Essar Projects is uniquely positioned among the Indian and overseas contracting fraternity to offer its clients unique, collaborative end-to-end projects’ delivery model integrated across the EPC Value Chain.
We also have the advantages of incorporating operational experience of our group companies into basic design and execution philosophy for new project:
Sectorial Capabilities:
Refineries
Essar Projects has proven capabilities in delivering world-class Refineries, having executed a Grassroots refinery for Essar Oil as well as key process Units for other prestigious Clients. We have executed projects delivering 35 MMTPA of Refining capacity. Some of the key projects undertaken include: 20 MMTPA Refinery with Nelson’s Complexity Index of 11.8, for Essar Oil at Vadinar, India; Key Process Units for the 15 MMTPA IOCL Refinery at Paradip, India; CDSP for 3.84 MMTPA DCU and Reactor Regenerator Package of 2.2 MMTPA FCCU for BPCL Refinery expansion at Kochi, India; Civil & Structural Works of CBDC Unit for TAKREER Refinery at Ruwais, Abu Dhabi; Brown Field facilities for Shayaba Crude Stabilization Project at Saudi Aramco Abqaiq Plant; Naptha Stripper Plant Diluted Crude Oil Project for PDVSA, Venezuela.
Our Major Process Unit’s experience encompasses: CDU/VDU/SGU; CCR/NHT/Isomerization Unit; VGOH/FCCU/ UGSU; DHDS/DHDT; DCU and ARU/SRU/SWSU
Tankages:
We have delivered 3.7 MMCM of Storage Tanks & Terminals capacity till date in India and Overseas. Some of the key EPC jobs undertaken include: 3.2 MMCM Tankages (Crude, Intermediate & Product) capacity for Vadinar Refinery; 0.5 MMCN Tankages & Storage Terminal and Marine Facilities for JAC, Singapore.
Recently we have won the Contract for Tankages, Civil Works, Roads & Bridges for Kuwait National Petroleum Company (KNPC) New Refinery Project (NRP) Package 4, at Al Zour, Kuwait.
We have also undertaken EPCM & PMC for implementation of OISD standards at Depots & Terminals across 104 locations in India for IOCL.
Petrochemicals & Fertilizers:
Essar Projects has executed a 3 MMTPA Fertilizer complex for Matix Fertilizers at Durgapur, India – which includes 2,200 MTPD Ammonia and a 3,850 MTPD Urea plant with associated utilities and cryogenic tanks. We have also executed a Sulphur Silo for IFFCO at Paradeep.
In Abu Dhabi we have executed EPC of process equipment and associated pipelines for PE Colour Grade Compounding (CGC) project for Abu Dhabi Polymers Company (BOROUGE), and are working on EPC of Spent Caustic Treatment Plant for Abu Dhabi Oil Refining Company (TAKREER) in Abu Dhabi, UAE.
Offshore& Subsea:
Essar Projects provides project management and engineering, procurement, construction, installation and commissioning (EPCIC) services to the offshore sector, for both shallow and deep waters. We also specialise in the development and construction of offshore terminals and in providing greenfield and brownfield solutions.
We have been a pioneer in this sector for more than two decades and have executed several turnkey projects. The capability of our project team encompasses surveys, design engineering, procurement, fabrication, transportation, installation and hook-up and commissioning of new well / process platforms, modification and refurbishment of existing platforms, subsea installations including laying of subsea pipelines (both rigid and flexible), subsea cables, pipeline end manifold (PLEM) and single point mooring (SPM) to name a few, and shallow water pipelay and shore pulls in highly challenging marine environments.
Pipelines:
Essar Projects is a leading EPC contractor for oil, gas, slurry and water pipelines. With capability to design, plan and execute complex pipeline projects, we have a track record of laying over 5,500 km of onshore pipelines in India, UAE and Madagascar.
In the Oil & Gas Segment, in India, we have laid over 900 km of Crude Oil Pipelines with diameter ranging from 24” to 28”; Product Pipeline of 18” dia for 550 km and around 700 km Gas Pipelines with diameters ranging from 30” to 48”. In UAE we have worked on includes around 200 km of 28” dia Inter-refinery Gas-Oil Pipelines for TAKREER and 110 km of 24” dia Condensate Pipeline for GASCO.
We have laid through toughest geographies around 630 km of Slurry Pipelines. These include the 16” dia x 267 km Bailadila-Vizag and 20” dia x Joda-Paradip Iron Ore slurry Pipelines in India; 12” dia x 3.5 km Slurry Pipeline in Minnesota and 24” Dia x 100 km Ambatovy Nickel Slurry Pipeline in Madagascar.
Around 100 km of Water Pipelines of diameter ranging from 2300 mm to 3000 mm have been laid by us in the state of Gujarat, India for GWIL and NWRWSKD
Minerals and Metals:
Essar Projects enjoys a distinct advantage in the steel sector having engineered, built and commissioned most of Essar Steel's assets with an extremely high level of integration – both forward and backward. This has enabled us to forge a significant presence in every stage of the steel manufacturing process – from iron ore to the end product.
Through this experience, we are now regarded as a world leader in the delivery of Beneficiation plants, Pellet plants, and Steel Plant units including HBI, DRI, blast furnace, sinter plant, Coke oven, Corex, SMP, CSP, HSM, CRM, RMHS and lime plant), Plate mills and Pipe mill. We have been executing projects for Steel Authority of India (SAIL), Jindal Steel & Power Ltd. (JSPL), Jindal Steel Works (JSW) and Tata Steel.
We have worked with renowned technology providers like SMS, Nippon Steel & Sumikin Engg., Danieli, Danieli-Corus, Siemens VAI (Primetals), Midrex, Metso, MCC, SDM, Cimprogetti, Kobe (Outotec), Fives Stein (Stein Hurtsey), Shougang, FLSmidth, UHT and All Minerals
Power:
Essar Projects has robust delivery capabilities across multi-fuel power generation plants. Our portfolio of power projects under various stages of design and execution includes gas-based, coal-fired as well as hydropower plants. We have delivered in excess of 4.000MW of multi-fuel generation capacity. We are currently executing Balance of Plant works for 2 x 500 MW Lignite Based Thermal Power Project of Neyvile Lignite Corporation.
Infrastructure:
The history of infrastructure construction at Essar Projects starts with the genesis of the Essar Group. Being India's first independent Indian Marine Contractor was the first distinction we achieved. Having worked on most of the major Ports in India Essar Projects has also constructed Greenfield Bulk Terminals for Liquid and Dry bulk cargo.We are now executing India’s first mega scale commercial RoRo jetty for Ropax ferries in waters with 10 m tidal variation. This is the highest tidal variation for any RoRo jetty in india and second highest in the world. We have also worked on an airport project in the challenging geography of Papua New Guinea.
Over the years we have executed Ports, Industrial Buildings and Hydroelectric Power projects. Today we are developing capabilities in Roads, Metro & Rail and Water treatment Plants.
Supporting Capabilities
In order to be competitive and provide value added services to our clients, we have forayed into following critical services required by EPC industry. Inclusion of these services into our service offering not only makes us competitive but also has provided us stand-alone business from their areas of operations.
Heavy Engineering:
Essar Heavy Engineering Services is the state-of-art Heavy Fabrication Facility of Essar Projects. Located on the banks of river Tapi, this state-of-the-art plant enjoys the strategic advantage of convenient waterfront access and has its own jetty for sea transport. It is a 355,000 sqm. facility, with capacity of 15000 MT for equipment and 40000 MT for structural fabrication
Its large open as well as covered yards and gantry bays enable fabrication and trial-assembly of large size equipment, structures and modules. We have the capability of delivering Over Dimensional Consignments (ODC), including in-situ assemblies wherever necessary, across diverse sectors
Over the years EHES has handled various metallurgies like CS, LAS, SS, Duplex, Alloy 20, Alloy 28, Inconel, Cupro Nickel, Hastelloy, Monel, Brass, Titanium and gathered experience of working with proprietary designs of renowned process licensors. We have in-house thermal & mechanical design capabilities – using latest software & codes – and in-house Mechanical, Chemical testing & NDT facilities. The yard has state-of-art machine tools, capable of handling large size components & prefabricated equipment and uses critical machining processes based on CNC software. EHES is certified for ISO:140001 and OHSAS:18001. Our welders are qualified as per ASME SEC-IX, AWS D1.1 and we have 400+ welding procedures qualified. Our facility has been approved by major international EPC companies and process Licensors
We manufacture process plant equipment, heavy machinery and Structures for Fertilizer, Refinery, Petrochemicals, Power, Steel, Port handling, & several other allied industries.
Equipment Bank:
At Essar Projects, we believe that successful project delivery is intrinsically dependent on the judicious selection and timely availability of the right type of construction equipment. We have a comprehensive and state-of-the-art equipment bank comprising:
- 1600 t Heavy Lifting Demag Crane; 500+ nos of other types of cranes including crawlers with capacity upto 680 T, Goliat, Mobile, Pick & Carry and Tower Cranes
- Derrick/Lay Barge equipped with 800 MT Huisman Crane capable of heavy lift & laying 6-60” subsea pipelines upto 200 mts depth; Jack Up Barge (Combifloat) suitable for 25-30 mts depth; Scanlay 1 Barge for Shallow Water Pipelay
- Heavy Earth moving Equipment; Hydraulic Piling Rigs; Batching Plants; Automatic Welding Machines; Power Generation Equipment; Automotive Commercial Vehicals, Trucks Trailors & Tippers
We have a highly skilled O&M crew that uses preventive & condition-based maintenance to minimize downtime. Equipment deployment planning, procuring, tracking, maintaining and retiring are closely monitored. Our equipment bank gives us competitive advantage, flexibility and control in minutely planning project execution and delivery.
