Why a single EPC contractor wins
Multi-vendor projects fail at the interfaces — the gap between civil and mechanical, between mechanical and E&I, between fabrication and commissioning. That is where schedule slips live and where blame gets passed. HAIL eliminates the interface problem by taking single-point accountability across every discipline. One contract, one project manager, one master schedule, one HSE plan, one liability. Twelve disciplines under one roof: storage tank construction, pressure vessel fabrication, piping, column erection, dismantling, LPG storage, structural steel, coatings, electrical, instrumentation, civil and B2B fabrication.
EPC scope we deliver
Petroleum terminals
Greenfield POL terminals, oil depots, multi-product tank farms — receipt, storage, blending, loading and unloading.
Refinery revamps
Coker, hydrocracker, FCC and product unit revamps inside operating refineries with full PTW compliance.
Fertiliser & ammonia
Ammonia tanks and decommissioning, urea/DAP/NPK plant utilities, bagging plant, water systems.
Chemical & petrochemical
Phosphoric acid, methanol, ethanol, butadiene and downstream petrochemical units.
LPG storage facilities
Mounded bullet farms, sphere farms, bottling plants — PESO certified.
Water & pipeline projects
Cross-country pipelines, water supply schemes, water treatment package units.
Disciplines under one contract
- Engineering & design — own engineering plus consortium with RINA Consulting S.p.A. for third-party assurance.
- Procurement — long-lead equipment, bulk materials, consumables; full vendor qualification and PMI traceability.
- Civil & structural — foundations, ring walls, dyke walls, pipe rack platforms, equipment foundations, buildings.
- Mechanical — tank construction, pressure vessel fabrication, equipment erection, heavy lift.
- Piping — process, offsite, underground (3LPE), hydrotest, flushing, pre-commissioning.
- Electrical & instrumentation — cathodic protection, earthing, MCC/PCC panels, DCS/PLC, SCADA, fire-and-gas detection.
- Coatings — surface preparation (SA 2.5), epoxy/PU/zinc-rich systems, intumescent fireproofing, internal tank linings.
- Pre-commissioning & commissioning — system testing, performance test, statutory close-out.
Reference projects
- IOCL Barauni Refinery — Coker-B Revamp (—105 Crore, ongoing): complete EPCC — piping, painting, electrical, cathodic protection, heavy equipment erection, civil and instrumentation. Single integrated team for UPS Constructions Pvt. Ltd.
- IOCL Petroleum Terminal — Amlekhgunj, Nepal: cross-border EPC — IFR product tanks, transmix tanks, water tanks, structural steel, piping (3LPE), pumps and complete painting.
- $50 million USD terminal projects — leadership-led international EPCC delivery.
- Phosphoric Acid Storage Tank — Krishna Phoschem, Jhabua MP: turnkey civil + tank for chemical service.
- Birla Copper Ammonia Tank Dismantling, Dahej: full decommissioning EPC for Ostwal Phoschem (India) Ltd.
Industries served
Oil & gas, refineries, petrochemical, fertiliser, chemical, agro-chemical, copper smelter, ports, water treatment, power and general industrial. Geographies: pan India and overseas in Nepal, UAE, Oman, Bahrain, Kuwait, Qatar, Indonesia and Malaysia.
Why HAIL for your EPC project
- Twelve disciplines under one roof — true single-point EPCC.
- Leadership track record — 2,000+ tanks, 300+ projects, 8 countries, $50 million USD international EPC.
- Owned 33,000 sq.ft. fabrication workshop and 200/100/50/20 MT crane fleet.
- RINA Consulting consortium for third-party design/engineering assurance.
- WPS/PQR-qualified welders, ASME U-stamp, PESO certification, OISD compliance.
- Zero major incidents inside live IOCL refineries (Barauni, Gujarat, NRL, BPCL).
EPC vs EPCC vs PMC vs EPCM — what India actually contracts
Indian process clients use four overlapping contracting models. Each has different risk allocation, payment terms and contractor responsibilities. Picking the wrong model is the #1 reason refinery / petrochemical projects miss schedule.
| Model | Stands for | Contractor responsibility | Payment basis | When to use |
|---|---|---|---|---|
| EPC | Engineering, Procurement, Construction | Design, buy, build to client spec. Mechanical completion handover. | Lump-sum or unit rate | Tank farms, terminals, well-defined scope |
| EPCC | EPC + Commissioning | Adds pre-comm + comm + performance test + start-up support | Lump-sum + commissioning milestone | Refinery revamps, full plant projects |
| EPCM | Engineering, Procurement & Construction Management | Engineering + procurement; construction managed (not self-performed) | Reimbursable fee + engineering | Mega-projects where client wants control over construction sub-contracting |
| PMC | Project Management Consultancy | Manages other EPC contractors on behalf of owner | Reimbursable + fee | Greenfield mega-projects, multiple EPC packages |
| LSTK | Lump Sum Turnkey | Same as EPCC but with single firm price | Fixed lump-sum | Bankable projects with limited scope change risk |
HAIL self-performs EPC, EPCC and LSTK contracts. We are the construction partner — not a pure design house — so we assume schedule and execution risk that pure EPCM/PMC firms cannot.
Twelve disciplines under one EPC contract
What separates an integrated EPC contractor from a "general contractor" is depth across every discipline. Below is the complete stack HAIL self-performs:
- Engineering & design. Process, mechanical, civil, structural, electrical, instrumentation, piping isometric and 3D modelling. Plus consortium with RINA Consulting S.p.A. for third-party design assurance and certification.
- Procurement. Long-lead equipment (vessels, exchangers, pumps, compressors, valves), bulks (plate, pipe, fittings, cable, structural steel), consumables. Vendor pre-qualification, technical bid evaluation, expediting and inspection.
- Civil & structural. Foundations (RCC raft, ring wall, pile cap, pedestal), dyke walls, pipe-rack civil, equipment platforms, control-room buildings, roads, drains, fire-water network civil. Structural steel fabrication and erection per IS 800 / AISC 360.
- Mechanical equipment installation. Storage tank construction (covered here), pressure vessel erection, heat exchanger installation, column erection (covered here), pump and compressor installation, boiler erection, furnace erection.
- Process piping. Process plant piping per ASME B31.3, offsite and utility piping, underground 3LPE pipelines, hydrotest, flushing. Detailed at our piping contractor page.
- Heavy lift & erection. 200 / 100 / 50 / 20 MT owned crane fleet, engineered lift studies, ground bearing capacity assessment, 350+ ton lifts at 60-metre height inside live refineries.
- Tank & plant dismantling. Reverse jacking for tanks, sectional dismantling for plant equipment, ammonia decommissioning. See tank dismantling and ammonia decommissioning.
- Electrical works. Substation, MCC/PCC panels, cable trays, conduits, lighting, motor terminations, cathodic protection, earthing grids, lightning protection.
- Instrumentation & control. Field instruments (transmitters, control valves, analyzers), DCS / PLC / SCADA, F&G detection, ESD, loop checking, pre-commissioning, commissioning.
- Painting & protective coatings. SA 2.5 surface preparation, primer + intermediate + topcoat, intumescent fireproofing, internal tank linings, NACE/SSPC compliant.
- HSE & quality. Documented HSE management system, safety officer at every site, JSA per task, Permit-to-Work, ITP per discipline, third-party inspection accepted.
- Pre-commissioning & commissioning. System testing, flushing, blowing, hydrotest, reinstatement, loop checking, no-load runs, performance test, start-up support and operations training.
Industries we serve as an EPC contractor
| Industry | Typical scope | Indian client examples |
|---|---|---|
| Oil refineries | Unit revamps, tank farms, crude/product receipts, FCC / CDU upgrades | IOCL Barauni, IOCL Gujarat, BPCL Mumbai/Kochi, HPCL Mumbai/Visakh, Reliance Jamnagar, Nayara Vadinar |
| Petrochemical | Steam crackers, downstream units, polymer plants | Reliance Hazira, GAIL Pata, Haldia Petrochemicals |
| Fertiliser | Ammonia/urea plants, NPK, ammonia storage, transfer terminals | GSFC, GNFC, IFFCO, KRIBHCO, RCF, NFL, Chambal, Coromandel, Deepak Fertilisers |
| Chemical | Inorganic acids, methanol, formaldehyde, alkalis | Krishna Phoschem, Ostwal Phoschem, Birla Copper, Nirma, Tata Chemicals |
| Petroleum terminals | POL terminals, oil depots, multi-product tank farms | IOCL terminals (incl. cross-border Amlekhgunj Nepal), BPCL/HPCL/IOC depots |
| Power & utilities | BoP for thermal, captive boilers, fuel storage, water systems | NTPC, Tata Power, Adani Power, Reliance Power |
| Ports & LNG | LNG receipt, regasification, marine loading arms | Petronet LNG, IOCL Ennore, Mundra LNG |
| Water & effluent | STP, ETP, raw water reservoirs, DM water plants | Public sector water utilities, industrial ZLD plants |
Active EPC project — IOCL Barauni Coker-B Revamp
HAIL is currently executing a —105 Crore multi-discipline EPCC contract at IOCL Barauni Refinery for UPS Constructions Pvt. Ltd. — covering the Coker-B Unit Revamp. Scope:
- Process piping fabrication & erection — high-pressure hydrocarbon piping per ASME B31.3, hydrotest, flushing.
- Industrial painting & coating — SA 2.5 surface preparation, NACE-compliant primer + topcoat on piping and structures.
- Electrical works — cable laying, terminations, motor connections, earthing.
- Cathodic protection — for buried vessels and pipelines.
- Heavy equipment erection — column & vessel placement using HAIL-owned 200 MT crane fleet.
- Civil construction — foundations, equipment platforms, drainage.
- Instrumentation — field instrument installation, cable tray, junction boxes, loop checking.
- Pre-commissioning & commissioning support — system testing inside live refinery operating environment.
All disciplines delivered by a single integrated team under one PO. The project demonstrates HAIL's ability to coordinate complex multi-disciplinary EPC inside a running refinery — without disrupting unit operations.
The HAIL EPC execution methodology
- Pre-FEED engagement. Joint scope clarification, basis-of-design review, procurement long-lead identification, schedule mapping. Saves 10—15% CAPEX through early decisions.
- FEED & engineering. Process flow diagrams, P&ID, equipment lists, piping line lists, electrical SLD, instrument index, civil GA. RINA Consulting consortium reviews critical design.
- Procurement. Vendor pre-qualification, technical bid evaluation, expediting, factory inspection. Long-lead items (vessels, exchangers, valves, structural steel) ordered immediately after FEED freeze.
- Construction mobilisation. Site office, lay-down area, crew housing, crane mobilisation, fabrication shop set-up.
- Civil-mechanical-piping coordination. Daily progress reviews, weekly schedule reviews, monthly client review meetings. 4D scheduling on critical path.
- Mechanical completion (MC) walkdown. Joint client + HAIL + AI walkdown of all systems, punch-list close-out, system handover for commissioning.
- Pre-commissioning. System flushing, chemical cleaning, blowing, hydrotest, reinstatement, instrument loop checking, motor solo runs.
- Commissioning & performance test. System start-up, no-load run, on-load run, parameter optimisation, performance test per contract.
- Final acceptance & warranty. Final acceptance test, deficiency close-out, defect liability period (typically 12—18 months).
EPC contract sizing — what HAIL handles
| Contract size | Typical project | Schedule |
|---|---|---|
| —5—25 Cr | Single-discipline mechanical contract — tank construction, vessel fabrication, piping spool | 3—9 months |
| —25—100 Cr | Multi-discipline mid-size EPC — refinery sub-system, fertiliser ammonia line, terminal expansion | 9—18 months |
| —100—500 Cr | Major refinery revamp, full terminal construction, fertiliser unit upgrade | 18—36 months |
| —500 Cr+ | Greenfield terminal, mega-tankage, large refinery EPCC (typically as JV / consortium) | 30—48 months |
Leadership has previously delivered terminal EPCC projects worth $50 million USD overseas. The current —105 Cr IOCL Barauni contract is at the upper end of HAIL's solo-execution range. For mega-projects (—500+ Cr) we work in consortium with RINA Consulting and other technology partners.
Why single-point EPC beats multi-vendor execution
The most common reason refinery / chemical / fertiliser projects miss schedule is interface gap — the boundary between civil-mechanical, mechanical-piping, piping-electrical, electrical-instrumentation. When five contractors deliver five packages, no one owns the interfaces. Each blames the other. The owner bears the schedule slip.
HAIL eliminates this by self-performing all twelve disciplines under one contract:
- One project manager — accountable for the whole scope.
- One master schedule — civil ready when piping arrives, piping ready when E&I arrives, E&I ready for commissioning.
- One safety regime — JSA + PTW + HSE training across all crews.
- One quality system — same ITP discipline across mechanical, civil, electrical, instrumentation.
- One liability — no finger-pointing between sub-contractors.
- One contract — owner manages one PO, one BG, one final acceptance.
Frequently asked questions
EPC vs EPCC — what is the difference?
EPC = Engineering + Procurement + Construction. EPCC adds Commissioning — the contractor delivers a running, performance-tested plant rather than just a mechanically complete asset. HAIL delivers full EPCC including pre-commissioning, commissioning, performance test and start-up support.
EPC vs EPCM — when to use which?
EPC: contractor self-performs construction (assumes execution risk). EPCM: contractor only manages construction sub-vendors (lower risk, lower margin, less control). HAIL operates as EPC/EPCC — we self-perform construction with our own crews, cranes and workshop. We are not an EPCM/PMC firm.
Which industries does HAIL serve as an EPC contractor?
Oil & gas refineries (IOCL, BPCL, HPCL, Reliance, Nayara), petrochemical, fertiliser (GSFC, GNFC, IFFCO, KRIBHCO, RCF, NFL, Chambal), chemical (Krishna Phoschem, Ostwal Phoschem, Birla Copper, Nirma, Tata), ports & LNG, power, water & effluent treatment.
What is HAIL's largest active EPC project?
—105 Crore IOCL Barauni Coker-B Revamp (ongoing) for UPS Constructions Pvt. Ltd. Multi-discipline EPCC: piping, painting, electrical, cathodic protection, heavy equipment erection, civil, instrumentation, pre-commissioning. Leadership has previously delivered EPCC terminal projects worth $50 million USD overseas.
Does HAIL execute EPC projects overseas?
Yes. We delivered the IOCL Petroleum Terminal at Amlekhgunj, Nepal end-to-end. We tender across UAE, Oman, Bahrain, Kuwait, Qatar, Indonesia and Malaysia. Overseas execution combines HAIL's owned engineering and crew with local logistics partners.
Why choose a single EPC contractor over multi-vendor packages?
The #1 cause of refinery / chemical project schedule slip is interface gap between civil, mechanical, piping, electrical and instrumentation contractors. Single-point EPCC under HAIL eliminates this — one project manager, one master schedule, one safety regime, one quality system, one liability, one PO.
What contract sizes does HAIL handle?
Single-discipline mechanical contracts —5—25 Cr (3—9 months). Multi-discipline mid-size EPC —25—100 Cr (9—18 months). Major refinery revamps —100—500 Cr (18—36 months). Mega-projects —500+ Cr in consortium (30—48 months).
What are the 12 disciplines HAIL self-performs?
Engineering & design, procurement, civil & structural, mechanical equipment installation, process piping, heavy lift & erection, tank & plant dismantling, electrical works, instrumentation & control, painting & coatings, HSE & quality, pre-commissioning & commissioning. All under one contract with single liability.
What is the HAIL execution methodology?
Pre-FEED engagement — FEED & engineering — procurement (long-lead first) — construction mobilisation — civil-mechanical-piping-E&I coordination — mechanical completion walkdown — pre-commissioning — commissioning & performance test — final acceptance & warranty (12—18 month DLP).
Does HAIL provide EPC for fertiliser ammonia plants?
Yes — full EPC scope: ammonia tank construction, transfer terminals, ammonia decommissioning (we are India's first reverse-jacking ammonia contractor). Target clients: GSFC, GNFC, IFFCO, KRIBHCO, RCF, NFL, Chambal Fertilisers, Coromandel International, Deepak Fertilisers, Yara India.
Does HAIL provide refinery EPC?
Yes — refinery revamps, unit upgrades, tank farms, crude/product receipts, FCC and CDU upgrades. Active project: IOCL Barauni Coker-B Revamp. Past projects: IOCL Gujarat (N-Butanol for Thyssenkrupp), and others led by leadership.
What is the typical EPC schedule from kick-off to commissioning?
Single-discipline: 3—9 months. Mid-size multi-discipline: 9—18 months. Major refinery revamp: 18—36 months. Greenfield terminal: 24—48 months. Long-lead procurement (vessels, valves, structural steel) is typically the schedule constraint.
How does HAIL handle HSE on EPC projects?
Documented HSE management system, Safety Officer at every site, JSA per task, Permit-to-Work integrated with client, daily toolbox talks, weekly walks, monthly KPI reporting. Track record: zero major incidents inside live IOCL refineries (Barauni, Gujarat).
What quality assurance does HAIL provide?
Documented ITP per discipline, ASME Section IX qualified WPS/PQR, third-party inspection accepted (Lloyd's, BV, T×V, RINA via consortium), full PMI traceability, calibrated test equipment, and complete data dossier at MC.
Does HAIL handle long-lead procurement?
Yes — vendor pre-qualification, technical bid evaluation, expediting, factory inspection. Long-lead items (vessels, exchangers, valves, structural steel) ordered immediately after FEED freeze to compress schedule.
Do you provide LSTK contracts?
Yes — Lump Sum Turnkey is suited to bankable projects with limited scope change risk. We assess scope completeness and risk profile before quoting LSTK. Our preference is EPCC with milestone-based payment for projects with engineering complexity.
What insurance and bonds does HAIL carry?
Workmen's Compensation, Public Liability (project-specific), Contractor's All Risk (CAR), Performance Bond / Bank Guarantee per tender, Defect Liability Period (12—18 months). Insurance values scaled to project size and risk.
Does HAIL provide pre-FEED consultancy?
Yes — joint scope clarification, basis-of-design review, code/standard selection, metallurgy advisory, procurement long-lead identification, schedule mapping. Engaging us at pre-FEED typically saves 10—15% CAPEX through early decisions on metallurgy, design margin and equipment standardisation.