Sets new industry benchmarks with integration of AI-powered drone surveillance with real-time video analytics
Haldia Petrochemicals Limited (HPL), a prominent player in India’s petrochemical sector, has triumphantly finished its renovation turnaround 2025 (TA25) at the HPL Complex in Haldia.
Beginning from 16 April, 2025 the planned 45-day maintenance and upgrade operation indicates a essential step within the corporation’s pursuing of operational excellence, technological improvement, accomplishing higher throughput on continuous basis and environmental sustainability.
The turnaround has yielded a couple of benefits for HPL, together with, enhanced infrastructure reliability, increased safety requirements, and a technological framework that helps future development and innovation. Improvements in gadget and process efficiency will yield better product output, decreased fuel consumption, and reduce CO₂ emissions, contributing to both operational excellence and sustainability. All statutory necessities for safety inspections and testing were had been met, ensuring compliance and long-term operational security.
The execution of TA25 was marked by outstanding planning and safety protocols, encompassing the deployment of over 11,000 workers at peak times. Extensive training projects contributed over 27,000 man-hours, ensuring all personnel were ready for operations in high-threat environments. HPL prioritized the well-being of all individuals, offering non-stop medical help, get access to clean drinking water, ORS supplies, and rigorous safety measures, inclusive fire detection systems, gas leak sensors, and strict compliance with personal protective equipment (PPE) standards.
Navanit Narayan, WTD & CEO, Haldia Petrochemicals Limited stated: “TA25 exemplifies HPL’s unwavering commitment to safety, innovation, and operational excellence. With the incorporation of digital technologies and industry-first initiatives, we are poised for improved productivity, more potent environmental stewardship, and dependable output for the future.”
HPL took a groundbreaking approach by incorporating advanced technologies into TA25, using AI-powered drone surveillance for real-time tracking of fire risks and PPE compliance. These drones, connected to the proprietary JARVIS platform, delivered instant alerts and comprehensive analytics, detected anomalies, potential fire dangers, and PPE violations to significantly enhance safety oversight all through the complex. A sturdy IT infrastructure was established throughout the complex, facilitating the smooth operation of digital platforms together with E-Permit system that enabled real-time job monitoring, interlocking mechanisms, and full compliance with OISD norms. Integrated dashboards for venture, safety, and manpower management supplied complete visibility of TA25 activities.
During TA25, a series of tremendous upgrade were undertaken to bolster plant reliability and throughput, consisting of, Replacement of major distillation columns and comprehensive overhaul of all machinery and drivers; Replacement of pipelines affected by corrosion below insulation (CUI); Cracking heater coil alternative, flare tip upgrade, upgradation of DCS and heat exchanger cleansing; Overhaul of control valves and substitute of gas turbine rotor; Transition from AIS to GIS panels and augmentation of the substation for the approaching 345 KTA Phenol Plant; and Implementation of improved safety protocols for pressure vessels and protection relief valves.
