ICI SODA ASH M.

FORM NO
MODIFICATION PROPOSAL FORM

Temporary Mod (Valid until ______________ Permanent Mod

PLANT: SECTION:
Date initiated ____________
Plant A Production
Plant B Mechanical
Plant C Ele Electrical
Power Services Instrument
Civil
Required Date for completion _____________
______________________________________________________________________________________

1 MODIFICATION PROPOSAL (Plant Unit _______________________________)

1.1 Proposed job description ( Attach Sketch )
Replacement of Boiler-6 Leak Off control valve Pneumatic controller with UDC controller

1.2 Reason of Modification

1.3
The objective of this project is to address to Safe operation of boiler-6 Feed water pumps. The
existing Pneumatic controller has completed its useful life and its spare parts are no more available
in market. Due to this reason Leak off control valve of boiler -6 is out of order since few months.

1.4 Estimated benefits Savings

1 Safe operation of Boiler-6 Feed water Pumps

1.4 Cost Code Initiator Section Head Department Head

Sign & Date Sign & Date Sign & Date

2 DESIGN DRAWINGS

Required Yes / No

Initiator Sign & Date

Technical Manager Sign & Date

Engineering / Operations Manager Sign & Date

Production Manager Sign & Date

3 AMENDMENT REQUIRED

3.1 Operating Instructions Yes / No

3.2 Maintenance Instructions Yes / No
3.3 Process Flow Diagrams Yes / No
3.4 P&ID Yes / No

3.5 Electrical Drawings Yes / No

3.6 Instrument Drawings Yes / No

3.7 Equipment Drawings Yes / No

Technical Manager Sign & Date

Engineering / Operations Manager Sign & Date

Production Manager Sign & Date

____________________________________________________________________
4 ESTIMATION & SCHEDULING

4.1 Estimated Cost Rs

4.2 Schedule / Date of completion ____________ Plant / Maintenance Manager

(Electrical / Mechanical/Instrument/Civil)
Sign & Date
______________________________________________________________________________________

5 RISK LEVEL & APPROVAL

5.1 Risk Level Acceptable Low Medium High Risk Accepted: Yes / No

(See Risk Matrix at End)

5.2 HSE Manager Sign & Date

5.3 Engineering / Operations Manager Sign & Date
5.4 Production Manager Sign & Date
5.5 Technical Manager Sign & Date
5.6 IR Manager (In case of IR Implications) Sign & Date
5.7 Admin. Manager (In case of Admin. Implications) Sign & Date
5.8 Product Steward (In case of Product Related Change) Sign & Date

6 AUTHORISATION FOR STARTING WORK

It is hereby authorized to start work on proposed modification.

Date: _________________ Works Manager

Sign & Date
______________________________________________________________________________________

7 EXECTUION

7.1 Date completed

______________________________________________________________________________________

8 INSPECTION

8.1 Job Completion Certificate:

Initiator
Sign & Date
______________________________________________________________________________________

9 COMMISSIONING

Date commissioned ________________ Initiator

Sign & Date

Handing over / Taking over _________ Area Operating Manger

Sign & Date

Area Maintenance Manager

 Sign & Date
______________________________________________________________________________________

10 MONITORING

Estimated Benefits __________

Benefits accrued ____________ Initiator

Sign & Date
______________________________________________________________________________________

11 Completion Status

11.1 Operating instructions Yes / No Area Operating Manager Sign & Date
11.2 Maint. Instructions Yes / No Area Maintenance Manager Sign & Date
11.3 Process Flow Yes / No Area Operating Manager Sign & Date

11.4 P&ID Yes / No Area Operating Manager Sign & Date

11.5 Electrical Drawing Yes / No E & I Manager Sign & Date

11.6 Instrument Drawing Yes / No E & I Manager Sign & Date

11.7 Equipment Drawing Yes / No P & D Manager Sign & Date

______________________________________________________________________________________
12 FILING (PRO FILE) Laboratory Manager
Sign & Date
HAZARD STUDY

1. CONSIDER THE EFFFECTS OF THE MODIFICATION / ADDITION AND ANSWER THE

FOLLOWING QUESTIONS BY TICKING BOXES AND OR ADDING THE LISTS .

1.1 WHAT PROCESS CONDITIONS ARE CHANGED BY THIS MODIFICATION / ADDITION?

Temperature Composition Reactions.
Pressure Inventory. Services
Flow Toxicity Chemicals.
Level Flammability Ignition Sources..
Effluents

1.2 HOW WILL THE MODIFICATION / ADDITION AFFECT THE DESIGN OF THE PLANT?
Design pressure Pipe Works.. Corrosion / Erosion
Design Temp Plant Layout Interlocks.
Mat. Of Construction Instrumentation Shutdown system
Reliefs Vents. Loads on Structures. Plant Equipments

1.3 WHICH OPERATIONAL METHODS ARE TO BE CHANGED?

Commissioning.. Abnormal Operation..
Start up. Emergencies
Normal Operation Preparation for Maintenance..
Shut down Opportunities for Error..

1.4 WHAT OTHER EQUIPMENT / PLANT IS AFFECTED BY THE MODIFICATION / ADDITION?

Portable Equipment.. Railway..
Lifting Equipment... Drains.
Lighting. Electrical Supplies.
Roads Other Plants
2. CONSIDERING THE ABOVE CHANGES AND EFFECTS WHAT HAZARDS CAN
RESULT.REFER TO PREVIOUS HAZARD STUDIES.
Broken Parts Pipe Leaks....
Moving Parts Gassings Vessels leaks.
Injury Released Energy Other Emissions
Falls. Hot Surfaces.
Noise Burns Flames..

Chemicals.
2.1 TO WHAT EXTENT IS THE ENVIRONMENT AFFECTED BY MODIFICATION / ADDITION ?
Working Conditions.. Brief Description if applicable...
Works Environment
Beyond Works Boundry
2.2 WHO NEEDS TO BE CONSULTED?
Divisions Experts.. Outside Authorities
List any consultation needed in summary of actions Section 9

3. BY EXAMINING THE EFFFECTS OF THE MODIFICATION / ADDITION WHAT

NEEDS CHANGING AS A RESULT.
3.1 DO ANY PROCESS REQUIRE CHANGE
Alarm & Trip Testing Electrical Classification.
Maintenance.. Isolation.
Inspection . Access for Operation....
Pipeline Registration. Maintenance
Vessel Registration Emergency..
Relief Stream Registration Clearance..

3.2 WILL ANY EXISTING SAFETY EQUIPMENT BE INADEQUATE WHEN THE

MODIFICATION / ADDITION IS COMPLETED
Personal Safety Equipment.

Clothing.. Fire Fighting...

Eye Protection.. Means of Escape...
Ear Protection Fire Detection.
Breathing Apparatus. Fire Protection
Lighting. Showers..

4 ARE ANY SPECIAL PRECAUTIONS NEEDED WHILE THE WORK IS BEING

CARRIED OUT?

Burning / Welding.. Breaking.

Scaffolding... Excavations....
Entry to Confined Spaces. Special Equipment.
Access.. ...

5 WHERE WILL BE THE DETAILS OF THE MOFIFICATION / ADDITION

RECORDED?

Changes to Line Diagrams. Notices...

Changes to Drawings.. Retraining..
New Drawings. Changes to Design Manual...
Changes to Operating Instructions.. Changes to Maint. Instructions..

8 DOES THE MOFIFICATION AFFECT HAZARDS AREA YES..

 CLASSIFICATION. NO
If YES
-Area is Classified as Zone.
-Specification Electrical Equipment is adequate for zone classified.
-Hazard area classification list and layout needs update...

9 ARE THERE ANY REGULATORY REQUIREMENTS TO MEET? YES

NO..
10 ARE FURTHER HAZARD STUDIES REQUIRED?.

HSE Manager Technical Manager

Sign & Date Sign & Date

11 SUMMARY OF ACTIONS RESULTING FROM ASSESSMENT.

AN Standard 8 Asset Integrity & Process Safety Annex 4 The AkzoNobel Risk matrix

The Risk Matrix is a tool that defines risks according to different levels of acceptability and
required actions for an individual risk scenario. It is a combination of severity and frequency or
probability. For the five categories affected (people, environment, assets, security and reputation) an
identical matrix is used.

Medium
Severity People1 Environmental Assets
Reputation
damage2 damage Security
damage High
Euro

S5 1external Catastrophic >2 International International.

fatality/several off site million media Attention Acceptable
fatalities on site damage attention
Low

S4 1fatality/ several Off site <2 National Fatal assault

severe injuries release with million media
long term attention/
clean-up official
investigation
S3 Severe injury Off site <500k Local media Sabotage
release or on attention/officia
l investigation
site release
with long
clean-up
S2 Reportable On site release <100k External Burglary
injury / site cleanup / complaint
permit
violation
S1 First aid Spill <20k None Trespass
 1.For the severity rating the risk matrix is aligned with the AkzoNobel reporting definitions for KPIs are according to Standard
2. Severities Hazards are linked to the Loss of Containment categories from our KPIs (St. 3: definition 3.3.1.30)

Severity rating
People safety
S1: FA: First Aid Treatment injury
S2: RI: reportable injury; Medical treatment Injury, Restricted Work Injury, or Lost Time Injury
not requiring in-patient hospital treatment.
S3: SI: Severe Injury; On-site injury to employees, contractors or members of the general
public, which leads to in-patient hospital treatment.
S4: F: Fatality One fatality, or several severe injuries on site, or one severe injury off-site
S5: One or more off-site fatalities, or several fatalities on site, or several severe injuries off-site.

Health

S1: Minor exposure: Exposure to an active agent well below OEL

S2: Exposure: Exposure to an active agent above OEL
S3: Occupational illness
S4: Severe Exposure: Exposure to an active agent with life threatening effect
S5: Fatal Exposure: Exposure to an active agent, which causes death, and or several severe
external exposures

Environmental

Hazards are linked to the Loss of Containment categories (LoC) from our KPIs
S1: LoCA , S2: LoCB, S3: LoCC, S4: LoCD, S5: >LoCD

Assets (equipment/buildings)

S1: < 20 k: small damage equivalent to an average family car

S2: < 100 k: medium damage equivalent to small flat or apartment
S3: < 500 k: important damage equivalent to average family house
S4: < 2 million: significant damage equivalent to a small storage building
S5: > 2 million: major damage equivalent to the loss of a plant
Reputation:

S1: No damage to company reputation

S2: External complaint, affects company reputation for some employees
S3: Damage (including financial and quality of life) to local stakeholders. Local media attention
S4: Damage (including financial and quality of life) to BU stakeholders. National media
attention
S5: Damage to AkzoNobel stakeholders, International media attention
Frequency Rating for Risk Categorization:

Frequencies are evaluated as F1, F2, F3, F4, F5 and F6

F6 indicates more than one incident per year
F5 indicates one incident per year
F4 indicates one incident in 10 years
F3 indicates one incident in 100 years
F2 indicates one incident in 1,000 years
F1 indicates one incident in 10,000 years
To come to the total risk, severity and frequencies are matched to categorize risk as Acceptable,
Low, Medium and High.