By: ICN Bureau
Last updated : June 20, 2025 11:26 am
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 completed its maintenance turnaround 2025 (TA25) at the HPL Complex in Haldia.
Starting from 16 April, 2025 the planned 45-day maintenance and upgrade operation signifies a pivotal step in the company's pursuit of operational excellence, technological enhancement, achieving higher throughput on continuous basis and environmental sustainability.
The turnaround has yielded multiple advantages for HPL, including, improved infrastructure reliability, heightened safety standards, and a technological framework that supports future growth and innovation. Improvements in equipment and process efficiency will yield higher product output, reduced fuel consumption, and lower CO₂ emissions, contributing to both operational excellence and sustainability. All statutory requirements for safety inspections and testing were 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 initiatives contributed over 27,000 man-hours, ensuring all personnel were prepared for operations in high-risk environments. HPL prioritized the well-being of all participants, providing continuous medical support, access to clean drinking water, ORS supplies, and rigorous safety measures, including fire detection systems, gas leak sensors, and strict compliance with personal protective equipment (PPE) standards.
Navanit Narayan, WTD & CEO, Haldia Petrochemicals Limited said: “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 enhanced productivity, stronger environmental stewardship, and reliable output for the future.”
HPL took a groundbreaking approach by incorporating advanced technologies into TA25, utilizing AI-powered drone surveillance for real-time monitoring of fire hazards and PPE compliance. These drones, connected to the proprietary JARVIS platform, delivered instant alerts and comprehensive analytics, detected anomalies, potential fire hazards, and PPE violations to significantly enhance safety oversight throughout the complex. A robust IT infrastructure was established across the facility, facilitating the smooth operation of digital platforms such as E-Permit system that enabled real-time job monitoring, interlocking mechanisms, and full compliance with OISD norms. Integrated dashboards for project, safety, and manpower management provided complete visibility of TA25 activities.
During TA25, a series of significant upgrades were undertaken to bolster plant reliability and throughput, including, Replacement of major distillation columns and comprehensive overhaul of all machinery and drivers; Replacement of pipelines affected by corrosion under insulation (CUI); Cracking heater coil replacement, flare tip upgrade, upgradation of DCS and heat exchanger cleaning; Overhaul of control valves and replacement of gas turbine rotor; Transition from AIS to GIS panels and augmentation of the substation for the upcoming 345 KTA Phenol Plant; and Implementation of enhanced safety protocols for pressure vessels and safety relief valves.