Hazard Study - 3
Project Project Title: 14 KTPA RSB Expansion Project
No.:
Study team members:
SMA (HS Leader), UA, SMWA, QAB, AS, AQ, MYA, MTA, HA,SA, FSK, MH, AK, HA
Site: Khewra Plant: Soda Ash Works
Drawing No. Drawing Title: 14 KTPA RSB Expansion Project
Use this worksheet to record the output from the study. See PGP-003/3.
Item / Line / Stage Deviation Causes
From Existing Low / No 1. Motor failure of
Conveyor-01/02 flow conveyor 1 or 2.
to the Reddler
1/2 2. Slide valve is
closed/partially open.
3. Star Feeders is not
operational.
4.Blockage in conveying
High Flow 1. High rpm of star feeder due
to malfunction/mal-
operation of the system.
2. High flow from existing
conveyor due to increased
loading on conveyor.
From Reddler Low / No 1. Upstream Causes.
Conveyor –1/2 flow 2. Motor failure of
to LSA Feed Reddler conveyor 1 or 2
Hopper 3. Scalping Screen not
operational/motor
tripping/malfunction.
4. Scalping Screen flow
rate reduced due to
Unit: RSB
Effect or Hazard Safeguards
0127-04-PID-001 (LSA Feed Preparation)
1. Low level in LSA 1. Motor failure
Feed Hopper. indication is available in
DAP area.
2.Decrease in LSA 2. Star Feeder motor
solution density indications & alarm
available in PLC to
notify the operator for
taking corrective
actions.
3. Level indication will
be available on PLC for
Feed Hopper.
4. Daily Knocking
Routine
Plant monitoring &
area round by relevant
area operator
5. Density indication
will be available on PLC.
1. Excessive Feed to LSA 1. Star Feeder motor
2. Star feeder motor can indications & alarm (Moto
burnout due to excessive EOCR) available in PLC to
current. notify the operator for tak
3. Reddler conveyor over corrective actions.
loading. 2. High Level indication is
available on PLC for Feed
Hopper.
1. Low level in LSA 1. Current indication is
Feed Hopper. available for Reddler
2. Decrease in LSA Conveyor.
solution density 2. Scalping Screen
current indication is
available.
3. Low Level indication
is available on PLC for
 blinding.
5. Scalping screen
choked due to outlet
chute blockage
/knotting chute
blockage.
6. Blockage of angular
chute of Reddler
conveyor.
7. Slide valve on bypass
around scalping screen
is in open condition
allowing flow
Feed Hopper.
3. Overflow material 4. Density indication
from scalping screen will be available on PLC.
will go into bags via 5. CCTV cameras are
chute. Screen motor available for
will eventually trip due monitoring.
to high load.
4. Possible issues in
dissolving tank due to
lumps and possible
increase in LSA
solution density.

Contaminati on 1. Contamination due to 1. Product contamination. 1. Plant area monitoring.

malfunction of Magnetic 2. Scalping screen damage.
separator.
2. Contamination due to
effect of rain/wind (dust) on
the scalping screen.

High Flow 1. Upstream Causes. 1. Accumulation on screen, 1. Plant area monitoring.

which may result in motor 2. High level indication is
tripping. available for feed hopper
2. High Level in LSA feed PLC.
hopper.

From LSA Feed No/Low 1. Outlet nozzle is 1. Process disturbance. 1. Plant area
Hopper to LSA Flow choked. 2. Decrease in LSA monitoring.
Dissolving Tank 2. Delumper/ Screw solution density. 2. CCTV cameras are
feeder malfunction. available.
3. Low level in LSA Feed 3. Level indication is
Hopper. available on PLC for
4. Screw feeder setting Feed Hopper.
lower than required. 4. Density indication
5. Screw feeder will be available on PLC.
malfunction. 5. Screw feeder current
indication is available
on PLC.
6. Vibrator is available
on lower portion of
hopper.
High Flow 1. Screw feeding setting 1. Level in the feed hopper 1. Level indication is availa
higher than required. will fall. on PLC for Feed Hopper.
2. Screw feeder malfunction. 2. Process disturbance 2. Plant area monitoring.
– increase in solution
density.

4-33-0007 High Level 1. Upstream causes. 1. Process disturbance. 1. Conveyor current

(LSA Feed Hopper) 2. Both Reddler operating.
3. Downstream flow
restriction.
4. High level Instrument
malfunction allowing star
feeder to continue operation.
Low Level 1. Upstream causes.
2. High outlet flow from
the feed hopper.
3. Low level Instrument
malfunction showing
false indication.
Maintenanc e
indication is available.
2. Conveyor delayed tripp
is available for conveyor d
run.
3. Level indication is availa
on Feed
hopper.LSHH40002/LS
H40003 is available.
4. Feed Hopper high level
interlock, with star feeder
tripping is available.
1. Process 1. Standby system will
disturbance. start to maintain feed
level in the hopper
2. LSL 40004 Low Level
switch available to alert
operator
3”-WL-CI-0027- High flow 1. FCV 40018 B mal- operation 1. Decrease in LSA feed 1. Density meter AIC 4000
1 ½ H (Recycled (open more than required) solution density. available.
Mother Liquor from 2. FCV 40018 B bypass fully 2.Rise in level of LSA 2. LSHH 40001/ LT 40001
RSB 1&2 to LSA open dissolving tank available for tank monitor
3. High flow of HSW addition 3.Overflow of LSA dissolving 3.Mag flow meters MF
due to malfunction of density tank 40018B/40005 are
control system AIT40001 available
and/or reduced flow to
recycled mother liquor line 3”
–WL-CI-0011.
4. Malfunction of
MF40005/MF40018B.

Low/no flow 1. FCV 40018 B mal-
operation (close more
than required)
2. Malfunction of
MF40018B.
3. Line
Leakage/Isolation valve
partially closed/closed
on mother liquor or
HSW lines.
1. Process disturbance. 1. Density meter AIC
40001 monitoring
2. Low level of LSA
dissolving tank 2. LT 40001 is available
tank level monitoring
3. Spillage in area.
3. Mag flow meters MF
40018B available.

4. Drain valve is stuck in open

position/passing.
5. Mother liquor pumps
malfunction.

3”-WL-CI-0011- High flow 1. FCV 40018 A mal- 1. Decrease in LSA feed 1. Density meter AIC
1½H operation (open more solution density. 40001 is available.
(Recycled than required)
Mother Liquor 2 Rise in level of LSA 2. LSHH 40001/ LT
from RSB 3&4 2. FCV 40018 A bypass dissolving tank 40001 is available for
to LSA fully open tank monitoring.
3.Overflow of LSA
3. High flow of HSW dissolving tank 3.Mag flow meters MF
addition due to 40018A/40005 are
malfunction of density available
control system

AIT40001 and/or
reduced flow to
recycled mother liquor
line 3” –WL-CI-0027.
4. Malfunction of
MF40005/MF40018A.
5. Mal-operation
resulting in mother
liquor third pump
manual operation by
operator`s intervention.
Low/no flow 1. FCV 40018 A mal- operation 1. Process disturbance.
(close more than required)
2. Malfunction of MF40018A. tank
3. Line Leakage/Isolation
valve partially closed/closed
on Mother liquor and HSW
lines.
4. Drain valve is stuck in open
position/passing.
5. Mother liquor pumps
malfunction/pump tripping.
4-23-01 High Level 1. Upstream cause.
(LSA Dissolving
Tank) 2. Downstream flow
restriction.
3. LSA transfer pumps
tripping or malfunction
(4-21-0001A/B/C
tripping- Normally two
out of three operate).
4. Flushing HSW valve
for vent stuck in open
position.
5. Downstream flow
restriction.
dissolving tank
2. Low level of LSA dissolving
3. Spillage in area.
1. Process disturbance.
2. Tank overflow could
result in hot liquor
splash in area.
Potential burn in case
of splashing to
personal
4. Pump operation
indication is available.
1. Density meter AIC 4000
monitoring
2. LT 40001 is available ta
level monitoring
3. Mag flow meters MF
40018A available
4. Mother Liquor pump
current indication is availa
on PLC.
1. Pumps current
indication is available.
2. Level indication is
available on Dissolving
Tank
LSHH40001/LIA40001 is
available.
3 Overflow line is
available. CCTV
cameras are available
for monitoring.
Low Level 1. Upstream causes.
2. Mal-operation resulting in 2. High solution
third pump manual operation temperature.
by operator`s intervention.
3. Drain valve stuck in open
/partially open condition.
4. Malfunction of
LT40001/LIA40001.
High Pressure 1. Rise in vessel pressure due
to vent blockage because of
accumulation of vapors in
vapor space.
High 1. Higher steam flow to
Temperatur dissolving tank jackets
e due to malfunction of
TIC circuit and/or
bypass around
TCV40001 is stuck in
open position.
1. Process Disturbance 1. Pumps current indicatio
available.
2. Level indication is availa
on Dissolving Tank
LSHH40001/LIA40001 is
available.
3. Level indication is availa
on Saturator feed tank
LIC30003.
1. Vent line discharge is
provided outside building
2. HSW entry is through
Sprinkler nozzle which
prevents flow of vapor int
the line.
3. Venting possible throug
LSA entry point, will cause
dust cloud.
1. Process disturbance. 1. Temperature
indication is provided
2. Dissolving tank on tank TT40001. No
temperature will rise. other instrumentation
on tank in case of
malfunction.
2. Temperature
indication TT40002 is
provided on pump dischar
line.
3. Density meter has
temperature compensatio
it.
 Low 1. Low steam flow to
Temperatur e dissolving tank jackets due to
malfunction of TIC circuit.
2. Line leakage.
3. Steam trap malfunction.
4. In adequate insulation on
jacket and vessel.
Change in 1. Agitator malfunction.
Composition
Increase in 1. Steam high flow due
vessel Jacket to TCV40001
Pressure malfunction.
2. Restriction in outlet
from jackets.
3. Bypass valve around
TCV40001 opens.
Decrease in 1. Steam low flow due to
Jacket Steam TCV40001 malfunction.
Pressure 2. Line leakage at
upstream/downstream of
TCV.
3. Decrease in steam pressure
of IP steam coming from
header.
4. Steam trap malfunction
5. Drain valve open
6”- BL – D101- Low/No 1. Line blockage/Scaling
0004-2H flow
(LSA Feed 2. Tank outlet valve is
Transfer Pump closed/partially open.
Suction Header)
4”- BL – D101- 3. Pump Suction valve
0126-2H closed/partially open.
4”- BL – D101-
1. Process disturbance.
2. Dissolving tank
temperature will drop.
3. Steam wastage and
possible personnel hazard.
4. Blockage of line due to
crystallization, as a result of
low temperature.
1. Process disturbance. Non- 1. Agitator current indicati
operation will trip LSA feed is available on PLC.
system to LSA feed hopper.
1. High pressure in
jackets possible
demage.
1. Low pressure in jacket.
1. Process Disturbance.
2. LSA transfer pumps
(4-21-0001A/B/C) will
lose suction & result in
cavitation
3. High level in LSA
1. Temperature indication
provided on tank TT40001
2. Temperature indication
TT40002 is provided on pu
discharge line.
3. Density meter has
temperature compensatio
it.
1. PSVs are provided on
main steam line.
2. Jacket design
pressure is more than
IP steam header
pressure.
1. FT 40001 is provided.
2. TT40001 is provided.
1.LT 40001 is available
for Dissolving tank with
level alarm.
2.Temperature
indication TI-40001 is
available.
0125-2H 4. Pump suction Dissolving tank 4-23-
4”- BL – D101- strainers choked. 0001, which will result 3.Pump discharge PI of
0090-2H in tank overflow. 4-21-0001 A/B/C is
(LSA Feed 5. Line leakage. available.
Transfer Pump 4. High temperature in
Suction Lines) 6. Restriction in dissolving tank.
downstream flow due
to LCV40001 or other
reasons.
High Flow 1. Mal-operation resulting in 1. Process Disturbance. 1. Pump current indication
third pump manual operation 2. Density will be decreased. available.
by operator`s intervention.

2. Flushing Hot soft water 3. Drop in level of dissolving 2. AIT40002 is available fo

valve stuck in open /partially tank. density measurement.
open condition. 3. Dissolving tank level
indication LIA40001 availa

4-42-0001A/B/C Low / No 1. Upstream causes. 1. Reduced Feed flow 1. Saturator Feed Tank
(LSA Feed Flow 2. Discharge valve stuck to Saturator Feed Level indication is
Solution in closed Tank. available (LT 0003 & LT
Transfer Pumps position/partially closed 30003
to Saturator and/or NRV 2. Process disturbance. 2. Operating
feed tanks) malfunction. procedures to ensure
3”-BL-D101- 3. Malfunction of correct plant operation
0127-1 ½ H 3. 4-21-0001 A/B/C either LCV with it for maintaining levels
3”-BL-D101- Pump motor tripping / opening more than in each saturator feed
0007-1 ½ H failure.(two normally required will lead to tank.
3”-BL-D101- operating) less flow to other tank. 3. Pump discharge PI of
0006-1 ½ H 4. Line choking/blocking No flow indication 4-21-0001 A/B/C
3”- BL – D101 – problem/NRV available however tank available
0024 – 1 ½ H malfunction. level indication is
5. LCV 40001A/B mal available.
3”- BL – D101 – operation/closed
0145 – 1 ½ H position/malfunction of
LIC30003 or LIC0003.
4”- BL – D101 – 6. Isolation valves
0145 – 1 ½ H partially closed/stuck in
closed position.
7. Line leakage/Drain
Valve open.
High Flow 1. Mal-operation resulting in 1. Process disturbance. 1. Saturator Feed Tank Le
third pump manual operation 2. Malfunction of either LCV indication is available (LT
by operator`s intervention. with it opening more than 0003 & LT 30003.
2. Bypass valves of required will lead to 2. Pump current
 LCV40001A/B stuck in open less flow to other tank. No indication is available on P
position. flow indication available 3. Saturator feed tank
3. Malfunction of however tank level overflow line is available.
LCV40001A/B open more than indication is available.
required. 3. By pass valve of either LCV
being open will lead to less
flow to tank.

High Pressure 1. LCV 40001 A/B closed more 1. Process disturbance. 1. PI`s available on pump
than required/Malfunction. 2. Rise in line pressure. discharge lines.
2. Isolation valve partially
closed/closed.
3. Third pump operated due
to operator error.
4. Line chocking, blockage,
NRV malfunctions.

Low Pressure 1. LSA transfer pumps 1. Process disturbance 1. PIs is available on pump
malfunctions/tripping. 2. Drop in line pressure discharge lines.
2. LCV40001 A/B open more
than required.
3. LCV leakage/drain valve
open.
4. Bypass valve around LCV is
open.

1” – WS – C111 No/Low flow 1. Valve in closed/pinched 1. Overheating of pump seal 1. HSW Supply Pump pres
– 0202 position and shaft to be regularly monitored
(Soft Water to LSA 2. Leakage upstream of supply 2. Loss of pump seal 2. Valve position should b
Feed Transfer Pump line lubrication. adjusted & ensured by are
Seals) 3. Deposition of scales on operator
pump seal

3”-SW-C111- High flow 1. Malfunction of ACV 40001 1. Decrease in LSA feed 1. Density meter AIC 4000
0031-1 ½ H B/AIC40001 control loop solution density monitoring
(HSW to Mother including AT40001 open more 2. High level of LSA 2. MF40005 is available
Liquor from RSB 1&2 than required. 2.Bypass open dissolving tank
and 3&4 of ACV 40001

Low/no flow 1. Malfunction of ACV
40001 B/AIC40001
control loop including
AT40001 open less than
required.
1.Increase in LSA feed 1.Density meter AIC
solution density 40001 monitoring
2. HSW Supply Pump
motor current
indication available on
 2. Valve Connecting to PLC
ML lines downstream of
ACV 40001 is in
closed/pinched
position/NRV
malfunction

3. Drain valve before

ACV40001B
open/passing resulting
in lower flow to ML
lines but MF40005
showing higher reading.

4. 2” Bypass to 3” WL-
CI-0011 fully open
reducing flow to 3” –
WL-CI-0027 or vice
versa
5. Failure of HSW water
supply.

0127- 04 – PID – 002– 1/2 (Saturator Feed System)

(Main header of Low/no flow 1. Line blockage/Scaling 1. Pumps (4-21- 1. Saturator Feed Tank
LSA feed 0002A/B/C) will Level indication is
solution to 2. Tank outlet valve is cavitate. available (LT 30003)
pump suction) closed/partially open.
4”- BL – D101- 2. Process disturbance. 2. Pump discharge PI of
0112 3. Pump Suction valve 4-21-0002 A/B/C is
3”-BL-D101- closed/partially open. 3. Rise in level of provided.
0015 saturator feed tank
3”-BL-D101- 4. Pump suction 3. HSW available for
0017 strainers choked. flushing.
3”-BL-D101-
0020 5. Line leakage.

6. Low level in saturator

feed tank.
High Flow 1. Mal-operation resulting in 1. Process Disturbance. 1. Pump current indication
third pump manual operation 2. Drop in level of saturator available.
by operator`s intervention. feed tank. 2. Saturator feed tank leve
2. Flushing Hot soft water available, LT30003.
valve stuck in open /partially
open condition.
4-21-0002A/B/C Low / No Flow 1. Upstream causes.
(Saturator Feed to 2. Discharge valve stuck in
Sand filters) 2”-BL- closed/partially closed
D101- position and/or NRV
0016 malfunction.
2”-BL-D101-
0018 3. 4-21-0002 A/B/C
2”-BL-D101- Pump motor tripping / failure.
0021 4. Line choking/blocking
2”-BL-CI-0109 problem.
3”-BL-D101- 5. Isolation valve partially
0045
closed/stuck in closed
position.
6. Line leakage/Drain valve
open.
7. Downstream flow
restriction (e.g. filter solenoid
valves do not open.)
High Pressure 1. Isolation valves partially
closed/closed.
2. Third pump operated due
to operator error.
3. Line choking/blockage/NRV
malfunction.
4. Downstream flow
restriction(e.g. filter solenoid
valve malfunction)
Low Pressure 1. Saturator feed pumps
malfunction / tripping.
2. Line leakage/drain valve
open.
3.Flow to three filters due to
solenoid valve malfunction
Corrosion Possible corrosion where line
2”-BL-CI- 0109 connect with
duplex header.
High Flow 1. Mal-operation
resulting in third pump
1. Reduced Feed flow to 1. Pump discharge PI of 4-
Saturator causing process 0002 A/B/C are available i
disturbance. PIs 40003, 40004, 40005.
2. Rise in pressure in 2. Saturator feed tank
saturator feed pumps’
discharge lines. level indication is available
LT30003.
3. Filter solenoid valve
position feed-back is avail
1. Process disturbance. 1. PIs 40003 / 40004 /
2. Rise in line pressure. 40005 available on pumps
discharge lines.
2. PI40008 available on in
header to filters. 3. PI4007
PI30072, PI30074 availabl
individual filters.
4. Filters solenoid valve
position feedback availabl
1. Process disturbance. 1.PIs 40003 / 40004 /
2. Drop in line pressure. 40005 available on pumps
discharge lines.
2. PI40008 available on in
header to filters. 3. PI4007
PI30072, PI30074 availabl
individual filters.
1. Process disturbance. 1. Saturator Feed Tank
2. Possible rise in line Level indication is
 High Flow

manual operation by pressure due to available (LT 0003 & LT

operator`s intervention. limitation on flow to 30003
feed filters. 2. Pump current
indication is available
on PLC.

1”-SW-C111- No/Low flow 1. Valve in closed/pinched 1. Unavailability of flushing 1. HSW Supply Pump
0045-1 ½ H position water pressure to be regularly
(HSW to Saturator 2. Leakage upstream of supply monitored
Feed Pump Suction line 2. SOP`s available to ensu
Header) 3. HSW supply pump correct operation of HSW
tripping/failure. valve.

1”-SW-C111- No/Low flow 1. Valve in closed/pinched 1. Overheating of pump seal 1. HSW Supply Pump
0203-1 ½ H position and shaft pressure to be regularly
(HSW to Saturator 2. Leakage upstream of supply 2. Loss of pump seal monitored
Feed Pump seals) line lubrication. 2. SOP`s available to ensu
3. HSW supply pump 3. Deposition of scales on correct operation of HSW
tripping/failure. pump seal valve.

0127-04-PID-002–
2/2 (Saturator Feed
System) High flow
3”-WL-CI-0011- 1. FCV 40018 A mal- 1. Decrease in LSA feed 1. Density meter AIC
16.
1 ½H operation (open more solution density. 40001 is available.
(Recycled than required)
Mother Liquor 2.High level of LSA 2. LSHH 40001/ LT
from RSB 3&4 2. FCV 40018 A bypass dissolving tank 40001 is available for
to LSA fully open tank monitoring.
3.Overflow of LSA
3. High flow of HSW dissolving tank 3.Mag flow meters MF
addition due to 40018A/40005 are
malfunction of density available
control system
AIT40001 and/or reduce
flow to recycled mother
liquor line 3” –WL-CI-
0027

4. Malfunction of
MF40005/MF40018A.

5. Mal-operation
resulting in third pump
manual operation by
operator`s intervention.
 Low/no 1. FCV 40018 A mal-
flow operation (close more
than required)
2. Malfunction of
MF40018A.
3. Line
Leakage/Isolation valve
partially closed.
4. Drain valve is stuck in open
position/passing.
5. Mother liquor pumps
malfunction/pump tripping.
1. Process disturbance.
2. Low level of LSA
dissolving tank
3. Spillage in area.
1. Density meter AIC
40001 monitoring
2. LT 40001 is available
tank level monitoring
3. Mag flow meters MF
40018A available
4. Mother Liquor pump

0127-04-PID-003– 1/2 (Saturator)

(Saturator Feed to Low / No Flow 1. Upstream causes. 1.Feed limitation to Saturator

Sand filter 4- 24- 2. Isolation valve stuck in column
0001C & 3- closed position.
24-0001A/B)

3”-BL-D101- 3. Solenoid valve malfunction. 2. Process disturbance.

0045
2”-BL-CI-0109
4. Line leakage. 3. Rise in pressure of
5. Line blockage. discharge line of saturator
feed pump.

(Saturator Feed Low / No Flow 1. Upstream causes. 1.High ∆P across sand

Filter outlet line to 2. Isolation valve stuck filter 4-24-0001C
PHE inlet)
in closed/partially 2. Process disturbance.
2”-BL-CI-0111 closed position.
3”-BL-CI-0154 3. Feed limitation to saturator
3” BL-CI-0155 3. Filter Solenoid valve column.
2”BL-CI-0032 malfunction. 4. Rise in pressure upstream
4. Strainer Choking of restriction.
5. Line blockage. 5. Process material spillage.
6.Line leakage.
7.Malfunction of FIC control
loop i.e.( FT 40010 ,FV U-
30010
Saturator feed to PHE FCV)
8. Valve open on bypass line
3”-BL-CI-0173

High Flow 1. Sequence failure allowing 1. Process disturbance.

all three filters
to operate 2. Saturator ratio control shall
simultaneously. be disturbed.

2. FV-30010 bypass
valve stuck in open
position.

3. FT 40010/FIC30010
control loop
malfunction.

4. HSW flushing water

line valve stuck in open
position.
Contamina tion. 1. Bed material carry over due 1. Possible Material carryover
to damage of holding screen. into the product.

Compositio n 1. Backwash regime is not 1. Product quality

Change appropriate or does not compromised.
operate in sequence.

Saturator Feed Filter High Pressure 1. Restriction in outlet of 1. Process disturbance.

(4-24- filters / solenoid valve 2. High ∆P across sand
00010) malfunction filter 4-24-0001C.
2. Fouling of filter bed
material.
(Saturator Feed Low / No Flow 1.Upstream Causes 1. Process disturbance.
Solution Exit PHE to 2. Scaling of PHE. 2.Feed limitation to Saturator
saturator) column

2”-BL-CI-0035 3. By pass line 3”-BL-C1- 0173 3. Rise in saturator feed

3”-BL-CI-0131 valve stuck in open position temperature if bypass valve is
3”-BL-CI-0160 4. Isolation valve stuck open.
3”-BL-CI-0162

3” BL-CI- in closed / partially

0173(bypass line) closed position.
5. Drain valve stuck in

open position.

6. PSH30013 closes PV-

U-30013 or closes due
to malfunction.
7. Line leakage.
8. Line choking.

High Flow 1. Upstream causes. 1. Rise in saturator feed

2. Restriction in flow to other temperature.
PHEs.

High 1. Cooling water flow 1. Process disturbance.

temperatur e restriction i.e. TCV- 40035 2. High feed temperature to
malfunction / TIC40035 saturator.
control loop malfunction.

2. Fouling/scaling of the
PHE.

3. Restricted flow to
saturator.

4. Higher cooling water

supply temperature
during summer season.
 Low Temperatu 1. High flow of cooling water 1. Process disturbance.
re due to malfunction of
TIC40035 control loop
/TCV40035.

2. Lower saturator feed flow

rate to PHE.
3. High flow of cooling water
due to bypass around
TIC40035 open.
4. Low cooling water supply
temperature during winter
season.

(Cooling Water Low / No Flow 1. TCV 40035 /TIC 40035 1. Increased saturator feed
Supply to control loop mal temperature to
Saturator Feed operation tower.
PHE)
3”-CWS-C111- 2. CWS pump tripping at plant 2. Process disturbance.
0136 A
2”-CWS-C111- 3. Line leakage.
0136

(Cooling Water 4. PHE fouling due to water

Return from quality.
Saturator Feed PHE 5. Isolation valve stuck in
to header) closed/partially closed
3”-CWR-C111- position.
0138 6. Drain valve stuck in open
2”-CWR-C111- position.
0138
3”-CWR-C111-

0164 7. Restriction in cooling

water return line to
main header.
 High Flow 1. Malfunction of TCV40035 / 1. Low temperature of feed to
TIC40035 control loop saturator.
malfunction.
2. Bypass valve across TCV is
stuck in open position.

Contamina tion 1. PHE damage allowing feed

leakage to cooling water
stream.

(HSW to Saturator Low / No Flow 1.Valve stuck in closed 1. Filter back flushing regime
feed filter) position won`t be followed.
2”-SW-C111- 2.HSW pump tripping. 2. Fouling of filter bed leading
00157-1 ½ H 3. Solenoid valve malfunction. to increased differential
4. Line leakage. pressure across filter bed.

0127-04-PID-003– 2/2 (Saturator)

6”-KGC-C111- Low / No Flow 1. Upstream causes. e.g. Kiln 1. Reduced kiln gas flow to
0036 gas compressor saturator.
to KOD (4-31- tripping.SC-09 tripping
0002) (if in service) etc., 2. Personnel hazard
due to gas leakage.
2.Line leakage

3. Isolation valve stuck

in close /partially closed
position.

4. PV101 operating with

associated valves
allowing gas to flow to
KG compressor suction
line.

5. Restricted outlet from

KOD (4-31-0002)

6. Liquid level in KO drum is

above inlet gas nozzle.
 7. If isolation valve on
compressor 9 discharge
header open/passing,
possible flow to TE gas
header depending on
pressure differential.
High Flow 1. Upstream causes.

KOD Exit KG to 3- Low/no flow 1. Upstream causes. 1. Reduced kiln gas flow to
P04-P01-60- saturator.
C1-150 Header 2.Line leakage
6”-KGC-C111- 2. Rise in pressure in
0165 3. Isolation valve stuck in KOD.
close/partially closed position.

4. Restricted outlet from

KOD due to demister fouling.

5. Pressure in existing line is
higher than the new line
causing restriction in flow.

4-31-0002 High Level of 1. Upstream causes i.e. 1.Liquid carry over in gas
liquid in carryover of moisture in stream to Saturator
(Kiln Gas KOD drum incoming stream.
upstream of 2. Poor separation 2. Process disturbance.
saturator)
efficiency. 3.Contamination/diluti on of
3. Drain operational regime Magma in Saturator
not followed.

Low /no level 1. Drain valve stuck in open 1.Gas loss to atmosphere
position/passing. 2. Process disturbance. 3.CO2
hazard in area
 High Pressure 1. Restriction in flow to outlet 1. Process disturbance.
line of KOD/restriction in flow 2. Rise in drum pressure.
to header.
2. Upstream causes.

Low pressure 1. Upstream causes. 1. Process disturbance.

2. Line leakage. 2. Possible reverse flow from
3. Drain valve open. header.

Compositio n 1. Increased moisture content 1. Moisture carry over in gas

change due to inefficient demister lien to saturator.
operation/damage.

0127-04-PID-004– 1/2 (Centrifuge-03 and Drying)

(Magma to Low / No Flow 1. Isolation valve stuck in 1. Centrifuge will not fill.
Centrifuge 4 from closed/partially closed
Magma Tank 3-23- position.
0004) 2.Low level in Magma tank 3-
6”-MM-D101- 24-0004
0050 3. Feed line blockage.
4. Centrifuge sequence
control malfunction closing
solenoid valve.
4. Line leakage/drain valve
open.

0127-04-PID-004– 2/2 (Centrifuge-04 and Drying)

2”-SS-C611- High flow 1. PIC40009 control loop 1. Air temperature exit air
0059-3 ½ H malfunction /PCV40009 open heater will increase
(HP steam to Air more than required. 2. Product quality will be
heater ) 2. PCV 40009 bypass valve in compromised.
open position.

Low/no flow 1. PIC40009 control loop 1.Air temperature exit air

malfunction /PCV40009 heater will decrease
open more than
required. 2. Product quality will be
compromised.
2. Line leakage.
3. Line Pressure will
3. Upstream issues in steam rise upstream of restriction.
supply.

4. Steam trap 4. Personnel hazard

passing/malfunction on due to leakage of

line 0201. steam.

5. Isolation valve stuck in

closed/partially closed
position.

6. PSV-40001

passing/lifting.
7. Outlet condensate flow
from heater is restricted.
 High Pressure 1. PIC40009 control loop
malfunction /PCV40009 open 2. Flow to the air heater is
more than required.
2. PCV 40009 bypass are stuck from required temperature
in open position.
3. Flow to the air heater is 3. Potential for line damage;
restricted.
4. Isolation valves
closed/partially closed.
Low Pressure 1. PIC40009 control loop
malfunction /PCV40009 open
more than required.
2. Upstream causes in steam
supply.
3. PSV-40001
passing/lifting.
4. Line leakage.
(Air Heater Exit High flow 1. Upstream causes.
Steam
condensate to 2. Steam trap malfunction.
4-50-0001 Flash
Vessel)
2”-SC-C112- 3. Steam trap bypass stuck in
0094-2 ½ H open position.
Low/no flow 1. Upstream causes.
2”-SC-C112-
2. Isolation valve
0098-2 ½ H closed/partially closed/NRV
malfunction/strainer choking.
2”-SW-C111- 3. Steam trap malfunction.
4. Drain valve open on outlet
from air heater.
1. Process disturbance.
restricted causing deviation
set point.
rise in pressure upstream of
restriction.
1. Process disturbance.
2. Low pressure downstream
of PCV40009; high pressure
upstream of PCV40009.
3. Personnel hazard due to
leakage of steam.
1.Increased liquid to
flash vessel 4-50-0001
2.Additional flash steam
vented
1. Condensate will
accumulate in heater,
affecting heat transfer.
2. Rise in pressure in heater
and steam inlet line.
3. Air heater performance will
be effected against the flow.
 2. Isolation valve
closed/partially closed/NRV
malfunction/strainer choking.
3. Steam trap malfunction.
0095-1 ½ H 4. Drain valve open on outlet
from air heater.
accumulate in heater,
affecting heat transfer.
2. Rise in pressure in heater
and steam inlet line.
3. Air heater performance will
be effected against the flow.

4-50-0001 Flash Low liquid level 1. Upstream causes. 1. Flashing of steam taking
Vessel 2. Drain valve open. place in line to HSW tank, two
phase flow restricting
condensate flow.

High liquid level 1. Upstream causes. 1. Rise in flash tank level.

2.Restriction of flow to HSW
tank
3. Isolation valve
closed/partially closed.

High Pressure 1. Upstream causes. 1. Rise in flash tank level.

2. Restriction of flow to HSW

tank/Isolation valves
closed/partially closed.
3. Flow from 3” –SC- C112-
0096 gets restricted due to
blockage.

16”-DA-C111- Low / No Flow 1.Fan tripping 1. Production disturbance,

0057-2 ½ H no/less
14”-DA-C111- 2. VFD malfunction. conveying of product;
0058 3. Damper (OV) closed more higher air temperature.
Air from dryer fan 4 than required. 2. TIC 40009 loop malfunction
(4-22- 4. More flow through bypass allowing more flow than
0001) to drier reducing flow through heater required, reduce air
feed table (4- because of TIC40009 loop temperature affecting dryer
42-0001) operation.
malfunctions/TCV40009
through air heater 4 malfunction.
(4-32-
0002)
 High Flow 1. VFD malfunction. 1. Product quality will be
2. TIC40009 loop valve compromised, as air
malfunctions and opens less temperature may increase.
than required increasing flow
through heater.

High Pressure 1. VFD setting is inaccurate. 1. Product residence time in

2. Damper is closed more drying table affected,
than required. compromising product
quality.

Low/no 1. VFD setting is inaccurate. 1. Product residence time in

pressure 2. Motor tripping. drying table affected,
2. Damper is open more than compromising product
required. quality.

High Temperatu 1. Malfunction of TIC40009 1. Product quality will be

re control loop. compromised.
2. Lower air flow through
heater.

Low Temperatu 1. Malfunction of TIC40009 1. Product quality will be

re control loop. compromised.
2. Higher air flow through
heater.

1”-SW-C111- Low / no flow 1.Isolation valve in closed 1.Inadequate flushing of

0062-1 ½ H position drying tube line
(HSW to Drying
Tube 4-49-0001) 2.HSW pump tripping

0127-04-PID-009 – 1/4 (CO2 Compressor System)

Kiln gas to Low/no 1. Upstream causes. 1. Process disturbance;

Compressor flow reduced flow of kiln gas
 flow
Suction from 2. Demister fouling /line to saturator.
Knock Off Vessel blockage.
12”-KGC-C111- 3. Drain valve of knock out
0102 vessel open/passing.

10”-KGC-C111- 4. Strainer restricts the flow of

0102 gas due to fouling.

5. PICA 101
malfunctions. (This regulates
operation of PV101 which
allows gas to flow from
discharge line to suction line
on pressure reduction.
6. PV101 malfunctions when
required and does not
operate.

7. Isolation valve stuck

in closed/pinched
position
High Flow 1. Upstream causes. 1. Increase in pressure in
2. By pass suction strainer suction line.
also operational.
3. PV101/PICA101
malfunctions allowing flow
from discharge line more than
required/when not required
4. Line leakage-causing
ingress of air.

High Pressure 1. Upstream causes. 1. High gas pressure to

2. PICA control compressor – possible
damage.

loop/PV101 malfunctions 2. Reduction in kiln gas flow

allowing more flow than to saturator incase PV101
required/when not required opens especially if fully open.
3. Bypass around PV101
open/partially open.
4. Compressor
trip/malfunction.
5. Isolation valve
closed/partially
closed/strainer fouling/line
restriction causing high
pressure upstream of
restriction.

Low Pressure 1. Upstream causes. 1. Process disturbance.

2. Isolation valve partially
closed.
3. PICA101 control loop
/ PV 1010 malfunctions - does
not allow enough flow from
discharge side/ does not
Operate.
 High Temperatu 1. Upstream causes. 1. Rise in temperature of gas
re at compressor discharge.

Compositio 1. Decrease in water 1. Process disturbance

n change level of lute pot/water seal due to lower CO2

tank located on kiln gas lines concentration.
resulting in air being sucked 2. Pressure will increase.
into compressor suction.
2. Sucked air entry into gas
due to line leakage.

Kiln Gas Screw Low / No Flow 1. Compressor 1. Rise in separator pressure if

Compressor to malfunctions/tripping. flow from it
separator. is restricted.
6”-KGC-C111- 2. NRV malfunction. 2. Reduced /no flow of Kiln
0186 3. Fouling of tubes in gas gas to saturator.
6”-KGC-C111- cooler. 3. Rise in pressure
0187

7 4. Restriction of flow to upstream of any

separator/in outlet flow from restriction.
separator.

5. Line leakage.

High Flow 1. Wrong settings for 1. Possible reduced discharge

compressor operation. pressure and higher gas
temperature.
2. Possible high moisture
carryover to saturator.
High pressure 1. Compressor malfunctions.
2. Wrong settings for
compressor operation.
3. Restriction of flow to
separator/in outlet flow from
separator.
4. Restriction of flow through
cooler due to fouling.
1. High pressure of gas
entering separator.
2. High pressure upstream of
restriction.
3. Rise in separator pressure.

Low Pressure 1. Compressor malfunctions. 1. Low pressure of gas

2. Wrong settings for entering separator & flowing
compressor operation. to separator
3. Line leakage. 2. Personnel hazard due to
exposure of personnel to gas.

High Temperatu 1. Compressor Malfunction 1. Higher temperature of gas

re 2. PCD water injection flow to entering cooler and separator.
compressor is less than 2. Process disturbance in
required due to malfunction saturator.
of

TICSA102 control loop, TV102,

TT102 or PCD
water upstream reasons.
3. Cooling water flow is
restricted e.g. isolation valve
closed/partially closed on
inlet and outlet line of CW.
4. PCD Water temperature is
high due to upstream causes.
 Low temperatur 1. Compressor Malfunction- 1. Lower temperature of gas
e lower discharge pressure entering saturator.
2. Higher cooling water flow
than required through cooler.
3. High PCD injection flow to
compressor due to
malfunction of
TICSA102/TV102 control loop.

Contamina tion 1. Contamination of gas with

cooling water due to tube
leakage.

PCD water injection Low /no flow 1. Upstream supply issues 1. Rise in temperature of kiln
line to new screw with PCD water gas discharge exiting
/PCD water compressor.
compressor 1”-PCD- temperature.
C111- 2. Malfunction of TICSA102
0105 control loop, TV102, TT102.
3. Isolation valve
closed/partially closed.
4. Strainer choking/NRV
malfunction.
5. Line leakage.

High Flow Malfunction of TICSA102 1. Drop in temperature of kiln

control loop gas discharge ex-
/TT102/TV102 open compressor.
more than required.
2. Bypass valve around
TV102 open.
 Low Pressure 1. Upstream supply issues 1. Lower flow to compressor
with PCD water. leading to rise in temperature
2. Isolation valve of kiln gas ex-compressor.
closed/partially 2. Standby strainer available.
closed/strainer choking
causing low pressure
downstream of restriction.

3. Line leakage.
High Pressure 1. Upstream supply issue. 1. Rise in pressure upstream
2.TICSA102/TV102 of restriction.
malfunction with valve
closed more than required
resulting in rise in upstream
pressure.
3. Isolation valve closed
/partially closed/strainer
choking.

High Temperatu 1. Higher temperature of PCD 1. Rise in temperature of kiln

re water. gas discharge exiting
compressor.
Low Temperatu 2. Lower temperature of PCD 1. Lower temperature of kiln
re water. gas discharge exiting
compressor.
Separator High Level of 1. Upstream causes i.e. 1. Higher Liquid carry over in
liquid in drum carryover of higher moisture gas stream to Saturator due
content in incoming stream. to loss of separation efficiency
2. Malfunction of LV101 and in demister pad
LICA101 control loop.

Low level in 1. Upstream causes. 1. Possible loss of kiln gas

Liquid through drains.
drum 2. Drain valve on 1 1/2
“-D-C111-0197 is left 2. Lower flow of kiln

open/partially open. gas to saturator.

3. Malfunction of LICA101
control

loop/LV101. that a certain level is alwa

maintained.
High Pressure 1. Restriction in outlet flow 1. Rise in internal pressure of 1. PG104 is available.
from separator. separator.
 High Pressure
separator.
2. Fouling of demister pad
restricting outlet
flow.
3. Upstream causes.
1. Rise in internal pressure of
2. PSV is available on
Separator
3. Design pressure of
separator is 120 PSI(g) wh
design pressure of screw
compressor is
45 PSIA.

Low Pressure 1. Upstream causes. 1. Process disturbance. 1. PG104 is available.

2. PSV passing /lift.
3. Passing of gas through
drains due to loss of liquid
load (damage to baffle)

GENERAL
Maintenance

Corrosion No Concern No Concern No Concern No Concern

Earthing and
Lightning
Protection
Fire Safety/Protect
ion

Noise

Access Platform /
Access to
equipment &
valves etc.,

Effluent Handling

Startup and Shut

Down Procedures

Engineering
procedures.
 Environmental
Protection

Failure of Services 1.Instrument Air

2. Power
3. Cooling water

4.Steam /RLS steam

Sampling
Arrangement

Control System 1. Integration between

control systems.

Health and Safety

Hazard Study 3 session, involving Works, CTED, Project teams and HS Leader carried out on 20 th and 21st October 2020 concl
HS3 of remaining P&IDs was shared with Syed Mohsin Ali (HS Leader) and his comments have been incorporated.

0127-04-PID-005– 1/2 (Separation – Scrubber 3 Section)

(Mother liquor from Low / no flow 1. Centrifuge 4 tripping 1. Mother liquor tank (3-33- 1. Centrifuge 4 independe
Centrifuge 4 to (3- 2. Line blockage. 0005) level will go down control sequence is availa
33-0005)
Mother liquor tank) 2. Scrubber pumps (4- 21- indicating centrifuge tripp
8”-BL-CI-0060 006A/B) can cavitate 2.LT 30007 available on
mother liquor tank.
3. There is a separate feed
line from Centrifuge 3 as w
to Mother liquor tank
4. Buffer available in moth
liquor tank as flow during
cloth washing is much hig

(Mother liquor from Low / no flow 1. Upstream causes. 1. Process disturbance. 1.Centrifuge 4 independen
dust control
scrubber to (3- 2.Low mother liquor level in 2. Mother liquor tank (3-33- sequence is available
33-0005) mother liquor tank (3-33- 0005) level will go down 2.LT 30007 available
Mother liquor tank) 0005)

6”-WL-C111- 3. Mother liquor line 3. Scrubber pumps (4- 21- 3. LSH 40010 is available o
0075 from Dust Scrubber Tank (4- 006A/B) can cavitate scrubber tank
31-0003) to
Existing mother liquor
tank is blocked 4. Dust scrubber tank level 4. LG 40009 is available on
4. Low level in Scrubber Tank will increase scrubber tank

5. Drain valve stuck in

open position.
(From (3-33- Low/No Flow 1. Low level in Mother liquor 1. Scrubbing efficiency 1. LT30007 / LIC 30007
0005) Mother liquor tank. reduced. with high & low-level alar
tank to new 2. Line blockage/Scaling provided on existing moth
scrubber liquor
pump) 3. Tank outlet valve is 2. Mother liquor tank (3-33- tank.
3”-WL-C111- closed/partially open. 0005) level will increase 2. HSW connection is
0063 4. Pump Suction valve 3. Scrubber pumps (4- 21- available for flushing of pu
closed/partially open. 006A/B) can cavitate suction line
5. Pump suction strainers 3. PIs 40018/40019 are
choked. available on discharge line
6. Scrubber pump tripping / scrubber pumps 4-21-000
failure A/B
7. Line leakage. 4. Scrubber pumps curren
indication is available
 High Flow 1. Mal-operation resulting in 1. Increased flow to dust 1. Pump current indication
standby pump manual scrubber raising liquid level available.
operation by operator`s in scrubber 2. LG 40009 is available
intervention. 3. LSH 40010 with high lev
2. Flushing Hot soft water alarm is available
valve stuck in open /partially
open condition.

(HSW to new Low/ No 1. Isolation valve stuck 1. Inadequate 1. HSW Supply Pump
scrubber pump flow in closed / partially open flushing/deblocking of current indication
suction line 3”- position lines available
WL-C111-0063)
1”-SW-C111- 2. HSW pump tripping
0069-1 ½ H

0127-04-PID-005 – 2/2 (Separation – Scrubber 4 Section)

1” – WS – C111 No/Low flow 1. Valve in closed/pinched 1. Overheating of pump seal 1. HSW Supply Pump pres
– 0216 position and shaft is regularly monitored. Pu
(Soft Water to 2. Leakage upstream of supply 2. Loss of pump seal current indication is availa
Scrubber Pumps line lubrication. 2. SOPs available to ensur
Seals) 3. HSW supply pump 3. Deposition of scales on correct operation of valve
tripping / failure pump seal

(Mother Liquor from Low / no flow 1. Upstream causes. 1. Reduced flow to dust 1. PI 40018/40019 are
Scrubber scrubber resulting in available for the
Pumps 4-21- 2. Discharge valve stuck high dust emission operational pump
0006A/B to in closed / partially
Scrubber Tank 4-31- closed position and/or 2. Drop in liquid level in 2. Stand by pump is availa
0003) NRV malfunction. scrubber
2”-WL-C111-
0042 3. Pump (4-21-0006A/B) 3. Pump current indication
2”-WL-C111- motor tripping available on PLC.
0062 4. Pump (4-21-0006A/B) 4. LG 40009 is available
3”-WL-C111- discharge line is blocked
0042

5. High liquid level on scrubber

3”-WL-C111-
0042

on scrubber
restricts flow into
scrubber.
6. Isolation valve
partially closed/stuck in
closed position.
7. Line leakage.

High Flow 1. Mal-operation resulting in 1. Process disturbance. 1. Dust scrubber level swi
standby pump manual 2. High level in dust scrubber and high level alarm LSH
operation by operator`s 40010/LAH40010 availabl
intervention. 2. LG 40009 is available
operation.
3. Pump current indication
available on PLC.
4. Dust scrubber tank
overflow line is available.

Drying Air from Low / No Flow 1. Lower flow of drying air to 1. Possibility of product dust 1. PT 40033 / PI 40033
Cyclone 4-42- cyclone. deposition in line is available with high
0003 to Dust and low alarm at
Scrubber 4-31- 2.Scaling at cyclone outlet scrubber inlet
0003
2. PT 40032 / PI 40032
18’’-DA-C111- 3. Tripping of dust scrubber is available with high
0066-P fan and low alarm at scrubber
4. Isolation valve closed outlet. Differential pressu
/ partially closed between PIs will indicate a
issues

3. HSW line connection

is available for line
flushing/deblocking.

4. Current indication of
scrubber fan is available o
PLC
(Drying air exit Low / No Flow 1. Dust scrubber fan (4- 22-
scrubber tank 4- 0002) Motor tripping
31-0031) / VFD malfunction / VFD
18”-DA-C111- setting low
0071 2. Line blockage due to scale
18”-DA-C111- deposits.
0070 3. Line leakage.
4. Damper valve closed or
closed more than required
1. Product quality will be 1.PT 40032 / PI 40032
compromised. with low pressure alarm w
2.Back pressure on dust show rise in pressure if
scrubber (4-31- damper restricts flow
0003) 2. Fan motor indication is
3. Product dust deposition in available on PLC.
line 3. HSW flushing connectio
provided; also access doo
washing line / duct

High Flow 1. VFD malfunction / VFD
setting high
2. Moisture carry over due to 2. Ingress of moisture in fan handling capacity
flushing hot soft
water valve stuck in
open position
1. Product quality will be 1. PT 40032 / PI 40032
compromised. is available with high
pressure alarm if fan
– possible inadequate
corrosion
3. Carryover of dust into
atmosphere if suction higher
than required; possible
carryover of mother liquor

High Pressure 1. VFD setting is inaccurate. 1. PT 40032 is available

Low/no 1. VFD setting is inaccurate. 1. PT 40032 is available

pressure 2. Damper is open more than
required.
(HSW Supply to Low flow 1. Isolation Valve/NRV stuck 1. Process disturbance. 1. HSW Supply Pump pres
Scrubber Tank from in closed. to be regularly monitored
header) 2. Line leakage. 2. Valve position should b
2”-SW-C111- 3. Upstream causes i.e. HSW adjusted & ensured by are
0067-1 ½ H pump tripping operator
1”-SW-C111-
0065-1 ½ H
1”-SW-C111-
0142-1 ½ H

4-31-0003 High level 1. Restriction at outlet to 1. Dust scrubber tank 1. LSH 40010 is available o
(Dust Scrubber Tank) mother liquor tank. overflow scrubber tank with high le
2. Increased mother liquor 2. Mother liquor carry over alarm
flow to scrubber into scrubber fan and 2. LG 40009 is available on
e.g. by standby mother liquor atmosphere scrubber tank
pump manual operation by 3. Mother Liquor pumps
operator`s intervention. current indication is availa
3. Flushing HSW valve for vent 4. Overflow line is availab
stuck in open position.

Low Level 1. Decreased mother liquor 1. Process Disturbance 1. Mother liquor scrubber
flow to scrubber i.e. scrubbing of dust pumps
e.g. through scrubber laden air shall be current indication is
pump tripping impacted available.

2. Drain valve stuck in 2. LG 40009 is available on

open /partially open scrubber tank
condition.
 High Pressure 1. Rise in vessel pressure due 1. Increase in pressure of 1. PT 40032 & PT 40033
to vent blockage dust scrubber; flow of drying are available with high ala
2. Scrubber fan tripping air into dust scrubber may 2. Fan current indication i
/ malfunction / VFD be affected available.

malfunction / VFD setting low

1. VFD setting is inaccurate.

0127-04-PID-006 – 1/2 (Hot Soft Water Tank System Set 1-3)

(RLS Steam to new High flow 1. Higher RLS pressure. 1. High HSW temperature in 1. TT40005 / TI 40005 is
HSW tank) HSW available on HSW
2”-RLS-C113- 2. Valve open at more than tank (4-33-0006) pumps discharge
0171-2 ½ H required position. causing water for centrifuge
at higher
temperature than
required

2. High hot water

temperature for HSW
pumps (HSW pumps are
designed at 95 oC)

Low/no flow 1. Isolation valve closed 1. Low HSW temperature in 1. TT40005 / TI 40005 is
/ partially closed HSW available on HSW
tank (4-33-0006) pumps discharge

2. Upstream causes i.e. low IP 2. Inadequate process

Steam pressure in main routines of equipment due
header to low HSW temperature

3. Restriction to flow in
sparger
4. Line leakage

High Pressure 1. Higher RLS steam pressure 1. Rise in HSW temperature 1. TT40005 / TI 40005
2. Isolation valve closed is available on HSW pump
/ partially closed / sparger discharge
blockage
(HSW to Centrifuge 4 Low/no flow 1. Low level in existing HSW 1. Process disturbance 1. PI 30066/30067 are
tank available on discharge
from Process of centrifuge HSW
HSW Pumps 3- 2. Isolating valve closed pumps
37-0001 A/B & / partially closed
Centrifuge HSW
Pumps 3-36- 3. Tripping of Centrifuge HSW 2. Alternative supply line 3
0001A/B) pumps (3-36- 0001A/B) SW-C111-0116 available f
3”-SW-C111- HSW pumps
0052-1 ½ H

4. Valve open on 3’’-SW-

C111-0168 line to
existing HSW tank /
malfunction of
regulating valve
5. Line leakage

High Flow 1. Mal-operation resulting in 1. Process disturbance. 2. Operating procedures t

standby pump manual 2. Low level in HW tank ensure plant operation.
operation by operator`s 3. PI 30066/30067 are
intervention. available.

(HSW Return from Low/no flow 1.Regulation valve 1. Back pressure on

Centrifuge 4 HSW malfunction / manual valve centrifuge pumps when both
Supply line 3”-SW- closed / partially closed centrifuges 3 & 4 are not in
C111-0052-1 ½ 2. Line leakage flushing cycle
H to Existing Hot
Soft Water Tank)
3”-SW-C111-
0168-1 ½ H

High Flow 1.Regulation valve 1. Reduced water flow 1. LS on existing tank

malfunction / manual valve towards centrifuge 2. LT 4008 on new tank
fully opened 2. HSW tank level will rise
2. Upstream causes i.e.
standby pump in service
inadvertently
(Balancing Line Low/no flow 1. Isolation valve closed
between HSW Tank / partially closed
1&2)
3”-SW-C111-
0119-1 ½ H
0127-04-PID-006 – 2/2 (Hot Soft Water Tank System Set 4)
(PCD water from Low/no flow 1. Upstream causes.
Existing PCD water 2. Isolation valve closed
line)
2”-PCD-CI-0169 / partially closed
3. Line leakage
(HSW Tank 2) Low level 1. Incoming HSW flow is
4-33-0006 reduced because of
outage/maintenance
2. Tank drain valve stuck in
open position
3. Mal-operation
resulting in standby HSW
pump manual operation by
operator`s intervention.
4. Leakage from tank
High Level 1. Increased flow into tank
2. Tripping of HSW
pumps
Tank outlet valve stuck in
closed position
1. Low level in new HSW
tank
1.Low level in HSW tank (4- 1.Balance line is available
33-0006). compensate level fluctuati
2.HSW Pumps (4-37-
0001A/B) will lose suction,
cavitate and downstream
users will be affected
1.HSW Pumps (4-37-
0001A/B) will lose
suction, cavitate and
downstream users will
be affected
1. LT 4008 is provided on
HSW tank.
2. Direct HSW provision fo
new HSW tank is part of
design
2.LT 4008 is available alon
with LIA 4008 (low level
alarm)
1.Balance line is available
from existing
HSW tank to
compensate level
fluctuations
2.LT 4008 is available alon
with LIA 4008
(low level alarm)
1.LT 4008 is available
2. Overflow line is
available
3. HSW pumps current
indication is available in P
 High Pressure 1. High pressure of RLS steam 1. Rise in tank pressure
to tank
2. Tank vent line blocked /
partly blocked

(HSW suction to Low/no flow 1. Low level in HSW tank 1.HSW tank (4-33- 1. PI40069 / 40066
HSW Pump 4- 0006) level will rise available on pump
37-0001A/B) 2. Isolation valve closed discharge
6”-SW-C111- / partially closed 2.HSW Pumps (4-37- 2. LT 4008 is available alon
0118-2H 3. Drain valve stuck in open 0001A/B) will lose suction, with low level alarm LIA 4
position. cavitate and downstream
users will be affected

6”-SW-C111- 4. Line leakage

0040-2H

6”-SW-C111-
0038-2H
High Flow 1. Mal-operation resulting in 1.HSW tank (4-33- 1. Pump current indication
standby pump manual 0006) level will reduce available.
operation by operator`s 2. Rise in HSW header 2. LT 4008 is available alon
intervention. pressure with low level alarm LIA 4
3. PI 40066 & PI 40069
available

(HSW Pumps Low/no flow 1. HSW pumps (4-37- 1. Process disturbance due 1. Standby pump is availab
Discharge) 0001A/B) tripping / pumps to non-availability of water 2.LT 4008 is available alon
3”-SW-C111- malfunction for downstream users with LIA 4008
0199-1 ½ H 2. Low level in HSW tank

3”-SW-C111- (4-33-0006) (low level alarm)

0039-1 ½ H 3. Pump discharge header 3. PI40069/40066
3”-SW-C111- valve(s) stuck in available
0041-1 ½ H closed/pinched position
/ NRV malfunction.
4. Drain valve stuck in open
position
5. Line leakage
 High Flow 1. Mal-operation resulting in 1.HSW tank (4-33- 1. Pump current indication
standby pump manual 0006) level will reduce available.
operation by operator`s 2. Rise in HSW header 2. LT 4008 is available alon
intervention. pressure with low level alarm LIA 4

Seal Water for HSW No/Low flow 1. Valve in closed/pinched 1. Overheating of pump seal 1. HSW Supply Pump pres
Pumps position and shaft to be regularly monitored
1”-WS-C111- 2. Leakage upstream of supply 2. Loss of pump seal 2. Valve position should b
0220 line lubrication. adjusted & ensured by are
3. Deposition of scales on operator
pump seal

0127-04-PID-007-1/1 (Cooling Water System)

Cooling Water Low/no flow 1. CWS pumps at Phase- 01 1. Process disturbance. 1. MF 40026 available as a
Supply Lines have tripped indicative measure of low
8”-CWS-C111- 2. Line leakage flow - this is on common l
0136 3. Isolation Valve closed to CO2 compressor gas co
6”-CWS-C111- partially closed and oil cooler
2. PIs available at inlet

0170 to gas cooler, oil

4. Restriction to flow at cooler, on 6’’ CWS
6”-CWS-C111- any supply point header and on inlet to
0104 saturator feed cooler
4”-CWS-C111-
0106

1”-CWS-C111-
0109
4”-CWR-C111- Low/no flow 1. Upstream causes. 1. Process disturbance.
0107 2. Isolation valve
1”-CWR-C111- closed/partially closed
0108 3. Line leakage
6”-CWR-C111-
0172
6”-CWR-C111-
0105
8”-CWR-C111-
0138

0127-04-PID-008-1/1 (CO2 Compressor System Gas Circuit)

(Kiln Gas to knock Low/no flow 1. Upstream causes. 1. Process disturbance. 1. PCV 4012 bypass is
out Reduced flow to new available.
Vessel V0804- 2. PCV 4012 malfunction CO2 compressor. 2. PCV 4013 bypass is
01 / PICA101 loop malfunction. 2. In case of bypass available.
12”-KGC-C111-
0100(Kiln Gas around V0804-01
from Kiln 1 to 6) 3. PCV 4013 possible increased moisture 3. PICA101 with low press
12”-KGC-C111- malfunction/PICA101 loop content in kiln gas to alarm available. PG101
malfunction. compressor.
0218 (Kiln Gas 7 4. Bypass valve around available.
Header) V0804-01 valve open/passing 4. Lute pots available at
12”-KGC-C111- low flow through vessel. drains. SOP`s to ensure wa
0101 (Kiln Gas 8 5. Isolation valve stuck in level is maintained.
Header) closed/pinched position.
12”-KGC-C111-
6. Drain valves open/passing.
0217 (Bypass around
V0804- 01)

Kiln gas to knock out High Flow 1. Upstream causes. 1. Rise in pressure of gas 1. PICA101 available with
vessel V0804-01 2. PCV4012 open more than flow to new compressor. pressure alarm.
12”-KGC-C111- required.PICA101 loop 2. Possible increased 2. PG101 is available.
0100(Kiln Gas from malfunction moisture carryover in kiln
Kiln 1 to 6) 3. PCV4013 open more than gas.
12”-KGC-C111- required/PICA101 loop
0218(Kiln Gas 7 malfunction.
Header) 4. Bypass valves around
12”-KGC-C111- PCV4012/PCV4013 open.
0101(Kiln Gas 8
Header)
12”-KGC-C111-

0217(Bypass around High Pressure 1. Upstream causes. 1. Rise in line pressure in 1. PICA101 available with
V0804- case of restriction, high-pressure
01) 2. Compressor tripping. this will be upstream of it. alarm.

3. Outlet flow from 2. PG101 is available.

01) this will be upstream of it.

2. PG101 is available.
knock out vessel
restricted, fouling of
demister.

4. Isolation valves
closed/partially closed.
V0804-1 High Liquid 1. Upstream causes. higher 1. Possible higher moisture 1. LG40014 available.
(Kiln Gas Suction Level moisture content in kiln gas. content in kiln gas flow to
Knock Out Vessel) 2. Drain valve not operated compressor
periodically restriction in line.

Low liquid Level 1. Upstream causes. lower 1. Possible ingress of air if 1. LG40014 available.
moisture content in kiln gas. water seal lost. 2. Water seal tank availab
2. Drain valve open/passing.

1 ½ -D-C111- Low/no flow 1. Isolation valve stuck in 1. Process disturbance. 1. LG 40014 is available
0198 closed/partially closed 2. High condensate level
(V0804-1 Drain to position.
Water Seal Tank) 2. Line blockage

0127-04-PID-009 – 2/4 (CO2 Compressor System)

Oil Tank Low Level 1. Drain valve stuck in open 1. Process disturbance. 1. LIT 102 is available with
/partially open position. low level alarm LIA102.
2. Line leakage/tank leakage. 2. Compressor trip on low
3. Lube oil loss in circuit. lube oil supply pressure
4. Lube oil level not
maintained.
Compressor lube oil Low/No flow 1. Failure of lube oil pumps.
circuit 2. Low level in oil tank.
3. Isolation valve
closed/partially closed.
4. NRV malfunction.
5. Choking of lube oil strainer.
6. Line leakage.
7. Flow restriction in circuit
High Flow 1. Both lube oil pumps
operate due to control
system malfunction.
1. Compressor operation will
be affected.
2. Rise in pressure in lube oil
circuit, upstream of
restriction: drop in
downstream pressure.
1. Rise in lube oil
temperature.
2. Rise in line pressure and
pressure
differential across
strainer.
1. Compressor has
proprietary control system
also covering lube oil syste
2. Lube oil pump motor
indication available.
3. PG105/106 available.
4. PT103/PICSA103 availa
with low low- pressure ala
5. PDG 102, PT 102,and
PDIA102 with high alarm a
available across strainers.
6. Stand by strainer is
available
7. PG108 to PG114 availab
at compressor inlet .PG11
outlet .
8. Sight glass is available t
monitor flow.
1. Lube oil motor indicatio
available.
2. PG105/106 available.
3. PT103/PISCA103 availa
4. PDG102/PT102 and PDI
102 with high differential
pressure available across
strainer.
5. PSV available on
pump discharge.
High pressure 1. Both lube oil pumps
operate.
2. Flow restriction in circuit;
isolation closed/partially
closed. NRV malfunction.
3. Choking of lube oil strainer.
Low pressure 1. Failure lube oil pump
malfunction.
2.Line leakage
High 1. High temperature of lube 1. Decomposition of lube oil.
temperatur e oil in tank due to electric
heater malfunction.
2. Reduced flow of cooling
water to lube oil cooler.
3. Rise in temperature across
compressor in lubrication
circuit.
1. Rise in pressure in lube oil
circuit.
2. Rise in pressure upstream
of flow restriction, drop in
downstream pressure.
1. Compressor trip on low
low lube oil supply pressure. available.
1. Lube oil motor indicatio
available.
2. PG105 /106
available.
3. PG108-114 available at
compressor inlet
PG115 at compressor outl
4. PDG102/PT102 and PDI
102 with high differential
pressure available across
strainer.
5. PSV available on pump
discharge.
1. Lube oil motor indicatio
2. PG105 /106
available.
3. PT103/PICSA103 availa
with low low pressure ala
1. TG104 / TT103 /
TIA103 available with high
temperature alarm.
2. PI40091 on cooling wat
supply line anad TT40092
CW outlet line.
3. TT104/TIA104
available with high alarm.
4.TG106 and 107
available.
 Low Temperatu 1. Failure of electric heater.
re 2. High flow of cooling
water /lower temperature of
cooling water.
1. Increased viscosity of lube 1.TT103/TIA103
oil affecting lubrication. available with low alarm.
2. Increased moisture in lube 2. PI40091 on cooling wat
oil. supply line and TT40092 o
CW outlet line.
3.TT104/TIA104
available.
4. TG 104 available

0127-04-PID-011 – 1/1 (Centrifuge 4)

4”-MM-D101- Low / No Flow 1. XV40002 malfunction 1. No filling of 1. Centrifuge 4 independe

0213 /centrifuge control system centrifuge/slower rate of control sequence is availa
6”-MM-D101- malfunction. filling. Indication available for
0050 2. Isolation valve XV40002.
(Magma Feed to closed/partially closed. 2. Line unblocking can be
Centrifuge 4) 3. Restriction in line / at entry done via HSW
to centrifuge

4. Line leakage

8”-BL-CI-0060 Low / No Flow 1. Line blockage/restriction. 1. Sight glass available on

(Mother Liquor from 2. No level in centrifuge. 2. LIC30007/LT30007
Centrifuge to 3. High level in mother liquor on mother liquor tank
Mother Liquor Tank) tank. available with high alarm.

3”-SW-C111- Low / no 1. Upstream supply 1. Inadequate 1.SOPs

0052-1 1/2 H flow issues e.g. HSW pump flushing/routine of
1”-SW-C111- tripping. centrifuge 04 2. Centrifuge control
0060-1 1/2 H 2. Centrifuge washing sequence is available.
1”-SW-C111- 2. Isolation valve in closed operation will not take
0059-1 1/2 H position place.
1”-SW-C111-
 sequence is available.
operation will not take
place.

0058-1 1/2 H 3. Restriction in lines.

1”-SW-C111-
0057-1 1/2 H 4. Malfunction of valve
1”-SW-C111- YS81.01/N62 not
0056-1 1/2 H allowing water flow.
1”-SW-C111-
0055-1 1/2 H
1”-SW-C111-
0054-1 1/2 H
(HSW to
Centrifuge 4
from main HSW
header
0127-04-PID-012 – 1/1 (Instrument Air Header)
2”-AI-S101-0124 Low Flow / No 1.Tripping of Instrument air 1.Process disturbance 1. PI 40064 available
(Main IA Supply Flow compressor 2. Plant shutdown 2. PT 40028 / PI 40028
Header) 2. Line leakage.

1”-AI-S101-0128 3. Isolation valve closed with low alarm available

(Instrument Air to / partially closed
RSB Area)
1”-AI-S101-0129
(Instrument Air to
Saturator)
1”-AI-S101-0130
(Instrument Air to
Centrifuge 4)
1”-AI-S101-0131
(Instrument Air to
new Kiln Gas
Compressor)
1”-AI-S101-0132
(Instrument Air to
Kiln Gas compressor)
1”-AI-S101-0133
(Instrument Air to
centrifuge 4)
1”-AI-S101-0134
(Instrument Air to
Centrifuge 4)

0127-04-PID-013 – 1/2 (Product Handling System)

4-42-0005A Low/no 1.Tripping of screw 1. Accumulation of 1. Screw & bucket
(Silo Screw Feeder) flow conveyor / malfunction product at inlet to bucket conveyor current indicatio
2. Tripping of bucket conveyor conveyor or at outlet of available on PLC.
3 – 41 – 0001 / malfunction bucket conveyor 2. Tripping of upstream
equipment

0127-04-PID-013 – 2/2 (Product Handling System)

(Dry Bicarb from Low / No Flow 1. Upstream causes. 1. Process disturbance. 1. PT 40031 / PIA
Drying Tube 4 to 4- 2. Line blockage. 40031 is available with hig
42- and low pressure alarms
0003 Cyclone) 12”- 2. Cleaning window is
DD-C111- available; HSW flushing po
0054-P connection is available
20”-DD-C111-
0032-P

4-42-0002 High level of 1. Downstream flow 1. Process disturbance. 1. LSH40048 with high- lev
(Cyclone 4) Product restriction. 2. Rise in pressure in cyclone alarm is available.
2. Cyclone star feeder and line 2. PT 40030 / PIA
tripping. 40030 is available with hig
and low pressure alarms
3. PT 40031 / PIA
40031 is available with hig
and low pressure alarms

4. Cyclone star feeder mo

current indication is availa
on PLC.

(Drying Air from 4- Low / No Flow 1. Reduced flow of drying air 1. Process disturbance. 1. PT 40030 / PIA
42-0003 to cyclone 40030 is available with hig
Cyclone to Dust 2. Line choking. and low pressure alarm.
Scrubber 4) 3.Isolation valve closed / 2. HSW connections are
18”-DA-C111- partially closed available for washing
0066-P

(Cyclone Star Low / No 1. Upstream causes. 1. Process disturbance. 1. Cyclone star feeder
feeder) Flow motor current
 1. Process disturbance.
Flow
4-42-0002 2. Star feeder tripping indication available on
PLC
Cyclone (4-42- 3. Product screen motor 2. Washing can be done
0003) to tripping / downstream through Access Door on
Product Screen (4- tripping Cyclone
24-0004A/B)

4. Choking of outlet
from cyclone / choking
of chutes.
5. Slip plate to product
screens closed / partially
closed
6. Blockage of chutes
 Sheet : 1

Issue No.: 01
Date:20th & 21st Oct
2020
Unit: RSB Completed by:

Safeguards Action required Action by Actio n

No.
1 (LSA Feed Preparation)
1. Motor failure 1. Level alarm (Low & HA/SA 1
indication is available in High) to be ensured in
DAP area. Feed Hopper.
2. Star Feeder motor
indications & alarm 2.SOPs need to be
available in PLC to developed to AS/MTA 2
notify the operator for incorporate Daily
taking corrective Knocking Routine,
actions. checking and cleaning
3. Level indication will of scaling in chute and
be available on PLC for slide valve,
Feed Hopper.
4. Daily Knocking 3. Plant monitoring & AS 3
Routine area round by relevant
Plant monitoring & area operator.
area round by relevant
area operator
5. Density indication
will be available on PLC.
1. Star Feeder motor 1. Plant monitoring & area AS 3.
indications & alarm (Motor round by relevant area AS 4.
EOCR) available in PLC to operator.
notify the operator for taking 2. DAP area operating staff
corrective actions. to communicate significant
2. High Level indication is variations in feed rate to
available on PLC for Feed conveyor to RSB plant
Hopper. operators. Operating
instructions to be modified
accordingly.

1. Current indication is 1. SOPs to cover area AS 5

available for Reddler
Conveyor.
2. Scalping Screen
current indication is
available.
3. Low Level indication
is available on PLC for
monitoring of scalping
screen vibrator by
relevant area operator
to be developed.
2. Provide vibrator on UA 6
angular chute and
develop associated
Feed Hopper.
4. Density indication
will be available on PLC.
5. CCTV cameras are
available for
monitoring.
1. Plant area monitoring.
1. Plant area monitoring.
2. High level indication is
available for feed hopper in
PLC.
1. Plant area
monitoring.
2. CCTV cameras are
available.
3. Level indication is
available on PLC for
Feed Hopper.
4. Density indication
will be available on PLC.
5. Screw feeder current
indication is available
on PLC.
6. Vibrator is available
on lower portion of
hopper.
1. Level indication is available
on PLC for Feed Hopper.
2. Plant area monitoring.
1. Conveyor current
SOPs.
3. Bypass chute has not UA/AQ/MY 7
been installed so far A
and needs to be
reviewed keeping in
view screen blockage,
screw feeder
malfunction and site
conditions.
1. Periodic inspection regime MTA 8.
to be developed for UA/MYA/A Q 9.
magnetic separator.
2. Confirm adequacy of
rain /wind protection.
1. SOP needs to be AS/FSK 10
developed to cover
operational adjustment
of screw feeder as per
density requirement.
2. Periodic inspection
and maintenance MTA 11
regime of screw feeder
and Delumper needs to
be developed.
1. SOP needs to be AS/FSK 10
developed to cover
operational adjustment of
screw feeder as per density
requirement.
1. Periodic inspection FSK 12
indication is available.
2. Conveyor delayed tripping
is available for conveyor dry
run.
3. Level indication is available
on Feed
hopper.LSHH40002/LS
H40003 is available.
4. Feed Hopper high level
interlock, with star feeder
tripping is available.
1. Standby system will
start to maintain feed
level in the hopper
2. LSL 40004 Low Level
switch available to alert
operator
and maintenance of level AS 13
instrumentation.
2. SOPs to be developed for
plant monitoring by relevant
area personnel.
1. SOPs need to be AS/MH 14
developed which state
that, manual operation
as per level switches
should be done only
under special
circumstances with
following procedures
defined for bypassing
the auto cut in
sequence.
2. Periodic inspection FSK 12
and maintenance of
level instrumentation.
3. SOPs to be
developed for plant AS 13
monitoring by relevant
area personnel.
1. Review provision of UA/MY/AS 15
isolation of screw feeder in
case of
malfunction/maintenan ce.
1. Density meter AIC 40001 is
available.
2. LSHH 40001/ LT 40001 is
available for tank monitoring.
3.Mag flow meters MF
40018B/40005 are
available
1. Density meter AIC
40001 monitoring
2. LT 40001 is available
tank level monitoring
3. Mag flow meters MF
40018B available.
1. Density meter AIC
40001 is available.
2. LSHH 40001/ LT
40001 is available for
tank monitoring.
3.Mag flow meters MF
40018A/40005 are
available
1. Periodic inspection & FSK 16.
maintenance of FCV AS 17.
40018B/ACV40001/MF
40005/MF40018B and
density control system.
2. SOPs to ensure close
monitoring of dissolving tank
levels and densities to
identify any abnormality
promptly needs to be
developed.
1. Periodic inspection,
testing & maintenance FSK 16
of control valves,
control loops and
density control system.
2. SOPs to ensure close AS 17
monitoring of dissolving
tank levels and
densities to identify any
abnormality promptly
needs to be developed.
3. SOPs for drain valves and AS 18
inspection of line needs to
be developed.
1. Periodic inspection, FSK 16
testing & maintenance
of control valves,
control loops and
density control system.
2. SOPs to ensure close
monitoring of dissolving AS 17
tank levels and
densities to identify any
4. Pump operation
indication is available.
1. Density meter AIC 40001
monitoring
2. LT 40001 is available tank
level monitoring
3. Mag flow meters MF
40018A available
4. Mother Liquor pump
current indication is available
on PLC.
1. Pumps current
indication is available.
2. Level indication is
available on Dissolving
Tank
LSHH40001/LIA40001 is
available.
3 Overflow line is
available. CCTV
cameras are available
for monitoring.
abnormality promptly
needs to be developed.
3. SOPs to be
developed for Mother AS 32
liquor pump manual
operation restriction to
avoid operation of
three pumps.
1. Periodic inspection, FSK 16
testing & maintenance of AS 17
control valves, control loops AS 18.
and density control system.
2. SOPs to ensure close
monitoring of dissolving tank
levels and densities to
identify any abnormality
promptly needs to be
developed.
3. SOPs for drain valves and
inspection of line needs to
be developed.
1. Periodic inspection FSK 12
and maintenance of
level instrumentation.
2. SOPs to be AS 13
developed for plant
monitoring by relevant
area personnel.
1. Pumps current indication is 1. Periodic inspection and FSK 12
available. maintenance of level AS 13
2. Level indication is available instrumentation. HA/SA/FSK 22
on Dissolving Tank 2. SOPs to be developed for
LSHH40001/LIA40001 is plant monitoring by relevant
available. area personnel.
3. Level indication is available 3. In-case of bad/false signal
on Saturator feed tank of level transmitter configure
LIC30003. logic such that transfer
pumps operation is
prohibited.

1. Vent line discharge is 1. S AS 23

provided outside building.
2. HSW entry is through
Sprinkler nozzle which
prevents flow of vapor into
the line.
3. Venting possible through
LSA entry point, will cause
dust cloud.

1. Temperature 1. SOPs need to be AS 24

indication is provided developed for periodic
on tank TT40001. No inspection, testing and
other instrumentation monitoring of
on tank in case of temperature
malfunction. transmitter.

2. Temperature
indication TT40002 is 2. Review provision of AQ/UA/MY 25
provided on pump discharge local temperature gauge on A
line. tank discharge line.
3. Density meter has
temperature compensation in
it.
1. Temperature indication is 1. Review steam trap AQ/UA/MY A 26
provided on tank TT40001 configuration on condensate AS / MTA 26A
2. Temperature indication line.
TT40002 is provided on pump 2. SOPs to cover inspection
discharge line. and testing of steam traps to
3. Density meter has be developed.
temperature compensation in
it.

1. Agitator current indication 1. SOPs to be developed for AS / MTA 61

is available on PLC. periodic inspection and
maintenance of agitator and
vessel.

1. PSVs are provided on 1. Review provision of AQ/MYA/U 27

main steam line.
2. Jacket design
pressure is more than
IP steam header
pressure.
1. FT 40001 is provided.
2. TT40001 is provided.
PT/PSV with alarm on IP A
steam line to Dissolving
tank jacketed line.
2. Review provision of 27A
PIs at inlet to each AQ/MYA/U
jacket. A
3. SOP`s to be 13
developed for plant
monitoring by relevant AS
area personnel.
1. SOPs to be developed for AS 28
communication of any AS 13
anomaly in main steam
circuit (IP steam header) to
the RSB plant operator.
2. SOPs to be developed for
plant monitoring by relevant
area personnel.

1. SOPs need to be FSK 19

1.LT 40001 is available
for Dissolving tank with
level alarm.
2.Temperature
indication TI-40001 is
available.
developed for periodic
inspection, testing and
maintenance of
instrumentation.
2. SOPs to cover AS 20
 AS 20
strainer maintenance
3.Pump discharge PI of and operational aspects
4-21-0001 A/B/C is of plant to be
available. developed.

1. Pump current indication is 1. SOPs need to be AS 21

available. developed for operation of
new LSA transfer pumps.

2. AIT40002 is available for 2. SOPs to be developed for AS 13

density measurement. plant monitoring by relevant
3. Dissolving tank level area operator.
indication LIA40001 available.

1. Saturator Feed Tank

Level indication is 1. Periodic inspection FSK 12
available (LT 0003 & LT and maintenance of
30003 level instrumentation.
2. Operating
procedures to ensure 2. SOPs to be AS 13
correct plant operation developed for plant
for maintaining levels monitoring by relevant
in each saturator feed area personnel.
tank.
3. Pump discharge PI of 3. SOPs to be
4-21-0001 A/B/C developed for line
available inspection and regular AS 28A
cleaning to avoid line
blockage.

1. Saturator Feed Tank Level 1. Periodic inspection and FSK 12

indication is available (LT maintenance of level
0003 & LT 30003. instrumentation.
2. Pump current
indication is available on PLC. 2. SOPs to be developed for AS 13
3. Saturator feed tank plant monitoring by relevant
overflow line is available. area personnel.

1. PI`s available on pump 1. SOPs to be developed for AS

discharge lines. close monitoring of PIs and
saturator feed tank level.

1. PIs is available on pump 1. SOPs to be developed for AS 13

discharge lines. plant monitoring by relevant
area personnel.

1. HSW Supply Pump pressure 1. SOPs need to be AS 29

to be regularly monitored developed incorporating
2. Valve position should be communication between
adjusted & ensured by area plant operators in case of
operator supply pump
trippage/supply

problems.

1. Density meter AIC 40001 1. Periodic inspection & FSK 30

monitoring
2. MF40005 is available
maintenance of ACV AS 13
40001/MF40005
2. SOPs to be developed for
plant monitoring by relevant
area personnel.

1.Density meter AIC 1. Periodic inspection & FSK 30

40001 monitoring
2. HSW Supply Pump
motor current
indication available on
maintenance of ACV
40001/MF40005
2. SOPs need to be AS 31
developed to indicate
 PLC how HSW flow will be
split, between the two
ML lines i.e. both 2”
valves will full open or
not.

3. SOPs need to be AS 29
developed
incorporating
communication
between plant operator
in case of supply pump
trippage/supply
problems.

4. SOPs to be AS 13
developed for plant
monitoring by relevant
area personnel.

– 1/2 (Saturator Feed System)

1. Saturator Feed Tank 1. SOPs need to be
Level indication is developed for periodic AS/FSK 10
available (LT 30003) inspection and
maintenance of
2. Pump discharge PI of instrumentation related
4-21-0002 A/B/C is to saturator feed
provided. system.

3. HSW available for

flushing. 2. SOPs to cover AS 20
strainer maintenance
and operational aspects
of plant to be
developed.

1. Pump current indication is 1. SOPs need to be AS 31A

available. developed for operation of
2. Saturator feed tank level is new Saturator feed pumps
available, LT30003. operation.
1. Pump discharge PI of 4-21- 1. SOPs to be developed for AS 13
0002 A/B/C are available i.e. plant monitoring by relevant AS 28A
PIs 40003, 40004, 40005. area personnel.
2. Saturator feed tank 2. SOPs to be

level indication is available, developed for line inspection HA/SA 33

LT30003. and regular cleaning to avoid AS / FSK 35
3. Filter solenoid valve line blockage.
position feed-back is available 3. Review provision of alarm
for solenoid valve position
feed-back failure.
4. SOPs to be developed for
solenoid valves inspection
and maintenance.

1. PIs 40003 / 40004 / 1. SOPs to be developed for AS 13

40005 available on pumps plant monitoring by relevant
discharge lines. area personnel.
2. PI40008 available on inlet
header to filters. 3. PI40072,
PI30072, PI30074 available on
individual filters.
4. Filters solenoid valve
position feedback available.

1.PIs 40003 / 40004 /

40005 available on pumps
discharge lines.
2. PI40008 available on inlet
header to filters. 3. PI40072,
PI30072, PI30074 available on
individual filters.

1. Review method of flange UA / MTA

gasketing to minimize contact
between two metals or have a
sacrificial spool piece of SS304
L.

1. Saturator Feed Tank 1. Periodic inspection FSK 12

Level indication is and maintenance of
available (LT 0003 & LT level instrumentation.
30003
2. Pump current
indication is available 2. SOPs to be AS 13
on PLC. developed for plant
monitoring by relevant
area personnel.
1. HSW Supply Pump 1. SOPs need to be developed AS 29
pressure to be regularly incorporating communication
monitored between plant operators in
2. SOP`s available to ensure case of supply pump
correct operation of HSW trippage/supply problems.
valve.

1. HSW Supply Pump 1. SOPs need to be developed AS 29

pressure to be regularly
monitored
2. SOP`s available to ensure
correct operation of HSW
valve.
incorporating communication
between plant operators in
case of supply pump trippage/
supply problems.

1. Density meter AIC 1. Periodic FSK

40001 is available. inspection & of
maintenance
FCV
40018A/ACV40
2. LSHH 40001/ LT 001/MF
40005/MF4001
40001 is available for 8A and control
density
tank monitoring. system.
2. SOPs to
3.Mag flow meters MF ensure closeof
monitoring
40018A/40005 are dissolving tank AS
available levels
and densities to
identify any
abnormality
promptly
needs to be
developed.
3. SOPs to be
developed for AS
pump
manual
operation
restriction to
avoid
high flow.
 1. Density meter AIC 1. Periodic
40001 monitoring inspection
maintenance & of FSK
FCV
40018A/ACV40
2. LT 40001 is available 001/MF
40005/MF4001
tank level monitoring 8A and control
density
system.
3. Mag flow meters MF 2. SOPs to
40018A available ensure closeof
monitoring
dissolving tank AS
4. Mother Liquor pump levels
and densities to
current indication is identify any abnormality
available on PLC. promptly needs to be
developed.
3. SOPs for drain valves and
inspection of line needs to AS 18
be developed.

-003– 1/2 (Saturator)

1. Solenoid valve position 1. Review provision of alarm HA/SA 33

feedback is available. for solenoid valve position
feedback signal failure.

2.Saturated Feed Tank

Level indication is available 2. SOPs to be AS 34
(LT 0003 & LT developed for Line cleaning
30003 in case of
chocking. AS/FSK 35
3. SOPs to be developed for
3. Pump discharge PI-
40003/40004/40005 valve inspection, cleaning

are available. and maintenance.

4.Plant monitoring & area

round by relevant AS 13
area operator
1. Solenoid valve position 1. Review provision of alarm HA/SA 33
feedback is available. for solenoid valve position
feedback
signal failure.
2.Saturated Feed Tank
Level indication is 2. SOPs to be AS 34
available (LT 0003 & LT developed for Line
30003
3. PIs available at outlet of
filters and inlet of coolers.
4.PIs available at filter inlet
and outlet lines for
differential pressure
monitoring
5. FT 40010 indication is
available
6. 1”-SW-C111-0074-1
½ H is available for flushing
of lines.
1. FT-U-40010
indication is available.
2. Differential pressure
monitoring is available
across filters.
1. Holding screen is
available.
1. SOPs are available for
filter operation.
1. Backwash regime is
already implemented on
plant.
2. Differential pressure
monitoring is available
across filters
cleaning in case of choking. AS/FSK 35
3. SOPs to be developed for AS 13
solenoid valve inspection, FSK 19
cleaning and maintenance.
4.Plant monitoring & area
round by relevant area
operator
5. SOPs need to be
developed for periodic
inspection, testing and
maintenance of
instrumentation
1. SOPs to be developed for AS/FSK 35
solenoid
valve inspection,
cleaning and maintenance.
2. SOPs to be developed for AS 37
periodic
estimate of filters
operating sequence.
1. Periodic MTA 36
inspection/maintenanc e of
bed and screen needs to be
done.
1. SOPs to be developed for AS/FSK 37
testing of filters operating
sequence.
 1. SOPs to be developed for AS 34
1. Periodic cleaning of PHE is Line cleaning in case of
done as per chocking.

available operating 2.Plant monitoring & area AS 13

procedure. round by relevant area
operator

3. SOPs need to be
developed for periodic
inspection, testing and FSK 19
maintenance of
instrumentation.

4. SOPs to be
developed for periodic AS 52
inspection of pipping
and valves.

1.PI40010 is available. 2.Plant monitoring & area AS 13

round by relevant area AS/FSK 35
operator.
3. SOPs to be developed for
valve inspection, cleaning
and maintenance.

1.TIC 40035 with high alarm 1. SOPs to be developed for AS 53

is available. periodic cleaning of PHE. FSK 19
2. PHE designed at 32oC 2. SOPs to be
cooling water

supply and 45OC return developed for periodic

temperature. inspection, testing and
maintenance of
3. TI40034 available on instrumentation.
cooling water outlet
line.
1. TIC40035 with low alarm
is available.

1. SOPs need to be FSK 19

1. PI40012A & TI40034 developed for periodic
is available. inspection, testing and
maintenance of
2. CWS/CWR provision from instrumentation. AS
old side is provided with 2. SOPs to be developed for
restricted flow. periodic cleaning of PHE.
53

3. SOPs need to be AS 29
developed incorporating
communication between
plant operators in case of
supply pump trippage /
supply problems.
 PI40012A and TI40034
available.

1. Daily monitoring of
cooling water chemistry is
carried out at plant.

1. HSW pump indication is

available on PLC.
2. Differential pressure
measurement is available
for filters

-003– 2/2 (Saturator)

1. PT 40015 is 1.Plant monitoring & area AS 13

available, PG104 is round by relevant
available on separator. area operator

2. SC-09 discharge can 2. Self-closing valve not

be taken in service installed. For manual AS 40
until KG compressor valve SOP to be
comes online. developed for periodic
operation of drain
3. PI40016 is available. valve of knock out
drum.
4. LSH40013 and LAH40013
available for 3. SOPs to define
AS 63
high liquid load in KO operating parameters,
drum. measures for turning
SC-09 in service and for
operation of PV-101
circuit.

4. SOPs to be AS 64
developed to define
measures to be taken in case
of gas leakage.
 developed to define
measures to be taken in case
of gas leakage.

PT40015 is available.

1.PT 40015 is available with 1.Plant monitoring & area AS 13

indication. round by relevant
area operator

2. PI40016 is available. 2. Review provision of high MYA / AQ / 38

3. PTs are provided on pressure alarm on PT40015. HA / SA

existing header.
3. Review methodology AQ/UA
of junction of lines.
4. FT-U-30012 is 38B
provided.

1.LG 40012 available 1. Periodic inspection, FSK 54

testing & maintenance
2.LAH 40013 available of LSH 40013.
2. Install a smaller

diameter valve /reduce UA/AQ 55

line size at outlet of drain
valve and route it to safe
location for drainage. This is
added
to control flow to
reduce exposure of the
personnel.
1.LG 40012 available
 1. PI40016 is provided on 1. SOPs to be developed for AS 13
KOD. plant monitoring & area
2. PT40015 provided on inlet round by relevant area
line with indication. operator.

2. Review provision of high MYA / AQ HA / 65

pressure alarm on PT40015. SA

1. PI40016 is available. 1. SOPs to be developed for AS 13

plant monitoring by relevant
area operator.

1. SOPs to be developed for AS 56

periodic inspection and
maintenance of demister.

/2 (Centrifuge-03 and Drying)

1. LT 30005 available with 1. As Centrifuge 3 and 4 will AS 62

low level alarm on Magma
tank.
2. RLS steam available for
line de-blocking.
3. Vent available on line to
allow for full drainage into
centrifuge.
operate from same Magma AS 39
tank, SOPs to be developed
for monitoring of tank level
and possible sequencing of
filling operation of each
centrifuge.
2.SOPs to be developed for
operation of RLS steam valve
and it should not be left
open.

/2 (Centrifuge-04 and Drying)

1. FT 40024 available with
indication.
2. TT 40025 is
available.TT40004 with
indication available on air
outlet from heater.
3. PI40071 is available
4. PT40009 is available with
indication.
1. SOPs need to be FSK 19
developed for periodic AS 13
inspection, testing and
maintenance of
instrumentation.
2. SOPs to be developed for
plant monitoring by relevant
area personnel.

1. FT 40024 available with 1. SOPs need to be FSK 19

indication. developed for periodic
inspection and
2. PSV 40001 available. maintenance of
instrumentation.
3. PT 40009/ TT 40025
available with
indication. 2. SOPs to be AS 13
developed for plant
4. PI40071 is available. monitoring by relevant
area personnel.

52
3. SOPs to be AS
developed for periodic
inspection of pipping and
valves.
66
4. Ensure PSV is MTA

periodically tested. 26A

5. SOP`s to cover inspection
and testing of steam traps to
be developed. MTA
1. PSV4001 is available. 1. High pressure alarm needs SA/HA/MYA 40
2. FT 40024 available with to be configured on
indication. PT40009.
3. PI40071 is available
4. PT40009 is available with
indication.

1.FT 40024 available with 1. SOPs need to be FSK 19

indication. developed for periodic
2. PI40071 is available inspection and maintenance
3. PT40009 is available with of instrumentation.
indication.

1. PI40071 available. 1. SOPs` to be developed for AS 13

2.PT40009 available which plant monitoring by relevant
will reduce flow on pressure area personnel.
increase
on inlet steam
3. PSV40001 available.
2.PT40009 available which plant monitoring by relevant
will reduce flow on pressure area personnel.
increase
on inlet steam
3. PSV40001 available.

1. SOPs` to be developed to AS 66
ensure no restriction in vent
line and condensate line to
HSW tank.

1. Isolation valve of HSW 1. SOPs` to be developed to AS 67

line to ensure
Condensate tank is normally no restriction in vent line
open. and condensate line to HSW
2. Vent line 3”-SC- C112- tank.
0096 is available for vent in
case of condensate flow
restriction to HSW tank.

1. Fan motor indication is 1. SOP`s to be developed for FSK 19

available on PLC. periodic
Dryer feed table trips inspection &
on fan tripping. maintenance of valve and
2. PT 40016 available with instrumentation.
indication. 2. Plant monitoring & area
3. PI 40022 available. round by relevant area
4. TT40004/TIC40004 operator.
available; TT400101 / 3. SOP`s to be developed
TT40010 available. defining parameters for AS 13
dryer AS 68

fan and air heater

operation.
 1. PT 40016 available with
indicator.
2. PI 40022 available.
3. TT40004 / TI40004
available; TT40010 /

TI40010 available.
1. PT 40016 available with
indication.
2. PI 40022 available

1. PT 40016 available with

indication.
2. PI 40022 available

1. TT40004 / TI40004 and

TT40010 / TI40010
available.

1. TT40004 / TI40004 and

TT40010 / TI40010
available.

1.SOPs 1. Plant monitoring & area AS 13

round by relevant
area operator.
2. Review provision of MYA / UA
PI on soft water 69

flushing line to indicate flow.

/4 (CO2 Compressor System)

1. Standby strainer is 1. SOPs to be AS 41

available. developed for the use
 41

2. PDT 101 is available at of TE gas from

compressor suction with compressor 9 discharge
high alarm (PDIA 101). header when kiln gas from
new compressor is not
available.

3. PICA101 is available with In this case, 6” valve on

high and low alarms. PG101 6”-KGC-C111-0235 will
is available. be opened and 6” valve
upstream of tie-in point will
be closed.
4. Stand by kiln gas supply As pressure of this TE gas
from compressor 9 TE gas will be lower, absorption
can be used. efficiency in saturator will be
5. PV101 recycles gas from affected. SOPs` to be
discharge to suction, to developed to cover this
maintain flow. aspect.
In case of valve passing,
there is a

possibility of Kiln gas

flowing into TE gas
header; review
provision of NRV.

2. In case of low
UA / AQ / MYA
pressure at new compressor AS
suction PICA 101 control AS
loop will operate PV101 to AS
divert flow from discharge to
suction of compressor and
reduce the gas pressure.
SOPs` to be developed to
ensure periodic inspection
and testing of control valve,
PV101 and PICA 101 control
loop. Since control valve
operation is occasional,
reliability of valve opening
when required could be
affected as valve is in
contact with kiln gas.
3. In case of operation of
PV101, kiln gas flow to
saturator will be reduced
affecting absorption
efficiency. SOPs` to cover
this aspect. PV101 is fail
open, so in case of loop
malfunction, flow to
saturator will drop sharply.
4. SOPs to be developed for
routine

checking of bypass valve

around PV101. It is
recommended that the
bypass valve be “locked
closed”. If it is open,
pressure compressor suction
will increase resulting in
possible damage.
5. Review provision of PSV UA / AQ / MYA
and PI downstream (low
pressure side) of
PV101.
1. PICA101 with high alarm 1. Plant monitoring and area AS 13
is available. round by relevant operator.
2. PG101 is available

1. PICA101 available with 1. SOPs to be developed for AS 13

high and low pressure plant monitoring and area
alarms. round by relevant area

2. PG101 is available. personnel.

3. Compressor operation
indication is available.

1. PICA/PV101 loops
available for recycling of gas
from discharge line to
suction
1. Compressor alarm on high
temperature available TT101
/ TIA101 / TG101

1. PT101 is available 1. SOPs` to ensure AS

which would show an monitoring of lute pots and

increase in pressure.
2. PG101 is available.
water seal tank to confirm
water levels.
2. SOP`s to be developed for
periodic inspection of pipe MTA
lines and fittings.

1. Independent control is 1. SOPs to be developed for AS

available to control
the compressor
operation
2. PT 102, PG 102, TT
102, TG 102/TT116 are
available.
new
compressor operation
covering normal
operation, start up, shut
down and emergency
operation.

3. PG104 available on
separator.

4. PSV available on
separator.
1. Independent control is
available to control the
compressor operation
2.PT 102, PG 102, TT
102, TG 102 are
available
3. TICSA102 control loop
available with

TV102 valve – water

injection to control
discharge temperature.
1. Independent control is 1. Compressor tripping HA/SA/FSK 57
available to control the needs to be configured on
compressor operation, high high pressure valve of
2. PT 102, PG 102, TT PT102 i.e. PIAHH-102.
102, TG 102 are
available with PIA102 high
and high high alarm on
PT102.
3. PSV available on
separator.

1. PT 102, PG 102, TT
102, TG 102 are
available.

1. TT 102, TG 102 , 1. SOPs` to be developed for FSK 19

TICSA 102 with high and periodic inspection, and
high high alarm, compressor testing of instrumentation.
trips on high high
temperature.
2. TIA116 is available at

cooler discharge which

enables check of cooler
performance
1. TT 102, TG 102,
TICSA 102 are
available.
2. TIA116 is available at
cooler discharge.

1. SOPs to be developed for AS / MTA 31B

periodic inspection and
maintenance of cooler.

TICSA102, TG102 1. Periodic inspection, FSK 12

available with high and high testing and maintenance of
high alarms.
2. TG110 available. instrumentation. AS 13
3. PG103 available. 2. SOPs to be developed for
4. PDG-40093 plant monitoring and area
available. round by relevant area
5. PT110/PICA110 with low personnel.
alarm available.

1. TICSA102, TG102 1. Periodic inspection, FSK 12

available testing and
maintenance of
2. PG103 available. instrumentation.
AS 13
2. SOPs to be
developed for plant
monitoring and area
round by relevant area
personnel.
 1. PT110/PICA110 with low
pressure alarm.
2. PG103 available.

1. PT110/PICA110
available.
2. PG103 available.

1. TG110 available.
2. TG102 available.

1. TG110 available.
2. TG102 available.

1.LG 101 is available 1. SOPs to be developed for FSK 19

2.LT 101/ LICA101 with periodic inspection, testing
high alarm is available & maintenance of
3. Manual drain available on instrumentation.
1 1/2 “-D- C111-0197 line.

1.LG 101 is available 1. SOPs to be developed for AS 13

plant
2. LT 101/ LICA101 with high monitoring by relevant
and low level area personnel.
alarm is available. 2. SOPs need to be

3. Internal arrangement is developed for periodic FSK 19

such inspection and maintenance
of
that a certain level is always instrumentation.
maintained.
1. PG104 is available. 1. SOPs to be developed for MTA 31C
periodic
 2. PSV is available on inspection, testing and
Separator monitoring of PSV.

3. Design pressure of 2. SOPs to be developed for AS 13

separator is 120 PSI(g) while plant monitoring by relevant
design pressure of screw area personnel.
compressor is
45 PSIA.
3. Isolation valve at AS/MTA 58
upstream of PSV
should be lock open.
1. PG104 is available. 1. Isolation valve at AS/MTA 58
upstream of PSV should be
lock open.

GENERAL
1. SOPs` to be developed for MTA / FSK
maintenance procedures
and inspection/testing
frequency for all new
equipment and
instrumentation.

No Concern 1. Define procedure to check MTA

presence of corrosion and
inspection frequency.

1. Lightning protection HA/SA 43

system to be reviewed to HA/SA
confirm adequacy of
protection of all new
installation.
2. Confirm adequacy of
earthing protection for new
installations.
1. Review equipment HA / AQ / UA / FS
/facilities provided for fire UA / AS
detection, fire protection,
safety and confirm adequacy
2. Ensure escape routes are
defined and sign posted.

1. Sign posting to be FS 44
done in high noise
area.
2. Procedures to be FS / AS 45
developed to ensure
PPE compliance.
1. Review as per Commission ing 46
requirements of HS-4. Manager
2. Checklist of HS-4 and HS-5
to be reviewed

1. Confirm handling MYA

capability of effluent
from new plant in existing
/new facilities and confirm
requirement to regulatory
requirements.

1. Plant operating
procedures to be developed
for normal operation,
startup, shut down and
emergency conditions.
2. Where integration is
AS 47
taking place with existing
plant, update existing
procedures as required.

1. Site responsible engineers Site Responsible 48

to review their respective Engineers
CEPs and identify items to
be registered and take
relevant actions.
Ensure all regulatory
requirements are met
 Confirm EPA regulatory MYA 49
requirements have been
completed with respect to
IEE/EIA and NOC has been
obtained.

1. SOPs` to be developed AS
relating to supply and
distribution

of utilities and actions to be

taken in case of supply
failure –partial overload.

1. Existing sampling regime SMWA 50

shall be followed. SOPs` to
cover procedure.

1. Since old and new systems HA/SA/AS 51

are being integrated, review
potential effects of failure of
one control system on the
other (either existing or
new). Written procedures to
be developed to cover all
aspects.

1.Review all facilities AS

provided against checklists
of HS-4/HS-5; identify
deficiencies and remedy

on 20 th and 21st October 2020 concludes here.

s have been incorporated.

1. Centrifuge 4 independent 1. SOPs to be followed for FSK 70

control sequence is available periodic inspection of
instrumentation on
indicating centrifuge tripping mother liquor tank
2.LT 30007 available on
mother liquor tank.
3. There is a separate feed
line from Centrifuge 3 as well
to Mother liquor tank
4. Buffer available in mother
liquor tank as flow during
cloth washing is much higher

1.Centrifuge 4 independent 1. SOPs to be followed for FSK 71

control periodic inspection
sequence is available of instrumentation on
2.LT 30007 available mother liquor tank and
scrubber tank

3. LSH 40010 is available on 2. SOPs to be followed for AS 72

scrubber tank plant rounds and periodic
routines

4. LG 40009 is available on
scrubber tank

1. LT30007 / LIC 30007 1. SOPs need to be AS / FSK 19

with high & low-level alarm is developed for periodic
provided on existing mother inspection and maintenance
liquor of
tank. instrumentation. AS 20
2. HSW connection is 2. SOPs to cover strainer
available for flushing of pump maintenance and
suction line operational aspects of plant
3. PIs 40018/40019 are to be developed.
available on discharge line of
scrubber pumps 4-21-0006
A/B
4. Scrubber pumps current
indication is available
1. Pump current indication is 1. SOPs need to be followed AS 73
available. for operation of scrubber
2. LG 40009 is available pumps
3. LSH 40010 with high level
alarm is available

1. HSW Supply Pump 1. SOPs need to be AS 74

current indication developed
available incorporating
communication
between plant
operators in case of
supply pump trippage.
2. SOPs to be
developed to ensure AS 75
valve is operated as
required and closed when
flushing is not being done

1. HSW Supply Pump pressure 1. SOPs need to be AS 74

is regularly monitored. Pump developed incorporating
current indication is available communication between
2. SOPs available to ensure plant operators in case of
correct operation of valve supply pump trippage.

1. PI 40018/40019 are 1. Periodic inspection and FSK 12

available for the maintenance of
operational pump level instrumentation.

2. Stand by pump is available. 2. SOPs to be AS 13

developed for plant
monitoring by relevant
3. Pump current indication is area personnel. AS 28A
available on PLC. 3. SOPs to be developed for
4. LG 40009 is available line inspection and regular
cleaning to avoid line
blockage.

on scrubber
 cleaning to avoid line
blockage.

on scrubber

1. Dust scrubber level switch 1. Periodic inspection and FSK 12

and high level alarm LSH
40010/LAH40010 available
2. LG 40009 is available
operation.
3. Pump current indication is
available on PLC.
4. Dust scrubber tank
overflow line is available.
maintenance of level AS 13
instrumentation.
2. SOPs to be developed for
plant monitoring by relevant
area personnel.

1. PT 40033 / PI 40033 1. SOPs to be developed for FSK 19

is available with high
and low alarm at
scrubber inlet
2. PT 40032 / PI 40032
is available with high
and low alarm at scrubber
outlet. Differential pressure area personnel.
between PIs will indicate any
issues
periodic
inspection, testing and
maintenance of
instrumentation.
2. SOPs to be developed for AS 13
plant monitoring by relevant

3. SOPs to be followed
3. HSW line connection for line flushing
is available for line
flushing/deblocking.

4. Current indication of
scrubber fan is available on
PLC
1.PT 40032 / PI 40032
with low pressure alarm will
show rise in pressure if
damper restricts flow
2. Fan motor indication is
available on PLC.
3. HSW flushing connections
provided; also access door for
washing line / duct
1. SOPs to be developed for FSK 19
periodic inspection, testing AS 13
and maintenance of AS 76
instrumentation.
2. Plant monitoring & area
round by relevant area
operator.
3. SOPs to be developed to
define parameters for dust
scrubber and dust scrubber
fan operation.

1. PT 40032 / PI 40032 1. SOPs to be developed for FSK 19

is available with high periodic
pressure alarm if fan inspection &
handling capacity maintenance of
inadequate instrumentation.
AS 77
2. Operational
parameters to be
followed ensuring hot soft
water valve is closed.
Periodic inspection of
flushing water valve

1. PT 40032 is available 1. SOPs to be developed for FSK 19

periodic inspection &
maintenance of
instrumentation.

1. PT 40032 is available 1. SOPs to be developed for FSK 19

periodic inspection &
maintenance of
instrumentation.
1. HSW Supply Pump pressure 1. SOPs need to be AS 74
to be regularly monitored developed incorporating AS
2. Valve position should be communication between MTA
adjusted & ensured by area plant operators in case of
operator supply pump trippage.
2. SOPs to be developed to
ensure valves are operated
as required and closed when
flushing is not being done
3. SOPs to be developed for
periodic inspection of NRVs
and

valves

1. LSH 40010 is available on 1. Periodic inspection and FSK 12

scrubber tank with high level
alarm
2. LG 40009 is available on
scrubber tank
3. Mother Liquor pumps
current indication is available
4. Overflow line is available
maintenance of level AS
instrumentation.
2. SOPs to be developed for
plant monitoring by relevant
area personnel

1. Mother liquor scrubber 1. Periodic inspection and FSK 12

pumps maintenance of
current indication is level instrumentation.
available.
2. SOPs to be
2. LG 40009 is available on developed for plant AS 13
scrubber tank monitoring by relevant area
personnel.
1. PT 40032 & PT 40033 1. SOPs to be developed for AS 23
are available with high alarms periodic inspection of vent
2. Fan current indication is line, especially check for bird
available. nest at top.

1. TT40005 / TI 40005 is 1. Periodic inspection and FSK 19

available on HSW maintenance of
pumps discharge instrumentation.
2. SOPs to be

developed for HSW

tank operation AS 78
especially RLS steam
valve opening
3. Review provision of high HA / SA
temperature alarm on TT 79
40005

1. TT40005 / TI 40005 is 1. Periodic inspection, FSK 19

available on HSW testing and
pumps discharge maintenance of
instrumentation.
2. SOPs to be developed for AS
plant monitoring by relevant
area personnel 13

1. TT40005 / TI 40005
is available on HSW pumps
discharge
especially IP steam
valve opening
3. Develop SOPs for
periodic inspection of AS / MTA 80
sparger and tank
1. SOPs to be developed for AS 81
plant monitoring by relevant AS / MTA 82
area personnel especially IP
steam valve opening
2. Develop SOPs for periodic
inspection of sparger and
tank
1. PI 30066/30067 are 1. Periodic inspection and FSK 19
available on discharge maintenance of
of centrifuge HSW instrumentation.
pumps 2. SOPs to be developed for AS 13
plant

2. Alternative supply line 3’’- monitoring by relevant

SW-C111-0116 available from area personnel
HSW pumps 3. SOPs to be developed for

monitoring of
adequate supply of
HSW to centrifuge 4

AS 82
2. Operating procedures to 1. Periodic inspection and FSK 12
ensure plant operation. maintenance of level
3. PI 30066/30067 are instrumentation.
available. .

1. Operating instructions to AS 83
be developed to ensure the
manual valve is opened at all
times on this line (as per
plant requirements)

1. LS on existing tank 1. Routine inspection / AS 84

2. LT 4008 on new tank maintenance and plant
rounds
1. LT 4008 is provided on new
HSW tank.
2. Direct HSW provision for
new HSW tank is part of
design
1. Operating instructions to AS 85
be developed to ensure MTA 86
isolating valve on balancing
line remains open at all
times.
2. Regular inspection and
maintenance of isolation
valve

1.Balance line is available to 1. Operating instructions to AS 87

compensate level fluctuations be developed to ensure the
manual valve is

2.LT 4008 is available along opened at all times on this

with LIA 4008 (low level line (as per plant
alarm) requirements)
2. Periodic inspection and
FSK 19
maintenance of
instrumentation.

1.Balance line is available 1. Operating instructions to AS 88

from existing be
HSW tank to developed to ensure
compensate level the manual valve on
fluctuations balancing line is
2.LT 4008 is available along opened at all times on this
with LIA 4008 line (as per plant
requirements)
(low level alarm) 2. Periodic inspection and FSK 19
maintenance of
instrumentation.

3. SOPs to be developed for

plant
monitoring by relevant AS 13
area personnel

1.LT 4008 is available 1. Periodic inspection and FSK 19

maintenance of
2. Overflow line is instrumentation.
available 2. SOPs to be developed for AS 13
3. HSW pumps current plant monitoring by relevant
indication is available in PLC area personnel
 1. SOPs to be developed for AS 90
periodic inspection and
cleaning of vent line

1. PI40069 / 40066 1. Periodic inspection and FSK 19

available on pump maintenance of
discharge instrumentation.
2. LT 4008 is available along 2. SOPs to be developed for AS 13
with low level alarm LIA 4008 plant monitoring by relevant
area personnel

3. Review provision for

tripping of pumps on MYA / AQ / 91
tank low level HA / SA

1. Pump current indication is 1. SOPs need to be AS 92

available. developed for operation of
2. LT 4008 is available along new HSW pumps.
with low level alarm LIA 4008
3. PI 40066 & PI 40069
available

1. Standby pump is available 1. Periodic inspection and FSK 12

2.LT 4008 is available along maintenance of level
with LIA 4008 instrumentation.
2. SOPs to be

(low level alarm) developed for plant AS 13

3. PI40069/40066 monitoring by relevant area
available personnel.
 1. Pump current indication is 1. SOPs need to be AS 93
available. developed for operation of
2. LT 4008 is available along new HSW pumps.
with low level alarm LIA 4008

1. HSW Supply Pump pressure 1. SOPs need to be AS 74

to be regularly monitored developed incorporating
2. Valve position should be communication between
adjusted & ensured by area plant operators in case of
operator supply pump trippage.

/1 (Cooling Water System)

1. MF 40026 available as an 1. SOPs to be developed to AS 94

indicative measure of low
flow - this is on common line
to CO2 compressor gas cooler
and oil cooler
2. PIs available at inlet
ensure monitoring of
adequate supply of cooling
water to all areas and
smooth return of cooling
water to return header

to gas cooler, oil

cooler, on 6’’ CWS
header and on inlet to
saturator feed cooler

1. Plant monitoring and area AS 3

round by relevant area
operator.
1. PCV 4012 bypass is
available.
2. PCV 4013 bypass is
available.
3. PICA101 with low pressure 2. Plant monitoring & area
alarm available. PG101 round by relevant
available.
4. Lute pots available at
drains. SOP`s to ensure water
level is maintained.
1. PICA101 available with high
pressure alarm.
2. PG101 is available.
1. PICA101 available with
high-pressure
alarm.
2. PG101 is available.
1. SOPs to be developed for FSK 19
routine
inspection testing and
maintenance of
instrumentation.
AS 13
area operator AS
3.SOPs` to be developed for
operation of PCV 4102
/ PCV 4013 defining control
parameters. As no flow
indication is available,
therefore control is based on
PICA101 and PG101.
SOPs` to cover variations in
supply from these sources
and action to be taken in
case of high and low level
alarms and compressor
tripping.
1. Review provision of PI at HA / SA
inlet to knock out
vessel.

2. PG101 is available.
1. LG40014 available.
1. LG40014 available.
2. Water seal tank available.
1. LG 40014 is available
/4 (CO2 Compressor System)
1. LIT 102 is available with 1. Plant monitoring & area AS
low level alarm LIA102.
2. Compressor trip on low low operator
lube oil supply pressure
vessel.
1.Plant monitoring & area AS 13
round by relevant area AS 37A
operator
2. SOP to be developed for
periodic operation of drain
valve as valve is manual
1.Plant monitoring & area AS 13
round by relevant area AS
operator
2. SOPs to be developed to
ensure water level in seal
tank is maintained
1. Plant monitoring & area AS 13
round by relevant area AS
operator
2. SOP to be developed for
periodic operation
of drain valve as valve is
manual
13
round by relevant area AS 97
2. SOPs need to be
developed for periodic
inspection, testing and
maintenance of Compressor
instrumentation
1. Compressor has
proprietary control system
also covering lube oil system.
2. Lube oil pump motor
indication available.
3. PG105/106 available.
4. PT103/PICSA103 available
with low low- pressure alarm.
5. PDG 102, PT 102,and
PDIA102 with high alarm are
available across strainers.
6. Stand by strainer is
1. SOPs` to be developed for AS
compressor operation AS
should include lube oil circuit
and monitoring of lube oil
level and consumption. Also
include monitoring of
pressure indication.
2.SOPs to be developed for
plant monitoring & area
round by relevant area
operator
13

available
7. PG108 to PG114 available
at compressor inlet .PG115 at
outlet .
8. Sight glass is available to
monitor flow.

1. Lube oil motor indication is 1. SOPs need to be FSK 19

available. developed for periodic
inspection, testing and
2. PG105/106 available. maintenance of
instrumentation.
3. PT103/PISCA103 available. 2. SOPs` to be developed for MTA 98
4. PDG102/PT102 and PDIA inspection and maintenance
102 with high differential of lube oil pumps and PSVs
pressure available across

strainer.

5. PSV available on
pump discharge.
1. Lube oil motor indication is
available.
2. PG105 /106
available.
3. PG108-114 available at
compressor inlet

PG115 at compressor outlet.

4. PDG102/PT102 and PDIA
102 with high differential
pressure available across
strainer.
5. PSV available on pump
discharge.

1. Lube oil motor indication is

available.
2. PG105 /106
available.
3. PT103/PICSA103 available
with low low pressure alarm

1. TG104 / TT103 / 1. SOPs to be developed for MTA

TIA103 available with high
temperature alarm.
2. PI40091 on cooling water
supply line anad TT40092 on
CW outlet line.
3. TT104/TIA104
available with high alarm.
4.TG106 and 107
available.
lube oil cooler inspection FSK
and maintenance MTA
2. SOPs need to be
developed for periodic
inspection, testing and
maintenance of
instrumentation.
3. SOPs to define frequency
of testing

and replacement of lube oil

 1.TT103/TIA103
available with low alarm.
2. PI40091 on cooling water
supply line and TT40092 on
CW outlet line.
3.TT104/TIA104
available.
4. TG 104 available
11 – 1/1 (Centrifuge 4)
1. Centrifuge 4 independent 1. Plant monitoring & area
control sequence is available. round by relevant area
Indication available for
XV40002.
2. Line unblocking can be
done via HSW
1. Sight glass available on line. Plant monitoring & area
2. LIC30007/LT30007
on mother liquor tank
available with high alarm.
1.SOPs
2. Centrifuge control
sequence is available.
1. SOPs to be developed for MTA
lube oil cooler inspection FSK
and maintenance
2. SOPs need to be
developed for periodic
inspection, testing and
maintenance of
instrumentation.
3. SOPs to define MTA
frequency of testing
and replacement of
lube oil
4. SOPs to be developed for MTA / FSK
inspection and
maintenance of electric
heater.
AS 13
operator
AS 13
round by relevant area
operator
1.Plant monitoring & AS 13
area round by relevant
area operator
2. Review provision of PI on HA / SA
the line for
monitoring purposes
 sequence is available.
HA / SA

monitoring purposes

1/1 (Instrument Air Header)

1. PI 40064 available 1. SOPs to be developed to AS 94
2. PT 40028 / PI 40028 monitor adequate supply at

with low alarm available required pressure to all

areas

/2 (Product Handling System)

1. Screw & bucket 1.Plant monitoring & AS 13
 conveyor current indication
available on PLC.
2. Tripping of upstream
equipment
area round by relevant area MTA 95
operator
2. SOPs to be developed for
inspection and maintenance
of conveying equipment

/2 (Product Handling System)

1. PT 40031 / PIA 1.Plant monitoring & area AS 13
40031 is available with high round by relevant area
and low pressure alarms operator
2. Cleaning window is
available; HSW flushing point
connection is available

1. LSH40048 with high- level Plant monitoring & area AS 13

alarm is available. round by relevant area
2. PT 40030 / PIA operator
40030 is available with high
and low pressure alarms
3. PT 40031 / PIA
40031 is available with high
and low pressure alarms

4. Cyclone star feeder motor

current indication is available
on PLC.

1. PT 40030 / PIA 1. Plant monitoring & area AS 13

40030 is available with high round by relevant area
and low pressure alarm. operator
2. HSW connections are
available for washing

1. Cyclone star feeder 1.Ensure Interlocking AS/MH 59

motor current sequence
indication available on
PLC 2.Plant monitoring &

2. Washing can be done area round by relevant

through Access Door on area operator
Cyclone

AS 13