Abstract
The basic objective of this study is to analyze the hazards and operational problems of plastic manufacturing plant and provide some recommendation to operate plant in a hazard free environment. HAZOP technique is used to study the whole process of the unit from the storage Silos (Propylene) to Winding machine (collection point of plastic film). Initially eight (08) nodes were selected and analyzed qualitatively as per process flow diagram (PFD) and piping and instrumentation diagram (P&IDs) of the plant. The analysis includes the deviation of the process parameters from the standard conditions, the causes of the deviation, the resulting consequences, and the existing safety measures and finally recommendations were suggested to avoid the damage and loss to equipment, product and personnel. Result shows 25 causes of deviations of process parameters, 19 consequences out of which 53% of the consequences were related to the product, 42 % were related to the equipment and 5% were related to the surrounding and personnel. Moreover, about 11 different existing safety measures were installed and practiced by the company and 16 recommendations were suggested.
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