Document Intelligence for
Petrochemical Plants
P&ID extraction, HAZOP register digitization, specialty alloy MTR traceability, and SAP PM integration for petrochemical process plants. 99.5% accuracy SLA.
Procuring specialty alloy piping, valves, or instrumentation for petrochemical units? Pair MTR traceability with Technical Bid Evaluation (TBE) automation to evaluate vendor bids against MR specs in 24 hours, with deviation lists referenced to ASME, ASTM, and applicable corrosion / metallurgy standards.
Extract P&ID data from petrochemical process unit drawings
Digitize HAZOP registers for periodic safety reviews
Build instrument indexes for complex process units
Automate MTR traceability for specialty alloy piping
Generate piping MTO from isometric drawings
Reconcile P&IDs against instrument datasheets and C&E matrices
Prepare OISD 118 compliance documentation
Load extracted data into SAP PM for plant maintenance
Pathnovo serves petrochemical operators across Indian PSU, Indian private, global tier-1 operators, and the engineering and procurement contractor partner ecosystem. Four named client tiers below.
Indian PSU petrochemical operators
Reliance Jamnagar (largest petrochemical complex globally, with cracker + polymer trains), GAIL Pata (ethylene cracker + polymer downstream), IOCL Panipat petrochemical (Paraxylene + PTA + cumene downstream), HPCL-Mittal Energy Bathinda (cracker + polymer), Nayara Energy (Vadinar refinery petrochemical scope), ONGC OPaL Dahej (cracker + polymer downstream), GSPC (Gujarat State Petroleum Corporation gas-to-petrochemical scope), BPCL Kochi petrochemical (PDPP + acrylic acid + polymers)
Indian private petrochemical operators
Reliance Industries petrochemical division, Adani Petrochemicals, JBF Industries (polyester / petrochemical), India Glycols (ethoxylates), Tata Chemicals (soda ash + petrochemical scope), Deepak Phenolics (phenol-acetone-cumene), Manali Petrochemicals (propylene oxide), Sahyadri Industries (chlor-alkali)
Global petrochemical operators
ExxonMobil (Singapore, Baytown), Shell Chemicals (Pennsylvania, Geismar), Dow Chemical (Freeport, Stade), BASF (Antwerp, Ludwigshafen, Nanjing), SABIC (Yanbu, Jubail), Aramco-Total SATORP (Jubail), ADNOC Borouge (Ruwais), Petronas (Pengerang), Sinopec, Formosa Petrochemical (Mailiao, Texas)
Engineering and procurement contractor partners
Tata Projects (Indian EPC tier-1 with strong petrochemical heritage), McDermott (named Pathnovo benchmark customer with 10,247 tags / 600 P&IDs / 99.5% measured), KBR (KBR petrochemical technology + EPC), Engineers India Limited (EIL, Indian PSU EPC with deep petrochemical scope), Toyo India, L&T Hydrocarbon Engineering, Larsen & Toubro, Bechtel, Lummus Technology (CB&I), Worley, JGC Corporation, Chiyoda Corporation, Saipem, Technip Energies
Petrochemical plants operate under multiple concurrent regulatory regimes spanning OISD layout and safety standards, IBR pressure equipment regulation, ASME B31.3 piping code with Category M toxic service provisions, NACE MR0175 sour service, PESO compressed gas licensing, and hazardous area classification per IEC 60079. The nine regulatory codes most directly applicable to petrochemical scope below.
OISD 118
Layout and inter-distance for petroleum and hydrocarbon installations applies to petrochemical plant cracker furnaces, ethylene storage, propylene storage, naphtha storage, gasoline blending, and intermediate storage. Inter-distance compliance per Petroleum Rules 2002 Third Schedule and OISD 118 Chapter 3 applies tank-to-tank, tank-to-equipment, tank-to-boundary, tank-to-public-road for all petrochemical site infrastructure. See the OISD 118 standard reference.
OISD 150
Fired heater design and operation governs ethylene cracker furnaces (typical fired heater duty 50-150 MW per furnace train), aromatics reformer fired heaters, hydrocracker preheat fired heaters, propylene oxide direct-fired reactors. SIL 2 or SIL 3 Burner Management System per IEC 61511 mandatory. See the OISD 150 standard reference.
OISD 116 and 117
Fire protection and tankage fire protection govern petrochemical tank farms (ethylene refrigerated storage at -103°C, propylene refrigerated, naphtha atmospheric, aromatics atmospheric, intermediate product storage). Fire-water capacity, foam fire-fighting systems, vapour recovery for high-volatility products, emergency shutdown valve provisions.
OISD 119
Atmospheric storage tank inspection covers petrochemical plant naphtha tanks, aromatics tanks, intermediate product tanks. Periodic API 653 inspection cycles align with OISD 119 requirements for in-service tank integrity management.
IBR 1950
Indian Boiler Regulations 1950 cover petrochemical plant pressure equipment: high-pressure quench oil tower (typical 5-15 bar at 350-400°C), quench water tower, transfer line exchanger (TLE) for cracker effluent, polymer reactor (typical polymerisation at 1500-3000 bar for low-density polyethylene LDPE process), aromatics extraction towers, hydrocracker reactors. IBR Form II / III / Form IV registration mandatory for IBR-scoped equipment. See the IBR compliance page.
ASME B31.3 Process Piping with Category M (toxic service)
Process piping per ASME B31.3 with Category M (toxic service) requirements covers ethylene piping (highly flammable), propylene piping, butadiene piping (highly toxic and reactive), 1,3-butadiene piping (carcinogen), benzene piping (carcinogen), ethylene oxide piping (highly toxic and reactive), propylene oxide piping. Category M designation drives 100% radiographic examination and stricter material control. See the ASME B31.3 standard reference.
NACE MR0175 / ISO 15156
Sour service materials standard applies to petrochemical plants processing sour gas feedstock or sour intermediate streams. Hardness limits 22 HRC for carbon steel, 235 HV for low-alloy steel, plus HIC testing per NACE TM0284 for plate material. Common in petrochemical hydrotreating and hydrocracking units. See the NACE MR0175 standard reference.
PESO Form XV
PESO Form XV covers compressed gas storage at petrochemical sites: ethylene atmospheric and refrigerated storage, propylene, butadiene, ammonia (where used for petrochemical scope), industrial gases (oxygen, hydrogen, nitrogen). See the PESO standard reference.
ATEX / IEC 60079 Hazardous Area Classification
Hazardous area classification per IEC 60079 (Zone 0, 1, 2 for gas; equivalent IS 5572) drives electrical equipment certification (Ex-d, Ex-e, Ex-ia, Ex-ic) at petrochemical plant scope. Pathnovo extracts hazardous area boundaries from P&IDs and layout drawings for PESO licence packaging.
Six real petrochemical project scope examples covering Reliance Jamnagar complex, ethylene cracker capacity expansion, aromatics complex revamp, polymer plant expansion, specialty chemical scope, and chlor-alkali revamp. Each example shows scope and typical engagement profile.
Reliance Jamnagar petrochemical complex P&ID extraction (Gujarat)
Reliance Jamnagar refinery + petrochemical complex with multi-train cracker, polymer trains (LDPE, HDPE, PP, PET), aromatics complex (paraxylene, benzene, toluene), and downstream specialty chemicals. Engineering documentation spans original 1999-2000 commissioning era plus multiple expansion phases through 2020s. Pathnovo brownfield engagement: 12-20 weeks for full plant scope across 20,000-30,000 drawings. Multi-licensor convention preservation (Lummus, ABB Lummus Global, Linde, KBR, UOP, Axens) with Indian PSU rate-card pricing.
Indian PSU ethylene cracker capacity expansion
GAIL Pata or BPCL Kochi cracker capacity expansion scope covering new ethylene cracker furnace train addition, polymer downstream tie-in, utility integration. ASME B31.3 Category M piping for ethylene and propylene streams. OISD 150 fired heater BMS verification at SIL 2 or SIL 3. IBR Form IV register for cracker effluent transfer line exchanger and quench oil tower. PESO Form XV for ethylene storage expansion. Pathnovo greenfield-equivalent engagement: 14-18 weeks for cracker train scope plus downstream polymer scope.
Aromatics complex paraxylene revamp
Indian PSU petrochemical plant aromatics complex revamp covering paraxylene + ortho-xylene + benzene + toluene production. UOP Parex separation technology or Axens Eluxyl process. Pathnovo extracts P&ID scope across reformer + crystallisation/adsorption separation + finishing scope. NACE MR0175 sour service compatibility for sulphur-bearing reformer feed. Engagement scope: 10-14 weeks across 10,000-15,000 drawings.
Polymer plant LDPE / HDPE expansion (Indian private operator)
Indian private polymer plant LDPE high-pressure or HDPE low-pressure expansion. High-pressure LDPE process operates at 1,500-3,000 bar in tubular or autoclave reactor; ASME Section VIII Division 3 high-pressure vessel scope. HDPE process operates at 30-50 bar with slurry or solution polymerisation. Lummus, INEOS, ExxonMobil, LyondellBasell, or Mitsui Chemicals licensor scope. Pathnovo engagement: 10-14 weeks.
Specialty chemical / phenol-acetone-cumene plant (Indian private operator)
Indian private specialty chemical plant phenol-acetone-cumene scope covering cumene synthesis (UOP Q-Max or Axens Detal process), hydroperoxidation, cleavage, separation. Bisphenol-A or alpha-methylstyrene downstream where applicable. Multi-product specialty chemical scope with tight quality control. Pathnovo engagement: 8-12 weeks.
Chlor-alkali plant revamp (Indian private operator)
Indian private chlor-alkali plant chlorine + caustic soda + hydrogen production revamp scope. Membrane cell or mercury cell technology (mercury cell phase-out per Minamata Convention 2020+ deadline). Multi-licensor scope (Asahi Kasei, AGC, Uhde Chlorine Engineers, INEOS). PESO chlorine storage compliance + CCOE compliance. Pathnovo engagement: 8-12 weeks.
Indian petrochemical industry uses technology from multiple global cracker, polymer, and aromatics licensors. Pathnovo preserves licensor-specific tag conventions, equipment numbering schemes, and documentation styles during extraction. Seven primary licensors covered below.
Lummus Technology (ethylene cracker)
Process units
Steam cracker furnaces (radiant box, convection section, transfer line exchanger), primary fractionator, quench water tower, quench oil tower, compression train, caustic wash, dryers, demethaniser, deethaniser, ethylene-ethane splitter, depropaniser, propylene-propane splitter, debutaniser, deheptaniser, hydrogenation reactors
Tag convention handling
Lummus tag conventions and proprietary cracker furnace design (SRT - Short Residence Time) preserved during extraction
Linde Engineering (ethylene cracker + air separation)
Process units
Steam cracker furnaces with Linde proprietary radiant box, air separation unit (ASU) for oxygen / nitrogen / argon production, hydrogen / syngas production via steam methane reforming (SMR), CO2 removal and capture
Tag convention handling
Linde tag conventions and German engineering documentation style preserved; multilingual document handling supported for German technical specifications
Mitsui Chemicals (polymer scope)
Process units
High-density polyethylene (HDPE) reactor, polypropylene (PP) reactor with Mitsui proprietary catalyst, polymer finishing (pelletisation, drying, additivation, packaging), polymer storage
Tag convention handling
Mitsui tag conventions preserved with Japanese engineering documentation style; multilingual document handling supported
Lummus / LyondellBasell (polypropylene Spheripol process)
Process units
Bulk slurry polymerisation reactor (Spheripol Loop Process), gas-phase polymerisation reactor for impact copolymer, polymer separation (centrifuge or flash), polymer finishing
Tag convention handling
Spheripol process tag conventions preserved with proprietary catalyst handling
UOP (aromatics)
Process units
Reforming process (UOP CCR Platforming), paraxylene production (UOP Parex), benzene-toluene-xylene (BTX) separation, Q-Max cumene process, transalkylation
Tag convention handling
UOP tag conventions and proprietary process licensing detail preserved
Axens (refining + petrochemical)
Process units
Aromatics extraction (Axens Eluxyl), reforming (Octanizing), hydrocracking (Hyvahl, T-Star), hydrotreating
Tag convention handling
Axens tag conventions preserved with French engineering documentation style; multilingual document handling supported
BASF / INEOS / SABIC (proprietary processes)
Process units
Site-specific BASF, INEOS, or SABIC proprietary process scope with vendor-specific catalyst, reactor design, and separation conventions
Tag convention handling
Vendor-specific tag conventions preserved; configurable per-project tag handling supported
Why do petrochemical plants need document intelligence?
Petrochemical plants operate complex process units with thousands of instruments, specialty materials, and safety-critical systems. Document intelligence automates the extraction of engineering data from P&IDs, HAZOP registers, and mill certificates, eliminating months of manual work and ensuring accuracy for safety compliance and plant operations.
What petrochemical documents can Pathnovo process?
P&IDs for all process units (cracker, polymerization, utilities), instrument datasheets, HAZOP studies, mill certificates for specialty alloys, piping isometrics, C&E matrices, and handover packages.
Can you handle specialty alloy material traceability?
Yes. Pathnovo processes mill certificates for specialty alloys (Inconel, Hastelloy, duplex stainless, etc.) with full heat number traceability and specification validation.
Do you support turnaround documentation?
Yes. Turnaround work packs, inspection scope documents, and as-found/as-left records are processed into structured data for maintenance planning.
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