Reliance Industries LimitedHazira Manufacturing Division

Hazira Manufacturing

Facilities

220 KV Switch yard

Tankages

Raw

water ponds

CPP&U

Ethylene terminal/Jetty

MEG 1

PVC

VCM

PE 1

GuestHouse

PP

CPP

ETP

Cracker

CK

R T

F

Tank Farm

Aromatics

PE-2

PTA-2

MP

P1(

PO

Y/P

ET

)

MP

P2(

PO

Y/P

SF

)

MP

P-3

Fib

re f

ill

ME

G-2

MEG-3

Cracker

Non

pla

nt b

ldg.

CK

R T

F

Ethylene terminal/Jetty

N

Reliance Industries Limited , HaziraOverall Plot Plan

PTA-1

4

Hazira progression

Plants Licensor Startup Capacity ( KTA )

TechnologyInstalled

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

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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 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

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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 distribution2. Power receipt, generation, sale and distribution

B. Utilities1. Raw water treatment and distribution2. Cooling water treatment and circulation.3. DM water production and distribution.4. Compressed air and instrument air generation and

distribution.

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 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

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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”

CommitmentAccountable

ility

Performance measure-

ment

Information Sharing

Incident Investigation

CAERIntegration

Siting

Codes and Standards

Emergency Management

Multiple Safe Guard

SafetyRevies

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 PROTECTIONEnv. Protection

Measures

Env. MonitoringStatutory

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

TOPManagemen

Support

HSE ReportingLevel

Quantity / Qualityof Resources

Line Responsibility forHSE Management

On going HSEAwareness & Training

Continuous Improvement

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Support Services : CTS

• Benchmarking

• Product development

• Quality assurance

• Pinch Technology

• Process Safety management

• Cost reduction

• Process evaluation

• Process Engineering

• Test runs & debottlenecking

• Energy Conservation

Safety Quality Cost

Benchmarks

Process Evaluation & Engineering

Test runs/ debottlenecking Changes

Continuous Improvement

Functions & Activities

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Support Services : CES Functions & Activities

1.0 MECHANICAL 1.1 Planning1.2 Inspection & Corrosion1.3 Condition Monitoring1.4 Contract Lineup1.5 Drawing & FCOs1.6 Documentation / Technical Library1.7 Machining & Overhauling

2.0 ELECTRICAL2.1 Motor Over Hauling2.2 Relay Testing & Calibration2.3 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 Analyzer3.3 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

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Support Services : About Maintenance

Maintenance SystemsThro ug h IT

Main ten ance Work Order System

Preven tive Maintenance Schedu les

Equ ipment Data Sheets

Shutdown Plann ingand Mon itorin g

Reliabi lity Studies

Main ten ance Cost

Failur e Analysis

Equ ipmen t Tag Meter

Equipmen t Service Schedu les

Equ ipmen t History

Material Management In ven tory Con trol

• 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”

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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 ITDevelopment, 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 CableSwitches HubsPCs PrintersModems 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 activitiesNetwork extension and modification projectDesktop supportSystem operation supportNetwork managementE-Mail administration

2, Application Development and technical support activitiesRecording of system requirementsApproval by HODSystem analysis and designProgramming, testing, implementation and documentationTestingImplementation and User' trainingDocumentation

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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 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

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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).

Support Services : Fire Fighting & Control System

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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 include predetermined emergency escape routes & occupancy wise evacuation plans]

Support Services : Fire Fighting & Control System

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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

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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