Esteem Projects Pvt Ltd - The Fired Heater Company

Feb 2020
Esteem Projects Pvt. Ltd.
Noida | Delhi | Baddi
India
epl@esteemprojects.com
Esteem Projects LLC
Delaware
USA
ep-us@esteemprojects.com
Fired Heaters | Cracking Furnaces | Reformers | Pre-fabricated piping
HGU Reformer and DHDT Heater at IOCL Bongaigaon refinery

2Fired Heaters | Cracking Furnaces | Reformers | Pre-fabricated piping
Safety First HGU Reformer for IOCL - BGR
ü OHSAS 18001 certified
ü Award winning performance
ü Safety Officer reports to Head Office in parallel to site incharge
Award for 5,00,000 Safe
work hours at a site
Award for 10,00,000 Safe
work hours at a site

About Esteem HGU Reformer for IOCL - BGR
ü Core Business – Fired Heaters
ü More than 25 Years of experience
ü More than 150 projects
ü Member of American Petroleum
Institute (API)
ü ISO 9001, 14001 and 18001
certified
ü Design & engineering
ü Vertically integrated with in-house
capabilities for complete heater
project execution

We are trusted by
Shown in no specific order

Best Turnaround Contractor
In November 2017, Esteem was
awarded by BPCL for best
performance in a turnaround
job. The award was in relation
to revamp of VDU Heater
Esteem executed during 1st
quarter of 2017 at BPCL’s
Mahul Refinery

Project locations

Inspection at our works
Shown in no particular order

Approved by Engineers India Ltd. for..
ü Fired Heaters
ü Modularization Packages for Fired Heaters
ü Modularization Packages for Pipe rack structures

What we do
Turnarounds
and
Revamps
Shop
Fabricated
Equipment
Supply
LSTK
Projects

A. LSTK Projects (new Installations)
• Fired Heaters
• Steam Methane Reformers (Hydrogen
Reformers)
• Naphtha/ Gas Cracking Furnaces
• Speciality Furnaces (EDC, Ketene, etc.)
Products
&
Services

B. Shop fabricated equipment
• Modular Fired Heaters
• Convection Modules
• Waste Heat Recovery Units
• Specialized Refractory Lined
equipment
• Vibrocast lined vessels
• Abrasion resistant lined equipment
• Steam/ Air distribution rings
• Pressure vessels
• Pre-fabricated piping
• Dampers
• Stacks/ Chimneys
Products
&
Services

C. Turnarounds, revamps, capacity
enhancement projects
• Fired Heaters
• Reformers
• Cracking Furnaces
• FCCU/ INDMAX
• WHRUs
• Air Pre Heaters (APH)
Products
&
Services
Esteem can take up studies to identity bottlenecks in throughput or efficiency issues
in heaters and execute rectification jobs on fast track basis.
Our past jobs such as revamp of DCU – I heater for IOCL – Bongaigaon Refinery
lead to heater efficiency increase of around 8% and substantial savings to client.

ü Fabrication of Smaller Fired
Heater Modules & Panels
ü Fabrication of Dampers,
Doors, Tube-sheets,
Supports, etc.
ü Fabrication of
Heaters
ü Erection
ü Refractory Lining
ü Quality Assurance
ü Pre-commission
(including refractory
dry-out)
ü Commissioning
ü Fabrication of Fired Heater Modules & Panels
ü Pre-fabricated piping of entire plant in knocked
down condition
ü Fabrication of Pressure Vessels
ü Pre-fabricated structures
ü Design & Engineering
ü Procurement
ü Planning
ü Accounting & Finance
Client
Site
Noida
Office
Baddi
Workshop
Noida
Workshop
Facilities

Baddi Workshop
§ Fully equipped Fired heater fabrication workshop
§ Two bays of 246 ft x 50 ft each (~ 70,000 sq. ft total area)
§ Each bay has one EOT crane of 20 MT (additional two planned)
§ Loading facility for 100 MT, external crane of 300 MT
§ Approved welding procedures for almost all metallurgy in Fired
heaters.
§ Easy and clear access for transportation of large modules and over
dimension cargo
§ Maximum size for mock assembly inside shop: 14.5 x 14.5 x 70m
§ Assembly can be done near port to form larger modules or
complete heaters.

Baddi
Workshop

Noida Workshop
§ Fully equipped workshop for fabrication of fired heater modules/
components
§ ~ 8,611 sq. ft total area
§ EOT crane of 25 MT
§ Max size of single piece: 3.5m x 3.0m x 20m weighing upto 25MT
§ Past jobs included:
§ heater modules
§ critical high temperature operation dampers
§ coils
§ access doors
§ counterweight systems

Ventillation Air dampers for HGU
Reformer
Stack Damper with 99.5% sealing
VC heater Shell plates being fabricated at our Noida works Cast access doors for Heater Cast peep doors for Heater
Noida Workshop

Design & Engineering
§ Active member of API
§ Participating in updation of API 560 (Standard for Fired heaters for
Refineries)
§ Participating in preparation of upcoming new standard API 561
(Standard for Steam Methane Reforming Furnaces)
§ Participating in refractory related committees (API 936, etc.)

Facilities Hardware Facilities
Central File Server with fine grained
access control
Centralized hourly data snapshots
Redundant storage and power
supplies
Online Backup
In-house plotting facility
Latest Thinkcenter Workstations
Gigabit LAN
VPN connection
Software Available
Fired Heater simulation - WinHeat
Aveva PDMS
Autodesk Plant 3D
Autodesk Revit
Autodesk MEP and P&ID
Autodesk Advance Steel
Autodesk Revit Structure
Autodesk Structural Detailer
Autodesk Architecture and Civil 3D
Autodesk Infraworks
Autodesk
Autocad
STAAD Pro
Autodesk structural analysis
Noida
HO

Supply of 2 heaters for KHDS project at BORL, Bina
Supply of 8 heaters (DHDT/ PrimeG) for various IOCL units for BS VI
project
Supply of 2 HDS heaters for BS VI project at CPCL
Supply of Convection Module for CDU-II heater at IOCL - Haldia
Ketene Furnace for LOIL, Mahad
Ketene Furnace for Jubilant Life Sciences Ltd., Nira
4 nos. (39 Mmkcal/hr) Naptha Cracking Furnaces for BCPL, Lepetkata
Regeneration Gas Heater for BCPL, Lepetkata
Reformer Package for 25,000 TPA Hydrogen Generation Unit
at Indian Oil Corporation Ltd. (Bongaigaon Refinery)
DHDT Heater Package (12.7 MMKcal/hr) at IOCL-BGR, india
Dehydration Reactor feed Heater B-110A and B-110B for IGL
HGU Reformer for DHDS Unit at HPCL, Mumbai
New Heater Projects / Supplies

Recent revamp jobs by Esteem
Job Title Client Brief Scope Year Service
Revamp of HGU
Reformer
CPCL, Manali
Replacement of all inlet system and transfer line,
replacement of convection coils, burners, burner
piping and associated works
2020 HGU
Revamp of HGU
Transfer Line
HMEL, Bathinda
Installation of HTER and modification for transfer
line in HGU Train -1 and Train - 2
2019,
2020
HGU
Modification of
Cracking Furnaces
RIL, Hazira
Replacement of all pressure parts excluding two
convection modules.
2017 Ethane
VDU Heater Revamp IOCL, Gujarat Replacement of Convection Modules 2017 VDU
VDU Heater Revamp BPCL, Mumbai Replacement of Cast tube support beams 2017 VDU
INDMAX revamp IOCL - Guwahati
Replacement of cyclones of Reactor & Regenerator,
replacement of Riser Spool Piece and Regenerated
Catalyst Stand Pipe Spool Piece
2016 FCCU
Rebuilding of OHCU
Heater
IOCL - Panipat Rebuilding of entire heater (Ongoing project) 2015 Crude
Revamp of LRVPS
Heater
HPCL, Mumbai
New Convection Section, Lifting of heater by 1m.
Replacement of radiant tubes and shell
2014 Crude

Details of some jobs

Name of
Job:
Transfer Line
Modification for
HGU Train – 1 & 2
Client: HMEL, Bathinda
Year: 2019, 2020
Brief
Scope:
Installation of
HTER, supply and
installation of
transfer line from
Reformer to WHB
through the HTER
Shutdown of 10
days was
completed before
time. Received
bonus from client
for excellent work.

Name of
Job:
Revamp of VDU
Heater
Client: IOCL Gujarat
Year: 2017
Brief
Scope:
Supply and
replacement of
convection
modules.
Job was
performed
without removal
of stack
Insertion time: 1
day per module

Name of
Job:
Modification of Five
Cracking Furnaces
Client: RIL, Hazira
Year: 2017
Brief Scope: Replacement of
Radiant Coils,
Crossovers, Two
convection
modules, Transfer
line, Burner piping,
Trough and Arch
Shadow Box

Name of
Job:
Revamp of RR
Section and
Gascon Section
of INDMAX unit
Client: IOCL Guwahati
Year: 2016

Name of
Job:
Riser Spool Piece
And
Regenerated
Catalyst Stand Pipe
Spool Piece
Client: IOCL Guwahati
Refractory: Rescocast 17EC
Vibrocast

Name of
Job:
Convection
Module for CDU II
Client: IOCL Haldia
Tonnage: 80 MT
Dimensio
ns:
5m wide x 4.5m
high x 8.5m long
Supplied
as:
Single Unit

Name of Job: LRVPS Heater
Client: HPCL, Mumbai
Consultant: EIL
Heat Duty: 27 MMkcal/hr
Tonnage: 230 MT
Supplied as: 4 nos. complete convection
modules (13m long) were
supplied from our Baddi
works
Ducting supplied in pre-
fabricated form

Name of Job: Regeneration Gas
Heater
Client: BCPL
Consultant: EIL
Heat Duty: 5.37 MMkcal/hr
Tonnage: 100MT
Supplied as: Complete Modules

Modular Fabrication of Vertical Cylindrical
Heater at Esteem, Baddi works
Radiant Shell (Fabricated in three petals)
Radiant Coil (Fabricated in four hairpins)
Convection Section : Fabricated in two completely
built modules including duly hydrotested coil and
dried-out refractory.
Stack: Fabricated in two modules. Dispatched duly
refractory lined and dried out.
Platforms: Fabricated in ready to install panels.
Regeneration Gas
Heater for BCPL

Complete Radiant Section in
assembled condition
Radiant Shell Petals dismantled for
painting and dispatch

Radiant Coil prefabricated in hairpin form

Refractory lined conv. panels Prefabricated Conv. Coil
Dried-out refractory
Conv.
modules
post-dryout

Convection modules ready for dispatch
Module being loaded onto trailer
Convection modules in assembled condition

Stack under fabrication
Complete stack after refractory dry-out
(with damper installed)

Circular Radiant Platforms
under fabrication
Convection Platforms under
fabrication

Name of Job: Naptha Cracking
Furnaces
Client: BCPL
Licensor: CB&I Lummus
Consultant: EIL
Heat Duty: 4 Nos. x 39 MMkcal/h
Tonnage: 1525 MT (725 MT
supplied from Baddi
Works and 800 MT
fabricated at site)
Supplied as: Panels

Box Heater Fabricated at Esteem, Baddi works
StacksTransistion Sections Radiant ArchRadiant
Walls
Radiant Floor

Various panels for BCPL Cracker Furnaces

Erection of convection modules
Weight : 55 MT
Length : 7.6 m
Width : 2.3 m
Height : 2.5 m

Erection supervision and construction management for heater at TCI, Egypt
Designed by Born
Heaters, Canada
Erection supervision by
Esteem
Radiant:
L = 13 m
B = 5 m
H = 8.1 m

Modular Fabrication of VC Heater for IGL, Kashipur
Convection section fabricated and erected in three modules

Modular Fabrication of VC Heater for IGL, Kashipur
Stack fabricated in two modules complete
with platforms and ladders

HGU Reformer for IOCL-BGR

DHDT Heater for IOCL-BGR

DCU-1 Revamp at IOCL-BGR – Please see separate presentation specific to heater revamp
1
2
4
3

Modular Fabrication of DCU Heater for IOCL-BGR
Prefabricated
convection
modules complete
with ITS and ETS

Pre-fabrication of Radiant Coils
Radiant Coil modules ready for erection

Conv. module being erected Conv. module being erected Module erected
Radiant coil erection Radiant coil erected

From: pjjr1@sanmargroup.com
Subject: Revamping
Date: 18 June 2013 12:18 pm
To: Esteem Projects Pvt. Ltd. epl@esteemprojects.com
Cc: Singh, Gurinder gurinder@esteemprojects.com, Oberoi M S msoberoi@esteemprojects.com, Singh, Tan
tanveer@esteemprojects.com
Bcc:
Mr.Gurcharan singh,
I appreciate your team has done a good job for the furnaces coil replacing.
Especially I appreciate Bhavesh Yadav who had involved the jobs in
depth,good planning and good follow up.Because of his good forecasting and
planning almost most of the jobs done in time and ﬁnally RE2C completed
with in very shortest period. He is an Good and growing knowledgeable
Engineer.
Also people who have done with out any injury is also appreciable for
taking care of safety by each and every one.
regards
P.James Johnson Rajamani
The information contained in this message is legally privileged and conﬁdential information intended only for
addressed individual or entity indicated in this message (or responsible for delivery of the message to such p
be read, copied, disclosed, distributed or used by any person other than the addressee. Unauthorised use, disclosu
strictly prohibited and may be unlawful. Opinions, conclusions and other information on this message that do not re
business of any of the constituent companies of the SANMAR GROUP shall be understood as neither given nor
Group.
If you have received this message in error, you should destroy this message and kindly notify the sender by e-ma
Thank you.
* * * * * * * * * * * * * * * * * * * * * * * * * * * * * *
RE2C completed within very
shortest period
Words of Appreciation
Revamp of RE2C at Chemplast Sanmar

The entire job was meticulously planned
& executed during shutdown period of
thirty five days
Revamp of DCU-1 PH-II at IOCL-BGR

The professional approach and the technical
competence displayed by the team was
appreciable.

No major/ minor flaws in construction of heater.

Completed the job in scheduled time. The
performance is satisfactory.

The critical job has been completed ahead of
schedule. We are satisfied with the quality of
work, and also professional approach and
dedication displayed by the team.

We appreciate the professional approach and
dedication of M/s Esteem Projects towards the
job.

Reformer Package for DHDS Project
is working satisfactory since March
27, 2000. Till today we are not
having any problem.

Summary HGU Reformer for IOCL - BGR
ü More than two decades of experience
ü More than 150 projects
ü ISO 9001, 14001 and 18001 certified
ü In-house design, engineering and detailing facilities
ü World class quality and safety
ü Ability to handle critical time bound projects on-
schedule and on-budget
Thanks for your attention!
Esteem Projects Pvt. Ltd.,
Address: B-39, Sector-67, Noida, UP – 201301, india Ph: 0120 6491904/05/06
Email: epl@esteemprojects.com Web.: www.esteemprojects.com

Esteem Projects Pvt Ltd - The Fired Heater Company

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