India sources approx. 80% of its energy consumption. To refine, store, and ultimately distribute it, the Government of India, along with HPCL, planned to build a world- class infrastructure. When completed, this is aimed to be the largest refinery ever built in INDIA. As per information available in common internet platforms, the refinery is expected cost of 8.7 billion USD to build with an expected capacity of 9 MMTPA, with an area covering 4700 acres of land at Pachpadra in the Barmer (Balotra) district of Rajasthan, India.
With due process of bidding and approvals through the execution partner of the HRRL project, M/S. Engineers India Limited (EIL), Derwiser certified partner M/S. Enrich Data Services Private Limited, and the DERWISER make were approved for the network backbone infrastructure for HPCL Rajasthan Refinery Limited (HRRL) at Pachpadra,Rajasthan, delivering high-capacity optical fiber and structured connectivity solutions aligned with refinery-grade standards.
Project Overview
The strict compliances of the Tender RFP considered the refinery site, which has various external factors like:
- Harsh Environmental Conditions: Cables must withstand extreme temperatures (high heat and extreme cold), which can cause insulation to harden, crack, or degrade. Exposure to chemicals, oils, moisture, and UV radiation necessitates specialized shielding.
- Electromagnetic Interference (EMI): Refineries are filled with large machinery, pumps, and motors that generate high levels of EMI, which can disrupt, slow, or corrupt data transmission, particularly on copper cabling.
- Physical Hazards: Cables are susceptible to being cut, crushed, abraded, or burned due to constant industrial activity.
- Extensive Infrastructure and Layouts: Refineries are sprawling sites. Long cable runs often exceed the distance limitations of standard Ethernet, requiring complex routing and specialized equipment to avoid signal loss.
- High-Density Metal Obstacles: The high density of metal structures and pipes makes installing, securing, and maintaining cabling infrastructure difficult, often making fiber optics necessary to span distances and overcome EMI.
Solutions Approved:
- DRY CORE (GEL-FREE) – OFC Cable: Eliminates the disposal of hazardous, messy gel waste. Provides a cleaner environment and is suitable for both indoor and outdoor applications.
- G.657.A1 Fiber Core: For superior bend resistance, easier installation in tight, highdensity spaces, and low signal loss across all operating wavebands.
- FR LSZH Cable: UV Stabilized outer sheathing cables, confirmed and tested/certified in accordance with IEC 60332-2-33 for better fire safety compliance and harsh environmental conditions.
- Many such technical specifications were mentioned in the tender RFP.
Compliance and Quality Assurance
Given the industrial nature of the project, compliance and testing were critical. The supplied cables:
- Complied with IEC 60332-3-22 flame propagation standards.
- Products were tested at a NABL-accredited laboratory.
- Products had pre-dispatch inspections by a global third-party inspection agency at Derwiser premises.
- Received approval under the supervision of one of India’s leading engineering organizations.
This rigorous validation process ensured that every kilometre of supplied cable met refinerygrade safety and performance standards before dispatch.
Deployment Scope
As a Greenfield refinery project, HRRL required a high-capacity backbone infrastructure to support:
- Plant-wide communication systems
- Control and monitoring networks
- Administrative and operational IT infrastructure
- Future digital expansion and industrial automation
The mix of 6, 12, 48, and 96 core FRLSZH optical fiber cables enabled scalable backbone architecture across process units, utilities, and administrative zones. In addition, CAT6A LSZH and FRLSZH cabling supported structured copper connectivity, delivering 10 Gigabit performance where required. Network racks were supplied to ensure organized and secure termination environments across facilities.
Outcome
The successful execution of this large-scale supply marked a significant milestone for Derwiser. Supporting one of India’s most prominent refinery developments reinforced Derwiser’s capability in delivering:
- High-volume industrial-grade optical fiber supply
- Compliance-driven infrastructure solutions
- Scalable backbone architecture for mission-critical environments
- Continuous material supply aligned with project timelines
Supply continues in alignment with project expansion requirements, demonstrating sustained trust and performance consistency.
Key Highlights
- Approximately 400 Km of FRLSZH Optical Fiber Cable Supplied
- Core Configurations from 6 Core to 96 Core
- IEC 60332-3-22 Compliant
- NABL Lab Tested
- Globally Inspected / Third-Party Approved
- Supports 10G and 40G, scalable up to 100G Fiber Performances.
- 10G Copper Connectivity via CAT6A
- Delivered for a Large-Scale Greenfield Refinery Project.
- Make in INDIA, Made for INDIA & Tested in INDIA.
Conclusion
The network backbone infrastructure supplied by Derwiser for HPCL Rajasthan Refinery Limited at Pachpadra represents a large-scale, compliance-driven deployment engineered for industrial resilience.
By delivering high-capacity FRLSZH optical fibersolutions, validated through stringent testing and inspection protocols, Derwiser contributed to establishing a scalable and performance-ready communication backbone for one of India’s landmark refinery projects.
