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• Ranked among top 300 companies in India ( ET Fortune 500
listings )
• Group Turnover over US$ 500 Million
• Total Employee Strength over 5500.
• 80 years in Business, 48 years in Boilers
• Strong presence in Captive Power Plants
• Supplied over 600 High Pressure Boilers.
Overview of Isgec
Utility
Boilers
Boilers
Sugar
Machinery
Power PlantsCFBC
AFBC,
TG & Biomass
Oil & Gas
WHRB, MSW
Vinasse
Pulverized Coal
Fired Boilers
Turnkey
Sugar Plants
PED
Isgec Heavy Engineering Limited
Contract
Manufacturing
Castings: Steel
& Iron
Presses:
Mechanical &
Hydraulic
Isgec – Hitachi
Zosen JV
EPC
Pressure Vessels
& Heat
Exchangers
Pollution Control
Equipments
(ESP)
Products & Services
4
877
130
1200
144
1363
364
1764
504
1810
315
2442
799
2749
1240
0
500
1000
1500
2000
2500
3000
2006 2007 2008 2009 2010 2011 2012
Turnover
Exports
$ 500 Millions
$ 225 Millions
Financial Year: October - September
Rs. In Crores
Growth Over Years
Noida
HO & Isgec Offices in
Suburb of New Delhi
Yamunanagar
Main Plant & Sugar Mill
200 km (125 Miles) from New
Delhi
Muzaffarnagar
115 km
(71 Miles) from New Delhi
Chennai
• Design Centre
• Regional Mktg
Kolkata
Regional Mktg.
Dahej
Our Coastal Plant
Mumbai
Branch Office
INDIA
Bay of BengalArabian Sea
International Offices:
• California, USA
• Dusseldorf, Germany
70 International Agents
New Delhi
Pune
•Design Centre
• Regional Mktg
Bawal
100 km (62 Miles)
from New Delhi
Bhubaneshwar
Regional Mktg.
Ratangarh
200 km (125 Miles) from
New Delhi
Locations
75 Countries across 6 Continents
Venezuela Vietnam Yemen ZimbabweZambiaUzbekistanUK USA
China Colombia Czech Republic Dominican Republic Ecuador EgyptCyprusChileCanada
France GermanyEl Salvador Honduras India Indonesia IranGuyanaFinlandEthiopia
Japan JordonIraq Kazakhstan Kuwait MalaysiaKenyaJamaicaItaly
Syria Tanzania Thailand Trinidad & Tabago Turkey UgandaUAESwedenSudan
Oman PakistanMauritius PhilippinesPeruNigeriaNepalMozambiqueMalta Mexico
Sri lankaRomania Saudi Arabia Singapore South KoreaSouth AfricaSenegalQatar Spain
Argentina Australia Bahrain Bangladesh Barbados Bulgaria CambodiaAlgeria BrazilBosnia
6
Isgec – Global Presence
36 Countries
USA
Guatemala
Barbados
Brazil
Chile
Colombia
Guyana
Sudan
Uganda
Kenya
Tanzania
Zambia
Mozambique
Mauritius
Ethiopia
Bangladesh
India
Pakistan
Malaysia
Vietnam
Indonesia
Philippines
Thailand
Senegal
Spain
Sierra Leone
Trinidad and Tobago Nicaragua
El Salvador
Honduras
Dominican Republic
UAE
Saudi Arabia
China
Boilers & Power Plants
Boilers
170 TPH TG Boiler for Mumias Sugar Company Ltd., Kenya 100 TPH CFBC Boiler for Nirma Ltd. India.
105 TPH AFBC Boiler at Gujarat Flurochemicals Limited, India 140 TPH Oil Fired Boiler for M/s Kochi Refinery, India
 Industrial Segment:
• Circulating Fluidized Bed Combustion Boilers*
• Travelling Grate Boilers for Bagasse and Biomass.
• Atmospheric Fluidized Bed Combustion Boilers.
• Oil & Gas Fired Boilers – Field Erected & Package Type *
• Slop / Vinesse Fired Boilers
• Waste Heat Recovery Type Boilers.
• Waste to Energy
*In Collaboration with Foster Wheeler, USA.
 Utility Segment:
• Pulverized Coal Fired Boilers* – Subcritical & Supercritical
10
Product Range
Boilers
Mid Siam Sugar Co. Ltd.,
Thailand
Boilers
Product Range includes:
• Biomass & Bagasse Fired Boilers – up to 250 TPH
• Oil & Gas Fired Boilers: Field Assembled – up to 200 TPH
• Oil & Gas Fired Boilers: Package Type – up to 260 TPH
• CFBC Boilers – up to 400 TPH
• AFBC Boilers – up to 160 TPH
• PC Boilers – Sub Critical & Super Critical
• Deaerators & Spares
11
12
Boilers - Fuels
• Wood Chips
• Olive Wood Trimmings
• Coconut Shell
• Groundnut Shell
• Subabul Wood
• Red Gram Husk
• Bengal Gram Husk
• Cashewnut Shell
• Woody Biomass
• Cane Top & Trash
• Cane Pith
• Other agricultural wastes, individually or in combinations
• Coal
• Oil, Natural Gas and Bio-Gas
• Slop/ Vinasse (Distillery Spent Waste)
Major Customers across Industries
• Sugar Industry
- White Nile Sugar, Sudan
- Magdalena Sugars, Guatemala
- EID Parry Group, India
• Cement Industry
- Fujairah Cements, UAE
- Jaypee Cements, India
- Dalmia Cements, India
• Oil & Refinery Industry
- Petrobras, Brazil
- Kochi Refinery, India
- HPCL, India
• Chemical & Fertilizer Industry
- National Fertilizers, India
- Hindustan Fertilizers, India
• Utility / IPP
- Aldebaran Energia, Spain
- Long View, USA
- Adani Power, India
- Vithai BioPower, Thailand
• Steel & Metal Industry
- Bhusan Steel, India
- Hindalco Industries, India
• Distillery Industry
- Mumias Sugar, Kenya
- Dharni Sugar, India
- NV Distilleries, India
• Paper Industry
- Arab Paper, Saudi Arabia
- BILT Paper, India
- SectorsBoilers
30.4 MW Power Plant (Bagasse Fired)
Zambia Sugar Plc, Zambia
Power Plants
Range:
up to 100 MW
14
Range:
• Complete Sugar Plant up to 30,000 TCD
• Milling plants up to 50” x 100”
• Energy efficient Process house equipments for
Raw, Plantation white & Refined sugar manufacturing.
15
Supplied
-Over 350 Mills
-Over 70 Sugar Plants and Major Expansions across 35 countries
45” x 90” Mill
Xinavane, Mozambique
(Owned by Tongaat Hulett, South
Africa)
Sugar Plant & Machinery
Sugar Plant & Machinery
Sugar:
Long experience in supplying green field sugar plants & doing up-gradation of sugar plants
for major Indian customers:
- HPCL, Bajaj Group, Balrampur Group, Shree Ram Ind. Enterprise Ltd.,
Dwarikesh & Mills in the Cooperative Sector
Sugar Plant & Machinery
Complete Sugar Plant
Daund Sugar Ltd., India
- Sectors
16
Lavalin, Canada for PDO, Oman
Pressure Vessel: weight-210T length-12.5 M
Process Plant Equipment
Reliance, Jamnagar
Tube Bundles – assembly under progress
Products include:
• Reactors
• High Pressure Vessels
• Shell and Tube Heat Exchangers
• Columns and Towers
• High Pressure Boiler Drums
• Boiler Pressure Parts
Materials include:
• Monel
• Cupro Nickel
• Brass
• Clad Steels
17
• Cr-Mo Alloy Steels
• Duplex Stainless Steels
• Stainless Steels
• Carbon Steels
Oil and Gas:
Supplies to major / Fortune 500 Indian customers:
- Indian Oil Corporation, Reliance, Bharat Petroleum, Hindustan Petroleum,
Gail, etc.
Through consultants:
-Toyo, Jacobs, Uhde, Engineers India Limited, Lurgi, Technip, Fluor, etc.
Products:
- Reactors, Hot HP Separators, Coke Drums, Helix Exchanger, etc.
EIL, India for HPCL, Mumbai
CCR Platform Reactor: length-43M; weight-125T
Process Plant Equipment
IOCL, Panipat, India
Atmospheric Column &
Vacuum Column
(Site Fabricated
Columns )
18
- Sectors
Fertilizers:
Supplies to almost all major customers:
- IFFCO, Kribhco, GNFC, NFL, Tata Chemicals, Chambal Fertilizers, etc.
Products:
- LT Shift Convertors, Secondary Waste Heat Exchangers, BFW Pre Heater, etc.
Process Plant Equipment
Burrup Fertiliser, Australia
:Heat Exchanger
19
- Sectors
Process Plant Equipment
Product: Liquified Gas Containers
20
The largest manufacturer of Ton Containers in the world
Over 100,000 Containers to 52 Countries
Patents awarded for design
& techniques for manufacturing of Containers
• US Patent
• Chinese Patent • Indian Patent
• Mexican Patent
Safety & reliability backed by
• Finite Element Analysis
• Destructive Testing on Prototype models
• 100% X-ray
ThyssenKrupp, India
1000T & 800T Press Lines
Presses: Mechanical & Hydraulic
Products include:
Mechanical Presses(up to 3000 T)
• Transfer Presses
• Tandem Press Lines
• Presses for Progressive Tooling
• Blanking Press Lines
Gap Frame Presses from 25-250 T
CIE Automotive, Spain
2500 T Transfer Press Line
21
Hydraulic Presses
• Double & Single Action Presses up to 3000T
• Presses (Wood & Panel industry) up to 7000T
Automobile:
Supplies to major OEMs & Tier 1 suppliers of Auto Industry
- Suzuki, TATA, Mahindra, Honda, Ford, Bellsonica, Bajaj, Ashok Leyland,
JBM etc.
- Proven track record for supplying over 2,700 Metal Forming Presses
Presses: Mechanical & Hydraulic
TATA Motors, India
100T Die Spotting Press
22
- Sectors
Force Motors, India
2000T Hydraulic Press
Ladle Turret for 2 ladles - 165 T each
Design : SMS Demag
Contract Manufacturing
Thin Slab Caster Segment
Design : SMS Demag
Experience: Over 15000 Tonnes of Mechanical Equipment made to
customers design covering fabrication, machining & assembly of:
Metallurgical Industry
• Hot / Cold Rolling Mills
• Processing Lines
• Continuous Slab / Billet / Bloom Casters
• Gas Cleaning Plants & Sinter Plants
Hydro Electric Power Industry
• Radial & Vertical Gates
• Penstocks
• Stop Logs
• Trash Racks
• Turbine Housings
23
Supplies to international consultants:
- IHI, MHI, SMS Demag, Paul Worth, etc.
GE Hydro- Canada
Steel Castings
Andritz- VA Tech, Flovel
Products include Castings in:
Creep Resistant Steels
Stainless Steels
Alloy & Carbon Steels
Alloy & Nodular Irons
Capacity:
500 MT/Month
Weight Range:
up to 50 MT single piece
Maximum Size:
8 M x 8 M x 4 M
Tyco FCT, France
24
Runner Hub
Steel Castings
Guide Vanes
25
Energy:
Supplies - Steel Casting to turbine OEMs:
- Alstom, Siemens, Ansaldo, Toshiba, Skoda, BHEL, GE, VOITH, VATech, etc.
- Sectors
Casing
Manufacturing Facilities
Location Products
Yamuna Nagar Drums, Pressure Vessels, Heat
Exchangers, Presses, Steel Plant
Equipment & CI castings
Rattangarh Panels & Coils
Dahej Pressure Vessels & Drums
Muzaffarnagar Special Castings
Bawal Small Presses
Yamunanagar Rattangarh Dahej - 1 Dahej - 2
Total Area (sq.m) 180,000 50,000 202,350 240,000
Covered Area (sq.m) 95,000 16,650 16,500
Greenfield
Plot
on Water
Front
for Future
Expansion
Crane Capacity
(max.) (MT)
200 20 300
Open Yard
Fabrication (sq.m)
4,000 8,000 15,000
Drum Thickness
(max.)
Hot Roll
Cold Roll
200 mm
90 mm
Exclusive for
Coils - 6600
MT
Panels –
2200 nos.
Piping – 4400
MT
per annum
300 mm
175 mm
Weight (max.) (MT) 250 1000
Diameter (max.)
(mm)
5,000 9,000
Manufacturing Infrastructure- Boilers
Isgec, Yamunanagar - Works
29
Isgec, Dahej, Gujarat – JV Isgec Hitachi Zosen Ltd.
30
Few critical equipment under execution
at Isgec Hitachi Zosen JV
8/14/2013 31
Equipment Client Weight (MT) Features
Ethylene Oxide
Reactor
Reliance Industries, India 375 Low Alloy Steel. First Tubular
Reactor for Petrochem plant.
Only L&T in India is qualified.
Ammonia
Convertor
IOWA Fertilizer Project, USA
to KBR’s Technology.
750 Shell in multilayer construction.
World wide only 4 fabricators
have this technology .
Urea Stripper Urea Plant of Chambal
Fertilizer, India to Toyo’s
technology.
150 Higlhy corrosion resistant Cr-Ni-
Mo alloy tubes
Ammonia
Convertor
YPFB Fertilizer project
Bolivia to KBR’s technology.
543 Shell in multilayer construction
Urea Reactor YPFB Fertilizer project
Bolivia to Toyo’s technology
200 High strength, multi layer
Carbon steel shell. Inside lined
with Duplex steel liner
Reactors Saipem for Jazan Refinery
project Saudi Arabia
775 Low Alloy Steel 21/4 Cr- 1Mo.
Shell - 199mm thick
U.P. Steels, Muzaffarnagar
32
Manufacturing Facilities – Drum Shop
Manufacturing Facilities – Tube Shop
• Carbon Steels
• Low Alloy Steels (T-11 and T-22)
• High Alloy Steels (T-91)
• Stainless Steel (TP304, TP347)
Manufacturing Facilities
Vertical Turning Lathe
H – 3.2 m, Dia – 6.2 m
Korea Gun Drill
X -3500 mm, Y – 3000 mm
Thk – 1000 mm
Manufacturing Facilities
ESSC O/L on Head Twin Head ESSC O/L in Shell
Alloy Steels
- Cr-Mo Steels- P3, P4, P5A, P5B, P9
- P91, P22 & P11
- T91, T22 & T11
- 2¼Cr 1Mo - step cooling & impact at -180C
- 5Cr ½Mo with impact at -50C
Exotic Materials
- Monel
- Cupro Nickel
- Incoloy 825
- Inconel 625
Cladded CS &AS
- SS Clad
- Monel Clad
- Duplex
- Inconel Clad
Stainless Steel
- Duplex/Super
- Duplex
- Super Austenitic
- Austenitic & Ferritic
Over 300
Qualified Welders
ASME
Manufacturing Facilities – Welding
Manufacturing Facilities – Welding
Tube to Tube Sheet
Orbital Welding
Automatic Nozzle
to Shell Welding
Manufacturing Facilities – Heat Treatment
Furnace max. size: 20m x 8m x 8m
Manufacturing Facilities – Fabrication
Package Boiler under Fabrication
6Mev Linear Accelerator
for Radiography
up to 350 mm thick
Manufacturing Facilities – Testing
Jarrell-Ash Spectrometer
43
New Facility for Boilers
• Automatic Plant
• TUBES in PRODUCT out.
• 100 % Shot blasting
• Online real time
inspection.
• Multihead SAW moving
panel welding machines
• PLC operated heat-
treatment furnace
• Hydro testing up to 600
Kg/ sq.cm g.
44
Coil Shop
45
Panel Shop
Automatic Tube Cutting & Preparation
Straight Tube Welders
Real Time Radiography
Swage Machine
Panel Welder
Panel Bender
EPC CAPABILITIES
• In-house Engineering Team for Design, Detailing and Integration for the following systems:
– Steam Generator Island – Steam Turbine Island
– Plant Water System – Fuel Handling System
– Ash Handling System – Plant Electrical
– Control & Instrumentation – Civil & Structural
– Plant piping
• Dedicated EPC Project Management Team
• Dedicated Construction Management Team.
• Experience in Global Sourcing
• Collaborative Approach with Associates for Critical Bought-outs.
• Commissioned ~ 215.4 MW with Max. unit size of 36 MW.
• Under execution -386.9 MW with Max. unit size of 33 MW
WHY ISGEC FOR EPC?
EPC CAPABILITIES
END TO END SOLUTION PROVIDER
• Topography Survey
• Soil Investigation
• Water Analysis
• Fuel Analysis
• Land Leveling, Boundary Walls, Fencing
• Engineering Services
– Preliminary Engineering
– Basic Engineering
– Detailed Engineering
– Erection, Testing and Commissioning
– Drawing and Documents
– Training
• Project Management
• Procurement.
• Civil Services
• Erection Services
• Commissioning Services .
• Performance Test
EPC Design Centre at Chennai with 90 Engineers
55
EPC CAPABILITIES
Responsibilities of EPC Design Center
Proposal Engineering & Cost Estimation
Project Basic & Detailed Engineering
Project Conceptualization & Development
Standardization to reduce repeat engineering
Developmental Activities for new technologies
Documentation, Training, Quality and IT
EPC CAPABILITIES
 Plant Layouts
 Heat and Mass Balance Diagrams
 Water Balance Diagrams
 Sizing and Specifying Boiler inputs.
 Specifying and reviewing STG
 Sizing and Specifying Water Systems like Storage Tanks, DM Plant and Cooling tower.
 Sizing and specifying Fuel Handling Plant including Layouts
 Sizing and Specifying Ash Handling Plant
 Sizing, Stress Analysis and BOQ preparation of complete Plant Piping
 Sizing and Specifying Complete Plant Electricals and over head Transmission line
 Engineering and specifications for Instrumentation and Control System and Interfacing.
 Civil Engineering, BOQ preparation and Specifying Civil Works along with water intake system
57
Engineering Capabilities
EPC CAPABILITIES
8/14/2013
 Manpower Assets
• Design Managers – 37
• Design Engineers – 200
• Draftsman – 150
• Checkers – 50
59
Design Capability
Engineering Staff - 437
Design Capabilities
Design & Engineering
Latest Software Used
• Drafting – Auto CAD 2010
•Design Softwares
• Cadison
•Solid Works 2010
•Prosteel 3D
•CAD Works
•Plant Design
•Structure Modeling
•3 D Modelling
• Electric Circuits
•Xelec
•E Plan
Software Available for Ladder Diagrams of most of the PLC manufacturers including
Telemechanique, Siemens, Allen Bradley, Mitsubishi
61
3 D Model of 24000 TCD process house for Whtie Nile Sugar Company, Sudan
3 D Modeling
Design & Engineering
Design & Engineering
Finite Element Analysis
Design Capabilities
Flow dynamic Analysis
-ANSYS Version 12
Document Management
System
- WINDCHILL 9.0 PDMLink
After flow modelingBefore flow modeling
Design Capabilities
Design & Engineering
HIGHLIGHTS
 Dedicated Project Management Group .
 Customer and site requirements are understood.
 Planning and Scheduling on MS Projects & Primavera
 Centralized ERP System (BaaN)
 Project Planning and Critical Path Analysis
 Project Based Team (PBT) reviews through Construction Linked Plan (CLP)
 Regular Reviews with Customer, Vendors & Contractors
 Site Reviews
67
 Video conferencing for reviews
 Project Alerts
 Separate Cell for Procurement
 Dedicated vendors for critical parts.
 Supplies as per Construction Linked Plan (CLP).
 ERP working for online monitoring of procurement, manufacturing &
supplies
 Field Expeditors to ensure deliveries in India and overseas
HIGHLIGHTS
68
PROJECT MANAGEMENT
SYSTEM – ERP BaaN
69
INDENT SUMMARY SESSION
ERP BaaN
Quality
Synopsis
• Aim to achieve the objective of attaining standards of quality equal to the best in
the world
• All goods and services whether procured or supplied shall be of good and specified
quality
• Quality as defined shall be attained even at higher cost
• Every failure of quality policy shall be thoroughly analyzed and reported to Top
Management
Quality
• Quality Management Systems conforming to ISO 9001 : 2008
• Centralized Quality Department
• Inspection at Vendor’s Works as per approved Quality Plans
• Manufacturing of Pressure Parts under Lloyds Appraisal.
• Third party / Client inspections as required
• Field Quality reviews
• Review of processes and objectives
• Feedback & continuous quality improvements
• Internal & External Audits
Quality Management
Quality
• ISO 9001:2008 Approval by Lloyds Register of Quality Assurance
• ASME ‘S’ ‘U’ ‘U-2’ & ‘U-3’ Stamps
• ASME ‘N’ Stamp
• ‘R’ Stamp
• ‘NB’ Stamp
• Approval by Lloyds as a Class I fabricator of
Fusion Welded Pressure Vessels up to 200 mm (8”) thickness
• China Safety Quality License
• ISO 14001 : 2004
• OHSAS 18001 : 1999
Quality, Safety and Environment
74
Health & Safety
Health & Safety
Health & Safety
Logistics Management – Planning & Supply Management
• Dedicated Logistics Cell
• Logistics Tie up with reputed shipping companies i.e. Bertling Logistics / LP Logistics
• Officers of Logistics Companies stationed at our Office
• Logistics Companies render following logistics services:
- Inland Transportation in India.
- Shipments from India to other countries.
- Warehouse Management.
- Meet & Greet Services
Logistics Management
Barging Operations of Pressure Vessels
from our Dahej Plant
Logistics Management – Packing & Forwarding
83
Construction & Commissioning
84
Highlights
 Dedicated site management team.
 ERP Connectivity to site.
 Expert supervisory team of Isgec.
 Adequate cranes and tools including tower cranes.
 Adequate skilled manpower.
 Quality & Safety engineer availability full time at site.
 Proper site storage and security.
 Covered storage for critical items such as refractory, insulation and
instrumentation.
 Own contingent of HP welders, pressure parts fitters and mill right fitters as
fall back option. Utmost attention to alignment of panels during erection.
 Visit of our CFBC Core Team to site during critical stage of installation.
 Refractory expert deployment to site during application. Expert
commissioning team including Electrical, Instrumentation, Mechanical and
Refractory experts.
 Dedicated After Sales Team for spares & services.
85
Transportation of Combustor Panels in Steel Crates
86
Stacking of Pressure Parts at Site
Boiler Under Construction
Boiler Under Construction
Boiler Under Construction
91
Customer Country Project Details
M/s Vithai Biopower Ltd. Thailand
Travelling Grate Boiler
1 x 50 TPH,43 Kg/cm2 g 455 Deg C Vaithai Grass and
Wood Chips Fired Boiler
Kampangpetch Bio Energy
Co. Ltd
Thailand
Travelling Grate Boiler
3 x 150 TPH,40 Kg/cm2 g 450 Deg C Bagasse fired
Boiler
Sukhothai Bio Energy Co.
Ltd.
Thailand
Travelling Grate Boiler
3 x 150 TPH,40 Kg/cm2 g 450 Deg C Bagasse fired
Boiler
Khon Kaen Sugar Co. Ltd Thailand
Travelling Grate Boiler
4x 150 TPH, 70 Kg/cm2 g 510 Deg C Bagassefired
Boiler
Experience in South East Asia
Customer Country Project Details
Mitr Phol Sugar Corporation
Limited.
Thailand
Travelling Grate Boiler
1 x 95 TPH, 60 Kg/cm2 g 500 +/- 5 Deg C Bagasse
Fired Boiler
San Carlos Bio Energy Inc
(Bronzeoak Philippines).
Philippines
Travelling Grate Boiler
1 x 45 TPH, 67 Kg/cm2 g 510 +/- 5 Deg C Bagasse
and Wood Chip Fired Boiler
Sugar Plant and Ethanol Plant
67.2 TCH Raw Syrup Plant with 125 KLPD
Ethanol Plant
JGC Philippines Inc Philippines
Travelling Grate Boiler
1 x 95 TPH, 67 kg/cm2 g 480 Deg C Bagasse Fired
Boilers
Phung Hiep Cane Sugar
Factory Vietnam
Sugar Plant
Complete Sugar Plant of 2000TCD
Experience in South East Asia
Customer Country Project Details
Phung Hiep Cane Sugar Factory Vietnam 300 TPD Sugar Refinery
Biscom Philippines Cane Mills and Process House equipment
PT Gunang Madu Plantation Indonesia
Dumping Grate Boiler
1 x 120 TPH, 20 kg/cm2 350 Deg C Bagasse Fired
Boilers
Engcon, San Jose I Power,
Philippines
Philippines
Travelling Grate Boiler
1 x 52.5TPH, 52 Kg/cm2 g 480 Deg C Rice Husk
Fired Boiler
Experience in South East Asia
Customer Country Project Details
Aldebran S.A. Spain 28 TPH Biomass fired Travelling Grate Boiler
Fujaraiah Cement Ltd UAE 2 Nos 90 TPH Coal fired AFBC boilers
Arab Paper Manufacturing Co. Saudi Arabia
3 x 16.5 MW Co-Generation Plant with Oil & Gas
fired Boilers
94
Experience in Middle East & Others
Experience in Latin America
(Total Order Booking in Latin America Over USD 270 Million in last 4 Years)
Customer Country Project Details
Lizitex S.A. Guatemala
Power Plant
61 MW Complete Power Plant (Turbo- Generator by
Client) with 1 x 220 TPH, 109 Kg/cm2 g 540 Deg C
Bagasse and Coal fired Travelling Grate Boiler
Enka De Colombia Colombia
Power Plant
14 MW Complete Power Plant (Turbo-Generator by Client)
with 1 x 62 TPH, 66 Kg/cm2 g 500 Deg C Coal fired AFBC
Boiler
Ingenio Magdalena S.A. Guatemala
Travelling Grate Boiler
1 x 220 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal
Fired Boiler
Ingenio Palo Gordo S.A. Guatemala
Travelling Grate Boiler
1 x 165 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal
Fired Boiler
Ingenio La Union S.A. Guatemala
Travelling Grate Boiler
1 x 165 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal
Fired Boiler
Experience in Latin America
Customer Country Project Details
Ingenio Agricola Industrial
Santa Ana S.A.
Guatemala
Travelling Grate Boiler
1 x 220 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal
Fired Boiler
Biomass Energy S.A.
(Repeat orders from
Magdalena Group)
Guatemala
Travelling Grate Boiler
2 x 220 TPH, 109 kg/cm2 g 540 Deg C Bagasse and Coal
Fired Boilers
Al Caravan Bio Energy
Project
Colombia
Travelling Grate Boiler
1 x 180 TPH, 70 Kg/cm2 g 515 Deg C Bagasse Fired Boiler
Ingenio Risaralda S.A. Colombia
Travelling Grate Boiler
1 x 159 TPH, 70 Kg/cm2 g 515 Deg C Bagasse and Coal
Fired Boiler
Ingenio Chaparrastique S.A.
de C.V.
El Salvador
Travelling Grate Boiler
1 x 220 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal
Fired Boiler
Experience in Latin America
Customer Country Project Details
Compania Azucarera Tres
Valles S.A. de C.V.
Honduras
Travelling Grate Boiler
1 x 60 TPH, 66 Kg/cm2 g 500 Deg C Bagasse Fired Boiler
Compania Azucarera del Sur
S.A.
Nicaragua
Pin Hole Grate Boiler
1 x 150 TPH, 85 Kg/cm2 g 515 Deg C Bagasse Fired Boiler
Compania Azucarera del Sur
S.A.
Nicaragua
Pin Hole Grate Boiler
1 x 150 TPH, 85 Kg/cm2 g 515 Deg C Bagasse Fired Boiler
Consorcio Naviero
Nicaraguense S.A.
Nicaragua
Pin Hole Grate Boiler
1 x 160 TPH, 85 Kg/cm2 g 515 Deg C Bagasse Fired Boiler
Ingenio Panuco SAPI De CV Mexico
Pin Hole Grate Boiler
1 x 200 TPH, 85 Kg/cm2 g 540 Deg C Bagasse Fired Boiler
Experience in Latin America
Customer Country Project Details
Petroquimicasuape (A Petro
brass Group Co.)
Brazil
Oil & Gas Fired Boilers
2 x 100 TPH, 100 Kg/cm2 g 510 Deg C Oil and Gas Fired
Boiler
Calesa Group Panama Panama
Technical Study for rehabilitation of existing Sugar Plant
and new Cogen Plant
Manuelita S.A. Colombia Technical Study for rehabilitation of existing Sugar Plant
Empresa Agroindustrial
Laredo S.A.A.
Peru Technical Study for rehabilitation of existing Sugar Plant
Customer Country Project Detail
Kwale International Sugar Co. Ltd Kenya
Complete Sugar Plant
3000 Tons of Cane Per Day with 18 MW Cogeneration
Consolidated Farming Ltd. Zambia
Complete Sugar Plant
1650 Tons of Cane Per Day
Expansion of Sugar Plant
2500 Tons of Cane Per Day from 1650 Tons of Cane
Per Day
Sugar & Allied Industries Limited Uganda
Complete Sugar Plant
1650Tons of Cane Per Day with 12MW Cogeneration
Butali Sugar Company Ltd. Kenya
Complete Sugar Plant
1650 Tons of Cane Per Day
(Total Order Book in Africa - Over USD 750 million in last 9 Years)
Presence in Africa’s Sugar / Ethanol Sector
Customer Country Project Detail
Kibos Sugar Company Ltd. Kenya
Complete Sugar Plant
1650 Tons of Cane per day
Transmara Sugar Ltd. Kenya
Complete Sugar Plant
1250 Tons of Cane per day
White Nile Sugar Company Sudan
Process / Boiling House
24000 Tons of Cane per day Complete Process
House (part of Greenfield Sugar Plant Project)
Wonji Shoa Sugar Factory Ethiopia
Cane Milling Plant
6250 Tons of Cane per day
Kenana Sugar Company Sudan
Modernization & Expansion
Of existing 28,500 Tons of Cane per day Sugar Plant
in Phases
Presence in Africa’s Sugar / Ethanol Sector
Customer Country Project Detail
Addax Bio-energy Ltd.
Sierra
Leone
Complete Cogeneration Plant
32 MW with 2 Nos. 80 TPH, 68 Bar (a), 485 oC
Bagasse Fired Boilers
Addax Bio-energy Ltd.
Sierra
Leone
Cane Milling Plant
5000 Tons of Cane per day
Nakambala Sugar Ltd (part of Illovo
Sugar, South Africa)
Zambia
Cogeneration Plant
30.4 MW with 1 No. 160 TPH, 32 kg/cm2(g), 500 Deg
oC Bagasse Fired Boiler
White Nile Sugar Company Sudan
Boilers
4 X130 TPH, 60 kg/cm2(g), 500 oC Bagasse Fired
Boilers
Kakira Sugars Ltd. Uganda
Boiler
160 TPH, 67 kg/cm2(g), 515 oC Bagasse Fired Boiler
Presence in Africa’s Sugar / Ethanol Sector
Presence in Africa’s Sugar / Ethanol Sector
Customer Country Project Detail
Mumias Sugar Company Ltd. Kenya
Boiler
22 TPH, 45 kg/cm2(g), 400 oC Vinasse (Distillery
Spent Wash) Fired Boiler
Mumias Sugar Company Ltd. Kenya
Boiler
170 TPH, 87 kg/cm2(g), 515 oC Bagasse Fired Boiler
Campagnie Sucriere Senegalaise
(part of Mimran Group, Switzerland)
Senegal
Boiler
150 TPH, 43 kg/cm2(g), 400 oC Bagasse Fired Boiler
TPC Ltd. ( part of Ciel Agro Group,
Mauritius)
Tanzania
Boiler
90 TPH, 45 kg/cm2(g), 400 oC Bagasse Fired Boiler
Kakira sugar Works Ltd. Uganda
Boiler
2 Nos. 50 TPH, 45 kg/cm2(g), 510 oC Bagasse Fired
Boilers
Customer Country Project Detail
Sudanese Sugar Corporation Sudan
Major Revamp of Controls & Instrumentation
System of 14 Nos. existing Boilers
Complete new Steam Distribution System for
existing Two Sugar Plants
SCOUL Sugar Uganda Major Revamp of existing Boiler
Tongaat Hulett Sugar Group Mozambique 45” x 90” size Dewatering Mill for existing Diffuser
White Nile Sugar Company Sudan
Complete Tie-in Piping for 24,000 Tons of Cane
Per Day capacity Greenfield Sugar Plant
Government of Malawi Malawi 1250 TCD Complete Sugar Plant
Presence in Africa’s Sugar / Ethanol Sector
Boilers – Travelling Grate Boilers
105
Biomass Fired Boiler for Aldebaran Energia Del, Spain
8/14/2013
28 TPH BIOMASS FIRED TG BOILER AT JYOTI BIO ENERGY
Boilers – Travelling Grate Boilers
1 x 52 TPH, Orient Green Power Ltd., Pollachi, Tamil Nadu
Fuels Fired – Coconut Husk, Coconut Frond, Cane Trash, Wood Chips
Boilers – Travelling Grate Boilers
1 x 70 TPH, Biomass Fired Boiler – Universal Biomass, Bhatinda
Fuels Fired – Cotton Stalk, Rice Husk, Wood Chips, Paddy Straw
Boilers – Travelling Grate Boilers
Boilers – Travelling Grate Boilers
109
Biomass Fired Boiler for Aldebaran Energia Del, Spain
1 X 220 TPH, 109 KG/CM2 (g), 540 oC 100% BAGASSE & 100% COAL FIRED TRAVELLING
GRATE BOILER FOR INGENIO MAGDALENA S.A, GUATEMALA
(repeat order for 2 Boilers of same capacity after commissioning of 1st Boiler)
Boilers – Travelling Grate Boilers
110
1 X 220 TPH, 109 KG/CM2 (g), 540 oC 100% BAGASSE & 100% COAL FIRED TRAVELLING
GRATE BOILER FOR INGENIO MAGDALENA S.A, GUATEMALA
(Boiler under construction)
190 TPH CFBC Boiler with Foster Wheeler technology
for 45 MW Power Generation
at BLA Power, India
Boilers
Boilers – Travelling Grate Boilers
35 TPH, Dharni Sugars and Chemicals Ltd., Chennai, Innovatively Designed Spent Wash / Vinasse (Distillery
Effluent) Fired Boiler
Boilers – Travelling Grate Boilers
113
1x170 TPH Travelling
Grate Boiler
Mumias Sugar Kenya
Boilers – Oil & Gas Boilers – Field Erected type
2 nos.100 TPH Natural Gas Fired Boilers
for PetroquimicaSquape, Brazil
(100% subsidiary of Petrobras, Brazil)
77 TPH Package Boiler
Longview, Maidsville,
West Virginia, USA
115
Boilers – Oil & Gas Boilers – Package type
Under Foster wheeler, USA License
Power Plants
30.4 MW Power Plant (Bagasse Fired) Zambia Sugar Plc, Zambia.
Range: up to 160 MW
Supplied 19 Nos. Complete Power Plants to Indian and Overseas customers
36 MW Bagasse / Coal based Power Plant
for Shree Dutta SSK, Kolhapur, India
Power Plants
JGC Philippines
EPC Power Plants
EPC Power Plants
20 MW Cogeneration Plant
for HPCL Biofuels, Lauriya, Bihar, India
1 x 61 MW BAGASSE & COAL BASED CAPTIVE POWER PLANT FOR
ROYTEX S.A., GUATEMALA (under construction)
EPC Power Plants
EPC Power Plants
1 x 14 MW COAL BASED POWER PLANT WITH 1X62 TPH 66 KG/CM2 (g), 500 oC 100% COAL
FIRED AFBC BOILER FOR ENKA DE COLOMBIA, COLOMBIA
Power Plant Under Construction
Sugar Plants & Machinery
Complete 3500 / 5000 TCD Sugar Plant
with 18 MW Cogeneration Plant near Pune, India
122
Sugar Plants & Machinery
20 MW Cogen 3500 TCD sugar plant with Chain less cane
diffuser for HPCL Biofuels, Lauriya - India
Sugar Plants & Machinery
Complete Cane Sugar Plant – Kibos Sugar & Allied Ind. , Kenya.
Sugar Plants & Machinery
Complete Cane Sugar Plant – Butali Sugar Mills Limited, Kenya.
Sugar Plants & Machinery
2500 TCD Complete Sugar Plant for Consolidated Farming Ltd.,
Zambia
5000 TCD Complete cane sugar plant with 25 MW cogeneration for Core
Green Sugar & Fuels, India
Sugar Plant and Machinery
24000 TCD Process House and 4 x 130 TPH Travelling Grate Boilers on turnkey basis for
White Nile Sugar Co. Ltd., Sudan
Sugar Plant and Machinery
Sugar Plants & Machinery
24000 TCD Process House & 4 x 130 TPH Boilers at White Nile Sugar, Sudan
Under Construction Commissioned
8/14/2013
131
132
133
Fixed
grate
bar
Movable grate
bar
135
136
137
Isgec company profile dsc

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Isgec company profile dsc

  • 1.
  • 2. • Ranked among top 300 companies in India ( ET Fortune 500 listings ) • Group Turnover over US$ 500 Million • Total Employee Strength over 5500. • 80 years in Business, 48 years in Boilers • Strong presence in Captive Power Plants • Supplied over 600 High Pressure Boilers. Overview of Isgec
  • 3. Utility Boilers Boilers Sugar Machinery Power PlantsCFBC AFBC, TG & Biomass Oil & Gas WHRB, MSW Vinasse Pulverized Coal Fired Boilers Turnkey Sugar Plants PED Isgec Heavy Engineering Limited Contract Manufacturing Castings: Steel & Iron Presses: Mechanical & Hydraulic Isgec – Hitachi Zosen JV EPC Pressure Vessels & Heat Exchangers Pollution Control Equipments (ESP) Products & Services
  • 4. 4 877 130 1200 144 1363 364 1764 504 1810 315 2442 799 2749 1240 0 500 1000 1500 2000 2500 3000 2006 2007 2008 2009 2010 2011 2012 Turnover Exports $ 500 Millions $ 225 Millions Financial Year: October - September Rs. In Crores Growth Over Years
  • 5. Noida HO & Isgec Offices in Suburb of New Delhi Yamunanagar Main Plant & Sugar Mill 200 km (125 Miles) from New Delhi Muzaffarnagar 115 km (71 Miles) from New Delhi Chennai • Design Centre • Regional Mktg Kolkata Regional Mktg. Dahej Our Coastal Plant Mumbai Branch Office INDIA Bay of BengalArabian Sea International Offices: • California, USA • Dusseldorf, Germany 70 International Agents New Delhi Pune •Design Centre • Regional Mktg Bawal 100 km (62 Miles) from New Delhi Bhubaneshwar Regional Mktg. Ratangarh 200 km (125 Miles) from New Delhi Locations
  • 6. 75 Countries across 6 Continents Venezuela Vietnam Yemen ZimbabweZambiaUzbekistanUK USA China Colombia Czech Republic Dominican Republic Ecuador EgyptCyprusChileCanada France GermanyEl Salvador Honduras India Indonesia IranGuyanaFinlandEthiopia Japan JordonIraq Kazakhstan Kuwait MalaysiaKenyaJamaicaItaly Syria Tanzania Thailand Trinidad & Tabago Turkey UgandaUAESwedenSudan Oman PakistanMauritius PhilippinesPeruNigeriaNepalMozambiqueMalta Mexico Sri lankaRomania Saudi Arabia Singapore South KoreaSouth AfricaSenegalQatar Spain Argentina Australia Bahrain Bangladesh Barbados Bulgaria CambodiaAlgeria BrazilBosnia 6 Isgec – Global Presence
  • 8.
  • 9. Boilers 170 TPH TG Boiler for Mumias Sugar Company Ltd., Kenya 100 TPH CFBC Boiler for Nirma Ltd. India. 105 TPH AFBC Boiler at Gujarat Flurochemicals Limited, India 140 TPH Oil Fired Boiler for M/s Kochi Refinery, India
  • 10.  Industrial Segment: • Circulating Fluidized Bed Combustion Boilers* • Travelling Grate Boilers for Bagasse and Biomass. • Atmospheric Fluidized Bed Combustion Boilers. • Oil & Gas Fired Boilers – Field Erected & Package Type * • Slop / Vinesse Fired Boilers • Waste Heat Recovery Type Boilers. • Waste to Energy *In Collaboration with Foster Wheeler, USA.  Utility Segment: • Pulverized Coal Fired Boilers* – Subcritical & Supercritical 10 Product Range Boilers
  • 11. Mid Siam Sugar Co. Ltd., Thailand Boilers Product Range includes: • Biomass & Bagasse Fired Boilers – up to 250 TPH • Oil & Gas Fired Boilers: Field Assembled – up to 200 TPH • Oil & Gas Fired Boilers: Package Type – up to 260 TPH • CFBC Boilers – up to 400 TPH • AFBC Boilers – up to 160 TPH • PC Boilers – Sub Critical & Super Critical • Deaerators & Spares 11
  • 12. 12 Boilers - Fuels • Wood Chips • Olive Wood Trimmings • Coconut Shell • Groundnut Shell • Subabul Wood • Red Gram Husk • Bengal Gram Husk • Cashewnut Shell • Woody Biomass • Cane Top & Trash • Cane Pith • Other agricultural wastes, individually or in combinations • Coal • Oil, Natural Gas and Bio-Gas • Slop/ Vinasse (Distillery Spent Waste)
  • 13. Major Customers across Industries • Sugar Industry - White Nile Sugar, Sudan - Magdalena Sugars, Guatemala - EID Parry Group, India • Cement Industry - Fujairah Cements, UAE - Jaypee Cements, India - Dalmia Cements, India • Oil & Refinery Industry - Petrobras, Brazil - Kochi Refinery, India - HPCL, India • Chemical & Fertilizer Industry - National Fertilizers, India - Hindustan Fertilizers, India • Utility / IPP - Aldebaran Energia, Spain - Long View, USA - Adani Power, India - Vithai BioPower, Thailand • Steel & Metal Industry - Bhusan Steel, India - Hindalco Industries, India • Distillery Industry - Mumias Sugar, Kenya - Dharni Sugar, India - NV Distilleries, India • Paper Industry - Arab Paper, Saudi Arabia - BILT Paper, India - SectorsBoilers
  • 14. 30.4 MW Power Plant (Bagasse Fired) Zambia Sugar Plc, Zambia Power Plants Range: up to 100 MW 14
  • 15. Range: • Complete Sugar Plant up to 30,000 TCD • Milling plants up to 50” x 100” • Energy efficient Process house equipments for Raw, Plantation white & Refined sugar manufacturing. 15 Supplied -Over 350 Mills -Over 70 Sugar Plants and Major Expansions across 35 countries 45” x 90” Mill Xinavane, Mozambique (Owned by Tongaat Hulett, South Africa) Sugar Plant & Machinery Sugar Plant & Machinery
  • 16. Sugar: Long experience in supplying green field sugar plants & doing up-gradation of sugar plants for major Indian customers: - HPCL, Bajaj Group, Balrampur Group, Shree Ram Ind. Enterprise Ltd., Dwarikesh & Mills in the Cooperative Sector Sugar Plant & Machinery Complete Sugar Plant Daund Sugar Ltd., India - Sectors 16
  • 17. Lavalin, Canada for PDO, Oman Pressure Vessel: weight-210T length-12.5 M Process Plant Equipment Reliance, Jamnagar Tube Bundles – assembly under progress Products include: • Reactors • High Pressure Vessels • Shell and Tube Heat Exchangers • Columns and Towers • High Pressure Boiler Drums • Boiler Pressure Parts Materials include: • Monel • Cupro Nickel • Brass • Clad Steels 17 • Cr-Mo Alloy Steels • Duplex Stainless Steels • Stainless Steels • Carbon Steels
  • 18. Oil and Gas: Supplies to major / Fortune 500 Indian customers: - Indian Oil Corporation, Reliance, Bharat Petroleum, Hindustan Petroleum, Gail, etc. Through consultants: -Toyo, Jacobs, Uhde, Engineers India Limited, Lurgi, Technip, Fluor, etc. Products: - Reactors, Hot HP Separators, Coke Drums, Helix Exchanger, etc. EIL, India for HPCL, Mumbai CCR Platform Reactor: length-43M; weight-125T Process Plant Equipment IOCL, Panipat, India Atmospheric Column & Vacuum Column (Site Fabricated Columns ) 18 - Sectors
  • 19. Fertilizers: Supplies to almost all major customers: - IFFCO, Kribhco, GNFC, NFL, Tata Chemicals, Chambal Fertilizers, etc. Products: - LT Shift Convertors, Secondary Waste Heat Exchangers, BFW Pre Heater, etc. Process Plant Equipment Burrup Fertiliser, Australia :Heat Exchanger 19 - Sectors
  • 20. Process Plant Equipment Product: Liquified Gas Containers 20 The largest manufacturer of Ton Containers in the world Over 100,000 Containers to 52 Countries Patents awarded for design & techniques for manufacturing of Containers • US Patent • Chinese Patent • Indian Patent • Mexican Patent Safety & reliability backed by • Finite Element Analysis • Destructive Testing on Prototype models • 100% X-ray
  • 21. ThyssenKrupp, India 1000T & 800T Press Lines Presses: Mechanical & Hydraulic Products include: Mechanical Presses(up to 3000 T) • Transfer Presses • Tandem Press Lines • Presses for Progressive Tooling • Blanking Press Lines Gap Frame Presses from 25-250 T CIE Automotive, Spain 2500 T Transfer Press Line 21 Hydraulic Presses • Double & Single Action Presses up to 3000T • Presses (Wood & Panel industry) up to 7000T
  • 22. Automobile: Supplies to major OEMs & Tier 1 suppliers of Auto Industry - Suzuki, TATA, Mahindra, Honda, Ford, Bellsonica, Bajaj, Ashok Leyland, JBM etc. - Proven track record for supplying over 2,700 Metal Forming Presses Presses: Mechanical & Hydraulic TATA Motors, India 100T Die Spotting Press 22 - Sectors Force Motors, India 2000T Hydraulic Press
  • 23. Ladle Turret for 2 ladles - 165 T each Design : SMS Demag Contract Manufacturing Thin Slab Caster Segment Design : SMS Demag Experience: Over 15000 Tonnes of Mechanical Equipment made to customers design covering fabrication, machining & assembly of: Metallurgical Industry • Hot / Cold Rolling Mills • Processing Lines • Continuous Slab / Billet / Bloom Casters • Gas Cleaning Plants & Sinter Plants Hydro Electric Power Industry • Radial & Vertical Gates • Penstocks • Stop Logs • Trash Racks • Turbine Housings 23 Supplies to international consultants: - IHI, MHI, SMS Demag, Paul Worth, etc.
  • 24. GE Hydro- Canada Steel Castings Andritz- VA Tech, Flovel Products include Castings in: Creep Resistant Steels Stainless Steels Alloy & Carbon Steels Alloy & Nodular Irons Capacity: 500 MT/Month Weight Range: up to 50 MT single piece Maximum Size: 8 M x 8 M x 4 M Tyco FCT, France 24
  • 25. Runner Hub Steel Castings Guide Vanes 25 Energy: Supplies - Steel Casting to turbine OEMs: - Alstom, Siemens, Ansaldo, Toshiba, Skoda, BHEL, GE, VOITH, VATech, etc. - Sectors Casing
  • 26.
  • 27. Manufacturing Facilities Location Products Yamuna Nagar Drums, Pressure Vessels, Heat Exchangers, Presses, Steel Plant Equipment & CI castings Rattangarh Panels & Coils Dahej Pressure Vessels & Drums Muzaffarnagar Special Castings Bawal Small Presses
  • 28. Yamunanagar Rattangarh Dahej - 1 Dahej - 2 Total Area (sq.m) 180,000 50,000 202,350 240,000 Covered Area (sq.m) 95,000 16,650 16,500 Greenfield Plot on Water Front for Future Expansion Crane Capacity (max.) (MT) 200 20 300 Open Yard Fabrication (sq.m) 4,000 8,000 15,000 Drum Thickness (max.) Hot Roll Cold Roll 200 mm 90 mm Exclusive for Coils - 6600 MT Panels – 2200 nos. Piping – 4400 MT per annum 300 mm 175 mm Weight (max.) (MT) 250 1000 Diameter (max.) (mm) 5,000 9,000 Manufacturing Infrastructure- Boilers
  • 30. Isgec, Dahej, Gujarat – JV Isgec Hitachi Zosen Ltd. 30
  • 31. Few critical equipment under execution at Isgec Hitachi Zosen JV 8/14/2013 31 Equipment Client Weight (MT) Features Ethylene Oxide Reactor Reliance Industries, India 375 Low Alloy Steel. First Tubular Reactor for Petrochem plant. Only L&T in India is qualified. Ammonia Convertor IOWA Fertilizer Project, USA to KBR’s Technology. 750 Shell in multilayer construction. World wide only 4 fabricators have this technology . Urea Stripper Urea Plant of Chambal Fertilizer, India to Toyo’s technology. 150 Higlhy corrosion resistant Cr-Ni- Mo alloy tubes Ammonia Convertor YPFB Fertilizer project Bolivia to KBR’s technology. 543 Shell in multilayer construction Urea Reactor YPFB Fertilizer project Bolivia to Toyo’s technology 200 High strength, multi layer Carbon steel shell. Inside lined with Duplex steel liner Reactors Saipem for Jazan Refinery project Saudi Arabia 775 Low Alloy Steel 21/4 Cr- 1Mo. Shell - 199mm thick
  • 34. Manufacturing Facilities – Tube Shop • Carbon Steels • Low Alloy Steels (T-11 and T-22) • High Alloy Steels (T-91) • Stainless Steel (TP304, TP347)
  • 35. Manufacturing Facilities Vertical Turning Lathe H – 3.2 m, Dia – 6.2 m Korea Gun Drill X -3500 mm, Y – 3000 mm Thk – 1000 mm
  • 36. Manufacturing Facilities ESSC O/L on Head Twin Head ESSC O/L in Shell
  • 37. Alloy Steels - Cr-Mo Steels- P3, P4, P5A, P5B, P9 - P91, P22 & P11 - T91, T22 & T11 - 2¼Cr 1Mo - step cooling & impact at -180C - 5Cr ½Mo with impact at -50C Exotic Materials - Monel - Cupro Nickel - Incoloy 825 - Inconel 625 Cladded CS &AS - SS Clad - Monel Clad - Duplex - Inconel Clad Stainless Steel - Duplex/Super - Duplex - Super Austenitic - Austenitic & Ferritic Over 300 Qualified Welders ASME Manufacturing Facilities – Welding
  • 38. Manufacturing Facilities – Welding Tube to Tube Sheet Orbital Welding Automatic Nozzle to Shell Welding
  • 39. Manufacturing Facilities – Heat Treatment Furnace max. size: 20m x 8m x 8m
  • 40. Manufacturing Facilities – Fabrication Package Boiler under Fabrication
  • 41. 6Mev Linear Accelerator for Radiography up to 350 mm thick Manufacturing Facilities – Testing Jarrell-Ash Spectrometer
  • 42.
  • 43. 43 New Facility for Boilers • Automatic Plant • TUBES in PRODUCT out. • 100 % Shot blasting • Online real time inspection. • Multihead SAW moving panel welding machines • PLC operated heat- treatment furnace • Hydro testing up to 600 Kg/ sq.cm g.
  • 46. Automatic Tube Cutting & Preparation
  • 52.
  • 53. EPC CAPABILITIES • In-house Engineering Team for Design, Detailing and Integration for the following systems: – Steam Generator Island – Steam Turbine Island – Plant Water System – Fuel Handling System – Ash Handling System – Plant Electrical – Control & Instrumentation – Civil & Structural – Plant piping • Dedicated EPC Project Management Team • Dedicated Construction Management Team. • Experience in Global Sourcing • Collaborative Approach with Associates for Critical Bought-outs. • Commissioned ~ 215.4 MW with Max. unit size of 36 MW. • Under execution -386.9 MW with Max. unit size of 33 MW WHY ISGEC FOR EPC?
  • 54. EPC CAPABILITIES END TO END SOLUTION PROVIDER • Topography Survey • Soil Investigation • Water Analysis • Fuel Analysis • Land Leveling, Boundary Walls, Fencing • Engineering Services – Preliminary Engineering – Basic Engineering – Detailed Engineering – Erection, Testing and Commissioning – Drawing and Documents – Training • Project Management • Procurement. • Civil Services • Erection Services • Commissioning Services . • Performance Test
  • 55. EPC Design Centre at Chennai with 90 Engineers 55 EPC CAPABILITIES
  • 56. Responsibilities of EPC Design Center Proposal Engineering & Cost Estimation Project Basic & Detailed Engineering Project Conceptualization & Development Standardization to reduce repeat engineering Developmental Activities for new technologies Documentation, Training, Quality and IT EPC CAPABILITIES
  • 57.  Plant Layouts  Heat and Mass Balance Diagrams  Water Balance Diagrams  Sizing and Specifying Boiler inputs.  Specifying and reviewing STG  Sizing and Specifying Water Systems like Storage Tanks, DM Plant and Cooling tower.  Sizing and specifying Fuel Handling Plant including Layouts  Sizing and Specifying Ash Handling Plant  Sizing, Stress Analysis and BOQ preparation of complete Plant Piping  Sizing and Specifying Complete Plant Electricals and over head Transmission line  Engineering and specifications for Instrumentation and Control System and Interfacing.  Civil Engineering, BOQ preparation and Specifying Civil Works along with water intake system 57 Engineering Capabilities EPC CAPABILITIES
  • 58.
  • 59. 8/14/2013  Manpower Assets • Design Managers – 37 • Design Engineers – 200 • Draftsman – 150 • Checkers – 50 59 Design Capability Engineering Staff - 437
  • 60. Design Capabilities Design & Engineering Latest Software Used • Drafting – Auto CAD 2010 •Design Softwares • Cadison •Solid Works 2010 •Prosteel 3D •CAD Works •Plant Design •Structure Modeling •3 D Modelling • Electric Circuits •Xelec •E Plan Software Available for Ladder Diagrams of most of the PLC manufacturers including Telemechanique, Siemens, Allen Bradley, Mitsubishi
  • 61. 61
  • 62. 3 D Model of 24000 TCD process house for Whtie Nile Sugar Company, Sudan 3 D Modeling Design & Engineering
  • 63. Design & Engineering Finite Element Analysis
  • 64. Design Capabilities Flow dynamic Analysis -ANSYS Version 12 Document Management System - WINDCHILL 9.0 PDMLink After flow modelingBefore flow modeling Design Capabilities Design & Engineering
  • 65.
  • 66. HIGHLIGHTS  Dedicated Project Management Group .  Customer and site requirements are understood.  Planning and Scheduling on MS Projects & Primavera  Centralized ERP System (BaaN)  Project Planning and Critical Path Analysis  Project Based Team (PBT) reviews through Construction Linked Plan (CLP)  Regular Reviews with Customer, Vendors & Contractors  Site Reviews
  • 67. 67  Video conferencing for reviews  Project Alerts  Separate Cell for Procurement  Dedicated vendors for critical parts.  Supplies as per Construction Linked Plan (CLP).  ERP working for online monitoring of procurement, manufacturing & supplies  Field Expeditors to ensure deliveries in India and overseas HIGHLIGHTS
  • 70.
  • 71. Quality Synopsis • Aim to achieve the objective of attaining standards of quality equal to the best in the world • All goods and services whether procured or supplied shall be of good and specified quality • Quality as defined shall be attained even at higher cost • Every failure of quality policy shall be thoroughly analyzed and reported to Top Management
  • 72. Quality • Quality Management Systems conforming to ISO 9001 : 2008 • Centralized Quality Department • Inspection at Vendor’s Works as per approved Quality Plans • Manufacturing of Pressure Parts under Lloyds Appraisal. • Third party / Client inspections as required • Field Quality reviews • Review of processes and objectives • Feedback & continuous quality improvements • Internal & External Audits Quality Management
  • 74. • ISO 9001:2008 Approval by Lloyds Register of Quality Assurance • ASME ‘S’ ‘U’ ‘U-2’ & ‘U-3’ Stamps • ASME ‘N’ Stamp • ‘R’ Stamp • ‘NB’ Stamp • Approval by Lloyds as a Class I fabricator of Fusion Welded Pressure Vessels up to 200 mm (8”) thickness • China Safety Quality License • ISO 14001 : 2004 • OHSAS 18001 : 1999 Quality, Safety and Environment 74
  • 75.
  • 79.
  • 80. Logistics Management – Planning & Supply Management • Dedicated Logistics Cell • Logistics Tie up with reputed shipping companies i.e. Bertling Logistics / LP Logistics • Officers of Logistics Companies stationed at our Office • Logistics Companies render following logistics services: - Inland Transportation in India. - Shipments from India to other countries. - Warehouse Management. - Meet & Greet Services
  • 81. Logistics Management Barging Operations of Pressure Vessels from our Dahej Plant
  • 82. Logistics Management – Packing & Forwarding
  • 84. 84 Highlights  Dedicated site management team.  ERP Connectivity to site.  Expert supervisory team of Isgec.  Adequate cranes and tools including tower cranes.  Adequate skilled manpower.  Quality & Safety engineer availability full time at site.  Proper site storage and security.  Covered storage for critical items such as refractory, insulation and instrumentation.  Own contingent of HP welders, pressure parts fitters and mill right fitters as fall back option. Utmost attention to alignment of panels during erection.  Visit of our CFBC Core Team to site during critical stage of installation.  Refractory expert deployment to site during application. Expert commissioning team including Electrical, Instrumentation, Mechanical and Refractory experts.  Dedicated After Sales Team for spares & services.
  • 85. 85 Transportation of Combustor Panels in Steel Crates
  • 86. 86 Stacking of Pressure Parts at Site
  • 90.
  • 91. 91 Customer Country Project Details M/s Vithai Biopower Ltd. Thailand Travelling Grate Boiler 1 x 50 TPH,43 Kg/cm2 g 455 Deg C Vaithai Grass and Wood Chips Fired Boiler Kampangpetch Bio Energy Co. Ltd Thailand Travelling Grate Boiler 3 x 150 TPH,40 Kg/cm2 g 450 Deg C Bagasse fired Boiler Sukhothai Bio Energy Co. Ltd. Thailand Travelling Grate Boiler 3 x 150 TPH,40 Kg/cm2 g 450 Deg C Bagasse fired Boiler Khon Kaen Sugar Co. Ltd Thailand Travelling Grate Boiler 4x 150 TPH, 70 Kg/cm2 g 510 Deg C Bagassefired Boiler Experience in South East Asia
  • 92. Customer Country Project Details Mitr Phol Sugar Corporation Limited. Thailand Travelling Grate Boiler 1 x 95 TPH, 60 Kg/cm2 g 500 +/- 5 Deg C Bagasse Fired Boiler San Carlos Bio Energy Inc (Bronzeoak Philippines). Philippines Travelling Grate Boiler 1 x 45 TPH, 67 Kg/cm2 g 510 +/- 5 Deg C Bagasse and Wood Chip Fired Boiler Sugar Plant and Ethanol Plant 67.2 TCH Raw Syrup Plant with 125 KLPD Ethanol Plant JGC Philippines Inc Philippines Travelling Grate Boiler 1 x 95 TPH, 67 kg/cm2 g 480 Deg C Bagasse Fired Boilers Phung Hiep Cane Sugar Factory Vietnam Sugar Plant Complete Sugar Plant of 2000TCD Experience in South East Asia
  • 93. Customer Country Project Details Phung Hiep Cane Sugar Factory Vietnam 300 TPD Sugar Refinery Biscom Philippines Cane Mills and Process House equipment PT Gunang Madu Plantation Indonesia Dumping Grate Boiler 1 x 120 TPH, 20 kg/cm2 350 Deg C Bagasse Fired Boilers Engcon, San Jose I Power, Philippines Philippines Travelling Grate Boiler 1 x 52.5TPH, 52 Kg/cm2 g 480 Deg C Rice Husk Fired Boiler Experience in South East Asia
  • 94. Customer Country Project Details Aldebran S.A. Spain 28 TPH Biomass fired Travelling Grate Boiler Fujaraiah Cement Ltd UAE 2 Nos 90 TPH Coal fired AFBC boilers Arab Paper Manufacturing Co. Saudi Arabia 3 x 16.5 MW Co-Generation Plant with Oil & Gas fired Boilers 94 Experience in Middle East & Others
  • 95. Experience in Latin America (Total Order Booking in Latin America Over USD 270 Million in last 4 Years) Customer Country Project Details Lizitex S.A. Guatemala Power Plant 61 MW Complete Power Plant (Turbo- Generator by Client) with 1 x 220 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal fired Travelling Grate Boiler Enka De Colombia Colombia Power Plant 14 MW Complete Power Plant (Turbo-Generator by Client) with 1 x 62 TPH, 66 Kg/cm2 g 500 Deg C Coal fired AFBC Boiler Ingenio Magdalena S.A. Guatemala Travelling Grate Boiler 1 x 220 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal Fired Boiler Ingenio Palo Gordo S.A. Guatemala Travelling Grate Boiler 1 x 165 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal Fired Boiler Ingenio La Union S.A. Guatemala Travelling Grate Boiler 1 x 165 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal Fired Boiler
  • 96. Experience in Latin America Customer Country Project Details Ingenio Agricola Industrial Santa Ana S.A. Guatemala Travelling Grate Boiler 1 x 220 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal Fired Boiler Biomass Energy S.A. (Repeat orders from Magdalena Group) Guatemala Travelling Grate Boiler 2 x 220 TPH, 109 kg/cm2 g 540 Deg C Bagasse and Coal Fired Boilers Al Caravan Bio Energy Project Colombia Travelling Grate Boiler 1 x 180 TPH, 70 Kg/cm2 g 515 Deg C Bagasse Fired Boiler Ingenio Risaralda S.A. Colombia Travelling Grate Boiler 1 x 159 TPH, 70 Kg/cm2 g 515 Deg C Bagasse and Coal Fired Boiler Ingenio Chaparrastique S.A. de C.V. El Salvador Travelling Grate Boiler 1 x 220 TPH, 109 Kg/cm2 g 540 Deg C Bagasse and Coal Fired Boiler
  • 97. Experience in Latin America Customer Country Project Details Compania Azucarera Tres Valles S.A. de C.V. Honduras Travelling Grate Boiler 1 x 60 TPH, 66 Kg/cm2 g 500 Deg C Bagasse Fired Boiler Compania Azucarera del Sur S.A. Nicaragua Pin Hole Grate Boiler 1 x 150 TPH, 85 Kg/cm2 g 515 Deg C Bagasse Fired Boiler Compania Azucarera del Sur S.A. Nicaragua Pin Hole Grate Boiler 1 x 150 TPH, 85 Kg/cm2 g 515 Deg C Bagasse Fired Boiler Consorcio Naviero Nicaraguense S.A. Nicaragua Pin Hole Grate Boiler 1 x 160 TPH, 85 Kg/cm2 g 515 Deg C Bagasse Fired Boiler Ingenio Panuco SAPI De CV Mexico Pin Hole Grate Boiler 1 x 200 TPH, 85 Kg/cm2 g 540 Deg C Bagasse Fired Boiler
  • 98. Experience in Latin America Customer Country Project Details Petroquimicasuape (A Petro brass Group Co.) Brazil Oil & Gas Fired Boilers 2 x 100 TPH, 100 Kg/cm2 g 510 Deg C Oil and Gas Fired Boiler Calesa Group Panama Panama Technical Study for rehabilitation of existing Sugar Plant and new Cogen Plant Manuelita S.A. Colombia Technical Study for rehabilitation of existing Sugar Plant Empresa Agroindustrial Laredo S.A.A. Peru Technical Study for rehabilitation of existing Sugar Plant
  • 99. Customer Country Project Detail Kwale International Sugar Co. Ltd Kenya Complete Sugar Plant 3000 Tons of Cane Per Day with 18 MW Cogeneration Consolidated Farming Ltd. Zambia Complete Sugar Plant 1650 Tons of Cane Per Day Expansion of Sugar Plant 2500 Tons of Cane Per Day from 1650 Tons of Cane Per Day Sugar & Allied Industries Limited Uganda Complete Sugar Plant 1650Tons of Cane Per Day with 12MW Cogeneration Butali Sugar Company Ltd. Kenya Complete Sugar Plant 1650 Tons of Cane Per Day (Total Order Book in Africa - Over USD 750 million in last 9 Years) Presence in Africa’s Sugar / Ethanol Sector
  • 100. Customer Country Project Detail Kibos Sugar Company Ltd. Kenya Complete Sugar Plant 1650 Tons of Cane per day Transmara Sugar Ltd. Kenya Complete Sugar Plant 1250 Tons of Cane per day White Nile Sugar Company Sudan Process / Boiling House 24000 Tons of Cane per day Complete Process House (part of Greenfield Sugar Plant Project) Wonji Shoa Sugar Factory Ethiopia Cane Milling Plant 6250 Tons of Cane per day Kenana Sugar Company Sudan Modernization & Expansion Of existing 28,500 Tons of Cane per day Sugar Plant in Phases Presence in Africa’s Sugar / Ethanol Sector
  • 101. Customer Country Project Detail Addax Bio-energy Ltd. Sierra Leone Complete Cogeneration Plant 32 MW with 2 Nos. 80 TPH, 68 Bar (a), 485 oC Bagasse Fired Boilers Addax Bio-energy Ltd. Sierra Leone Cane Milling Plant 5000 Tons of Cane per day Nakambala Sugar Ltd (part of Illovo Sugar, South Africa) Zambia Cogeneration Plant 30.4 MW with 1 No. 160 TPH, 32 kg/cm2(g), 500 Deg oC Bagasse Fired Boiler White Nile Sugar Company Sudan Boilers 4 X130 TPH, 60 kg/cm2(g), 500 oC Bagasse Fired Boilers Kakira Sugars Ltd. Uganda Boiler 160 TPH, 67 kg/cm2(g), 515 oC Bagasse Fired Boiler Presence in Africa’s Sugar / Ethanol Sector
  • 102. Presence in Africa’s Sugar / Ethanol Sector Customer Country Project Detail Mumias Sugar Company Ltd. Kenya Boiler 22 TPH, 45 kg/cm2(g), 400 oC Vinasse (Distillery Spent Wash) Fired Boiler Mumias Sugar Company Ltd. Kenya Boiler 170 TPH, 87 kg/cm2(g), 515 oC Bagasse Fired Boiler Campagnie Sucriere Senegalaise (part of Mimran Group, Switzerland) Senegal Boiler 150 TPH, 43 kg/cm2(g), 400 oC Bagasse Fired Boiler TPC Ltd. ( part of Ciel Agro Group, Mauritius) Tanzania Boiler 90 TPH, 45 kg/cm2(g), 400 oC Bagasse Fired Boiler Kakira sugar Works Ltd. Uganda Boiler 2 Nos. 50 TPH, 45 kg/cm2(g), 510 oC Bagasse Fired Boilers
  • 103. Customer Country Project Detail Sudanese Sugar Corporation Sudan Major Revamp of Controls & Instrumentation System of 14 Nos. existing Boilers Complete new Steam Distribution System for existing Two Sugar Plants SCOUL Sugar Uganda Major Revamp of existing Boiler Tongaat Hulett Sugar Group Mozambique 45” x 90” size Dewatering Mill for existing Diffuser White Nile Sugar Company Sudan Complete Tie-in Piping for 24,000 Tons of Cane Per Day capacity Greenfield Sugar Plant Government of Malawi Malawi 1250 TCD Complete Sugar Plant Presence in Africa’s Sugar / Ethanol Sector
  • 104.
  • 105. Boilers – Travelling Grate Boilers 105 Biomass Fired Boiler for Aldebaran Energia Del, Spain
  • 106. 8/14/2013 28 TPH BIOMASS FIRED TG BOILER AT JYOTI BIO ENERGY Boilers – Travelling Grate Boilers
  • 107. 1 x 52 TPH, Orient Green Power Ltd., Pollachi, Tamil Nadu Fuels Fired – Coconut Husk, Coconut Frond, Cane Trash, Wood Chips Boilers – Travelling Grate Boilers
  • 108. 1 x 70 TPH, Biomass Fired Boiler – Universal Biomass, Bhatinda Fuels Fired – Cotton Stalk, Rice Husk, Wood Chips, Paddy Straw Boilers – Travelling Grate Boilers
  • 109. Boilers – Travelling Grate Boilers 109 Biomass Fired Boiler for Aldebaran Energia Del, Spain 1 X 220 TPH, 109 KG/CM2 (g), 540 oC 100% BAGASSE & 100% COAL FIRED TRAVELLING GRATE BOILER FOR INGENIO MAGDALENA S.A, GUATEMALA (repeat order for 2 Boilers of same capacity after commissioning of 1st Boiler)
  • 110. Boilers – Travelling Grate Boilers 110 1 X 220 TPH, 109 KG/CM2 (g), 540 oC 100% BAGASSE & 100% COAL FIRED TRAVELLING GRATE BOILER FOR INGENIO MAGDALENA S.A, GUATEMALA (Boiler under construction)
  • 111. 190 TPH CFBC Boiler with Foster Wheeler technology for 45 MW Power Generation at BLA Power, India Boilers
  • 112. Boilers – Travelling Grate Boilers 35 TPH, Dharni Sugars and Chemicals Ltd., Chennai, Innovatively Designed Spent Wash / Vinasse (Distillery Effluent) Fired Boiler
  • 113. Boilers – Travelling Grate Boilers 113 1x170 TPH Travelling Grate Boiler Mumias Sugar Kenya
  • 114. Boilers – Oil & Gas Boilers – Field Erected type 2 nos.100 TPH Natural Gas Fired Boilers for PetroquimicaSquape, Brazil (100% subsidiary of Petrobras, Brazil)
  • 115. 77 TPH Package Boiler Longview, Maidsville, West Virginia, USA 115 Boilers – Oil & Gas Boilers – Package type Under Foster wheeler, USA License
  • 116. Power Plants 30.4 MW Power Plant (Bagasse Fired) Zambia Sugar Plc, Zambia. Range: up to 160 MW Supplied 19 Nos. Complete Power Plants to Indian and Overseas customers
  • 117. 36 MW Bagasse / Coal based Power Plant for Shree Dutta SSK, Kolhapur, India Power Plants
  • 119. EPC Power Plants 20 MW Cogeneration Plant for HPCL Biofuels, Lauriya, Bihar, India
  • 120. 1 x 61 MW BAGASSE & COAL BASED CAPTIVE POWER PLANT FOR ROYTEX S.A., GUATEMALA (under construction) EPC Power Plants
  • 121. EPC Power Plants 1 x 14 MW COAL BASED POWER PLANT WITH 1X62 TPH 66 KG/CM2 (g), 500 oC 100% COAL FIRED AFBC BOILER FOR ENKA DE COLOMBIA, COLOMBIA Power Plant Under Construction
  • 122. Sugar Plants & Machinery Complete 3500 / 5000 TCD Sugar Plant with 18 MW Cogeneration Plant near Pune, India 122
  • 123. Sugar Plants & Machinery 20 MW Cogen 3500 TCD sugar plant with Chain less cane diffuser for HPCL Biofuels, Lauriya - India
  • 124. Sugar Plants & Machinery Complete Cane Sugar Plant – Kibos Sugar & Allied Ind. , Kenya.
  • 125. Sugar Plants & Machinery Complete Cane Sugar Plant – Butali Sugar Mills Limited, Kenya.
  • 126. Sugar Plants & Machinery 2500 TCD Complete Sugar Plant for Consolidated Farming Ltd., Zambia
  • 127. 5000 TCD Complete cane sugar plant with 25 MW cogeneration for Core Green Sugar & Fuels, India Sugar Plant and Machinery
  • 128. 24000 TCD Process House and 4 x 130 TPH Travelling Grate Boilers on turnkey basis for White Nile Sugar Co. Ltd., Sudan Sugar Plant and Machinery
  • 129. Sugar Plants & Machinery 24000 TCD Process House & 4 x 130 TPH Boilers at White Nile Sugar, Sudan Under Construction Commissioned
  • 131. 131
  • 132. 132
  • 134.
  • 135. 135
  • 136. 136
  • 137. 137