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Sets new industry benchmarks with integration of AI-powered drone surveillance with real-
time video analytics
National, June 19, 2025: 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 this meticulously 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.”
Leading the Way in Digitization and AI-Enhanced Safety Monitoring
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.
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