71 ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................... Harnessing process safety capabilities We can safely perform all processes for a given project and conduct comprehensive process safety evaluations. We have developed a systematic process safety strategy by doing a desktop assessment of hazards presented by a potential new project. Our “start early approach “ helps us integrate HSE through the project life cycle right from the first step to scale-up and commercial manufacturing. Our in-house capabilities enable us to conduct preliminary process safety assessments (DSC, TSU, Temperature, and gas evolution monitoring), followed by process hazard assessment studies, during the technology transfer process between R&D Manchester to India. The steps in process safety evaluation start with literature search, calculations to estimate material and energy balances and laboratory testing. The scale-up strategy is fully supported by evaluating chemical reaction hazards, deriving safe operating limits and design of safety-critical equipment. Before commercialisation, we assess the suitability of process equipment, define critical parameters, standard operating procedures with the inclusion of process safety precautions in the batch production records. Process safety strategy for scale-up Literature search: MSDS, CHIM (Chemical Hazard Information Matrix), compatibility work sheets, past histories Desktop calculation: Material/Mole/Energy balances, Oxygen balances, CAMEO fact sheets Laboratory testing: Thermal Screening (TSu & DSC), What if/ checklist analysis, review of preliminary hazard analysis Evaluate chemical reaction hazards: Desired and undesired reaction by using SRC, uRC, ARC other thermal and Impact studies (if critical) are captured in CPHE report Powder safety testing: MIE, MHT, shock & impact Sensitivity Evaluate equipment hazards: Suitability, Mechanical integrity of the process equipment’s. (P&ID’s, Equipment specifications) Define critical parameters: Critical Parameters, operating procedure, & Process interlock Process safety assessments: Hazard Analysis: Activity based Risk assessment. PSSR checklist, inclusion of HSE instruction in BPRs .
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