Essar Heavy Engineering Services Brochure
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FABRICATION & HEAVY ENGINEERING CAPABILITIES FABRICATING TO PRECISION Fabricating to Precision PROCESS PLANT EQUIPMENT STRUCTURAL FABRICATION Static Equipment for Oil & Gas, Structure, Modules & Skids Refinery, Petrochemical & Fertilizer HEAVY MACHINERY Steel Plant & Power Plant Equipment STATE-OF-ART HEAVY FABRICATION ENGINEERING FACILITY GEARED TO MEET CHANGING NEEDS OF CLIENTS • 355,000 sqm. facility, with annual capacity of 15000 MT for equipment and 40000 MT for structural fabrication • Strategically located at Hazira, Gujarat, on banks of Tapi with water front & port access • Large open as well as covered yards and gantry bays, to fabricate and trial-assemble large size equipment, structures and modules • Capability of delivering Over Dimensional Consignments (ODC), including in-situ assemblies wherever necessary, across diverse sectors • Handled various metallurgies like CS, LAS, SS, Duplex, Alloy 20, Alloy 28, Inconel, Cupro Nickel, Hastelloy, Monel, Brass, Titanium • Experience of working with proprietary designs of renowned process licensors • In-house thermal & mechanical design capabilities – using latest software & codes • Available in-house Mechanical, Chemical testing & NDT facilities • State-of-art machine tools, capable of handling large size components & prefabricated equipment • Use of critical machining processes using CNC software • Raw material sourcing advantage - proximity to Essar Steel Plant, Plate Mill and Pipe Mill • IMS Certifications (ISO:140001 OHSAS:18001) • Welders qualified as per ASME SEC-IX, AWS D1.1 and 400+ welding procedures qualified • Facility approved by major international EPC companies and process Licensors OVERVIEW OVERVIEW Essar – the multinational conglomerate with presence in over 29 countries – began as a construction company in 1969; working on marine, ports and offshore contracts. It was the first Indian Company to venture into the challenging environment of Offshore Construction and lay Subsea Pipelines back in early 1980s. With diversification of the Group’s business activities, the construction business was incorporated as a separate company in 1989. Since then, “Essar Projects” has honed its skills as an EPC contractor offering innovative execution and delivery solutions across diverse sectors and geographies. It has delivered projects of scale and complexity across multiple segments like Hydrocarbon: Oil & Gas, Water and Slurry Pipelines; Tankages & Terminals; Offshore & Subsea; Infrastructure; Minerals & Metals and Power. Essar Projects’ footprint spreads across India, Middle-East, South-East Asia, Americas and also some challenging geographies of Africa and Australasia. Essar Heavy Engineering Services (EHES) was established in 2005, as Essar Projects’ heavy fabrication facility in Hazira (Gujarat) strategically on the banks of river Tapi with a jetty for sea transport. Since then, EHES has manufactured several critical equipment and machinery for Refinery, Fertilizers, Steel Plant, Power Plant and other core industries, meeting stringent specification and quality requirements. Over the past decade EHES has evolved into a leading heavy engineering and fabrication facility in India, with a global footprint, having specialized competency both in terms of capacity as well as capabilities. Key Achievements • 80 m Long x 7 m dia, 360 MT Stainless Steel Column • 65 m long x 5.2 m dia, 227 MT Deisohexaniser column manufacturing and transportation in single piece • 64 nos. of PSA vessels for Hydrogen plants for Technology Providers like Air Products and UOP • 65 nos. of Heat Exchangers and Pressure Vessels supplied to Dangote Fertilizer- Nigeria • 30 nos. of Over Dimensional Consignment (ODC) vessel of varying size and Metallurgy for Dangote Refinery – Nigeria • 2500 TPH Capacity (360 MT) Bucket Wheel Reclaimer at Paradeep, India • 30200 MT technological structures, impact tested at (–)800C, for Integrated Steel Plant in Minnesota, USA • 44 sets of Coal Pulveriser Housing for Super Critical Thermal Power Plants of various clients like MAHAGENCO and NTPC • Hi-end equipment supply for one of the prestigious project in India – RIL Jamnagar Refinery Expansion (J3) through Linde • Supply of equipment for major PSU like BPCL, IOCL, HPCL, RCFL, MFL, etc. • More than 300 process equipment weighing more than 25000 MT manufactured and delivered to global customer • More than 500 equipment’s supplied to various steel, power, port and mines sectors weighing more than 40000 MT • More than 80000 MT of modular/technological structures for clients like RIL, KNPC, KOC, CITGO. SOCAR Safety At our fabrication yard, Safety is accorded prime importance, not just by the Management and by all the staff. There are various initiatives for periodic training and awareness programmes to enhance adherence to HSE norms. During the four year period (April 2010 – August 2014) we achieved a bench mark of LTI Free 28.59mn Man Hours and thereafter LTI Free 9.17mn Man Hours till date. PROCESS PLANT EQUIPMENT In past 8 years EHES has manufactured and delivered hi- end process plant equipment in various industrial sectors like Oil and Gas, Refinery, Petrochemicals and Fertilizers. Setting benchmark in fabrication industries, today EHES is regarded as one of the top end PROCESS manufacturer of static equipment with State-of-Art technical, engineering and manufacturing expertise. PLANT EQUIPMENT Key Jobs Undertaken COLUMNS • 80 m x 7 m ID, 360 MT stainless steel (SS316L) Quench Tower for Vadinar Refinery, Gujarat • 65m long x 5.2 m ID, 227 MT Deisohexaniser Column - manufacturing & transportation to site in single piece for Vadinar Refinery • 84 MT, 42 m tall Carbon Steel LP tower for Indogulf Fertilsers, India PRESSURE VESSELS, REACTORS, SEPARATORS, DRUMS Splitter Column for Refinery • 220 MT, 98 mm thick Carbon Steel HP Separator Drum for DHDS unit • 156 MT, 137 mm thick Carbon Steel Seperator Vessel with 4.5 mm Stainless Steel Cladding by ESSC Surge Drum for Air Separation Plant for BPCL Kochi Refinery Expansion Project • 140 MT, 7.2 m dia. Liquid-Liquid separator for Linde: Exxon Mobil Refinery, USA • Secondary Reformer (KBR Design) including refractory application for KRIBHCO Fertilizer Plant, Hazira, Gujarat, India • 140 MT Low Alloy Steel (SA 387 Gr. 11) 2 nos. Secondary Reformer (Saipem Design) and 27 nos. Pressure Vessels for Dangote Fertilizer Plant, Nigeria • 130 mm thick Low Alloy Steel (SA 387 Gr. 22) Pre-Reformer for HMU unit • ASME S Stamped 75.5 MT Carbon Steel Steam Drum, for ITTKI : Takreer Refinery, UAE • 75 MT, SS 321 clad 2nd HDS reactor of FCC unit for HPCL Vishakh Refinery, Vizag, India • 69 MT (20 Nos.) Air Products Proprietary design Hydrogen Service PSA vessels (20 nos.) for BPCL Kochi Refinery and 40 MT (42 nos) UOP Proprietary design Equipment for Cyclic Effluent Chamber Transfer Line for Fertilizer Plant, IOWA USA Operation • Outlet system with cross header & 6 manifolds having 216 Nozzels of Alloy 800H, for ITTKI : Takreer Refinery, UAE • Pneumatically tested (at 50 kg/cm2) Carbon Steel Transfer Line with Alloy 800H liner and Refractory application, for ITTKI : IOWA Urea-Ammonia Plant, USA • Spent Caustic Separating Vessel with 3 mm Hastelloy (C-276) Lining on Carbon Steel • SA240 S32205 Complete SS Duplex construction vessel for Reliance Industries Ltd., Hazira • 30 nos of ODC vessel of varying size and Metallurgy, largest and heaviest one with 9.9 m dia x 37 m long, total weight 920 MT (2 Nos.) Flash Drum for Refinery Secondary Reformer for Dangote Fertilizer, Nigeria Contact Condenser (SS 304L Clad) for Reliance J3 Project through Linde Desalter Vessel for Vadinar Refinery HEAT EXCHANGERS • Hydro-tested (at 210 kg/cm2) High Pressure Effluent Feed Heat Exchanger having LAS (SA 387 Gr. 11) Shell and Stainless Steel (SS 321) Tubes • Tube Bundle with 1170 nos. Titanium (SB 338 Gr. 2) tubes and Titanium (SB 265 GR. 2) clad tube sheet for Stabilizer Condenser • Heat Exchanger with 2480 nos. Al-Ni-Br tubes & CS tube sheet with Al-Ni-Br 10 mm thick weld overlay • Heat Exchanger Reformer based on Haldor Topsoe proprietary design HP Separator Drum for Refinery • 36 nos. Heat Exchanger of varies Metallurgies (CS, LAS, SS) for Dangote Fertilizer Plant, Nigeria • Duplex tubes (SS31803) Heat Exchanger hydro-tested at 108 bar Advantage EHES • Experience of handling various Metallurgies including ¡ Carbon Steel (all grades) ¡ Low Alloy Steel ¡ Stainless Steel (SS 347, SS321, SS316L, SS316, SS304L, Nonferrous Tubes and Clad SS304, SS410, ) Heat Exchanger for Refinery ¡ Duplex & Super Duplex ¡ Non Ferrous Metals like Alloy 20, Alloy 28, Inconel, Cupro Nickel, Hastelloy, Titanium, Monel, Brass • Capabilities of working with proprietary designs of renowned process Licensors • In-house Thermal & Mechanical Design capabilities – using latest software and codes • Expertise of working on Over Dimensional Consignments, including In-situ assembly (where ever necessary) Steam Drum for Takreer Refinery, UAE Export Steam Deaerator for BPCL Kochi Refinery Expansion Project HEAVY MACHINERY Having assembled and fabricated equipment for Group companies as well as external customers, EHES has honed its skills in critical fabrication, machining and assembling equipment of varying sizes, weights and complexities across diverse sectors like Power, Steel, Ports, Mining. Precision is given utmost importance in our deliveries. Key Jobs Undertaken STEEL • Assembly of 46 m dia 600 MT Sinter Coolers with stringent dimensional tolerances for Siemens VAI: JSPL and NMDC, India • Assembly of 25m long 409 MT Cooling bed lifting