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HAZOP Study for Jotun Paints

Elixir Engineering  was awarded to perform HAZOP Study for Jotun Paints

Project Summary

Jotun Oman shall be the hub of Jotachar manufacturing to cater the requirement of MEIA region. Based on the volume forecast, Jotun Oman will have to produce 1 million kg in the first year which will gradually increase to 2.5 million kgs by the fourth year. This required a detailed planning to ensure uninterrupted flow and output starting from Raw Material arrangements until the Finished Goods moved to FG Warehouse.

To meet the demand, the designed capacity is 2.7 million kgs in two shifts (Two batch each of Comp A & B in one shift). This includes two floor mounted dissolvers and two pressing unit and two filling units. To avoid cross contamination, both Comp A & B will be processed and filled from dedicated pot mixer, dissolver and filling machine.

To reduce ergonomics, one scissor table (adjustable height) for charging powder raw material, additive station, power pot mover and one drum manipulator to stack the filled drums on the pallet are planned. Most of the liquid raw materials will be added directly into the pot mixer through the PLC & Pit scale to have a better accuracy of RM addition and quality. Provision for future expansion as well considered in the plan (one floor mounted dissolver).

Raw materials such as Epoxy Resin 2540, Trimethylolpropane triacrylate 11452, Aradur 3745# 11441, ROFLEX T70 11453 and Dimethylaminomethyl (Phenol) 11451 are weighed from weighing pit scale. Raw materials from Weighing pit scale is then mixed with RM Powders in a 4-shaft Mixer. The finished product is then pressed in Hydraulic Press and send to Pail filler unit for its Subsequent packing.

Process flow

In order to address future demand and assess possible risks in both design and operation, Jotun Paints planned to conduct a HAZOP study, which it has granted to Elixir Engineering.

Methodology

The process/utility system and related interfaces are the main emphasis of the HAZOP. The fundamental idea of a HAZOP study is to take a detailed description of the process and question every aspect of it in brainstorming sessions attended by the various experts involved in the process design in order to first identify potential deviations from the intended design and identify potential causes and consequences for those deviations.

The following are the primary steps in a HAZOP study

  1. Select the node (Line, equipment or a system) on the P&ID.
  2. List of the intention & process parameters, guidewords for the nodes.
  3. List all deviations an ignore deviations that are not meaningful and apply the deviation.
  4. List all of the potential explanations of the divergence that come to mind, ignoring any that don't seem plausible.
  5. Analyze the effects of the variations caused by each of the given plausible causes.
  6. Identify safeguards already provided in the system.
  7. Provide suggestions or actions in the event that the security measures are insufficient.
  8. Reiterate steps 3 to 7 for each deviation.
  9. Reiterate steps from one 1 to 8 on the next node until all the nodes are covered.
HAZOP methodology

Elements of HAZOP Study:

Node definition

The HAZOP study traverses the plant node by node. Before the study begins, the facilitator selects the node sizes and the route through the plant. The node ought to be explained using: -

  • Brief description of the node
  • Typical operating and design conditions
  • Procedure of maintenance, operation, and requirement for operator intervention.

Parameters

Temperature, pressure, and flow are typically thought of as the primary factors or parameters. General factors like maintenance, safety, relief, corrosion/erosive erosion, instrumentation, start-up and shutdown, etc. are related to additional parameters. Based on their applicability and the team members' concerns, some of these might be chosen as study nodes.

Guidewords

Guide words are simple words or phrases used to qualify or quantify the intention and associated parameters in order to suggest deviations.

Standard guide words; No/less, more/Less, As Well As/Part of, Reverse/Other Than, Early/Late, Before/After are applicable to each parameter.

Causes

When determining the causes, all plausible and plausible situations leading to the deviations should be taken into account. "Local" means that they should relate to the node under study. Only after enumerating every cause is consideration given to the effects. Two events happening simultaneously without any correlation should not be considered.

Consequence

"Global" impacts need to be taken into account while analyzing the outcomes; that is, you need keep studying the reactions that follow until you find the ultimate effect of a deviation.

Safeguards

Risk is a function of both Probability and Consequence. Safeguards reduce either Probability or Consequence.

These could be either related to hardware or operator practices & intervention., While selecting safeguards, you may consider engineering or administrative safeguards, but it is necessary to check whether these are existing & functional for the operating plant.

Recommendations

Action-based language (e.g., Check, Provide, Consider, Ensure, Review, etc.) should be used when reporting recommendations, and they should be assigned to designated work groups. It should be verified whether three primary questions have been explained, viz.

  • What is to be done?
  • Where is it to be done?
  • Why is it to be done?

Deliverables: HAZOP Report

Elixir Engineering

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