1. Reliance Industries Limited
Hazira Manufacturing Division

2. Hazira Manufacturing Facilities

3. Reliance Industries Limited , Hazira
Overall Plot Plan N
220 KV Switch yard PP
PE-2
Raw water ponds
Cracker
Cracker
CPP
PE 1
CKR TF
Aromatics
PTA-2
Non plant bldg.
VCM
CKR TF
CPP&U
PVC
Ethylene terminal/Jetty
Ethylene terminal/Jetty
PTA-1
MEG-3
Tank Farm
MEG 1
MEG-2
Tankages
MPP2(POY/PSF)
MPP-3 Fibre fill
MPP1(POY/PET)
ETP
Guest
House

4. Hazira progression Plants Licensor Startup Capacity ( KTA )
Technology Installed
CPP & U May MW
MEG 1 Shell Sep
PVC Geon Dec
VCM Geon Apr
PE 1 Du Pont Jul
POY Du Pont Dec
PP UCC Sep
PSF Du Pont Sep
PTA 1 ICI Jan

5. Hazira progression Plants Licensor Startup Capacity ( KTA )
Technology Installed
CPP MW
Cracker S & W Mar
Aromatics HRI/Mobil Mar
MEG 2 Shell Mar
PE 2 Nova May
PET Sinco Oct
PFF Du Pont Oct
MEG 3 Shell Oct
PTA 2 ICI Nov

6. Hazira - CPP and Utility
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.

7. 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, 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.

8. 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

9. “Safety of Person Overrides All Production Targets”
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
Periodic health checkup for all employees
Regular audits, both internal & external
Community awareness & emergency response / disaster management plan

10. 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

11. 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

12. Support Services : CES Functions & Activities 3.0 INSTRUMENTATION
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 ELECTRONICS
4.1 Telecommunication
4.2 Plant Address System
4.3 Fire Protection System
4.4 Maintenance of UPS
4.5 Power Electronics
5.0 CIVIL
5.1 Maintenance of Buildings & Roads
5.2 Mini Projects Execution
5.3 Town Ship Maintenance

13. 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

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
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. 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.

17. 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).

18. 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]

19. 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].

20. Support Services : Fire Fighting & Control System
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 :-