Process Safety Management (PSM)

Asian Paints has continued to strengthen its Process Safety Management systems through a technology-enabled, proactive approach. Grounded in the globally recognised 14 elements of PSM, our strategy integrates process hazard analysis, mechanical integrity, training, emergency planning, incident investigation, and more – forming the foundation of our safety culture across AP Infinity plants.

Progress so far

Over the past year, we focussed on maturing six core PSM elements across eight sites. This included deploying the PSM IoT interface at seven plants, enabling realtime hazard detection and actionable alarms. This year, we completed 362 Bowtie risk profiles and 879 Human Reliability Analyses (HRAs), which supported the development of visual SOPs for high-risk operations.

To enhance operational safety, we implemented:

• Overfill protection systems

• Breakaway couplings to prevent mechanical damage

• Inhibitor dosing mechanisms to control runaway polymerisation

• Real-time earthing checks via CEMS technology

We also expanded our certified PSM trainer pool through structured Train-the-Trainer programmes. Guidelines were developed for managing abnormal situations in waterbased emulsion reactors, and Power BI dashboards were rolled out for MOC tracking and monitoring. Additional efforts included dust explosion hazard assessments, corrosion and dyke integrity programmes, and initiatives in permit-to-work systems, behaviour-based safety, and contractor management.

Focus Ahead

As we continue to embed process safety across operations, our focus for the coming year will be on deepening implementation of Asset Integrity and Emergency Arrangements – two critical PSM elements that will further enhance operational resilience and preparedness. These areas will be supported by continued training, system audits, and cross-functional collaboration to ensure consistent safety performance across all sites.