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Reliance Industries LimitedHazira Manufacturing Division
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220 KV Switch yard
Tankages
CPP&U
MEG 1
PVC
VCM
PE 1
Guest
House
PP
CPP
ETP
Cracker
CK
RTF
Tank Farm
Aromatics
PE-2
PTA-2
MPP2(POY/PSF)
MEG-2
MEG-3
Cracker
CKR
TF
N
Reliance Industries Limited , HaziraOverall Plot Plan
PTA-1
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Hazira progression
Plants Licensor Startup Capacity ( KTA )Technology Installed
CPP & U May 1991 60 MW
MEG 1 Shell Sep. 1991 100
PVC Geon Dec. 1991 160
VCM Geon Apr. 1992 160PE 1 Du Pont Jul. 1992 160
POY Du Pont Dec. 1995 120
PP UCC Sep. 1996 360
PSF Du Pont Sep. 1996 160
PTA 1 ICI Jan. 1997 350
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Plants Licensor Startup Capacity ( KTA )Technology Installed
CPP 2 1996-1998 190 MW
Cracker S & W Mar. 1997 750
Aromatics HRI/Mobil Mar. 1997 350
MEG 2 Shell Mar. 1997 120PE 2 Nova May 1997 200
PET Sinco Oct. 1997 80
PFF Du Pont Oct. 1997 30
MEG 3 Shell Oct. 1997 120
PTA 2 ICI Nov. 1997 350
Hazira progression
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CPP-Utility is providing utility services to all plants in complex.
These utilities are generated and supplied from :
A. Captive Power Plant :-
1. Steam generation and distribution
2. Power receipt, generation, sale and distribution
B. Utilities
1. Raw water treatment and distribution
2. Cooling water treatment and circulation.
3. DM water production and distribution.
4. Compressed air and instrument air generation anddistribution.
Hazira - CPP and Utility
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Major Equipment Supplier in CPP/Utility :
Gas Turbines by M/s. Thomassen International BV of Holland and
BHEL of India.Heat Recovery Steam Generators (HRSGs) and one Aux. Boiler by
M/s. Stork BV of Holland.
DM Water Plant by M/s. Thermax Ltd.
Cooling Tower by M/s. Paharpur Cooling Towers.
Air Compressors are supplied by M/s. Elliot U. K.Air drying units by M/s. Lloyds Steel Industries Ltd.
Raw water treatment and Effluent treatment plants by M/s. Hindustan
Oliver Ltd.
Cogeneration Plant At Hazira :-
The Cogeneration Plant was commissioned in September, 1991.
Cogeneration is the combined production of Heat and Electric Power. Each
cogeneration plant has Gas Turbines and 125 TPH Heat Recovery Steam
Generator. The fuel for the Congeneration plant is natural gas and HSD.
Hazira - CPP and Utility
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PRIMARY FUNCTIONS :
Receipt of material from plant// Bagging in 25 Kg. Bag andJumbo Bag on automatic bagging machine// Storage in theWarehouse // Documentation // Dispatch as per marketingadvise & Payment of Excise Duty
FEATURES :Solid movement about 550 truck per day - POY, PSF, PP, PE,PVC, etc. // Liquid movement -- about 475 truck per day -MEG, Bz, Xy, EDC, etc // Provision for moving out polymersand polyesters in bulk / containers // Provision for hoppercar loading // Adequate tankages and warehousing capacities
/ loading-unloading facilities // Drumming facility for DEGand TEG
Support Services : Logistics
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Support Services : HSE
HSE Managementbased on ResponsibleCare
Focus on safety duringEngineering,Construction, Startup &Operation
Ongoing training andvalidation for all theemployees includingcontractors
100% compliance withall pollution controlnorms
Periodic health checkupfor all employees
Regular audits, both
internal & external Community awareness
& emergency response /disaster managementplan
Safety of Person Overrides All Production Targets
Commitment
Accountableility
Performancemeasure-
ment
InformationSharing
IncidentInvestigation
CAERIntegration
Siting
Codes andStandards
EmergencyManagement
Multiple SafeGuard
SafetyRevies
Maint. andInspection
FACILITY
MANAGEMENTLEADERSHIP
TECHNOLOGY
PERSONNEL
Design Documentation
Management ofChange
Process HazardAnalysis
ProcessHazard information
HealthSurveillance
MedicalMutual Aid
EmergencyTreatment
CPR Training/Hazcom
HEALTH
ENVIRONMENT PROTECTION
Env. Protection
Measures
Env.MonitoringStatutory
Compliance
Reduction/ Recycle ofWaste/ Safe Disposal
JobSkills
Consumer Premises Audit
TankerDriver'sTraining
Tanker Inspection
TransportEmergency
Team
PRODUCT STEWARDSHIP
EmployeeProficiency
InitialTraining
Safe WorkPractice
Fitness forDuty
Contractors
Based on Responsible Care
TOP
Managemen
Support
HSE Reporting
Level
Quantity / Quality
of Resources
Line Responsibility for
HSE Management
On going HSE
Awareness & Training
Continuous Improvement
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Support Services : CTS
BenchmarkingProduct development
Quality assurance
Pinch Technology
Process Safety management
Cost reduction
Process evaluation
Process Engineering
Test runs & debottlenecking
Energy Conservation
Functions & Activities
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Support Services : CES Functions & Activities
1.0 MECHANICAL
1.1 Planning
1.2 Inspection & Corrosion
1.3 Condition Monitoring
1.4 Contract Lineup
1.5 Drawing & FCOs
1.6 Documentation / Technical Library
1.7 Machining & Overhauling
2.0 ELECTRICAL
2.1 Motor Over Hauling
2.2 Relay Testing & Calibration
2.3 Transformer Oil Filtration & Oil Checking
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Support Services : CES Functions & Activities
3.0 INSTRUMENTATION3.1 Testing & Calibration of Instruments / Control Valves3.2 Maintenance of Analyzer
3.3 Maintenance of DCS3.4 Maintenance of PLCs3.5 Import Substitution
4.0 POWER ELECTRONICS4.1 Telecommunication4.2 Plant Address System4.3 Fire Protection System4.4 Maintenance of UPS4.5 Power Electronics
5.0 CIVIL5.1 Maintenance of Buildings & Roads5.2 Mini Projects Execution5.3 Town Ship Maintenance
S S i b
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Support Services : About Maintenance
Maintenance Systems
Through IT
Maintenance Work Order System
PreventiveMaintenance Schedules
Equipment Data Sheets
Shutdown Planning
and Monitoring
Reliability Studies
Maintenance Cost
Failure Analysis
Equipment Tag Meter
Equipment Service Schedules
Equipment History
Material Management Inventory Control
TPMBenchmarked against World
Standards by A T KearneySpecial attention to
-Technician productivity
-ERV tracking and control
-Reliability and uptime
Contracting strategies
Least cost maintenance
Material management improvements
-Stocking policy/JIT
-Procurement cycle time reduction-Vendor development/rating
World Class Maintenance
S t S i S
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Support Services : MIS Set Up & Activities
The MIS/IT department at hazira is centralised function for whole site looking
after the followings
Installation and maintenance of infrastructure required for IT
Development, implementation and support of application system for
areas of manufacturing and commercial (Now apart from SAP)
Providing central help desk support to overcome user' problems in
relation to computerised system
All the computer system and plant process control systems are connected to a
system of network comprising of following
Fibre optic cable UTP Cable
Switches Hubs
PCs PrintersModems Servers
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S t S i Fi Fi hti & C t l S t
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All the plants are designed and erected / constructed with due regards
to the appropriate fire protection measures, [under relevant / adapted
standards & codes of practices] broadly in terms of (i) safety
distances between equipment as well as between the plants, (ii) fire /
safety risk analysis including hazard operability study (hazop) and
hazard analysis (hazan) (iii) isolation of process equipment includingof emergency shut-down systems & (iv) passive fire protection viz.
fire doors, fire barriers, fire resistant coatings & sealant etc.
Support Services : Fire Fighting & Control System
S t S i Fi Fi hti & C t l S t
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PROVISIONS :-
Two full-fledged fire stations manned by qualified and experienced fireservice personnel including officers (i.e. total complement of 65 personnel).
Availability of six major / mobile fire fighting appliances viz. Foam
Tenders (04), DCP Tender (01) & Emergency cum Rescue Tender (01).
Fixed fire fighting installations viz. Deluge valves, water spray system,
pressurized fire water / hydrant system, riser system, water / foam monitors,
foam system, modular DCP, CO2 system, Halon system, heat shield water
spray units etc.
Fire alarm panels [installed in plant control rooms as well as in control
rooms of fire stations] interfaced with automatic detectors viz. smoke
detectors, heat detectors, UV / IR detectors, & LEL detectors.
Portable fire extinguishers, trailer / trolley mounted extinguishers as wellas monitors (water / foam).
Support Services : Fire Fighting & Control System
Support Services : Fire Fighting & Control S stem
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PROVISIONS :-
Reservoirs / storages of fire water for carrying out fire fighting operations
[at a stretch] for 9 hrs.
Dedicated fire pumps are installed at two separate locations to feed /
convey this water through the net-work of pressurized fire water mains /
headers protecting the plants / complex.
Adequate inventories of other special extinguishing media viz. foam
concentrates / DCPs.
Availability of adequate Breathing Apparatus sets, emergency escape sets,
special PPEs & emergency tool kits.
Mutual Aid agreements with the neighboring industries viz. KRIBHCO,
ONGC & NTPC.
Well defined On-site & Off-site emergency plans. [which also includepredetermined emergency escape routes & occupancy wise evacuation
plans]
Support Services : Fire Fighting & Control System
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Support Services : Fire Fighting & Control System
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ACTIVITIES :-
Tactical Functions Of Fire Service Personnel :-
(a) Handling of Fire Emergencies
(b) Handling of Non - Fire Emergencies [i.e. Spillage, Leakages Etc.] :-
(c) Special Services
Maintenance of Fire Protection Systems :-
Communication Systems :-
Preparedness :-
Training :-
Support Services : Fire Fighting & Control System