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8/16/2019 HAZOP Work Sheet Zaltoprofen
1/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
Work Sheet No. !"#
Work Sheet No. "
Sta$e No- " !S%nthes&s of ZaltoProfen Cr'(e#
Pro)ess ste* No
!+es&$n Intent#
Rea)t&on
Pro)ess s', ste*
No-
1. Charging of poly-phosphori ai!". Charging of D# $a%&r'. S%irring(. Cooling). Charging of Di-ai!*. Charging of #&%hyl yloh&+an&,. H&a%ing. Dis%illa%ion. Cooling1/. Charging Of Tol0&n&11. Charging Of D# a%&r 21". 3ay&r S¶%ion
No(e No. "."." to "."."
Ref. P+ ZaltoProfen Cr'(e
". Char$&n$ of *ol%-*hos*hor&) a)&(.
+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons
Low Te1*erat're • H04an &rror-
5&&ping %h& 6rin&
7al7& Op&n8 6rin&
7al7& passing.
• Poly-phosphori
ai! Soli!ifying
in %h& r&a%or
• Agi%a%or
9a44ing
• Pro!0%ion
No%hing 2 T&4p&ra%0r&
n!ia%or is pro7i!&! 60%
sa4& is no% r&or!ing
6&for& an! !0ring Poly-
phosphori ai!
1; ----Pro&!0ral on%rol--
op&ra%or %o log %h& r&a%or
%&4p&ra%0r& 6&for& harging
%h& Poly-phosphori ai! in
%h& r&a%or.
"; A%ion %a5&n 6& on lo$
'
8/16/2019 HAZOP Work Sheet Zaltoprofen
2/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
!&lay
• Prop&r%y!a4ag& 2 4o%or
!a4ag&<
agi%a%or shaf%
Da4ag&
%&4p&ra%0r& 6y op&ra%or
sho0l! 6& !o04&n%&! an!op&ra%ors %o 6& %rain&!
7ali!a%&!.
'; 3o$ %&4p&ra%0r& s&nsor
$i%h a0%o4a%ion %o sh0% of
6rin& inl&% on
pr&!&%&r4in&! lo$
%&4p&ra%0r& %o 6& pro7i!&!
Conta1&nat&on • H04an &rror.
• rong 4a%&rial 0s&!
for $ashing
• 3&a5ag& in r&a%or
• #a%&rial =0ali%y
!&gra!a%ion.
• 3oss of
pro!0%ion.
• >0ali%y h&5<
pro&!0ral
on%rol &+is%s forall ra$ 4a%&rials
R&a%or %hi5n&ss
s0r7&y is arri&! o0%
on& in " y&ars.
9a5&% pr&ss0r& %&s%
is !on& on& in "
y&ars.
.
S*&lla$e. • #a%&rial loss . • SOPs ar& a7aila6l&.
• Training is i4par%&!
%o op&ra%ional s%a?.
• P&rsonn&l 7igilan&.
• PPEs ar& pro7i!&!.
• SC@A s&% is a7aila6l&
in plan% 60il!ing.
(/
8/16/2019 HAZOP Work Sheet Zaltoprofen
3/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
-Char$&n$ of +2 water
3&$h 0'ant&t%. • H04an &rror. • >0ali%y !&gra!a%ion.
• 3&an sl0rry for4a%ion.
• @#R pro&!0r&s ar&
follo$&!.
• a%&r 4&%&r8
#&as0r&! =0an%i%y
harging.
Low 0'ant&t% • H04an &rror. • R&a%ion 4ay 6&
a?&%&!.
• @#R pro&!0r&s ar&
follo$&!.
• Dips%i5 is a7aila6l& %o
4&as0r& l&7&l in
!r04s.
A$&tator sto**e(. • Po$&r fail0r&.
• Agi%a%or a44&!.
• 4prop&r !issol0%ion. • DB s&% is a7aila6l&.
• P# of agi%a%or 4o%or
arri&! o0% p&rio!ially.
Less t&1e allowe(
for A$&tat&on.
• H04an &rror. • >0ali%y !&gra!a%ion. • SOP is a7aila6l&.
No Cool&n$ water
a/a&la,le
• Po$&r fail0r&
• S%&a4 lin&! 0p %o
r&a%or a5&% 6y
4is%a5&.
• E+o%h&r4i
r&a%ion.
• D&lay&! 6a%h %i4&
• D&gra!&! =0ali%y
•
T&4p&ra%0r& inr&as&s.
• SOPs ar& a7aila6l&.
• P&rsonal 7igilan&.
• #&hanial lo5 %o 6&
pro7i!&! s0h %ha% only on&
0%ili%y an 6& lin&! 0p a% a
%i4&.
4-St&rr&n$
A$&tator sto**e(.
Po$&r fail0r&.
Agi%a%or a44&!.
Thi5 sl0rry for4a%ion.
4prop&r 4i+ing.
#an0al 7igilan&.
DB s&% is a7aila6l&.
(1
8/16/2019 HAZOP Work Sheet Zaltoprofen
4/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
P# of agi%a%or 4o%or
arri&! o0% p&rio!ially.Less t&1e allowe(
for st&rr&n$.
H04an &rror.
Po$&r ail0r&.
#o%or ail0r&.
Agi%a%or a44&!.
4prop&r !issol0%ion.
SOP is a7aila6l&.
DB s&% is a7aila6l&.
P# of agi%a%or 4o%or
arri&! o0% p&rio!ially.
3&$h
te1*erat're.
Po$&r fail0r&.
No ooling $a%&r
a7aila6l&.
a0l%y
%&4p&ra%0r&
in!ia%ion.
Un!&sir&! r&a%ion.
>0ali%y !&gra!&!.
DB s&% is a7aila6l&.
P# ali6ra%ion of
%&4p&ra%0r&
in!ia%or is !on&p&rio!ially.
@#R pro&!0r&s ar&
follo$&!.
PPEs shall 6& $orn
6y op&ra%ional s%a?.
R&!0n!an% %&4p&ra%0r&
in!ia%ion $i%h alar4 %o
6& pro7i!&!.
Low te1*erat're H04an &rror.
Chilling or 6rin&
lin&! 0p %o
r&a%or a5&% 6y4is%a5&
a0l%y
%&4p&ra%0r&
in!ia%ion.
>0ali%y !&gra!a%ion. P# ali6ra%ion of
%&4p&ra%0r&
in!ia%or is !on&
p&rio!ially.
R&!0n!an% %&4p&ra%0r&
in!ia%ion $i%h lo$
%&4p&ra%0r& alar4 %o 6&
pro7i!&!.
5-Cool&n$
("
8/16/2019 HAZOP Work Sheet Zaltoprofen
5/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
3&$h te1*erat're • S%&a4 lin&! 0p
%o r&a%or a5&%6y 4is%a5&
• No ooling $a%&r
a7aila6l&.
• D&lay&! 6a%h %i4&. • SOPs ar& a7aila6l&.
• P&rsonal 7igilan&.
• #&hanial lo5 %o 6&
pro7i!&! s0h %ha% onlyon& 0%ili%y an 6& lin&!
0p a% a %i4&.
Low te1*erat're • No assigna6l&
a0s&.
6- Char$&n$ of +&a)&(
3&$h 0'ant&t% • H04an &rror • #a%&rial loss.
• Un!&sir&! =0ali%y.
• SOP is a7aila6l&.
S*&lla$e !+'r&n$
)har$&n$ of (r'1s #
• No assigna6l&
a0s&
• • •
7-Char$&n$ of 2eth%l)%)lohe8ane
3&$h 0'ant&t% • H04an &rror • #a%&rial loss.
• Un!&sir&! =0ali%y.
• SOP is a7aila6l&.
S*&lla$e !+'r&n$
)har$&n$ of (r'1s #
• No assigna6l&
a0s&
9-3eat&n$
3&$h te1*erat're • S%&a4 lin&! 0p %o • D&lay&! 6a%h %i4&. • SOPs ar& a7aila6l&. • #&hanial lo5 %o 6&
('
8/16/2019 HAZOP Work Sheet Zaltoprofen
6/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
r&a%or a5&% 6y
4is%a5&
• No ooling $a%&r
a7aila6l&.
• P&rsonal 7igilan&. pro7i!&! s0h %ha% only on&
0%ili%y an 6& lin&! 0p a% a
%i4&.
.
Low te1*erat're • No assigna6l&
a0s&.
:-+&st&llat&on
3&$h Te1*erat're • High s%&a4 loa! in
r&a%or a5&%.
• High ra%& of
&7apora%ion..
• R&a%or o7&r-pr&ss0ria%ion.
• SOP is a7aila6l&.
• T&4p&ra%0r& in!ia%ion
is a7aila6l&.
• P&rsonn&l 7igilan&.
• T&4p&ra%0r& on%rol 7al7&
in s%&a4 s0pply %o 6&
pro7i!&!.
Low Te1*erat're • Po$&r fail0r&.
• H04an &rror.
• H&a%ing s%&a4 no%
a7aila6l&.
• @a%h %i4& inr&as&s.
3&$h *ress're • High s%&a4 loa! in
r&a%or a5&%
• #a%&rial l&a5 an!
froa%hing
• T&4p&ra%0r&8Fo$ on%rol
7al7& in s%&a4 s0pply %o 6&pro7i!&!.
.
;- Cool&n$
3&$h te1*erat're • S%&a4 lin&! 0p
%o r&a%or a5&%
6y 4is%a5&
• D&lay&! 6a%h %i4&. • SOPs ar& a7aila6l&.
• P&rsonal 7igilan&.
• #&hanial lo5 %o 6&
pro7i!&! s0h %ha% only
on& 0%ili%y an 6& lin&!
((
8/16/2019 HAZOP Work Sheet Zaltoprofen
7/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
• No ooling $a%&r
a7aila6l&.
0p a% a %i4&.
.
Low Te1*erat're No assigna6l&
a0s&8 no haar!
•
"0ali%y !&gra!a%ion.
• @#R pro&!0r&s ar&
follo$&!.
.
Low 0'ant&t% • H04an &rror. • R&a%ion 4ay 6&
a?&%&!.
• @#R pro&!0r&s ar&
follo$&!.
.
S*&lla$e. H04an &rror in
4an0al han!ling of
%h& on%ain&rs.
• ir&
• P&rsonn&l in0ry.
• S0?oa%ion.
• SOPs ar& a7aila6l&.
• Training is i4par%&! %o
op&ra%ional s%a?.
• P&rsonn&l 7igilan&.
• PPEs ar& pro7i!&!.
• SC@A s&% is a7aila6l& in
plan% 60il!ing.
.
""- Char$&n$ Of +2 Water
()
8/16/2019 HAZOP Work Sheet Zaltoprofen
8/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
3&$h 0'ant&t%. • H04an &rror. • Sol7&n% loss.
• >0ali%y !&gra!a%ion.
• @#R pro&!0r&s ar&follo$&!.
.
Low 0'ant&t% • H04an &rror. • R&a%ion 4ay 6&
a?&%&!.
• @#R pro&!0r&s ar&
follo$&!.
• Dips%i5 is a7aila6l& %o
4&as0r& l&7&l in
!r04s.
A$&tator sto**e(. • Po$&r fail0r&.
•
Agi%a%or a44&!.
• 4prop&r !issol0%ion. • DB s&% is a7aila6l&.
•
P# of agi%a%or 4o%orarri&! o0% p&rio!ially.
Less t&1e allowe(
for A$&tat&on.
• H04an &rror. • >0ali%y !&gra!a%ion. • SOP is a7aila6l&.
No Cool&n$ water
a/a&la,le
• Po$&r fail0r&
• S%&a4 lin&! 0p %o
r&a%or a5&% 6y
4is%a5&.
• E+o%h&r4i
r&a%ion.
• D&lay&! 6a%h %i4&
• D&gra!&! =0ali%y
• T&4p&ra%0r& inr&as&s.
• SOPs ar& a7aila6l&.
• P&rsonal 7igilan&.
• #&hanial lo5 %o 6&
pro7i!&! s0h %ha% only on&
0%ili%y an 6& lin&! 0p a% a
%i4&.
"- La%er Se*arat&on
Conta1&nat&on • 3&ss s&%%ling %i4&
• #ishan!ling
• H04an &rror
• Pro!0% loss
• >0ali%y !&gra!a%ion.
• P&rsonn&l 7igilan&
• Sa4pl& is h&5&! in
>C 3a6.
(*
8/16/2019 HAZOP Work Sheet Zaltoprofen
9/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
Work Sheet No. !#
Work Sheet No.
Sta$e No- " !S%nthes&s of ZaltoProfen Cr'(e
Pro)ess ste* No
!+es&$n Intent#
!Centr&f'$&n$ an( /a)''1 (r%&n$ #
Pro)ess s', ste*
No-
". Char$&n$ = s*&nn&n$.
. Tol'ene Wash
4. Cake >nloa(&n$
5. ?a)''1 (r%&n$
No(e No.
(,
8/16/2019 HAZOP Work Sheet Zaltoprofen
10/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
Ref. P+ ZaltoProfen Cr'(e
". Char$&n$ = s*&nn&n$.
+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons
3&$h Press're • 4prop&r
harging.
• C&n%rif0g& o7&r
pr&ss0ri&!.
• C&n%rif0g& 60rs%.
• Prop&r%y !a4ag&.
• Da4ag& %o lo%h.
• Prop&r lin&0p is
&ns0r&! 6&for&
spinning.
3&$h @'ant&t% •
#is-o440nia%ion
• High pr&ss0r& in
r&a%or.
• R&a%or 7al7&
passing.
• H04an &rror.
•
#a%&rial loss.• E+pos0r& of sol7&n% %o
op&ra%ional s%a?.
• or4a%ion of Fa44a6l&
7apors in plan% 60il!ing.
• Da4ag& %o &n%rif0g&.
• P&rsonn&l in0ry.
• Spillag&.
#an0al op&ra%ion
8/16/2019 HAZOP Work Sheet Zaltoprofen
11/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
2ore T&1e • H04an &rror. • D&lay&! 6a%h %i4&. • @#R pro&!0r& in
pla&.
• Co4pl&%ion of l%ra%ion
is &ns0r&! fro4 sigh%
glass in 4o%h&r li=0or
lin&.
+r&/e a&l'reSto* • Po$&r fail0r&. • D&lay&! 6a%h %i4&. • DB s&% is a7aila6l&.
Also !Centr&f'$e
)o/er o*en ('r&n$
)har$&n$.#
• #an0al harging
fro4 &n%rif0g& %op
o7&r.
• Sol7&n% 7apor &+pos& %o
op&ra%ional s%a?.
• or4a%ion of Fa44a6l&
7apor.
• ir&.
• PPEs ar& pro7i!&! %o
op&ra%ional s%a?.
• 3i4i% s$i%h %o s%op
spinning in as& of %op
o7&r op&n %o 6&
inorpora%&! in all
&n%rif0g&s.
Also !Centr&f'$e
)o/er o*en ('r&n$
s*&nn&n$#.
• H04an &rror.
• ail0r& of la%h.
• ail0r& of l i4i%
s$i%h.
• Sol7&n% 7apor &+pos& %o
op&ra%ional s%a?.
• or4a%ion of Fa44a6l&
7apor.
• ir&.
• 3i4i% s$i%h s%ops
spinning in as& of %op
o7&r is op&n IN&$
&n%rif0g&s;.
• 3i4i% s$i%h %o s%op
spinning in as& of %op
o7&r op&n %o 6&
inorpora%&! in all
&n%rif0g&s.
Low s*ee( • 3oos& 6&l%. • n&Gi&n% l%ra%ion.
• D&lay&! 6a%h %i4&.
• &% a5& for4a%ion.
• Sp&&! in!ia%ion %o 6&
pro7i!&!.
3&$h Sol&(s !&n
1other l&0'or#
• il%&r 6ag l&a5ag&.
• il%&r 6ag passing.
• >0ali%y !&gra!a%ion. • SOPs ar& a7aila6l&.
• il%&r 6ags ar&
r&pla&! af%&r &7&ry
&igh% 6a%h&s.
Wet )ake. • il%&r 6ag ho5ing.
• #o%h&r li=0or lin&
ho5ing.
• D&lay&! 6a%h %i4&.
• #a%&rial loss.
• SOP is a7aila6l& for
0sag& of &n%rif0g&
6ag.
(
8/16/2019 HAZOP Work Sheet Zaltoprofen
12/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
• 3o$ &n%rif0g&
sp&&!.
BeforeAfter
!)har$&n$ (one
,efore start&n$
s*&nn&n$#.
• H04an &rror. • High 7i6ra%ion.
• n&Gi&n% l%ra%ion.
• C&n%rif0g& i46alan&!.
• Di?&r&n% sp&&! s&l&%ion %o
6& pro7i!&! !0ring
harging spinning.
• A0%o4a%ion Iharging 6lo5
7al7& shall op&n only $h&n
&n%rif0g& is a% appropria%&
RP#;.
3&$h /&,rat&on • 4prop&r harging.
• Charging !on&
$i%ho0% s%ar%ingspinning.
• C&n%rif0g&
o7&rloa!.
• #o%h&r li=0or lin&
ho5&!.
• Spar5.
• ir&.
• Da4ag& %o &=0ip4&n%.
• A0%o4a%ion I&n%rif0g&
4o%or shall s%op a% high
7i6ra%ion;.
S*&lla$e !2other
l&0'or#
• #3 a%h po% I#3
%an5; o7&r Fo$.
• #3 %ransf&r p04p
no% $or5ing.
• ir&.
• Sol7&n% loss.
• #a%&rial loss.
•
To+i &?&%.
• SOP is a7aila6l&. • #3 a%h po% apai%y %o 6&
r&7i&$&!.
• 3&7&l ga0g& %o 6& pro7i!&!
%o #3 %an5.
• D04p %an5 %o 6& pro7i!&!
%o s%or& #3 !0ring
&n%rif0ging in as& of #3
p04p fail0r&.
. Tol'ene Wash
Conta1&nat&on • H04an &rror.
• rong 4a%&rial
0s&! for $ashing
• #a%&rial =0ali%y
!&gra!a%ion. No saf&%y
iss0&
.
)/
8/16/2019 HAZOP Work Sheet Zaltoprofen
13/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
S*&lla$e E8*os're • #an0al a%i7i%y. • #a%&rial loss.
• ir&.
• n&Gi&n% $ashing.
• H&al%h haar!.
• PPEs ar& $orn 6yop&ra%ional s%a?.
• SOP on%rol
• Train&! p&rsons
• ir& &+%ing0ish&rs ar&
pro7i!&!.
+r&/e sto* • Po$&r fail0r& • D&lay&! 6a%h %i4&. • DB s&% is a7aila6l&.
4.Cake >nloa(&n$
S*&lla$e • H04an &rror
• #ishan!ling.
• To+i 7apor &+pos0r&. • PPEs IOrgani 7apor
4as5; ar& pro7i!&! %o
op&ra%ional p&rsonn&l.
Also !+a1a$e to
lter )loth#
• Us& of har! %ools
%o srap o0% har!
a5&.
• Clo%h !a4ag&. • @#R pro&!0r& is
a7aila6l&.
• #an0al 7igilan&.
4. /a)''1 (r%&n$
S*&lla$e H04an &rror.
4prop&r
han!ling.
Japor &+pos0r&.
#a%&rial loss.
S0?oa%ion.
PPEs ar& a7aila6l&
%o op&ra%ional
s%a?.
3&$h
Te1*erat're
T&4p&ra%0r&
on%rol sys%&4
fail0r&.
#a%&rial =0ali%y
!&gra!&!.
#a%&rial loss.
ir&.
T&4p&ra%0r&
in!ia%ion is
a7aila6l&.
Low
Te1*erat're
T&4p&ra%0r&
on%rol sys%&4
#a%&rial =0ali%y
!&gra!&!.
T&4p&ra%0r&
in!ia%ion is
)1
8/16/2019 HAZOP Work Sheet Zaltoprofen
14/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
fail0r&. a7aila6l&.
#an0al sa4plingis !on& for
&ns0ring 4ois%0r&
on%&n%.
3&$h low
!(r%&n$ a&r#
No assigna6l&
a0s&.
Po$!&r arry o7&r
$i%h !rying air
LowNo low
!(r%&n$ a&r#
Cho5ing of air
l%&r.
Po$&r fail0r&.
@lo$&r fail0r&.
D&lay&! 6a%h %i4&. #an0al sa4pling
is !on& for
&ns0ring 4ois%0r&
on%&n%.
Less T&1e H04an &rror. High 4ois%0r&
on%&n%.
#an0al sa4pling
is !on& for
&ns0ring 4ois%0r&
on%&n%.
2ore T&1e H04an &rror. D&lay&! 6a%h %i4&. @#R pro&!0r& in-
lin&.
S*&lla$e+'st&n
$.
#an0al a%i7i%y
Poor
ho0s&5&&ping
E+pos0r& %o %o+i
!0s%
PPEs ar& a7aila6l&
%o op&ra%ional
s%a?.
)"
8/16/2019 HAZOP Work Sheet Zaltoprofen
15/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
Work Sheet No. !4#
Work Sheet No. 4
Sta$e No- !BZB-B# P'r&)at&on of Zalto*ren )r'(e
Pro)ess ste* No
!+es&$n Intent#
Rea)t&on
Pro)ess s', ste*
No-
". Char$&n$ of Zalto*ren )r'(e
. Char$&n$ of A)etone
4. Char$&n$ of Car,on sl'rr%
5. 3eat&n$ an( st&rr&n$
No(e No. ".4." to ".4.6
Ref. P+ P'r&)at&on of Zalto*ren )r'(e
"-Char$&n$ of Zalto*ren )r'(e
+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons
Conta1&nat&on • H04an &rror. • #a%&rial =0ali%y
!&gra!a%ion.
• 3oss of pro!0%ion.
>0ali%y h&5<
pro&!0ral on%rol
&+is%s for all ra$
4a%&rials
SOP on%rol.
S&0ri%y 6y !&7i&
on%rol.
No 0na0%hori&!
&n%ry.
)'
8/16/2019 HAZOP Work Sheet Zaltoprofen
16/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
@&s% Ho0s&5&&ping
pra%i&s
-Char$&n$ of A)etone
+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons
3&$h 0'ant&t% • H04an &rror • #a%&rial loss.
• Un!&sir&! =0ali%y.
• SOP is a7aila6l&.
S*&lla$e No assigna6l&
a0s&< only &rror
!0ring 4an0al
han!ling
• Japor &+pos0r& • SOP< PPE
4-Char$&n$ of Car,on Sl'rr% 3eat&n$ an( st&rr&n$
+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons
3&$h 0'ant&t% • H04an &rror • #a%&rial loss.
• Un!&sir&! =0ali%y.
• SOP is a7aila6l&.
S*&lla$e No assigna6l&
a0s&<
• No onsi!&ra6l&
haar!
5- 3eat&n$ an( st&rr&n$
+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons
A$&tator sto**e(. Po$&r fail0r&.
Agi%a%or a44&!.
Thi5 sl0rry for4a%ion.
4prop&r 4i+ing.
#an0al 7igilan&.
DB s&% is a7aila6l&.
P# of agi%a%or 4o%or
arri&! o0% p&rio!ially.
Less t&1e allowe(
for st&rr&n$.
H04an &rror.
Po$&r ail0r&.
4prop&r !issol0%ion. SOP is a7aila6l&.
DB s&% is a7aila6l&.
)(
8/16/2019 HAZOP Work Sheet Zaltoprofen
17/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
#o%or ail0r&.
Agi%a%or a44&!.
P# of agi%a%or 4o%or
arri&! o0% p&rio!ially.
3&$h te1*erat're • S%&a4 lin&! 0p %o
r&a%or a5&% 6y
4is%a5&
• No ooling $a%&r
a7aila6l&.
• D&lay&! 6a%h %i4&. • SOPs ar& a7aila6l&.
• P&rsonal 7igilan&.
#&hanial lo5 %o 6& pro7i!&!
s0h %ha% only on& 0%ili%y an 6&
lin&! 0p a% a %i4&.
.
Low te1*erat're • No assigna6l&
a0s&.
Work Sheet No. 5
Sta$e No- !BZB-B# P'r&)at&on of Zalto*ren )r'(e
Pro)ess ste* No Press're lter&n$ (&st&ll&n$ an( see(&n$ of the 1ass
))
8/16/2019 HAZOP Work Sheet Zaltoprofen
18/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
!+es&$n Intent#
Pro)ess s', ste*No-
"- Press're lter&n$- +&st&ll&n$
4-See(&n$
No(e No. ".4." to ".4.6
Ref. P+ P'r&)at&on of Zalto*ren )r'(e
"- Press're lter&n$
+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons
Chok&n$ of the
lter
No saf&%y Haar! Pro!0%ion !&lay • SOP on%rol
S*&lla$e 3&a5ag& in %h&
l%&r
A%4osph&r&
on%a4ina%ion< h&a%h
haar!
• SOP8 PPE
- +&st&ll&n$
+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons
3&$h Te1*erat're • High s%&a4 loa! inr&a%or a5&%.
• High ra%& of &7apora%ion..
• R&a%or o7&r-
pr&ss0ria%ion.
• SOP is a7aila6l&.
• T&4p&ra%0r& in!ia%ion
is a7aila6l&.
• P&rsonn&l 7igilan&.
• T&4p&ra%0r& on%rol 7al7&in s%&a4 s0pply %o 6&
pro7i!&!.
Low Te1*erat're • Po$&r fail0r&.
• H04an &rror.
• @a%h %i4& inr&as&s.
)*
8/16/2019 HAZOP Work Sheet Zaltoprofen
19/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
• H&a%ing s%&a4 no%
a7aila6l&.
- See(&n$
+e/&at&on Ca'ses Conse0'en)es Safe$'ar(s Re)o11en(at&ons
No onsi!&ra6l&
haar! in any
!&7ia%ion only pro&ss
!&lay- No saf&%y ss0&
No onsi!&ra6l&
haar! in any
!&7ia%ion only
pro&ss !&lay- No
saf&%y ss0&
No onsi!&ra6l& haar! in
any !&7ia%ion only pro&ss
!&lay- No saf&%y ss0&
SOP on%rol for
pro&ss- %his is pro&ss
=0ali%y ri%ial a%i7i%y
$i%h no saf&%y r&la%&!
saf& g0ar!s r&=0ir&!.
•
Work Sheet No. !5#
Work Sheet No. 5
Sta$e No- P'r&)at&on of Zalto*ran )r'(e !BZB-B#
Pro)ess ste* No
!+es&$n Intent#
Centr&f'$&n$ an( /a)''1 (r%&n$
),
8/16/2019 HAZOP Work Sheet Zaltoprofen
20/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
Pro)ess s', ste*
No-
"- Char$&n$ = s*&nn&n$.
- A)etone Wash
4-Cake >nloa(&n$
5- ?a)''1 (r%&n$
No(e No. ".5." to ".5.5
Ref. P+ 2PCRBZB-B
8/16/2019 HAZOP Work Sheet Zaltoprofen
21/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
pla&.
•
Co4pl&%ion of l%ra%ionis &ns0r&! fro4 sigh%
glass in 4o%h&r li=0or
lin&.
2ore T&1e • H04an &rror. • D&lay&! 6a%h %i4&. • @#R pro&!0r& in
pla&.
• Co4pl&%ion of l%ra%ion
is &ns0r&! fro4 sigh%
glass in 4o%h&r li=0or
lin&.
+r&/e a&l'reSto* •Po$&r fail0r&.
•
D&lay&! 6a%h %i4&. •
DB s&% is a7aila6l&.Also !Centr&f'$e
)o/er o*en ('r&n$
)har$&n$.#
• #an0al harging
fro4 &n%rif0g& %op
o7&r.
• Sol7&n% 7apor &+pos& %o
op&ra%ional s%a?.
• or4a%ion of Fa44a6l&
7apor.
• ir&.
• PPEs ar& pro7i!&! %o
op&ra%ional s%a?.
• 3i4i% s$i%h %o s%op
spinning in as& of %op
o7&r op&n %o 6&
inorpora%&! in all
&n%rif0g&s.
Also !Centr&f'$e
)o/er o*en ('r&n$
s*&nn&n$#.
• H04an &rror.
• ail0r& of la%h.
• ail0r& of l i4i%
s$i%h.
• Sol7&n% 7apor &+pos& %o
op&ra%ional s%a?.
• or4a%ion of Fa44a6l&
7apor.
• ir&.
• 3i4i% s$i%h s%ops
spinning in as& of %op
o7&r is op&n IN&$
&n%rif0g&s;.
• 3i4i% s$i%h %o s%op
spinning in as& of %op
o7&r op&n %o 6&
inorpora%&! in all
&n%rif0g&s.
Low s*ee( • 3oos& 6&l%. • n&Gi&n% l%ra%ion.
• D&lay&! 6a%h %i4&.
• &% a5& for4a%ion.
• Sp&&! in!ia%ion %o 6&
pro7i!&!.
Wet )ake. • il%&r 6ag ho5ing.
• #o%h&r li=0or lin&
ho5ing.
• D&lay&! 6a%h %i4&.
• #a%&rial loss.
• SOP is a7aila6l& for
0sag& of &n%rif0g&
6ag.
)
8/16/2019 HAZOP Work Sheet Zaltoprofen
22/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
• 3o$ &n%rif0g&
sp&&!.
BeforeAfter
!)har$&n$ (one
,efore start&n$
s*&nn&n$#.
• H04an &rror. • High 7i6ra%ion.
• n&Gi&n% l%ra%ion.
• C&n%rif0g& i46alan&!.
• Di?&r&n% sp&&! s&l&%ion %o
6& pro7i!&! !0ring
harging spinning.
• A0%o4a%ion Iharging 6lo5
7al7& shall op&n only $h&n
&n%rif0g& is a% appropria%&
RP#;.
3&$h /&,rat&on • 4prop&r harging.
• Charging !on&
$i%ho0% s%ar%ingspinning.
• C&n%rif0g&
o7&rloa!.
• #o%h&r li=0or lin&
ho5&!.
• Spar5.
• ir&.
• Da4ag& %o &=0ip4&n%.
• A0%o4a%ion I&n%rif0g&
4o%or shall s%op a% high
7i6ra%ion;.
S*&lla$e !2other
l&0'or#
• #3 a%h po% I#3
%an5; o7&r Fo$.
• #3 %ransf&r p04p
no% $or5ing.
• ir&.
• Sol7&n% loss.
• #a%&rial loss.
•
To+i &?&%.
• SOP is a7aila6l&. • #3 a%h po% apai%y %o 6&
r&7i&$&!.
• 3&7&l ga0g& %o 6& pro7i!&!
%o #3 %an5.
• D04p %an5 %o 6& pro7i!&!
%o s%or& #3 !0ring
&n%rif0ging in as& of #3
p04p fail0r&.
6. A)etone Wash
Conta1&nat&on • H04an &rror.
• rong 4a%&rial
0s&! for $ashing
• #a%&rial =0ali%y
!&gra!a%ion. No saf&%y
iss0&
.
*/
8/16/2019 HAZOP Work Sheet Zaltoprofen
23/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
S*&lla$e E8*os're•
#an0al a%i7i%y. • #a%&rial loss.• ir&.
• n&Gi&n% $ashing.
• H&al%h haar!.
•PPEs ar& $orn 6yop&ra%ional s%a?.
• SOP on%rol
• Train&! p&rsons
• ir& &+%ing0ish&rs ar&
pro7i!&!.
+r&/e sto* • Po$&r fail0r& • D&lay&! 6a%h %i4&. • DB s&% is a7aila6l&.
4.Cake >nloa(&n$
S*&lla$e • H04an &rror
• #ishan!ling.
• To+i 7apor &+pos0r&. • PPEs IOrgani 7apor
4as5; ar& pro7i!&! %o
op&ra%ional p&rsonn&l.
Also !+a1a$e to
lter )loth#
• Us& of har! %ools
%o srap o0% har!
a5&.
• Clo%h !a4ag&. • @#R pro&!0r& is
a7aila6l&.
• #an0al 7igilan&.
7. /a)''1 (r%&n$
S*&lla$e H04an &rror.
4prop&r
han!ling.
Japor &+pos0r&.
#a%&rial loss.
S0?oa%ion.
PPEs ar& a7aila6l&
%o op&ra%ional
s%a?.
3&$h
Te1*erat're
T&4p&ra%0r&
on%rol sys%&4
fail0r&.
#a%&rial =0ali%y
!&gra!&!.
#a%&rial loss.
ir&.
T&4p&ra%0r&
in!ia%ion is
a7aila6l&.
Low
Te1*erat're
T&4p&ra%0r&
on%rol sys%&4
#a%&rial =0ali%y
!&gra!&!.
T&4p&ra%0r&
in!ia%ion is
*1
8/16/2019 HAZOP Work Sheet Zaltoprofen
24/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
fail0r&. a7aila6l&.
#an0al sa4plingis !on& for
&ns0ring 4ois%0r&
on%&n%.
3&$h low
!(r%&n$ a&r#
No assigna6l&
a0s&.
Po$!&r arry o7&r
$i%h !rying air
LowNo low
!(r%&n$ a&r#
Cho5ing of air
l%&r.
Po$&r fail0r&.
@lo$&r fail0r&.
D&lay&! 6a%h %i4&. #an0al sa4pling
is !on& for
&ns0ring 4ois%0r&
on%&n%.
Less T&1e H04an &rror. High 4ois%0r&
on%&n%.
#an0al sa4pling
is !on& for
&ns0ring 4ois%0r&
on%&n%.
2ore T&1e H04an &rror. D&lay&! 6a%h %i4&. @#R pro&!0r& in-
lin&.
S*&lla$e+'st&n
$.
#an0al a%i7i%y
Poor
ho0s&5&&ping
E+pos0r& %o %o+i
!0s%
PPEs ar& a7aila6l&
%o op&ra%ional
s%a?.
*"
8/16/2019 HAZOP Work Sheet Zaltoprofen
25/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
Work Sheet No. !6#
Work Sheet No. 6
Sta$e No- P'r&)at&on of Dalto*ofren )r'(e !BZB-B#
Pro)ess ste* No
!+es&$n Intent#
P'l/er&Dat&on = ,a$ ll&n$
Pro)ess s', ste*
No-
".
No(e No. ".5." to ".5.5
Ref. P+ 2PCRBZB-B
8/16/2019 HAZOP Work Sheet Zaltoprofen
26/26
IPCA
IPCA LABORATORIES-Ankleshwar JOGI
HAZOP STUDY
REPORT NO.:- ZaltoProfen
S%a%i 60il! P0l7&ria%ion E+plosion in %h&
&=0ip4&n%
Ear%hing - Ni%rog&n
6lan5&%ing $i%h %rip
of p0l7&ri&r on lo$
Ni%rog&n pr&ss0r&.
D0s% oll&%ors E+plosion in %h&
&=0ip4&n%
Nil - #&%alli s%rips in
!0s% oll&%or an!
onn&%&! %o &ar%h
pi%.
@ag lling ir& An%is%a%i 6ags ar&
0s&! in op&ra%ion-
onn&%&! %o 4&%alli
h0%&.
-
-
*(