Reliance Industries Limited

Hazira Manufacturing Division

Hazira Manufacturing
Facilities
220 KV Switch yard
Tankages
CPP&U
MEG 1
PVC
VCM
PE 1
Guest
House
PP
CPP
ETP
Cracker
C
K
R

T
F

Tank Farm
Aromatics
PE-2
PTA-2
M
P
P
2
(
P
O
Y
/
P
S
F
)


M
E
G
-
2

MEG-3
Cracker
C
K
R

T
F

N
Reliance Industries Limited , Hazira Overall Plot Plan
PTA-1
4
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 160
PE 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
5
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 120
PE 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
6
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 and
distribution.

Hazira - CPP and Utility
7
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
8
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

Support Services : Logistics
9
Support Services : HSE
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 awareness
& emergency response /
disaster management
plan
Safety of Person Overrides All Production Targets
Commitment
Accountable
ility
Performance
measure-
ment
Information
Sharing
Incident
Investigation
CAER
Integration
Siting
Codes and
Standards
Emergency
Management
Multiple Safe
Guard
Safety
Revies
Maint. and
Inspection
FACILITY
MANAGEMENT
LEADERSHIP
TECHNOLOGY
PERSONNEL
Design Documentation
Management of
Change
Process Hazard
Analysis
Process
Hazard information
Health
Surveillance
Medical
Mutual Aid
Emergency
Treatment
CPR Training/
Hazcom
HEALTH
ENVIRONMENT PROTECTION
Env. Protection
Measures
Env.
Monitoring
Statutory
Compliance
Reduction/ Recycle of
Waste/ Safe Disposal
Job
Skills
Consumer Premises Audit
Tanker
Driver's
Training
Tanker Inspection
Transport
Emergency
Team
PRODUCT STEWARDSHIP
Employee
Proficiency
Initial
Training
Safe Work
Practice
Fitness for
Duty
Contractors
Based on Responsible Care
TOP
Managemen
Support
HSEReporting
Level
Quantity / Quality
of Resources
Line Responsibility for
HSEManagement
On going HSE
Awareness & Training
Continuous Improvement
10
Support Services : CTS
Benchmarking
Product development
Quality assurance
Pinch Technology
Process Safety management
Cost reduction
Process evaluation
Process Engineering
Test runs & debottlenecking
Energy Conservation
Functions & Activities
11
Support Services : CES
Functions & Activities
1.0 MECHANI CAL
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 ELECTRI CAL
2.1 Motor Over Hauling
2.2 Relay Testing & Calibration
2.3 Transformer Oil Filtration & Oil Checking

12
Support Services : CES
Functions & Activities
3.0 I NSTRUMENTATI ON
3.1 Testing & Calibration of Instruments / Control Valves
3.2 Maintenance of Analyzer
3.3 Maintenance of DCS
3.4 Maintenance of PLCs
3.5 Import Substitution

4.0 POWER ELECTRONI CS
4.1 Telecommunication
4.2 Plant Address System
4.3 Fire Protection System
4.4 Maintenance of UPS
4.5 Power Electronics

5.0 CI VI L
5.1 Maintenance of Buildings & Roads
5.2 Mini Projects Execution
5.3 Town Ship Maintenance

13
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
Failur e Analysis
Equipment Tag Meter
Equipment Service Schedules
Equipment History
Material Management Inventory Control
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
World Class Maintenance
14
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 Printers
Modems Servers

15
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

16
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.

Support Services : Fire Fighting & Control System
17
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, CO
2
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).


Support Services : Fire Fighting & Control System
18
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]

Support Services : Fire Fighting & Control System
19
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].

Support Services : Fire Fighting & Control System
20
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