Strengthening critical safeguards
We continued to invest in PSM projects that address key risk areas across storage, handling and process operations. These projects were focused on improving containment, maintaining equipment reliability and enabling earlier detection of process deviations before they escalate. Key upgrades included:
Dedicated recirculation and heat-exchange upgrades in styrene systems to prevent thermal stratification.
Strengthened venting systems to ensure pressure integrity during high-load scenarios
Enhanced isolation protocols to eliminate potential leakage points and maintain containment.
New sensing capabilities to identify condenser choking and backflushing deviations before they impact operations.
Together, these interventions strengthen the performance of critical barriers and support a more preventive approach to managing process safety risks. They also help improve consistency in how process deviations are identified, assessed and addressed across sites.
Strengthening process safety standards
Alongside engineering controls, we also strengthened process safety standards and training systems to improve the way employees, contractors and visitors understand site-specific hazards, safe operating practices and emergency expectations. The focus was on making process safety requirements more accessible, consistent and relevant to day-to-day operations.
Digital PSM induction
We introduced 3D-animated induction modules in multiple regional languages to support better understanding of process hazards, site-specific controls and expected safe behaviours. The modules are designed to make safety orientation more engaging and easier to absorb for employees and contractors working across different operating environments.
Risk-based engineering
Bowtie risk profiling and Human Reliability Analysis were used to identify critical safety intersections across decorative paint plants. Based on this assessment, 412 SOPs were developed to improve standardisation, with 155 high-risk SOPs prioritised to strengthen controls at critical stages of operations and reduce dependence on individual judgement in high-risk tasks.
Bowtie risk profiling and Human Reliability Analysis (HRA)
We continued to strengthen our hazard identification and risk assessment framework through the application of Bowtie risk profiling and HRA across our decorative paint plants.
Bowtie analysis helps visualise hazards by mapping threats, preventive and mitigative barriers, and potential consequences, while HRA evaluates the likelihood of human error in critical tasks.
During the year, we significantly expanded the coverage of these methodologies. Standardisation was further strengthened through the development of Master Bowties derived from incident learnings, common highrisk activities and shared raw materials.
47%
Annual increase in HRA
38
New master bowties identified and deployed
Digital monitoring and oversight
Digital tools are increasingly being used to improve visibility, responsiveness and oversight in PSM-scoped areas. During the year, we advanced IoT-enabled monitoring and digital twin simulations to help teams better track critical safeguards, understand process behaviour and assess potential failure scenarios.
IoT integration
Real-time monitoring across PSM-scoped areas provides visibility into critical interlocks, instrument health and alarm performance. This enables teams to identify deviations more promptly and take corrective action with better operational context.
Digital twin simulation
Digital replicas of physical assets are being used to simulate failure scenarios, validate safeguards and support more informed safety decisions. These simulations provide a controlled environment to assess process responses and strengthen preparedness for abnormal operating conditions.
Independent benchmarking
Internal compliance assessments and external PSM audits at the Vizag and Khandala sites helped benchmark system maturity and identify further improvement opportunities. The insights from these reviews are being used to strengthen governance, close gaps and improve alignment with good industry practices.
Enhancing biocide safety through rigorous
engineering standards at Sriperumbudur
To proactively mitigate the risk of potential chemical spillages, Sriperumbudur team implemented a safety initiative to strengthen biocide handling and eliminate hazards from non-standard pipeline fabrication.
The intervention
The team introduced standardised engineering designs, isometric drawings, and stress-control measures. Welders were qualified in line with the American Society of Mechanical Engineers Boiler and Pressure Vessel Code (ASME BPVC) supported by the creation of Welding Procedure Specifications (WPS), radiography, and strict quality checks.
The impact
These preventive measures strengthen pipeline integrity and significantly reduce the likelihood of chemical spillage. The initiative ensures long-term operational reliability, lower maintenance costs, and a robust culture of safe chemical handling.
Process Safety Golden Rules (PSGR)
Asian Paints adopted Process Safety Golden Rules to reinforce the frontline behaviours that are critical to preventing high-severity incidents. Adapted from industrial good practices, the rules translate key process safety expectations into simple and actionable behaviours, with emphasis on barrier integrity, operating discipline, hazard recognition and timely intervention.
The initiative was rolled out as a leadership-led cultural campaign under the theme ‘Safer Process, Safer Workplace’. Communication elements such as rollout teasers and the ‘Voice of the System’ concept were used to explain the consequences of deviations in relatable terms and encourage early intervention. The rules are being embedded into toolbox talks, pre-job planning, risk assessments and walkabouts, helping make process safety a visible and shared responsibility in everyday operations.