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Reliance Industries Limited

Hazira Manufacturing Division

Hazira
Manufacturing
Facilities

Overall Plot Plan

Reliance Industries Limited , Hazira


N
220 KV Switch yard

rp
wate
Raw

PP
PE-2

CPP&U

Non plant bldg.

PTA-2

PE 1
VCM
PVC

MPP-3 Fibre fill

MEG-2

MEG-3

PTA-1
MPP2(POY/PSF)

Guest
House

CPP

MPP1(POY/PET)

CKR TF
CKR TF

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J/eJettt
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yylele
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E
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Tank Farm

Aromatics

onds

Cracker

MEG 1
Tankages
ETP

Hazira progression
Plants
( KTA )

Licensor

Startup

Technology

CPP & U

Capacity
Installed

May 1991

60 MW

MEG 1

Shell

Sep. 1991

100

PVC

Geon

Dec. 1991

160

VCM

Geon

Apr. 1992

160

PE 1

Du Pont

Jul.

160

POY

Du Pont

Dec. 1995

120

PP

UCC

Sep. 1996

360

PSF

Du Pont

1992

Sep. 1996

160
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Hazira progression
Plants
( KTA )

Licensor

Startup

Capacity

Technology

CPP 2

Installed

1996-1998

190 MW

Cracker

S&W

Mar. 1997

750

Aromatics

HRI/Mobil Mar. 1997

350

MEG 2

Shell

Mar. 1997

PE 2

Nova

May 1997

200

PET

Sinco

Oct. 1997

80

PFF
MEG 3

Du Pont
Shell

120

Oct. 1997

Oct. 1997

30
120

Hazira - CPP and Utility


CPP-Utility is providing utility services to all plants in complex.
These utilities are generated and supplied from :
A.
1.
2.

Captive Power Plant :Steam generation and distribution


Power receipt, generation, sale and distribution

B.
1.
2.
3.
4.

Utilities
Raw water treatment and distribution
Cooling water treatment and circulation.
DM water production and distribution.
Compressed air and instrument air generation and
distribution.
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Hazira - CPP and Utility


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.

Support Services : Logistics


PRIMARY FUNCTIONS :
Receipt of material from plant// Bagging in 25 Kg. Bag
and Jumbo Bag on automatic bagging machine// Storage
in the Warehouse // Documentation // Dispatch as per
marketing advise & 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
polymers and polyesters in bulk / containers // Provision
for hopper car loading // Adequate tankages and
warehousing capacities / loading-unloading facilities //
Drumming facility for DEG and TEG
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Support Services : HSE


Safety of Person Overrides All Production Targets

MANAGEMENT
LEADERSHIP
Commitment
Accountable
ility
Integration

FACILITY

CAER

Siting
Emergency
Management
Multiple Safe
Guard

Emergency
Treatment

CPR Training/
Hazcom

ENVIRONMENT PROTECTION
Env. Protection

Measures

Statutory

Performance
measureIncident ment
Investigation

Design Documentation
Management of
Change

Process

Hazard information

Process Hazard
Analysis

PERSONNEL

Health
Surveillance

Compliance

Sharing

Maint. and
Inspection

HEALTH

Medical
Mutual Aid

Information

Codes and
Standards
Safety
Revies

TECHNOLOGY

TOP
Managemen
Support
HSE Reporting
Level
Quantity / Quality
of Resources

Contractors
Fitness for
Duty

Safe Work
Practice
Initial
Training

Employee
Proficiency

Line Responsibility for


HSE Management
On going HSE
Awareness & Training

PRODUCT STEWARDSHIP

Continuous Improvement

Consumer Premises Audit

Env.

Transport

Monitoring

Reduction/ Recycle of
Waste/ Safe Disposal

Job
Skills

Emergency

Based on Responsible Care

Team

Tanker
Driver's
Training

Tanker Inspection

HSE Management
based on
Responsible Care
Focus on safety
during
Engineering,
Construction,
Startup &
Operation
Ongoing training
and validation for
all the employees
including
contractors
100% compliance
with all pollution
control norms
Periodic health
checkup for all
employees
Regular audits,
both internal &
external
Community

Support Services : CTS


Functions & Activities
Benchmarking
Continuous Improvement

Product development
Quality assurance

Test ru ns/ d ebottlenecking

Changes

Process Evalu ation & Engineering


Benchm arks

Safety

Quality

Pinch Technology
Process Safety
management
Cost reduction

Cost

Process evaluation
Process Engineering
Test runs &
debottlenecking
Energy Conservation

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Support Services : CES

Functions & Activities

1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7

MECHANICAL
Planning
Inspection & Corrosion
Condition Monitoring
Contract Lineup
Drawing & FCOs
Documentation / Technical Library
Machining & Overhauling

2.0
2.1
2.2
2.3

ELECTRICAL
Motor Over Hauling
Relay Testing & Calibration
Transformer Oil Filtration & Oil Checking

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Support Services : CES

Functions & Activities

3.0
3.1
3.2
3.3
3.4
3.5

INSTRUMENTATION
Testing & Calibration of Instruments / Control Valves
Maintenance of Analyzer
Maintenance of DCS
Maintenance of PLCs
Import Substitution

4.0
4.1
4.2
4.3
4.4
4.5

POWER ELECTRONICS
Telecommunication
Plant Address System
Fire Protection System
Maintenance of UPS
Power Electronics

5.0
5.1
5.2
5.3

CIVIL
Maintenance of Buildings & Roads
Mini Projects Execution
Town Ship Maintenance
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Support Services : About Maintenance


World Class Maintenance

Material M anagement In ven tory Con trol

Shutdown Plann ing


and Mon itorin g

Preven tive M aintenance Schedu les

Equ ipmen t History

Reliability Studies
Maintenance Systems
Thro ug h IT

Equ ipment Dat a Sheets

Main ten ance Cost


Failur e Analysis

Main ten ance Work Order System

Equipmen t Service Schedu les


Equ ipmen t Tag Meter

TPM
Benchmarked against World
Standards by A T Kearney
Special 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
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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
Switches
PCs
Modems

UTP Cable
Hubs
Printers
Servers
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Support Services : MIS

Set Up & Activities

Hazira site is network is connected to Reliance group through settalite Insat


1C for the office of Makers-Mumbai, Patalganga and Jamnagar. This
connection is also used for video conferencing between the offies working at
these locations. The IT department is dividied in two sections
1, Infrastructure support activities
Network extension and modification project
Desktop support
System operation support
Network management
E-Mail administration
2, Application Development and technical support activities
Recording of system requirements
Approval by HOD
System analysis and design
Programming, testing, implementation and documentation
Testing
Implementation and User' training
Documentation

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Support Services : Fire Fighting & Control System

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 including
of emergency shut-down systems & (iv) passive fire protection viz.
fire doors, fire barriers, fire resistant coatings & sealant etc.

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Support Services : Fire Fighting & Control System


PROVISIONS :Two full-fledged fire stations manned by qualified and experienced fire
service 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 well
as monitors (water / foam).
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Support Services : Fire Fighting & Control System


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 include
predetermined emergency escape routes & occupancy wise evacuation
plans]
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Support Services : Fire Fighting & Control System


ACTIVITIES :The following activities are normally carried out : Hot work permit / site monitoring by fire service personnel.
Deployment of fire tender(s) and crews [at various plants / areas] for
standby duties.
Fire prevention audits as per checklist.
Detailed investigation into cause of fire / explosion.
Daily surveillance round by shift fire officer / personnel.
Maintenance of round the clock watch and ward by security
department [which includes, inter-alia, fire watch from arson / sabotage
angles].

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Support Services : Fire Fighting & Control System


ACTIVITIES :Tactical Functions Of Fire Service Personnel :(a)
(b)
(c)

Handling of Fire Emergencies


Handling of Non - Fire Emergencies [i.e. Spillage, Leakages Etc.] :Special Services
Maintenance of Fire Protection Systems :Communication Systems :Preparedness :Training :-

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