or
Tank to PET R-419 No flow from
Vessel. Existing GMA
Tank to PET R-419
Vessel.
5 Less or No Flow 5.1 Valve 5.1.1 Product Degradation. 5.1.1 MES/ DCS Control 2 2 4
Section
Description:

of Water in PET R- (R4_XV590234) system is available which
419. Malfunctioned will hold the sequence in
(Closed). case of no flow.
6 Less or No Flow 6.1 Valve 6.1.1. Reaction is 6.1.1.1 Temperature 3 2 6

of Cooling Water (R4_XV590242) exothermic in PET R-419 transmitter
in PET R-419. Malfunctioned due to loss of cooling (R4_TT590232/ 590233)
(Closed). water will lead to reaction is available with high
exotherm result in over temp alarm and
pressurization and interlock to lineup
increase in temperature chilled water.
in tank, possible leakage
through flanges/ gasket of
the tank may lead to loss
of containment in
environment, Possible fire.
7 Less or No Flow 7.1 Pump (PR- 7.1.1 Less or no flow of 7.1.1.1 MES/ DCS 2 4 8
from PET R-419 to 419A/B) pre emulsion will lead to Control system is
R-401. Malfunctioned. process delay. available which will give
Indication in DCS
through load cell value in
PET R-419 and R-401 in
case of no flow.
Section
Description:

7.1.1.2 Stand by pump is

available.
7.1.1.3 SOP is available
for pump Flushing with
water after each batch
transfer.
7.2 Strainer 7.2.1 Less or no flow of 7.2.1.1 SOP is available 2 4 8
Chocked. pre emulsion will lead to for strainer cleaning on
process delay. periodic basic.
7.3 NRV Stuck 7.3.1 Pump will run-in 7.3.1.1 Safety valve is 3 2 6
Closed. blocked-in condition, high provided on pump
pressure will lead to discharge line.
leakage through flanges
may lead to pipe rupture,
Possible Fire.
N3.02 Flow More 1 More Flow/ 1.1 Malfunction 1.1.1 Quality degradation 1.1.1.1 Due to 2 3 6
Quantity from of R4_ WT590232 of the product. malfunction of weight
Existing GMA (Load / weight Indicator whole
Tank to PET R-419 Indicator). sequence will stop
Vessel. through DCS.
1.2 Malfunction 1.2.1 Operational Delay, 1.2.1.1 MES/DCS is 2 2 4
of R4_XV-590236. Product degradation. available to stop the
Section
Description:

pump and close the
pump discharge
R4_XV86119.
2 More flow from Refer N3.02,
Existing MA Tank More Flow/
to PET R-419 Quantity from
Vessel Existing GMA
Tank to PET R-419
Vessel.
Existing BA Tank More Flow/
to PET R-419 Quantity from
Tank to PET R-419
Vessel.
Existing MMA More Flow/
Tank to PET R-419 Quantity from
Tank to PET R-419
Vessel.
5 More Flow of Refer N3.02,
Water in PET R- More Flow/
Section
Description:

419. Quantity from
Existing GMA
Tank to PET R-419
Vessel.
6 More Flow of NFH
Cooling Water in
PET R-419.
7 More Flow from 7.1 Malfunction 7.1.1 Due to excess flow of 7.1.1.1 Cooling and 2 3 6 7.1.1.1.1 Provide Asian
PET 419 to R-401. of R4_ WT590232 pre emulsion in the Chilling arrangement on Flow Transmitter Paints
(Load / Weight reactor will lead low the reactor R-401 to
on Pump
Indicator) temperature in reactor control the exotherm.
leading to slowdown of discharge line and
7.1.1.2 Temp
reaction and accumulation interlock with
Transmitter is provided
of unreacted material. on the reactor and pump VFD and
Subsequently while mixing interlock in case of high provide high flow
this unreacted material temp in reactor, pump alarm.
will lead to possible PMP-A1/A2 will trip.
exotherm results in over
7.1.1.4 Pressure
pressurization and
possible leakage through
on the reactor and
flanges.
interlock in case of high
temp in reactor, pump
PMP-A1/A2 will trip.
Section
Description:

7.1.2 Due to excess flow of 7.1.2.1 Temp 4 1 4 7.1.2.1.1 Provide Asian
pre emulsion in the Transmitter is provided additional PRV on Paints
reactor will lead low on the reactor and
reactor which is
temperature in reactor interlock in case of high
leading to slowdown of temp in reactor, pump able to handle
reaction and accumulation PMP-A1/A2 will trip. reactor
of unreacted material. 7.1.2.2 Pressure emergency vent
Subsequently while mixing Transmitter is provided relief.
this unreacted material on the reactor and 7.1.2.1.2 Provide
will lead to possible interlock in case of high Flow Transmitter
exotherm results in over temp in reactor, pump
pressurization and on Pump
possible rupture of the discharge line and
7.2.1.3 Rupture Disk is
reactor, loss of interlock with
Provided
containment and fatality. pump VFD and
provide high flow
alarm.

Flow Scenario
N3.04 Flow Other than/ 1 Unintended 1.1 Isolation 1.1.1 Excess material/ 3 3 9 1.1.1.1.1 Asian
misdirected material in PET R- valves of any of Unintended material will Appropriate Paints
419. the inlet line is lead to product
method for
Section
Description:

passing/leakage. degradation and overflow detection of valve
of the material through passing shall be
Man hole / local vent of
considered
the PET R-419, Loss of
Containment, Possible fire (Acoustic
and Human hazard. detection /
Infrared
/Ultrasound
detection)
N3.05 Pressure High 1 High Pressure in 1.1 Wrong 1.1.1 PET R-419 will be 1.1.1.1 SOP for Valve 3 3 9 1.1.1.1.1 Provide
PET R-419. feedback of overpressure possible Maintenance Handover. PT on PET R-419
R4_XV590233 leakage through flanges, and Interlock in
(Valve actually loss of containment, case of high Asian
closed but Possible fire and Human pressure Paints
sending open hazard. respective
signal to DCS). running pump will
trip.
N3.06 Pressure Low 1 Low Pressure in 1.1 Malfunction 1.1.1 Pressure will 3 3 9 1.1.1.1.1 Provide
PET R-419. of R4_XV590232. decrease in PET R-419 PT on PET R-419 Asian
during material transfer to and Interlock in Paints
rector R-401, Possible case of low
Section
Description:

Buckling of the tank will pressure transfer
lead to loss of PMP-A1/A2 pump
containment, fire and will trip.
health hazard.
N3.07 Temperatu High 1 High temp in Refer N.3.01, Less
re PET R-419. or No Flow of
Cooling Water in
PET R-419
(Deviation-6).
N3.08 Temperatu Low 1 Low temp in NFH
re PET R-419.
N3.09 High level 1 High level in PET 1.1 Malfunction 1.1.1 Overflow of the 1.1.1.1 R4_LS590232 is 3 2 6
Level
R-419. of R4 material through available which will close
_WT590232. Manhole, loss of all the inlet XVs.
containment, fire and
health hazard.
N3.10 Level Low level 1 Low Level in PET NFH

R-419.
Section
Description:


Scenario
2 Wrong Material 2.1 Other/ 2.1.1 Off spec will affect 2.1.1.1 DCS Indication of 3 2 6
Line Up. Unintended the product quality and XV is available and
material inlet XV material will overflow interlock is provided that
malfunction through manhole, loss of if more than one valve is
(open). containment, fire and open sequence will be
health hazard. hold.
2.1.1.2 R4_WT590232 is
provided with interlock
with High High Weight to
hold the sequence.
2.1.1.3 R4_LS590232 is
provided with interlock
with High High Level to
hold the sequence.
2.1.1.4 HAC is available.
Section
Description:

2.1.1.5 Fire Fighting
System is available

shut down

Erosion

Associated Tag
Asian Paint
No’s and
Equipment Tile
Block
N3.15 Others 1 Agitator 1.1 Agitator 1.1.1 Improper mixing will 1.1.1.1 Cooling and 2 3 6
Malfunction. lead to phase separation Chilling arrangement on
in PET R-419 and the reactor R-401 to
subsequently abnormal control the exotherm.
reaction reactor R-401, 1.1.1.2 Temp
will lead to possible Transmitter is provided
exotherm results in over on the reactor and
pressurization and interlock in case of high
Section
Description:

possible leakage through temp in reactor, pump
flanges. PMP-A1/A2 will trip.
1.1.1.3 Pressure
on the reactor and
1.1.1.4 Interlock is
provided if agitator is
stopped working for
estimated time period
(Calculated based on
Process phase
separation) then whole
transfer sequence will be
under hold condition
1.2 Agitator 1.2.1 Improper mixing will 1.2.1.1 Cooling and 2 2 4
Decoupled. lead to phase separation Chilling arrangement on
in PET R-419 and the reactor R-401 to
subsequently abnormal control the exotherm.
reaction reactor R-401, 1.2.1.2 Temp
will lead to possible Transmitter is provided
Section
Description:

exotherm results in over on the reactor and
pressurization and interlock in case of high
possible leakage through temp in reactor, pump
flanges. PMP-A1/A2 will trip.
1.2.1.3 Pressure
on the reactor and
1.2.1.4 Low Current
interlock is provided to
hold transfer sequence.
1.3 Agitator Blade 1.3.1 Loose Agitator 4 2 8
Loosen up. Blade/ Bolts may strike on
Vessel wall / bottom and
create spark which will
result in fire and explosion
in presence of flammable
mixture inside the PET R-
419.
Section Material transfer in PET 401/2 through Storage Tank, Catalyst preparation Vessel R-403 and discharge into PET
Section/Node No: N4
Description: 401/2.
Material transfer in PET 401/2 through Iso Octane Storage Tank ST-R410, Catalyst preparation Vessel R-403 and
Design Intention: discharge into PET 401/2. Revision No: 00
OP: Atmospheric , OT: Ambient, DP:; DT: (Design Condition need to be provided here by Asian Paints)
Drawings No.: 4-APL-PSLY-18039 Rev No. 04 Revision Date:
N4.01 Flow Less / No 1 Less or No flow 1.1 Malfunction 1.1.1 Delay in the process. 1.1.1.1 R4_WT-90251 is 1 3 3
from 27 Lt Vessel of R4_XV590254. provided in 27 Lt Vessel.
to PET-1/2. 1.1.1.2 R4_WT7102
/WT7107 are provided in
PET 401/2.
2 Less or No flow 2.1 Malfunction 2.1.1 Delay in the process. 2.1.1.1 R4_WT-90251 is 1 3 3
from Vess R-403 of R4_XV590258. provided in 27 Lt Vessel.
to PET-1 /2. 2.1.1.2 R4_WT7102
/WT7107 are provided in
PET 401/2.
3 Less or No flow 3.1 Malfunction 3.1.1 Delay in catalyst 3.1.1.1 R4_WT590257 is 1 3 3
of Water in Vess of R4_XV590257. preparation. provided in Vess R-403.
R-403 (Closed). 3.1.1.2 R4_WT7102/WT-
7107 are provided in PET
401/2.
N4.02 Flow More 1 More Quantity Not a Credible
from 27 Lt Vessel Scenario
to PET-1/2.
2 More Quantity Not a Credible
from Vess R-403 Scenario
to PET-1 /2.
Section/Node No: N4
Description: 401/2.
3 More Quantity 3.1 Malfunction 3.1.1 Level will increase in 1 3 3
of Water in Vess of R4_XV590257. Vess R-403 and material
R-403 will overflow through
Manhole, possible slip and
trip injury.
Flow Scenario
N4.04 Flow Other than/ 1 Wrong Vessel 1.1 Malfunction 1.1.1 Deterioration of 1 4 4
misdirected (27 Lt Vessel to of any of Product quality.
PET-1/2) Line Up. R4_XV590264/59
0267.
1 Wrong Vessel 1.1 Malfunction 1.1.1 Deterioration of 1 4 4
(Ves-503 to PET- of any of Product quality.
1/2) Line Up. R4_XV590264/59
0267.
N4.05 Pressure High 1 High pressure in Not a Credible
Vess R-403. Scenario.
2 High pressure in Prefer Node 3.05
PET-1/2. High Pressure in
PET R-419.
Section/Node No: N4
Description: 401/2.
N4.06 Pressure Low 1 Low pressure in Not a Credible

Vess R-403. Scenario
2 Low pressure in Prefer Node 3.06
PET-1/2 Low Pressure in
PET R-419.
N4.07 Temperatu High 1 High Temp in Not a Credible
re Vess R-403. Scenario
2 High Temp in Prefer Node 3.07

PET 401/2. High temp in PET
R-419.
N4.08 Temperatu Low 1 Low Temp in Not a Credible
re Vess R-403. Scenario
2 Low Temp in NFH

PET 401/2.
N4.09 Level High level 1 High Level in Prefer Node 3.09
Vess R-403. High level in PET
R-419.
Section/Node No: N4
Description: 401/2.
2 High level in PET Prefer Node 3.09

401/2. High level in PET
R-419.
N4.10 Level Low level Not a Credible

Scenario
N4.11 Composition Prefer Node 3.11

Off spec.

shut down

Erosion

Errors the P&ID with Asian Paint
Associated Tag
Section/Node No: N4
Description: 401/2.
No’s and
Equipment Tile
Block
Section
ISO OCTANE Tank System Section/Node No: N5
Description:
To Unload ISO OCTANE From Tanker to ISO OCTANE Tank (ST-R410) and Transfer ISO OCTANE to PET 401 and PET
Design Intention: 402. Revision No: 00
OP: Atmospheric, OT: Ambient. DP- , DT-:(Design Condition need to be provided here by Asian Paints)
N5.01 Flow Less / No 1 Less or No flow 1.1 Malfunction 1.1.1 Delay in transfer 1.1.1.1 Stand by Pump. 1 4 4
from Tanker to of Pump Operation.
ISO OCTANE Tank R4_PR4051U.
(ST R-410).
1.2 Malfunction 1.2.1 No Significant
of R4_XV830053 Consequences as
another XV, R4_XV-
(Open).
830055 is present
(Closed).
1.3 Strainer 1.3.1 Dry run of Pump 1.3.1.1 Flow Switch is 4 2 8 1.3.1.1.1 Review Asian Paint
Chocked. may lead to seal damage present R4_FS830051
the requirement of
causing loss of which will trip the pump
containment, possible in case of Low Flow. Pressure Switch/
fire which may lead to 1.3.1.2 HAC is Available. Transmitter and
fatality. 1.3.1.3 Firefighting Provide Low
system is available. pressure trip of
Pump.
1.3.1.1.2 Providing
differential
pressure
Section
Description:
transmitter across
the strainer.
1.4 NRV Stuck 1.4.1 Pump will run in 1.4.1.1 Flow Switch is 4 2 8 1.4.1.1.1 Review Asian
Closed blocked condition, present R4_FS830051
the requirement of Paints
temperature will which will trip the pump
(Discharge). Pressure Switch /
Increase, Possible in case of Low Flow.
leakage of seal may lead 1.4.1.2 HAC is Available Transmitter and
loss of containment and 1.4.1.3 Firefighting Provide High
fire which may lead to system is available. pressure trip of the
fatality. Pump.
1.5 Malfunction 1.5.1 Delay in transfer 1.5.1.1 R4_LT830051 is 1 3 3
of R4_XV_830051 Operation. provided to monitor the
level in ST-R401.
(Open).
5.1.1.2 R4_XV_830051
which will trip whole
unloading sequence.
Low 2 Less or No flow 2.1 Malfunction 2.1.1 Delay in transfer 2.1.1.1 Stand by Pump. 1 4 4
Flow
From ISO OCTANE of Pump Operation.
Tank (ST R-410) to R4_PR4051A.
Plant.
Section
Description:
2.2 Malfunction 2.2.1 Dry run of Pump 2.2.1.1 Flow Switch is 4 2 8 2.2.1.1.1 Review Asian Paint
of R4_XV830051 may lead to seal damage present R4_FS830052
the requirement of
(Closed). causing loss of which will trip the pump
fire which may lead to Transmitter and
fatality. Provide Low
pressure trip of
Pump.
2.2.1.1.2 Providing
differential
pressure
transmitter across
the strainer.
2.3 Strainer 2.3.1 Dry run of Pump 2.3.1.1 Flow Switch is 4 2 8 2.3.1.1.1 Review Asian Paint
Chocked. may lead to seal damage present R4_FS830052
the requirement of
causing loss of which will trip the pump
fire which may lead to 2.3.1.2 HAC is Available Transmitter and
fatality. 2.3.1.3 Firefighting Provide Low
system is available pressure trip of
Pump.
Section
Description:
2.3.1.1.2 Providing
differential
pressure
transmitter across
the strainer.
2.4 NRV Stuck 2.4.1 Pump will run in 2.4.1.1 Flow Switch is 4 2 8 2.4.1.1.1 Review Asian
Closed. blocked condition, present R4_FS830052
the requirement of Paints
temperature will which will trip the pump
Increase, Possible in case of Low Flow. Pressure Switch /
leakage of seal may lead Transmitter and
loss of containment and Provide High
fire which may lead to pressure trip of the
fatality. Pump.
2.5 Malfunction 2.5.1 Pump will run in 2.5.1.1 Flow Switch is 4 2 8
of R4_XV83055 blocked condition, present R4_FS830052
(Closed). temperature will which will trip the pump
Increase, Possible in case of Low Flow.
leakage of seal may lead 2.5.1.2 R4_WT590251/
loss of containment and R4_WT7102/ 7107 is
fire which may lead to available if level will not
fatality. Also Level in 27 increase in selected
Section
Description:
Lt Tank/ PET R-401, 4022 Tank, whole sequence
will not Increase. will hold.
3 Less or No Flow 3.1 NRV Stuck 3.1.1 Vessel will observe 3.1.1.1 Dyke is provided. 4 1 4
of Nitrogen in ISO Closed. Low Pressure during 3.1.1.2 Area is classified.
material transfer from 3.1.1.3 Fire Fighting
OCTANE Tank (ST
ISO OCTANE Tank to Arrangement is
R-410). Plant, Possible Bucking available.
of the tank may lead to 3.1.1.4 Breather Valve is
loss of Containment to provided to avoid low
environment, possible pressure inside the tank.
fire. Pump may Damage
due to Cavitation.
4 Less or No Flow 4.1 HE Tube 4.1.1 Not a Credible
ISO OCTANE in Chocked. Scenario as IO OCTANE is
Clean Fluid.
Vent Condenser.
N5.02 Flow More 1 More Flow of Not a Credible

ISO OCTANE From Scenario.
Tanker to Tank
(ST R-410).
Section
Description:
2 More Flow of Not a Credible
ISO OCTANE From Scenario.
Tank (ST R-410) to
Plant.
3 More Flow of 3.1 Malfunction 3.1.1 Tank will get 3.1.1.1 Breather valve is 4 2 8 3.1.1.1.1 Provide
Nitrogen to ST R- of Nitrogen pressurised, Possible available.
PT/PS with High Asian
Leakage from Tank/
410 Regulator (Fully Pressure Alarm and Paints
Flanges. Fire also it may
Open). lead to fatalities. Operator Action.
N5.03 Flow Reverse 1 Reverse Flow Not a Credible

from ISO OCTANE Scenario.
Tank (ST R-410) to
Tanker.
2 Reverse Flow NFH.
From Plant to ISO
OCTANE Tank.
N5.04 Flow Other than/ 1 Misdirected 1.1 Not Credible
misdirected Flow to Plant Scenario as three
while Unloading XV’s
Tanker to ISO (R4_XV830053,
Section
Description:
Octane Tank (ST R4_XV83055 and
R-410). R4_XV590251)
are available in
closed condition.
2 Misdirected 2.1 Human Error. 2.1.1 Material Overflow 2.1.1.1 SOP Is available 1 2 2
flow due to through Unloading Pot, for Unloading Procedure
Manual Valve
Possible Spillage of ISO 2.1.1.2 Spill Kit is
(HV-C3) Open
while Unloading OCTANE and Health Available
from tanker to Hazard.
2.1.1..3 Appropriate PPE
ISO OCTANE Tank are available.
(ST_R-410).
N5.05 Pressure High 1 High pressure in 1.1 Malfunction 1.1.1 Tank will get 1.1.1.1 Breather valve is 4 2 8 1.1.1.1.1 Provide Asian
ISO Octane Tank of Nitrogen pressurized, Possible available. PT/PS with High Paints
(ST R-410). Regulator (Fully Leakage from Tank/
Pressure Alarm and
Flanges. Fire also it may
Open). Operator Action.
lead to fatalities.
2 High Pressure in 2.1 Malfunction 2.1.1 NFH as Sequence
27 Litre Vessel. of XV_590252 of Transfer will not start
(Closed). until XV-590252 is not in
open Condition.
Section
Description:
N5.06 Pressure Low 1 Low Pressure in 1.1 NRV Stuck 1.1.1 Vessel will observe 1.1.1.1 Dyke is provided. 4 1 4
ISO OCTANE Tank Closed. Low Pressure during 1.1.1.2 Area is classified.
(ST R-410). material transfer from 1.1.1.3 Fire Fighting
ISO OCTANE Tank to Arrangement is
Plant, Possible Bucking available.
of the tank may lead to 1.1.1.4 Breather Valve is
loss of Containment to provided to avoid low
environment, possible pressure inside the tank.
fire. Pump may Damage
due to Cavitation.
2 Low Pressure in NFH
27 Litre Vessel.
N5.07 Temperatu High 1 High Temp in 1.1 Loss of 1.1.1 Temp and Press in 1 3 3 1.1.1.1.1 Ensure Asian
re ISO Octane Tank Cooling water in ISO OCTANE Tank (ST R- that Breather Valve Paints
(ST R-410). Vent Condenser.
410) will Increase and is at safe Location.
Loss of Containment to
environment through
Breather Valve.
2 High Temp in 27 Not a Credible
Liter Vessel Scenario.
Section
Description:
N5.08 Temperatu Low 1 Low Temp in Not a Credible

re ISO Octane Tank Scenario.
(ST R-410).
2 Low Temp in 27 Not a Credible
Liter Vessel. Scenario.
N5.09 Level High 1 High Level in 1.1 Malfunction 1.1.1 Overflow of the ISO 1.1.1.1 R4_LS830051 is 4 1 4
ISO Octane Tank of R4_LT830051. OCTANE from Breather available to trip the
(ST R-410). Valve, Loss of pump unloading
Containment, and sequence in high level.
Possible fire. 1.1.1.2 Dyke is Provided.
1.1.1.3 Firefighting
system is available.
1.1.1.4 Emergency
Control Plan is available.
1.1.1.5 HAC is available.
1.1.1.6 Inventory
Management system in
SAP is available.
Section
Description:
2 High Level in 27 2.1 Malfunction 2.1.1 Overflow of the ISO 2.1.1.1 R4_LS590251 is 4 1 4
Litre Vessel. of R4_WT590251. OCTANE from Breather available to trip transfer
Valve, Loss of sequence in high level.
Containment, and 2.1.1.2 Firefighting
Possible fire. system is available.
2.1.1.3 HAC is Available.
2.1.1.4 Ideal Sequence
timer is available.
N5.10 Level Low 1 Low Level in ISO 1.1 Malfunction 1.1.1 Pump may run dry, 1.1.1.1 R4_FS830051 / 4 1 4
Octane Tank (ST of R4_LT830051. possible seal damage FS830052 are available.
R-410). leading to small fire. 1.1.1.2 No flow Logic is
available which will hold
transfer sequence.
1.1.1.3 HAC is available
1.1.1.4 Firefighting is
available.
Section
Description:
2 Low Level in 27 NFH

Litre Vessel.
N5.11 Composition 1 Off spec of ISO 1.1 Off spec 1.1.1 Product Quality 1.1.1.1 QA/QC 3 1 3
OCTANE. material Coming degrade. procedure is available.
from outside/
Vendor.
2 Non-Compatible 2.1 Human Error. 2.1.1 ISO OCTANE may 2.1.1.1 Permit system is 3 3 9 2.1.1.1.1 Asian
Material Line Up. degrade and will affect available, and operation Appropriate system Paints
the final product quality. is supervised. shall be provided
(Key arrangement /
Color Coding) to
avoid wrong
Connections.
N5.12 Start-up / 1 Inappropriate 1.1 Human Error. NFH 1.1.1.1.1 Show

draining during Asian
shut down proper drain points
Paints
shut down. on P&ID’s.
Section
Description:

Erosion

Associated Tag No’s Asian Paint
and Equipment Tile
Block.
N5.15 Others 1 Leakage 1.1 Leakage 1.1.1 Loss of 1.1.1.1 Area is Classified 1 4 4
through flanges. containment, possible 1.1.1.2 Fire Fighting
fire and human health arrangement is in Place.
hazard.
1.2 Leakage in 1.2.1 Water ingress in 3 2 6 1.2.1.1.1 Review Asian
Vent Condenser ISO OCTANE tank (ST_R- the requirement of Paints
tubes.
410) may lead to sampling on ISO
degradation of product OCTANE Tank (SR
quality. R-410) for water
contamination.
Section
Description:
2 Static Energy 2.1 2.1.1 In the presence of 2.1.1.1 Earthing, Bonding 4 1 4
Transportation of flammable mixture in and Grounding are
material at high
the tank and associate provided.
velocity / Free
falling of material piping, fire and explosion 2.1.1.2 Area is Classified
during unloading may occur. inside the Storage tank.
of material in 2.1.1.3 Nitrogen
tank.
Blanketing is provided.
2.1.1.4 J-Bend is present
which will avoid
splashing.
Section
Description:
2.2 Unloading 2.2.1 In the presence of 2.2.1.1 Earthing and 4 1 4
material from Flammable Mix in the Grounding is provided.
Tanker to Tank
Tank and associate 2.2.1.2 Earthrise System
turbulence during
transportation. piping Fire and Explosion is available.
may occur.
2.2.1.3 Proper relaxation
time for the Tanker is
available.
2.2.1.4 Nitrogen
Blanketing is provided.
Section
To collect GMA from main header and transfer to the New PET-419 Section/Node No: N6
Description:
To collect GMA from main header and transfer GMA to the New PET-419
OP: Atmospheric , OT: Ambient, DP: ; DT: (Design Condition need to be provided here by Asian Paints)
N6.01 Flow Less / No 1 Less or No flow 1.1 Malfunction 1.1.1. Level in DT-446 will 1.1.1.1 DCS indication of 2 2 4
from GMA of R4_XV-XXXX decrease. Downstream XV is available
Header to DT-446 (Closed) operation may delay 1.1.1.2 R4_LT-XXXX is
available
2 Less or No Flow 2.1 Pump 2.1.1 Operational Delay, 2.1.1.1 MES/ DCS 2 2 4
from DT-446 to R4_PXXXX No safety concern. Control system is
NEW PET-419 malfunctioned. available which will hold
no flow.
2.1.1.2 R4_LT-XXXX is
available
2.1.1.3 R4_WT-590232 is
available
2.1.1.4 R4_LS-590232 is
available
2.2 Strainer 2.2.1 Operational Delay, 2.2.1.1 MES/ DCS 2 3 6 2.2.1.1.1 Consider Asian
Chocked. No safety concern. Control system is Providing Paints
available which will hold
differential
no flow. pressure
transmitter across
available the strainer.
Section
Description:
2.2.1.3 R4_WT-590232 is
available
2.2.1.4 R4_LS-590232 is
available
2.3 NRV Stuck 2.3.1 Pump may run-in 2.3.1.1 MES/ DCS 2 3 6 2.3.1.1.1 Consider Asian
Closed. blocked-in condition, Control system is Providing Paints
leakage through the available which will hold
pressure
pump, loss of containment the sequence in case of
may lead to human health no flow. transmitter in
hazard. Operational Delay. pump discharge
available line and interlock
2.3.1.3 R4_WT-590232 is to trip the pump
available in case of high
2.3.1.4 R4_LS-590232 is pressure.
available
2.3.1.5 PPES are
available
2.4 Malfunction 2.4.1 Pump may run-in 2.4.1.1 MES/ DCS 2 3 6 2.4.1.1.1 Consider
of R4_XV-XXXXX blocked-in condition, Control system is Providing
(Closed). leakage through the available which will hold
pressure
pump, loss of containment the sequence in case of
may lead to human health no flow. transmitter in
Section
Description:
hazard. Operational Delay. 2.3.1.2 R4_LT-XXXX is pump discharge
available line and interlock
2.3.1.3 R4_WT-590232 is to trip the pump
available in case of high
2.3.1.4 R4_LS-590232 is pressure.
available
2.3.1.5 PPES are
available
3 Less or No Flow 5.1 Valve (R4_XV- 5.1.1 Temperature will 5.1.1.1 Temperature 2 2 4 5.1.1.1.1 High Asian
of Chilled Water XXXXX) increase in DT-446. transmitter (R4_TT temperature Paints
in DT R-446. Malfunctioned Product Degradation. XXXX) is available.
alarm shall be
(Closed).
provided on
Temperature
transmitter
(R4_TT XXXX) and
suitable operator
action.
N6.02 Flow More 1 More Flow/ 1.1 Malfunction 1.1.1 Level/Pressure will 1.1.1.1 R4_LT-XXXXX is 2 2 4 1.1.1.1 Vent shall
Quantity from of R4_XV-XXXXX increase in Vessel DT-446. available be provided on
GMA Header to (Open). Possible leakage/overflow. 1.1.1.2 PPEs are DT-446 and
DT-446. Human Health Hazard available
Section
Description:
1.1.1.3 DCS indication of location of vent

XV is available shall be at safe
location
2 More Flow of 2.1 Not a credible
Chilled Water in scenario
DT-446.
3 More Flow from 3.1 Not a credible
DT 446 to PET- scenario
419.
Flow Scenario
N6.04 Flow Other than/ Not a Credible

misdirected Scenario
N6.05 Pressure High 1 High Pressure in 1.1 Refer 6.02.1 Asian

DT-446. Paints
N6.06 Pressure Low 1 Low Pressure in 1.1 During GMA 1.1.1 Pressure will 1.1.1.1 PPEs are 2 5 9 1.1.1.1 Vent shall
DT-446. transfer from decrease in DT-419 during available be provided on Asian
Pump to PET-419. material transfer, Possible DT-446 and Paints
Buckling of the tank will location of vent
Section
Description:
lead to loss of shall be at safe
containment, Human location
health hazard.
N6.07 Temperatu High 1 High temp in Refer N.6.01.3,
PET R-419. Less or No Flow of Asian
re
Chilled Water in Paints
DT-446
N6.08 Temperatu Low 1 Low temp in DT- NFH
re 446.
N6.09 Level High level 1 High level in DT- Refer N6.02.1 Asian
446. Paints
N6.10 Level Low level 1 Low Level in PET Refer N6.01.1

R-419.

Scenario

shut down
Section
Description:

Erosion

Associated Tag
Asian Paint
No’s and
Equipment Tile
Block
Section
To heat the water in 15KL PHV-R407 and transfer to the REA-01 Section/Node No: N7
Description:
To heat the water in 15KL PHV-R407 and transfer to the REA-01

Drawings No.: 3-APL-PSLY-18038 Rev-05 Revision Date:
N7.01 Flow Less / No 1 Less or No 1.1 Malfunction 1.1.1. Level in 15 KL PHV 1.1.1.1 DCS indication of 2 2 4
flow from Solar of R4_XV-590221 will decrease. R4_XV-590221 is available
Tank to 15KL (Closed) Downstream operation 1.1.1.2 R4_LS-590221 is
PHV may delay available
2 Less or No 2.1 Malfunction 2.1.1. Level in 15 KL PHV 2.1.1.1 DCS indication of 2 2 4
flow of Process of R4_XV-590222 will decrease. R4_XV-590222 is available
water to 15KL (Closed) Downstream operation 2.1.1.2 R4_LS-590221 is
PHV may delay available
3 Less or No 3.1 Pump R4_PR 3.1.1 Operational Delay, 3.1.1.1 MES/ DCS Control 2 2 4
Flow from 15 KL 4044/4045 No safety concern. system is available which
PHV to REA-01 malfunctioned. will hold the sequence in
case of no flow.
3.1.1.2 R4_FS-590221/222 is
available
3.1.1.3 R4_WT-590221/222
is available
3.1.1.4 R4_LS-590221 is
available
3.1.1.5 Stand-By Pump is
available
3.2 Malfunction 3.2.1 Operational Delay, 3.2.1.1 MES/ DCS Control 2 2 4
of R4_XV-590229 No safety concern. system is available which
Section
Description:

(Closed) will hold the sequence in
case of no flow.
3.2.1.2 MES/ DCS Control
system is available which
will hold the sequence in
case of no flow.
3.2.1.3 R4_FS-590221/222 is
available
3.2.1.4 R4_WT-590221/222
is available
3.2.1.5 R4_LS-590221 is
available
3.3 NRV Stuck 3.3.1 Pump may run-in 3.3.1.1 MES/ DCS Control 2 3 6 3.3.1.1.1 Consider Asian
Closed. blocked-in condition, system is available which Providing Paints
leakage through the will hold the sequence in
pressure
pump, Operational case of no flow.
Delay. transmitter in
3.3.1.2 R4_FS-590221/222 is
pump discharge
available
line and interlock
3.3.1.3 R4_WT-590221/222
is available to trip the pump
in case of high
3.3.1.4 R4_LS-590221 is
available pressure.
Section
Description:

3.3.1.5 PPES are available
3.4 Malfunction 3.4.1 Pump may run-in 3.4.1.1 MES/ DCS Control 2 3 6 3.4.1.1.1 Consider Asian
of R4_XV-590230 blocked-in condition, system is available which Providing Paints
(Closed). leakage through the will hold the sequence in
pressure
pump, Operational case of no flow.
Delay. transmitter in
3.4.1.2 R4_FS-590221/222 is
pump discharge
available
line and interlock
3.4.1.3 R4_WT-590221/222
is available to trip the pump
in case of high
3.4.1.4 R4_LS-590221 is
available pressure.
3.4.1.6 R4_XV-590230
indication is available on
DCS
4 Less or No 4.1 Valve (R4_XV- 4.1.1 Temperature will 4.1.1.1 R4_XV-590223/224 2 3 6 4.1.1.1.1 R4_TT- Asian
Flow of Steam 590223 or R4_XV- decrease in 17 KL PHV. indication is available on 590221/222 shall Paints
in 17 KL PHV 590224) Delay in downstream DCS
be provided with
Malfunctioned operation. 4.1.1.2 R4_TT-590221/222 is
(Closed). alarm and
provided
Section
Description:

suitable operator
action.
N7.02 Flow More 1 More Flow/ 1.1 Malfunction 1.1.1 Level/Pressure will 1.1.1.1 R4_LS-590221 is 2 2 4 1.1.1.1.1Vent Asian
Quantity from of R4_XV-590221 increase in Vessel DT- available shall be provided Paints
Solar Tank to (Open). 446. Possible 1.1.1.2 PPEs are available on 15 KL PHV and
15KL PHV leakage/overflow of hot
1.1.1.3 DCS indication of XV location of vent
water. Human Health
is available shall be at safe
Hazard
location
1.1.1.1.2Provide
high level alarm
on R4_LS-590221
Steam in 15 KL scenario
PHV.
3 More Flow 3.1 Not a credible
from 15 KL PHV scenario
to REA-01
Flow Scenario
Section
Description:


N7.05 Pressure High 1 High Pressure 1.1 Refer 7.02.1 Asian

in 15KL PHV. Paints
N7.06 Pressure Low 1 Low Pressure 1.1 During Water 1.1.1 Pressure will 1.1.1.1 PPEs are available 2 5 10 1.1.1.1 Vent shall
in 15KL PHV. transfer from decrease in 15 KL PHV be provided on 15
15KL PHV to REA- during water transfer, KL PHV and Asian
01. Possible Buckling of the location of vent
Paints
tank will lead to loss of shall be at safe
health hazard.
N7.07 Temperatu High 1 High temp in 1.1 Not a credible
re 15 KL PHV. scenario
N7.08 Temperatu Low 1 Low temp in 1.1 Refer 7.01.4 Asian

re 15KL PHV. Paints
N7.09 Level High level 1 High level in Refer N7.02.1 Asian

15KL PHV. Paints
Section
Description:

N7.10 Level Low level 1 Low Level in Refer N7.01.1

15KL PHV.

Scenario

shut down

Erosion

Associated Tag
Asian Paint
No’s and
Equipment Tile
Block
N7.15 Others 1 Agitator 1.1 Agitator 1.1.1 Improper mixing. 1 4 4

Malfunction. No safety Concern
1.2 Agitator 1.2.1 Improper mixing. 1.2.1.1 Low Current 1 3 3
Decoupled. No safety Concern interlock is provided to hold
transfer sequence.
Section
Description:

1.3 Agitator Blade 1.3.1 Improper mixing. 1 3 3
Loosen up. No safety Concern.
Section
To store Material in ST-R468 and transfer material to the REA-01. Also Transfer material from Ves-R406 to REA-01 Section/Node No: N8
Description:
Transfer Material from ST-R468 and Ves-R406 to REA-01

N8.01 Flow Less / No 1 Less or No 1.1 Malfunction 1.1.1. Level in ST-R468 1.1.1.1 DCS indication of 2 2 4
flow from REA- of R4_XV-590212 will decrease. R4_XV-590212 is available
01 to ST-R468 (Closed) Downstream operation 1.1.1.2 R4_LS-590201 is
may delay available
1.1.1.3 R4_WT-590201 is
available
2 Less or No 2.1 Malfunction 2.1.1. Downstream 2.1.1.1 DCS indication of 2 2 4
flow of Water to of R4_XV-590202 operation may delay R4_XV-590202 is available
ST-R468 (Closed) 2.1.1.2 R4_LS-590201 is
available
2.1.1.3 R4_WT-590201 is
available
3 Less or No 3.1 Malfunction 3.1.1. Downstream 3.1.1.1 DCS indication of 2 2 4
flow of Water to of R4_XV-590215 operation may delay R4_XV-590215 is available
VES-R406 (Closed) 3.1.1.2 R4_LS-590215 is
available
3.1.1.3 R4_WT-590215 is
available
4 Less or No 4.1 Pump PR - 4.1.1 Operational Delay, 4.1.1.1 MES/ DCS Control 2 2 4 4.1.1.1.1 R4_PS-
Flow from VES- R4089/4090 No safety concern. system is available which 590215/216 shall
R406 to REA-01 malfunctioned. will hold the sequence in be provided with
case of no material transfer. low pressure
Section
Description:

4.1.1.2 R4_PS-590215/216 is alarm

available
4.1.1.3 R4_WT-590215 is
available
4.1.1.4 R4_LS-590215 is
available
available
4.2 Malfunction 4.2.1 Operational Delay, 4.2.1.1 MES/ DCS Control 3 2 6 4.2.1.1.1 R4_PS- Asian
of R4_XV-590216 Pump may run dry system is available which 590215/216 shall Paints
(Closed) leading to seal damage will hold the sequence in be provided with
and loss of containment. case of no material transfer. low pressure
Human health Hazards 4.2.1.2 R4_PS-590215/216 is alarm and
available interlock to trip
the running pump
4.2.1.3 R4_WT-590215 is
available
4.2.1.4 R4_LS-590215 is
available
4.2.1.6 R4_XV-590216
DCS
Section
Description:

4.3 Strainer 4.3.1 Operational Delay, 4.3.1.1 MES/ DCS Control 3 2 6 4.3.1.1.1 R4_PS- Asian
Choked Pump may run dry system is available which 590215/216 shall Paints
leading to seal damage will hold the sequence in be provided with
Human health Hazards 4.3.1.2 R4_PS-590215/216 is alarm and
available interlock to trip
the running pump
4.3.1.3 R4_WT-590215 is
available
4.3.1.4 R4_LS-590215 is
available
4.4 NRV Stuck 4.4.1 Pump may run-in 4.4.1.1 MES/ DCS Control 3 2 6 4.4.1.1.1 R4_PS- Asian
Closed. blocked-in condition, system is available which 590215/216 shall Paints
leakage through the will hold the sequence in be provided with
pump/flanges, Human case of no material transfer. high pressure
Health Hazard, 4.4.1.2 R4_PS-590215/216 is alarm and
Operational Delay. available interlock to trip
the running pump
4.4.1.3 R4_WT-590215 is
available
4.4.1.4 R4_LS-590215 is
available
Section
Description:

4.5 Malfunction 4.5.1 Pump may run-in 4.5.1.1 MES/ DCS Control 3 2 6 4.5.1.1.1 R4_PS- Asian
of R4_XV-590213 blocked-in condition, system is available which 590215/216 shall Paints
(Closed). leakage through the will hold the sequence in be provided with
pump/flanges, Human case of no material transfer. high pressure
Health Hazard, 4.5.1.2 R4_PS-590215/216 is alarm and
Operational Delay. available interlock to trip
the running pump
4.5.1.3 R4_WT-590215 is
available
4.5.1.4 R4_LS-590215 is
available
4.5.1.6 R4_XV-590213
DCS
5 Less or No 5.1 Pump PR - 4.1.1 Operational Delay, 5.1.1.1 MES/ DCS Control 2 2 4 5.1.1.1.1 R4_PS- Asian
Flow from ST- 468A/B No safety concern. system is available which 590201/202 shall Paints
R468 to REA-01 malfunctioned. will hold the sequence in be provided with
case of no material transfer. low pressure
5.1.1.2 R4_PS-590201/202 is alarm
available
5.1.1.3 R4_WT-590201 is
available
Section
Description:

5.1.1.4 R4_LS-590201 is
available
available
5.2 Malfunction 5.2.1 Operational Delay, 5.2.1.1 MES/ DCS Control 3 2 6 5.2.1.1.1 R4_PS- Asian
of R4_XV-590205 Pump may run dry system is available which 590201/202 shall Paints
(Closed) leading to seal damage will hold the sequence in be provided with
Possible fire and Human 5.2.1.2 R4_PS-590201/202 is alarm and
health Hazards available interlock to trip
the running pump
5.2.1.3 R4_WT-590201 is
available 5.2.1.1.2 Ensure
that firefighting
5.2.1.4 R4_LS-590201 is
arrangement is
available
available
5.2.1.6 R4_XV-590205
DCS
5.2.1.7 Hazards area
classification is done
5.3 Strainer 5.3.1 Operational Delay, 5.3.1.1 MES/ DCS Control 3 2 6 5.3.1.1.1 R4_PS- Asian
Choked Pump may run dry system is available which 590201/202 shall Paints
Section
Description:

leading to seal damage will hold the sequence in be provided with
Possible fire and Human 5.3.1.2 R4_PS-590201/202 is alarm and
health Hazards available interlock to trip
the running pump
5.3.1.3 R4_WT-590201 is
that firefighting
5.3.1.4 R4_LS-590201 is
arrangement is
available
available
5.4 NRV Stuck 5.4.1 Pump may run-in 5.4.1.1 MES/ DCS Control 3 2 6 5.4.1.1.1 R4_PS- Asian
Closed. blocked-in condition, system is available which 590201/202 shall Paints
leakage through the will hold the sequence in be provided with
pump/flanges, Possible case of no material transfer. high pressure
fire and Human health 5.4.1.2 R4_PS-590201/202 is alarm and
Hazards, Operational available interlock to trip
Delay. the running pump
5.4.1.3 R4_WT-590201 is
that firefighting
5.4.1.4 R4_LS-590201 is
arrangement is
available
available
Section
Description:


5.5 Malfunction 5.5.1 Pump may run-in 5.5.1.1 MES/ DCS Control 3 2 6 5.5.1.1.1 R4_PS- Asian
of R4_XV-590214 blocked-in condition, system is available which 590201/202 shall Paints
(Closed). leakage through the will hold the sequence in be provided with
pump/flanges, Possible case of no material transfer. high pressure
fire and Human Health 5.5.1.2 R4_PS-590201/202 is alarm and
Hazard, Operational available interlock to trip
Delay. the running pump
5.5.1.3 R4_WT-590201 is
that firefighting
5.5.1.4 R4_LS-590201 is
arrangement is
available
available
5.5.1.7 R4_XV-590205
DCS
N8.02 Flow More 1 More Flow/ 1.1 Malfunction 1.1.1 Level/Pressure will 1.1.1.1 R4_LS-590215 is 1 4 4 1.1.1.1.1Vent Asian
Quantity of of R4_XV-590215 increase in Vessel VES- available shall be provided Paints
Water to VES- (Open). R406. Possible leakage 1.1.1.2 PPEs are available on VES-R406 and
R406 though flanges/overflow
Section
Description:

of water. 1.1.1.3 DCS indication of XV location of vent
is available shall be at safe
1.1.1.4 R4_WT-590215 is location
available 1.1.1.1.2 Provide
high level alarm
on R4_LS-590215
Material from scenario
VES-R406 to
REA-01.
3 More Flow/ 3.1 Malfunction 3.1.1 Level will increase 3.1.1.1 R4_LS-590201 is 3 1 3 3.1.1.1.1 Provide Asian
Quantity of of R4_XV-590202 in Vessel ST-R468. available high level alarm Paints
Water to ST- (Open). Possible leakage though 3.1.1.2 PPEs are available on R4_LS-590201
R468 flanges/overflow.
3.1.1.3 DCS indication of XV
Human Health Hazards
is available
3.1.1.4 R4_WT-590201 is
available
3.1.1.1.5 Vent is provided
on ST-R468 and routed to
scrubber
Section
Description:

4 More Flow/ 4.1 Not a credible

Quantity of scenario as two
Material from XVs are available
REA-01 to ST-
R468
Material from scenario
ST-R468 to REA-
01.
Flow Scenario

N8.05 Pressure High 1 High Pressure 1.1 Refer 8.02.1 Asian

in VES-R406. Paints
2 High Pressure 2.1 Malfunction Pressure will increase in 2.1.1.1 R4_PT-590201 is 4 3 12 2.1.1.1.1 R4_PT-
Asian
in ST-R468. of R4_XV-590203 ST-R468 during material available 590201 shall be
provided with Paints
(Closed) intake. Possible leakage / 2.1.1.2 PPES are available
Section
Description:

rupture of Vessel, Fire 2.1.1.3 Hazards area high pressure
and human health classification is done alarm and
interlock to close
hazards 2.1.1.4 R4_XV-590203
R4_XV-
indication is available on 590201/202
DCS
2.1.1.1.2 Ensure
that firefighting
arrangement is
available
N8.06 Pressure Low 1 Low Pressure 1.1 During 1.1.1 Pressure will 1.1.1.1 PPEs are available 2 5 10 1.1.1.1 Vent shall
in VES-R406. material transfer decrease in VES-R406 be provided on
from VES-R406 to during material transfer, VES-R406 and Asian
REA-01. Possible Buckling of the location of vent
Paints
tank will lead to loss of shall be at safe
health hazard.
2 Low Pressure 2.1 Malfunction Pressure will decrease in 2.1.1.1 R4_PT-590201 is 4 3 12 2.1.1.1.1 R4_PT-
in ST-R468. of R4_XV-590204 ST-R468 during material available 590201 shall be
(Closed) transfer to REA-01, 2.1.1.2 PPES are available provided with low
pressure alarm
Possible Buckling of the 2.1.1.3 Hazards area
and interlock to
tank will lead to loss of classification is done
trip pump PR-
Section
Description:

containment, Fire and 2.1.1.4 R4_XV-590204 468A/B
Human health hazard indication is available on 2.1.1.1.2 Ensure
DCS that firefighting
arrangement is
available
N8.07 Temperatu High 1 High temp in 1.1 Not a credible

re VES-R406. scenario
2 High temp in 2.1 Not a credible

ST-R468. scenario
N8.08 Temperatu Low 1 Low temp in 1.1 Not a credible
re VES-R406. scenario
2 Low temp in 2.1 Not a credible

ST-R468. scenario
N8.09 Level High level 1 High level in Refer N8.02.1 Asian
VES-R406. Paints
2 High level in Refer N8.02.3 Asian

ST-R468. Paints
Section
Description:

N8.10 Level Low level 1 Low level in NFH

VES-R406.
2 Low level in NFH
ST-R468.
Scenario

shut down

Erosion

Associated Tag
Asian Paint
No’s and
Equipment Tile
Block
N8.15 Others 1 Agitator in 1.1 Agitator 1.1.1 Improper mixing. 1 4 4

VES-R406 Malfunction. No safety Concern
Section
Description:

1.2 Agitator 1.2.1 Improper mixing. 1.2.1.1 Low Current 1 3 3
Decoupled. No safety Concern interlock is provided to hold
transfer sequence.
1.3 Agitator Blade 1.3.1 Improper mixing. 1 3 3
Loosen up. No safety Concern.
2 Agitator in ST- 1.1 Agitator 1.1.1 Improper mixing 2 3 6
R468 Malfunction. will lead to phase
separation in ST-R468
causing off spec product
1.2 Agitator 1.2.1 Improper mixing 1.2.1.1 Low Current 2 3 6
Decoupled. will lead to phase interlock is provided to hold
separation in ST-R468 transfer sequence.
causing off spec product.
1.3 Agitator Blade 1.3.1 Loose Agitator 4 2 8
Loosen up. Blade/ Bolts may strike
on Vessel wall / bottom
and create spark which
will result in fire and
explosion in presence of
flammable mixture
inside the ST-R468.
Section
Material Transfer from DT-430 to BT-401. Section/Node No: N9
Description:
Material Transfer from DT-430 to BT-401.

OP:, OT: , DP:; DT: (Operating and Design Condition need to be provided here by Asian Paints)
N9.01 Flow Less / No 1 Less or No flow 1.1 Malfunction 1.1.1 Operational Delay. 1.1.1.1 DCS Indication 1 4 4
from DT-430 to of R4_XV836002. for XV is available.
Bt-401. 1.1.1.2 R4_WT836001
and R4_WT7104 are
available.
1.2 Malfunction 1.2.1Operational Delay. 1.2.1.1 DCS Indication 1 4 4
of Pump. for Pump running is
available.
1.2.1.2 R4_WT836001
and R4_WT7104 are
available.
1.3 NRV Stuck 1.3.1 Operational Delay, 1.3.1.1 R4_WT836001 1 4 4
Closed. Pump will run in blocked and R4_WT7104 are
in condition, pump may available.
damage.
N9.02 Flow More 1 More Quantity 1.1 WT-7104 1.1.1 Level will increase, 1.1.1.1 LS-7104 is 1 3 3
to BT-401. malfunctioned. possible overflow from BT- available with interlock
401 to Scrubber, No safety to close the XV 590262.
hazard.
Flow Scenario
Section
Description:


N9.05 Pressure High Already captured

in previous
HAZOP
N9.06 Pressure Low 2 Low Pressure in NFH
Pump Discharge
Line
N9.07 Temperatu High 1 High temp 1.1 Loss of chilled 1.1.1 Polymerisation of 1.1.1.1 TT-836001 is 2 4 8 1.1.1.1.1 TT-
Monomer water in DT-403. monomer in transfer line provided with high 836001 Shall be
re
transfer from DT- may lead to chocking of temperature alarm. provided with
430 to BT-401 the line, Process delay, interlock in case Asian
pump may damage due to of High High temp Paints
blocked in condition. pump
(SOV_836020)
will trip.
N9.08 Temperatu Low Not a Credible

re Scenario
Section
Description:

N9.09 Level High level Already captured

in previous
HAZOP
N9.10 Level Low level Already captured

in previous
HAZOP
N9.11 Composition Already captured

in previous
HAZOP

shut down

Erosion
N9.14 Drawing 1.1.1.1 Update

Asian Paint
Section
Description:

Associated Tag
No’s and
Equipment Tile
Block
Batching Tank (BT-R413) System N10
Description: No:
To collect Indofil ASE 60, CALFAX DB-45, NEOPON ANP-30, CRESMER and transfer to reactor REA-R401.
OP: , OT: , DP:; DT: (Operating and Design Condition need to be provided here by Asian Paints)
Ref. Action
No. By
N10.01 Flow Less / No 1.Less / No 1.1 1.1.1 Delay of Batch 1.1.1.1 MES / DCS is 1 4 4
flow of DM Unavailability operation. available to provide a
of DM water signal for delay.
water
1.2. 1.2.1 Delay of Batch 1.2.1.1 MES / DCS is 1 3 3
Malfunction of operation. available to provide a
XV-R7402 signal for delay.
inadvertently of XV-R7402 is
available
2 Less / No 2.1. 2.1.1 Delay of Batch 2.1.1.1 MES / DCS is 1 3 3
flow of Indofil Malfunction of operation. available to provide a
ASE 60
inadvertently of XV-R7401 is
available
flow of CALFAX Malfunction of operation. available to provide a
TV-R7403 signal for delay.
DB-45,
inadvertently of TV-R7403 is
Description: No:
Ref. Action
No. By
NEOPON ANP- available
30, CRESMER
4. Less / No 4.1. 4.1.1 Delay of reactor 4.1.1.1 MES / DCS is 1 3 3

flow from BT- Malfunction of Batch operation. available to provide a
R413 to XV-R7404 signal for delay.
reactor REA- closes 4.1.1.2 DCS
R401 inadvertently Indication of XV-
R7404 is available
N10.02 Flow More 1. More Flow / 1.1. 1.1.1 High level in 1.1.1.1 LS-R7401 is 1 3 3 1.1.1.1.1 Consider Asian
quantity of DM Malfunction of batch tank may lead provided with high Vent routing to paints
water XV-R7402 open to overflow of Batch level alarm and safe location or
inadvertently tank BT-R413, Loss of interlock to close the provide overflow
DM water. Delay in feed inlet valve line
operation. 1.1.1.2 WT-R7401 is
available with high
high alarm and
interlock to close the
feed inlet valve.
Description: No:
Ref. Action
No. By
1.1.1.3 DCS
Indication of XV-
R7402 is available
2.More flow / 2.1 2.1.1 High level in 2.1.1.1 LS-R7401 is 2 3 6 2.1.1.1 Consider
quantity of Malfunction of batch tank may lead provided with high Vent routing to
Indifil ASE 60 XV-R7401 open to overflow of Batch level alarm and safe location or
inadvertently. tank BT-R413, Loss of interlock to close the provide overflow
Containment, Human feed inlet valve line
health Hazards. Delay 2.1.1.2 WT-R7401 is
in operation. Asian
available with high
paints
high alarm and
feed inlet valve.
2.1.1.3 DCS
Indication of XV-
R7401 is available
Description: No:
Ref. Action
No. By
3 Less / No 3.1 3.1.1 High level in 3.1.1.1 LS-R7401 is 2 3 6 3.1.1.1.1 Consider

flow of CALFAX Malfunction of batch tank may lead provided with high Vent routing to
DB-45, TV-R7403 open to overflow of Batch level alarm and safe location or
NEOPON ANP- inadvertently. tank BT-R413, Loss of interlock to close the provide overflow
30, CRESMER Containment, Human feed inlet valve line
health Hazards. Delay 3.1.1.2 WT-R7401 is
in operation. Asian
available with high
paints
high alarm and
feed inlet valve.
3.1.1.3 DCS
Indication of TV-
R7403 is available
4 More flow / 4.1 Not a

quantity from credible
BT-R413 to scenario.
reactor REA-
R401
Description: No:
Ref. Action
No. By
N10.03 Flow Reverse 1.1 Not a

Flow credible
scenario.
N10.04 Flow Other 1.1 Not a
than/ credible
scenario.
misdirected
N10.05 Pressure High 1 High 1.1 Not a

pressure in BT- credible
scenario.
R413
N10.06 Pressure Low 1 Low pressure 1.1 Not a

in BT-R413 credible
scenario.
N10.07 Temperature High 1 High 1. Not a
temperature in credible
scenario.
BT-R413
Description: No:
Ref. Action
No. By
N10.08 Temperature Low 1 Low 1.1 Not a

scenario.
BT-R413
N10.09 Level High level 1 High level in 1.1 Refer

BT-R413 N10.02.1/2/3
N10.10 Level Low level 1 Low level in 1.1 NFH

BT-R413
N10.11 Composition 1.1 Not a

significant
hazard
N10.12 Start-up / 1.1 Not a
hazard
N10.13 Corrosion/ 1.1 Not a
significant
Erosion
hazard
identified.
Description: No:
Ref. Action
No. By
N10.14 Drawing 1. NA
Errors
N10.15 Others 1. NA
Catalyst Vessel (VSA-R410) System N11
Description: No:
To blend Catalyst and water in Catalyst Vessel and transfer to reactor REA-R401.
Design Intention: OP: Atmospheric, OT:, DP: ; DT: ; DT: (Operating and Design Condition need to be provided here by Revision No: 00
Asian Paints)
Ref. Action
No. By
N11.01 Flow Less / No 1.Less / No 1.1 1.1.1 Delay of Batch 1.1.1.1 MES / DCS is 1 4 4
flow of DM Unavailability operation. available to provide a
water of DM water signal for delay.
1.2 1.2.1 Delay of Batch 1.2.1.1 MES / DCS is 1 3 3

Malfunction of operation. available to provide a
closes 1.2.1.2 DCS
inadvertently Indication of XV-
R7417 is available
flow of Catalyst Malfunction of operation in the available to provide a
from VSA-R410 FBV-R7456 reactor. signal for delay.
to reactor REA- closes 2.1.1.2 DCS
R401 inadvertently Indication of FBV-
R7456 is available
N11.02 More 1.More Flow / 1.1 1.1.1 High level in 1.1.1.1 WT-R7402 is 1 3 3
Flow
quantity of DM Malfunction of vessel leading to provided with high
water overflow of DM alarm
Description: No:
Asian Paints)
Ref. Action
No. By
XV-R7417 open water. Delay of Batch
inadvertently operation
2.More 2. Human error 2.1 Formation of off 2.1.1 SOP for manual 2 3 6
quantity of spec product in dosing is available.
catalyst in VSA- reactor.
R410
3. More Flow / 3.1 Not a

quantity of credible
catalyst from scenario.
VSA-R410 to
reactor REA-
R401
N11.03 Flow Reverse 1. Not a

Flow credible
scenario.
Description: No:
Asian Paints)
Ref. Action
No. By
N11.04 Flow Other 1. Not a

than/ credible
scenario.
misdirected
N11.05 Pressure High High Pressure 1. Not a

in VSA-R410 credible
scenario.
N11.06 Pressure Low Low Pressure 1. Not a
in VSA-R410 credible
scenario.
N11.07 Temperature High High 1. Refer
temperature in N11.02 – Cause
VSA-R410 3&4
N11.08 Temperature Low Low 1. Not a
VSA-R410 scenario.
N11.09 Level High High level in 1. Refer
VSA-R410 N11.02.1
Description: No:
Asian Paints)
Ref. Action
No. By
N11.10 Level Low Low level in 1. Not a

VSA-R410 significant
hazard.
N11.11 Composition 1. Other 1.1 Human 1.1.1 Formation of 1.1.1.1 SOP for 2 3 6 1.1.1.1.1 SOP to
catalyst line-up error off spec product in material transfer is include that
reactor. Reactor available. operation is
Asian
batch operation may supervised by
paints
delay. (four eye
principle).
N11.12 Start-up / 1. Not a

hazard
N11.13 Corrosion/ 1. Not a
credible
Erosion
scenario.
N11.14 Drawing 1. NA
Errors
Description: No:
Asian Paints)
Ref. Action
No. By
N11.15 Others 1.Agitator 1.1 1.1.1 Improper 1.1.1.1 Periodic 2 3 6 1.1.1.1.1 Agitator Asian
Malfunction of mixing of catalyst check / maintenance. running feedback paints
Agitator
may lead to shall be provided
incomplete / on DCS.
insufficient reaction
in the reactor causing
formation off spec.
1.2. Agitator 1.2.1 Improper 1.2.1.1 Periodic 2 3 6 1.2.1.1.1 low
blade loosen mixing of catalyst check / maintenance. current indication
up
may lead to and alarm shall
incomplete / be provided on
insufficient reaction DCS and interlock
in the reactor causing to hold the
formation off spec. sequence.
RISK RANKING MATRIX
FREQUENCY CODES [F]:
F1 F2 F3 F4 F5
Once in 1000 years Once in 100 years Once in a 10 year Once in 1 year Once in a month
SEVERITY CODES [S]:
Severity Safety Asset Environment
[S1] Minor Small injury Loss <1k USD Small localized impact
[S2] Appreciable Reversible LTI Loss <10k USD Minor localized impact
[S3] Major Irreversible LTI Loss <100k USD Major localized impact
[S4] Severe Up to 3 fatalities Loss <1M USD Major impact
[S5] Catastrophic >3 fatalities Loss >1M USD Major impact outside plant
RISK MATRIX
F5 5 10 15 20 25
F4 4 8 12 16 20
F3 3 6 9 12 15
F2 2 4 6 8 10
F1 1 2 3 4 5
S1 S2 S3 S4 S5

J1237 Asian Paints HAZOP WS

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J1237 Asian Paints HAZOP WS

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HAZOP WORKSHEET

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

N1.01 Flow Less / No 1. Less / No 1.1. 1.1.1 Delay of 1.1.1.1MES / DCS is 1 4 4

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

3.Less / No 3.1. 3.1.1 Delay of 3.1.1.1 MES / DCS is 1 4 4

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

2.More 2.1 Malfunction 2.1.1 No significate

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

3.More flow/ 3.1 Not a

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

6.More flow 6.1. Not a

7.More flow of 7.1. Not a

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

8.More flow of 8.1. Not a

N1.03 Flow Reverse 1. Not a credible

N1.05 Pressure High 1.High 1.1 Refer

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

1.2.1.4 Hazardous area

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

N1.08 Temperature Low 1.Low 1.1 Refer

N1.09 Level High level 1.High level in 1.1 Refer

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

N1.11 Composition 1.1 Not a

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

Drawings No.: TCE-5381A-300-PI-8674 Rev No. R3 Revision Date:

Design Transfer Ammonia from SOV-749 and store in BT-407

Drawings No.: 3-APL-PSLY-18039 Rev 04 Revision Date:

Design Transfer Ammonia from SOV-749 and store in BT-407

Drawings No.: 3-APL-PSLY-18039 Rev 04 Revision Date:

N2.04 Flow Other than/ 1 Wrong 1.1 1.1.1 Deterioration of 1 4 4

Design Transfer Ammonia from SOV-749 and store in BT-407

Drawings No.: 3-APL-PSLY-18039 Rev 04 Revision Date:

N2.06 Pressure Low 1 Low Pressure Not a Credible

N2.10 Level Low level 1 Low Level in NFH

N2.11 Composition 1 Off spec. Not a credible

Design Transfer Ammonia from SOV-749 and store in BT-407

Drawings No.: 3-APL-PSLY-18039 Rev 04 Revision Date:

N2.12 Start-up / NFH

N2.13 Corrosion/ NFH

N2.14 Drawing 1.1.1.1.1 Update

To prepare pre emulsion and transfer to the reactor (R-401)

Drawings No.: 3-APL-PSLY-18039 Revision Date:

To prepare pre emulsion and transfer to the reactor (R-401)

Drawings No.: 3-APL-PSLY-18039 Revision Date:

1.4 Malfunction 1.4.1 Product Degradation, 1.4.1.1 MES/ DCS 2 2 4

To prepare pre emulsion and transfer to the reactor (R-401)

Drawings No.: 3-APL-PSLY-18039 Revision Date:

To prepare pre emulsion and transfer to the reactor (R-401)

Drawings No.: 3-APL-PSLY-18039 Revision Date:

To prepare pre emulsion and transfer to the reactor (R-401)

Drawings No.: 3-APL-PSLY-18039 Revision Date:

4 Less or No flow Refer 3.01,

To prepare pre emulsion and transfer to the reactor (R-401)

Drawings No.: 3-APL-PSLY-18039 Revision Date:

6 Less or No Flow 6.1 Valve 6.1.1. Reaction is 6.1.1.1 Temperature 3 2 6

To prepare pre emulsion and transfer to the reactor (R-401)

Drawings No.: 3-APL-PSLY-18039 Revision Date:

7.1.1.2 Stand by pump is