HAZOP Work Sheet Zaltoprofen

IPCA LABORATORIES-Ankleshwar
JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
IPCA
Work Sheet No.: (1):
Work Sheet No.:
Stage No:-
1 (Synthesis of ZaltoProfen Crude)
Process step No:
Reaction
(Design Intent)
Process sub step
No:-
Node No.:
1. Charging of poly-phosphoric acid

2. Charging of DM water
3. Stirring
4. Cooling
5. Charging of Di-acid
6. Charging of Methyl cyclohexane
7. Heating
8. Distillation
9. Cooling
10. Charging Of Toluene
11. Charging Of DM Water
12. Layer Separation
1.1.1 to 1.1.12
Ref. PFD:
1.
ZaltoProfen Crude
Charging of poly-phosphoric acid.

Deviation
Low Temperature
Causes
Human
keeping the
valve Open/
valve passing.
Consequences
errorbrine
brine
Poly-phosphoric
acid Solidifying
in the reactor
Agitator
Jamming
Production
Safeguards
Nothing Temperature
Indicator is provided but
same is not recording
before and during Polyphosphoric acid
Recommendations
1) ----Procedural control-operator to log the reactor

temperature before charging
the Poly-phosphoric acid in
the reactor.
2) Action taken be on low
39
JOGI
HAZOP STUDY
IPCA
delay
Contamination
Spillage.
Property
damage motor
damage,
agitator
shaft
Damage
Human error.
Wrong material used

for washing
Material quality
degradation.
Loss
production.
Leakage in reactor
Material loss
temperature by operator
should be documented and
operators to be trained
validated.
3) Low temperature sensor

with automation to shut of
brine
inlet
on
predetermined
low
temperature to be provided
of
Quality
check,
procedural
control exists for
all raw materials
Reactor thickness
survey is carried out
once in 2 years.
Jacket pressure test

is done once in 2
years.
SOPs are available.
Training is imparted
to operational staff.
Personnel vigilance.
PPEs are provided.
SCBA set is available

in plant building.
40
JOGI
HAZOP STUDY
IPCA
2-Charging of DM water
High quantity.
Low quantity
Agitator stopped.
Human error.
Human error.
Quality degradation.
Lean slurry formation.
may
be
BMR procedures
followed.
Water
Measured
charging.
BMR procedures
followed.
Dipstick is available to
measure
level
in
drums.
DG set is available.
PM of agitator & motor

carried out periodically.
Power failure.
Agitator jammed.
Less time allowed

for Agitation.
Human error.
SOP is available.
No Cooling
available
Power failure
Delayed batch time
SOPs are available.
Steam lined up to
reactor jacket by
mistake.
Degraded quality
Personal vigilance.
Temperature increases.
Improper dissolution.
are
meter/
quantity
water
Reaction
affected.
Exothermic
reaction.
Power failure.
Thick slurry formation.
Manual vigilance.
Agitator jammed.
Improper mixing.
are
Mechanical lock to be
provided such that only one
utility can be lined up at a
time.
3-Stirring
Agitator stopped.
41
JOGI
HAZOP STUDY
IPCA
Less time allowed

for stirring.
High
temperature.
Low temperature

SOP is available.
Human error.
Power Failure.
Motor Failure.
Agitator jammed.

Power failure.
Undesired reaction.
No cooling water
available.
Quality degraded.
Faulty
temperature
indication.
PM & calibration of
temperature
indicator is done
periodically.
BMR procedures are

followed.
PPEs shall be worn

by operational staff.
PM & calibration of
temperature
indicator is done
periodically.
Human error.
Chilling or brine
lined
up
to
reactor jacket by
mistake
Faulty
temperature
indication.
Redundant temperature
indication with alarm to
be provided.
Redundant temperature
indication
with
low
temperature alarm to be
provided.
4-Cooling
42
JOGI
HAZOP STUDY
IPCA
High temperature
Low temperature
Steam lined up
to reactor jacket
by mistake
No cooling water
available.
No
cause.
Delayed batch time.
SOPs are available.
Personal vigilance.
SOP is available.
provided such that only
one utility can be lined
up at a time.
Mechanical
assignable
5- Charging of Diacid
High quantity
Spillage
(During
charging of drums )
Human error
No
cause
Material loss.
Undesired quality.
assignable
6-Charging of Methylcyclohexane
High quantity
Spillage
(During
charging of drums )
Human error
No
cause
Steam lined up to
Material loss.
Undesired quality.
Delayed batch time.
SOP is available.
SOPs are available.
assignable
7-Heating
High temperature
lock
to
be
43
JOGI
HAZOP STUDY
IPCA
reactor jacket
mistake
Low temperature
No cooling
available.
by

time.
Personal vigilance.
water
No
cause.
High steam load in

reactor jacket.
assignable
8-Distillation
High Temperature
Low Temperature
High pressure
Power failure.
Human error.
Heating steam not

available.
High steam load in

reactor jacket
High
rate
evaporation..
of
Reactor
pressurization.
over-
Batch time increases.
Material
froathing
leak
SOP is available.
Temperature indication
is available.
and
Temperature control valve

in steam supply to be
provided.
Temperature/flow
control
valve in steam supply to be
provided.
.
9- Cooling
High temperature
Steam lined up
to reactor jacket
by mistake
Delayed batch time.
SOPs are available.
Personal vigilance.
provided such that only
one utility can be lined
44
JOGI
HAZOP STUDY
IPCA
Low Temperature
up at a time.
No cooling water
available.
No
assignable
cause/ no hazard
10- Charging Of Toluene

Contamination
High quantity.
Human error.
Human error.
Material
quality
degradation.
Loss of production.
Solvent loss.
Quality
check,
procedural
control exists for
all raw materials
BMR procedures
followed.
are
.
Low quantity
Human error.
Reaction
affected.
may
be
BMR procedures
followed.
are
.
Spillage.
Human error in
manual handling of
the containers.
Fire
SOPs are available.
Personnel injury.
Suffocation.
Training is imparted to
operational staff.
PPEs are provided.
SCBA set is available in

plant building.
11- Charging Of DM Water

45
JOGI
HAZOP STUDY
IPCA
High quantity.
Human error.
Solvent loss.
BMR procedures
followed.
are
Low quantity
Human error.
may
be
BMR procedures
followed.
Dipstick is available to
measure
level
in
drums.

Power failure.
Agitator jammed.
Less time allowed

for Agitation.
Human error.
SOP is available.
No Cooling
available
Power failure
Delayed batch time
SOPs are available.
Steam lined up to
reactor jacket by
mistake.
Degraded quality
Personal vigilance.
Temperature increases.
Agitator stopped.
water
Reaction
affected.
are
time.
Exothermic
reaction.
12- Layer Separation

Contamination
Less settling time
Product loss
Personnel vigilance
Mishandling
Human error
Sample is checked in
QC Lab.
46
JOGI
HAZOP STUDY
IPCA

Work Sheet No.:
Stage No:-
1 (Synthesis of ZaltoProfen Crude
Process step No:
2 (Centrifuging and vacuum drying )
(Design Intent)
Process sub step
No:-
1. Charging & spinning.

2.
Toluene Wash
3. Cake Unloading
4.
Vacuum drying
Node No.:
47
JOGI
HAZOP STUDY
IPCA
Ref. PFD:
ZaltoProfen Crude

Deviation
High Pressure
Causes
Consequences
Improper
Centrifuge
pressurized.
Centrifuge burst.
Property damage.
Damage to cloth.
Material loss.
Exposure of solvent to
operational staff.
Formation of flammable
vapors in plant building.
Damage to centrifuge.
Personnel injury.
Spillage.
Inefficient filtration.
Delayed batch time.
Wet cake formation.
charging.
High Quantity
Low Quantity
Less Time
Miscommunication
High pressure
reactor.
Reactor
passing.
Human error.
in
valve
Miscommunication
Human error.
Human error.
Safeguards
over
Recommendations
Proper
lineup
is
ensured
before
spinning.
Manual operation,
SOP controlled trained
persons
doing
centifusing
Manual vigilance.
BMR
procedure
place.
Completion of filtration
is ensured from sight
glass in mother liquor
line.
in
48
JOGI
HAZOP STUDY
IPCA
More Time
Human error.
Delayed batch time.
BMR
procedure
place.
line.
in
Drive Failure/Stop
Power failure.
Delayed batch time.
Also
(Centrifuge
cover open during
charging.)
Manual
charging
from centrifuge top
cover.
Solvent vapor expose to

operational staff.
PPEs are provided to

operational staff.
vapor.
Fire.
Limit
switch
to
stop
spinning in case of top
cover
open
to
be
incorporated
in
all
centrifuges.

operational staff.
vapor.
Limit
switch
stops
cover is open (New
centrifuges).
Fire.
Limit
switch
to
stop
cover
open
to
be
incorporated
in
all
centrifuges.
Delayed batch time.
Speed indication
provided.
Wet cake formation.
Also
(Centrifuge
cover open during
spinning).
Low speed
High
Solids
mother liquor)
Wet cake.
Human error.
Failure of latch.
Failure
switch.
(in
of
limit
Loose belt.
Filter bag leakage.
Filter bag passing.
Filter bag choking.
Delayed batch time.
Mother liquor line

chocking.
Material loss.
SOPs are available.
Filter
bags
replaced after
eight batches.
SOP is available for

usage of centrifuge
bag.
to
be
are
every
49
JOGI
HAZOP STUDY
IPCA
Low
speed.
Before/After
(charging
done
before
starting
spinning).
Human error.
High vibration
Spillage
liquor)
(Mother
centrifuge
High vibration.
Centrifuge imbalanced.
Improper charging.
Spark.
Charging
without
spinning.
Fire.
Damage to equipment.
done
starting
Centrifuge
overload.
Mother liquor line

chocked.
ML catch pot (ML

tank) over flow.
Fire.
Solvent loss.
ML transfer pump
not working.
Material loss.
Toxic effect.
Material
quality
degradation. No safety
issue
SOP is available.
Different speed selection to

be
provided
during
charging & spinning.
Automation (charging block

valve shall open only when
centrifuge is at appropriate
RPM).
Automation
(centrifuge
motor shall stop at high
vibration).
ML catch pot capacity to be

reviewed.
Level gauge to be provided

to ML tank.
Dump tank to be provided

to
store
ML
during
centrifuging in case of ML
pump failure.
2. Toluene Wash
Contamination
Human error.
Wrong
material
used for washing
50
JOGI
HAZOP STUDY
IPCA
Spillage /Exposure
Drive stop
Manual activity.
Material loss.
Fire.
Inefficient washing.
SOP control
Health hazard.
Trained persons
PPEs are worn

operational staff.
by
Fire extinguishers are

provided.
Power failure
Delayed batch time.
Human error
Toxic vapor exposure.
Mishandling.
PPEs (Organic vapor

mask) are provided to
operational personnel.
Use of hard tools

to scrap out hard
cake.
Cloth damage.
BMR
procedure
available.
Manual vigilance.
PPEs are available

to
operational
staff.
3.Cake Unloading
Spillage
Also (Damage
filter cloth)
to
is
3. vacuum drying
Spillage
High
Temperature
Human error.
Vapor exposure.
Improper
handling.
Material loss.
Suffocation.
Temperature
control system
failure.
Low
Temperature
Temperature
control system
Material
degraded.
quality
Material loss.
Temperature
indication
available.
is
Fire.
Material
degraded.
quality
Temperature
indication
is
51
JOGI
HAZOP STUDY
IPCA
failure.
available.
Manual sampling
is
done
for
ensuring moisture
content.
High
Flow
(drying air)
No assignable
cause.
Powder carry over

with drying air
Low/No
Flow
(drying air)
Chocking of air
filter.
Delayed batch time.
Manual sampling
is
done
for
ensuring moisture
content.
Power failure.
Blower failure.
Less Time
Human error.
High
content.
moisture
Manual sampling
is
done
for
ensuring moisture
content.
More Time
Human error.
Delayed batch time.
BMR procedure inline.
Spillage/Dustin
g.
Manual activity
Poor
housekeeping
Exposure
dust
PPEs are available

to
operational
staff.
to
toxic
52
JOGI
HAZOP STUDY
IPCA
Work Sheet No.:
Stage No:-
Process step No:
(BZB-B) Purification of Zaltopren crude
Reaction
(Design Intent)
Process sub step
No:-
1.
Charging of Zaltopren crude
2.
Charging of Acetone
3. Charging of Carbon slurry

4.
Node No.:
Ref. PFD:
Heating and stirring
1.3.1 to 1.3.5
Purification of Zaltopren crude
1-Charging of Zaltopren crude
Deviation
Contamination
Causes
Human error.
Consequences
Material
quality
degradation.
Loss of production.
Safeguards
Quality
procedural
exists
for
materials
Recommendations
check,
control
all
raw
SOP control.
Security by device
control.
No
entry.
unauthorized
53
JOGI
HAZOP STUDY
IPCA
Best Housekeeping
practices
2-Charging of Acetone
Deviation
High quantity
Causes
Spillage
Human error
No
assignable
cause, only error
during
manual
handling
Consequences
Material loss.
Undesired quality.
Vapor exposure
Safeguards
Recommendations
SOP is available.
SOP, PPE
3-Charging of Carbon Slurry Heating and stirring

Deviation
High quantity
Causes
Spillage
4-
Human error
No
cause,
assignable
Consequences
Material loss.
Undesired quality.
No
hazard
Safeguards
Recommendations
SOP is available.
considerable
Heating and stirring
Deviation
Agitator stopped.
Less time allowed

for stirring.
Causes
Consequences
Safeguards
Power failure.
Thick slurry formation.
Manual vigilance.
Agitator jammed.
Improper mixing.

SOP is available.
Human error.
Power Failure.
Recommendations
54
JOGI
HAZOP STUDY
IPCA
High temperature
Motor Failure.
Agitator jammed.
Steam lined up to
reactor jacket by
mistake
Delayed batch time.
No cooling
available.
Low temperature
No
cause.
Work Sheet No.:
Stage No:-
2 (BZB-B) Purification of Zaltopren crude
Process step No:

SOPs are available.
Personal vigilance.
water
Mechanical lock to be provided

such that only one utility can be
lined up at a time.
.
assignable
Pressure filtering, distilling and seeding of the mass
55
JOGI
HAZOP STUDY
IPCA
(Design Intent)
Process sub step
No:-
1- Pressure filtering
2- Distilling
3-Seeding
Node No.:
1.3.1 to 1.3.5
Ref. PFD:
Purification of Zaltopren crude
1- Pressure filtering
Deviation
Choking
filter
of
Causes
the
Consequences
No safety Hazard
Spillage
Leakage
filter
in
Safeguards
Production delay
the
contamination,
hazard
Atmosphere
heath
SOP control
SOP/ PPE
Recommendations
2- Distilling
Deviation
High Temperature
Low Temperature
Causes
High steam load in

reactor jacket.
Power failure.
Human error.
Consequences
Safeguards
High
rate
evaporation..
of
Reactor
pressurization.
over-
SOP is available.
Temperature indication
is available.
Recommendations
Temperature control valve

in steam supply to be
provided.
Batch time increases.
56
JOGI
HAZOP STUDY
IPCA
Heating steam not

available.
2- Seeding
Deviation
Causes
No
considerable
hazard
in
any
deviation only process
delay- No safety Issue
No
considerable
hazard
in
any
deviation
only
process delay- No
safety Issue
Consequences
No considerable hazard in
any deviation only process
delay- No safety Issue
Safeguards
SOP
control
for
process- this is process
quality critical activity
with no safety related
safe guards required.
Recommendations

Work Sheet No.:
Stage No:-
2 Purification of Zaltopran crude (BZB-B)
Process step No:
Centrifuging and vacuum drying
(Design Intent)
57
JOGI
HAZOP STUDY
IPCA
Process sub step
No:-
1- Charging & spinning.

2- Acetone Wash
3-Cake Unloading
4-
Vacuum drying
Node No.:
1.4.1 to 1.4.4
Ref. PFD:
MPCR/BZB-B/05 Dated:30/09/13

Deviation
High Pressure
Causes
Consequences
Improper
Centrifuge
pressurized.
Centrifuge burst.
Property damage.
Damage to cloth.
Material loss.
Exposure of solvent to
operational staff.
vapors in plant building.
Damage to centrifuge.
Personnel injury.
Spillage.
Delayed batch time.
Wet cake formation.
charging.
High Quantity
Low Quantity
Less Time
Miscommunication
High pressure
reactor.
Reactor
passing.
Human error.
in
valve
Miscommunication
Human error.
Human error.
Safeguards
over
Recommendations
Proper
lineup
is
ensured
before
spinning.
Manual operation,
SOP controlled trained
persons
doing
centrifuging
Manual vigilance.
BMR
procedure
As above.
in
58
JOGI
HAZOP STUDY
IPCA
place.
More Time
Human error.
Delayed batch time.
line.
BMR
procedure
place.
line.
in
Drive Failure/Stop
Power failure.
Delayed batch time.
Also
(Centrifuge
cover open during
charging.)
Manual
charging
from centrifuge top
cover.

operational staff.
PPEs are provided to

operational staff.
vapor.
Fire.
Limit
switch
to
stop
cover
open
to
be
incorporated
in
all
centrifuges.

operational staff.
vapor.
Limit
switch
stops
cover is open (New
centrifuges).
Fire.
Limit
switch
to
stop
cover
open
to
be
incorporated
in
all
centrifuges.
Delayed batch time.
Speed indication
provided.
Wet cake formation.
Also
(Centrifuge
cover open during
spinning).
Low speed
Wet cake.
Human error.
Failure of latch.
Failure
switch.
of
limit
Loose belt.
Filter bag choking.
Delayed batch time.
Mother liquor line

chocking.
Material loss.
to
be
SOP is available for

usage of centrifuge
bag.
59
JOGI
HAZOP STUDY
IPCA
Low
speed.
Before/After
(charging
done
before
starting
spinning).
Human error.
High vibration
Spillage
liquor)
(Mother
centrifuge
High vibration.
Centrifuge imbalanced.
Improper charging.
Spark.
Charging
without
spinning.
Fire.
Damage to equipment.
done
starting
Centrifuge
overload.
Mother liquor line

chocked.
ML catch pot (ML

tank) over flow.
Fire.
Solvent loss.
ML transfer pump
not working.
Material loss.
Toxic effect.
Material
quality
degradation. No safety
issue
SOP is available.
Different speed selection to

be
provided
during
charging & spinning.
Automation (charging block

valve shall open only when
centrifuge is at appropriate
RPM).
Automation
(centrifuge
motor shall stop at high
vibration).
ML catch pot capacity to be

reviewed.
Level gauge to be provided

to ML tank.
Dump tank to be provided

to
store
ML
during
centrifuging in case of ML
pump failure.
5. Acetone Wash
Contamination
Human error.
Wrong
material
used for washing
60
JOGI
HAZOP STUDY
IPCA
Spillage /Exposure
Drive stop
Manual activity.
Material loss.
Fire.
Inefficient washing.
SOP control
Health hazard.
Trained persons
PPEs are worn

operational staff.
by
Fire extinguishers are

provided.
Power failure
Delayed batch time.
Human error
Toxic vapor exposure.
Mishandling.
PPEs (Organic vapor

mask) are provided to
operational personnel.
Use of hard tools

to scrap out hard
cake.
Cloth damage.
BMR
procedure
available.
Manual vigilance.
PPEs are available

to
operational
staff.
3.Cake Unloading
Spillage
Also (Damage
filter cloth)
to
is
6. vacuum drying
Spillage
High
Temperature
Human error.
Vapor exposure.
Improper
handling.
Material loss.
Suffocation.
Temperature
control system
failure.
Low
Temperature
Temperature
control system
Material
degraded.
quality
Material loss.
Temperature
indication
available.
is
Fire.
Material
degraded.
quality
Temperature
indication
is
61
JOGI
HAZOP STUDY
IPCA
failure.
available.
Manual sampling
is
done
for
ensuring moisture
content.
High
Flow
(drying air)
No assignable
cause.
Powder carry over

with drying air
Low/No
Flow
(drying air)
Chocking of air
filter.
Delayed batch time.
Manual sampling
is
done
for
ensuring moisture
content.
Power failure.
Blower failure.
Less Time
Human error.
High
content.
moisture
Manual sampling
is
done
for
ensuring moisture
content.
More Time
Human error.
Delayed batch time.
BMR procedure inline.
Spillage/Dustin
g.
Manual activity
Poor
housekeeping
Exposure
dust
PPEs are available

to
operational
staff.
to
toxic
62
JOGI
HAZOP STUDY
IPCA

Work Sheet No.:
Stage No:-
2 Purification of zaltopofren crude (BZB-B)
Process step No:
Pulverization & bag filling
(Design Intent)
Process sub step
No:-
1.
Node No.:
1.4.1 to 1.4.4
Ref. PFD:
MPCR/BZB-B/05 Dated:30/09/13
Pulverization
Deviation
Causes
Consequences
Safeguards
Recommendations
63
JOGI
HAZOP STUDY
IPCA
Static build
Pulverization
Explosion in the
equipment
Earthing
Nitrogen
blanketing with trip
of pulverizer on low
Nitrogen pressure.
Dust collectors
Explosion in the
equipment
Nil
Metallic strips in
dust collector and
connected to earth
pit.
Bag filling
Fire
Antistatic bags are

used in operationconnected to metallic
chute.
64

HAZOP Work Sheet Zaltoprofen

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HAZOP Work Sheet Zaltoprofen

Загружено:

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Доступные форматы

IPCA LABORATORIES-Ankleshwar

REPORT NO.:- ZaltoProfen

1 (Synthesis of ZaltoProfen Crude)

Process step No:

1. Charging of poly-phosphoric acid

Charging of poly-phosphoric acid.

1) ----Procedural control-operator to log the reactor

REPORT NO.:- ZaltoProfen

Wrong material used

3) Low temperature sensor

Jacket pressure test

SOPs are available.

PPEs are provided.

SCBA set is available

REPORT NO.:- ZaltoProfen

Lean slurry formation.

PM of agitator & motor

Less time allowed

Delayed batch time

SOPs are available.

Thick slurry formation.

REPORT NO.:- ZaltoProfen

Less time allowed

PM of agitator & motor

PM of agitator & motor

BMR procedures are

PPEs shall be worn

REPORT NO.:- ZaltoProfen

Delayed batch time.

SOPs are available.

Delayed batch time.

SOPs are available.

REPORT NO.:- ZaltoProfen

provided such that only one

High steam load in

Heating steam not

High steam load in

Batch time increases.

Temperature control valve

Delayed batch time.

SOPs are available.

REPORT NO.:- ZaltoProfen

10- Charging Of Toluene

SOPs are available.

PPEs are provided.

SCBA set is available in

11- Charging Of DM Water

REPORT NO.:- ZaltoProfen

PM of agitator & motor

Less time allowed

Delayed batch time

SOPs are available.

12- Layer Separation

Less settling time

REPORT NO.:- ZaltoProfen

Work Sheet No.: (2):

1 (Synthesis of ZaltoProfen Crude

Process step No:

2 (Centrifuging and vacuum drying )

1. Charging & spinning.

REPORT NO.:- ZaltoProfen

1. Charging & spinning.

Delayed batch time.