Reliance Industries Limited

Hazira Manufacturing Division

Hazira Manufacturing Facilities

Overall Plot Plan

Reliance Industries Limited , Hazira

N
220 KV Switch yard

PP PE-2 Cracker CPP CKR TF CKR TF PE 1 VCM

CPP&U

Aromatics

PTA-2

PVC PTA-1 Tank Farm MPP2(POY/PSF) MEG-3 MEG-2 MEG 1 Tankages

ETP

Guest House

Hazira progression
Plants CPP & U MEG 1 Shell Licensor Technology Startup May 1991 Sep. 1991 Capacity ( KTA )
Installed

60 MW 100

PVC
VCM PE 1 POY PP PSF PTA 1

Geon
Geon Du Pont Du Pont UCC Du Pont ICI

Dec. 1991
Apr. 1992 Jul. 1992 Dec. 1995 Sep. 1996 Sep. 1996 Jan. 1997

160
160 160 120 360 160 350
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Hazira progression
Plants CPP 2 Cracker Aromatics S&W Licensor Technology Startup 1996-1998 Mar. 1997 HRI/Mobil Mar. 1997 Capacity ( KTA )
Installed

190 MW 750 350

MEG 2
PE 2 PET

Shell
Nova Sinco

Mar. 1997
May 1997 Oct. 1997

120
200 80

PFF
MEG 3 PTA 2

Du Pont
Shell ICI

Oct. 1997
Oct. 1997 Nov. 1997

30
120 350
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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. B. 1. 2. 3. 4. Captive Power Plant :Steam generation and distribution Power receipt, generation, sale and distribution 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
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

MANAGEMENT LEADERSHIP FACILITY

Siting Emergency Management Multiple Safe Guard Codes and Standards Safety Revies Maint. and Inspection Commitment Accountable ility Integration CAER
Information

TECHNOLOGY
Design Documentation Process Management of Change
Hazard information

Sharing

Performance measureIncident ment Investigation

Process Hazard Analysis

HEALTH
Health Surveillance Medical Mutual Aid
Hazcom
TOP Managemen Support HSE Reporting Level Quantity / Quality of Resources Line Responsibility for HSE Management On going HSE Awareness & Training Continuous Improvement

PERSONNEL
Job Skills Contractors Fitness for Duty Safe Work Practice Initial Training

Emergency Treatment

CPR Training/

Employee Proficiency

Periodic health checkup for all employees

Regular audits, both internal & external Community awareness & emergency response / disaster management plan 9

ENVIRONMENT PROTECTION
Env. Protection

PRODUCT STEWARDSHIP
Consumer Premises Audit Transport
Emergency

Measures Statutory
Compliance

Env.
Monitoring

Team

Tanker Driver's Training

Reduction/ Recycle of Waste/ Safe Disposal

Based on Responsible Care

Tanker Inspection

Support Services : CTS

Functions & Activities
Benchmarking Product development Quality assurance Pinch Technology Process Safety management Cost reduction Process evaluation

Process Engineering
Test runs & debottlenecking Energy Conservation
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Support Services : CES

1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.0 2.1 2.2 2.3

Functions & Activities

MECHANICAL Planning Inspection & Corrosion Condition Monitoring Contract Lineup Drawing & FCOs Documentation / Technical Library Machining & Overhauling ELECTRICAL Motor Over Hauling Relay Testing & Calibration Transformer Oil Filtration & Oil Checking

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Support Services : CES

3.0 3.1 3.2 3.3 3.4 3.5 4.0 4.1 4.2 4.3 4.4 4.5

Functions & Activities

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

Material Management Inventory Control

Shutdown Planning and Monitoring Reliability Studies

PreventiveMaintenance Schedules

Equipment History Equipm Data Sheets ent

Maintenance Systems Through IT

Maintenance Cost

Failur e Analysis Equipment Service Sche dules Equipment Tag Meter

Mainte nance Work Order Syste m

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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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