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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 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]



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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 :-


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