India's green hydrogen opportunity — and why you need the right EPC partner
India's National Green Hydrogen Mission commits Rs 19,744 crore to building 5 million tonnes per annum of green hydrogen capacity by 2030. Refineries, fertiliser plants, and steel mills will replace grey hydrogen with electrolytic green hydrogen. New green ammonia export terminals are planned along India's western coast. Gujarat alone targets 3 MTPA — the world's largest concentrated green hydrogen build-out.
These projects need EPC contractors who can handle high-pressure hydrogen piping (ASME B31.12), electrolyser foundation and structural works, hydrogen-rated electrical systems, and the unique safety requirements of hydrogen service. As an experienced mechanical and EPC contractor with proven capabilities in pressure vessel fabrication, high-integrity piping, and structural steel, HAIL brings the execution discipline that green hydrogen projects demand.
Green hydrogen & green ammonia EPC scope
Electrolyser plant EPC
Civil foundations, structural steel building, electrolyser module installation, DM water system piping, hydrogen collection headers, electrical bus-bar and rectifier installation for alkaline, PEM and SOEC electrolysers.
Hydrogen compression & storage
Compressor foundation, high-pressure hydrogen storage vessels, SS 316L and duplex hydrogen piping per ASME B31.12, PSA purification skid erection, and tube trailer loading facilities.
Green ammonia synthesis
Balance-of-plant EPC for Haber-Bosch ammonia synthesis — reactor foundations, column and vessel erection, ammonia piping, refrigerated ammonia storage tanks, and ammonia handling systems.
BESS (Battery Energy Storage)
Civil pad, structural steel for battery container racks, electrical bus-bar, DC cable installation, fire suppression piping, HVAC supports, fencing, and balance-of-plant for grid-scale battery storage.
Carbon capture (CCUS)
Absorber column erection, amine regeneration unit piping, CO2 compressor installation, CO2 pipeline, structural platforms, and associated civil works for refinery and fertiliser plant decarbonisation.
Hydrogen pipeline infrastructure
Cross-country hydrogen pipelines, city gas distribution tie-ins, hydrogen blending stations, and metering skids. Pipeline construction per ASME B31.12 with hydrogen embrittlement-rated metallurgy.
Why green hydrogen projects need a mechanical EPC contractor — not just a technology vendor
Electrolyser OEMs (Nel, Thyssenkrupp, Siemens, L&T) supply the technology module. But 60-70% of a green hydrogen plant's CAPEX is balance-of-plant — foundations, structural steel, piping, electrical, instrumentation, storage tanks, and utilities. This is mechanical and EPC contractor scope, and it determines whether the plant starts on schedule.
HAIL's value in green hydrogen projects:
- Hydrogen-rated piping: ASME B31.12 qualified welding procedures for SS 316L and duplex stainless steel in high-pressure hydrogen service. Orbital welding capability for critical joints.
- Heavy lift capability: Owned 200/100/50/20 MT crane fleet for electrolyser module, reactor, and column erection.
- Fabrication workshop: 33,000 sq.ft. workshop in Vadodara for modular skid fabrication — hydrogen purification skids, compressor packages, BESS container racks, and piping spools.
- Ammonia experience: Proven track record in ammonia storage, handling, and decommissioning — directly applicable to green ammonia plant EPC.
- Multi-discipline integration: Single-point EPC covering civil, mechanical, piping, electrical, instrumentation, and commissioning — the same turnkey EPC model we deliver for refineries and fertiliser plants.
Green hydrogen value chain — where HAIL fits
| Value chain stage | Scope | HAIL's EPC role |
|---|---|---|
| Renewable power generation | Solar / wind farms | BOP civil, structural, cable trenching (via partners) |
| Electrolysis | Water splitting to H2 + O2 | Electrolyser building, DM water piping, H2 headers, electrical |
| Purification | PSA / deoxygenation | Skid fabrication, erection, piping tie-ins |
| Compression | 30-350 bar H2 compression | Compressor foundation, installation, HP piping |
| Storage | Gaseous / liquid H2 tanks | Pressure vessel fabrication, tank erection |
| Transport | Pipeline / tube trailer | Pipeline construction, loading facility EPC |
| Ammonia synthesis | H2 + N2 → NH3 (Haber-Bosch) | Reactor erection, piping, ammonia tank, refrigeration |
| BESS integration | Grid-scale battery storage | Civil pad, structural, electrical, fire suppression |
| Carbon capture | Flue gas CO2 capture | Absorber/regenerator erection, CO2 piping, compression |
Codes & standards for hydrogen service
- ASME B31.12 — Hydrogen Piping and Pipelines (primary hydrogen piping code).
- ASME B31.3 — Process Piping (for non-hydrogen utility piping within H2 plants).
- ASME BPVC Section VIII — Pressure vessels for hydrogen storage and process service.
- NFPA 2 — Hydrogen Technologies Code (safety distances, ventilation, detection).
- ISO 19880 — Gaseous Hydrogen Fuelling Stations.
- CGA G-5.4 — Standard for Hydrogen Piping Systems at Consumer Locations.
- API 510 / API 570 — In-service inspection for hydrogen vessels and piping.
- IS 15916 — Indian Standard for Hydrogen Safety.
- IEC 62282 — Fuel cell technologies (relevant to H2 electrolyser installations).
Green hydrogen project locations in India
As a Gujarat-based green hydrogen EPC contractor, HAIL is strategically positioned to serve India's primary green hydrogen corridors:
| Cluster | Why this location | Key projects / developers |
|---|---|---|
| Kutch, Gujarat | India's best solar irradiance (5.5+ kWh/m2/day) + port access at Mundra and Kandla | Adani New Industries, ACME, ReNew, NTPC |
| Jamnagar, Gujarat | Reliance refinery complex — world's largest single-site refinery replacing grey H2 | Reliance Industries |
| Dahej-Hazira, Gujarat | Petrochemical and fertiliser corridor, PCPIR zone, existing gas infrastructure | GSFC, GNFC, ONGC, L&T |
| Mundra, Gujarat | Adani Port + solar park proximity for green ammonia export terminal | Adani Group |
| Rajasthan | Solar belt (Jodhpur-Jaisalmer), lowest renewable LCOE in India | ACME, NTPC, SJVN |
| Andhra Pradesh | NTPC Pudimadaka green hydrogen hub, port access for NH3 export | NTPC Green Energy |
| Odisha | Steel corridor — green H2 for DRI (direct reduced iron) applications | Jindal Steel, Tata Steel |
HAIL's Vadodara headquarters is 250 km from Kutch, 300 km from Jamnagar, and 100 km from Dahej — enabling rapid mobilisation to Gujarat's green hydrogen corridor. For projects across India and in the UAE / Middle East, we deploy experienced site teams with the same execution discipline proven on our refinery and petrochemical EPC projects.
BESS — Battery Energy Storage Systems
Grid-scale BESS is the enabling technology for green hydrogen — electrolysers need stable power, and BESS smooths intermittent solar/wind output. India's BESS market is projected to reach 42 GWh by 2030 under the National Framework for Promoting Energy Storage Systems. HAIL provides the EPC infrastructure for BESS installations:
- Civil works: Grading, foundations, cable trenches, drainage, access roads, security fencing.
- Structural steel: Battery container support racks, inverter platforms, transformer pads.
- Electrical: HV/LV switchgear foundations, bus-bar installation, DC cable routing, earthing grid, lightning protection.
- Fire suppression: Piping for aerosol, clean-agent, or water-mist fire suppression systems per NFPA 855.
- HVAC supports: Structural supports for battery container HVAC units, ductwork, and thermal management piping.
- Balance-of-plant: Control room, communication systems, perimeter infrastructure.
Carbon capture — CCUS EPC scope
Carbon capture, utilisation and storage (CCUS) is becoming mandatory for Indian refineries and fertiliser plants under evolving emissions policy. HAIL's EPC scope for carbon capture projects includes:
- Absorber column erection: Heavy-lift installation of amine-based CO2 absorber towers — typically 30-50 metre tall columns requiring HAIL's 200 MT crane capability.
- Amine regeneration unit: Complete mechanical and piping installation — reboiler, condenser, lean/rich amine exchangers, amine storage tanks.
- CO2 compression: Multi-stage CO2 compressor installation, inter-cooler piping, dehydration unit.
- CO2 pipeline: Carbon steel or SS CO2 transport piping to utilisation or sequestration point.
- Structural & civil: Equipment foundations, pipe racks, platforms, access stairs, and blast-resistant control room.
Modular skid fabrication for hydrogen plants
Green hydrogen projects increasingly use modular construction to compress schedules. HAIL's 33,000 sq.ft. fabrication workshop in Vadodara builds modular skids for hydrogen and ammonia plants:
- Hydrogen purification skids — PSA vessels, piping, valves, and instrumentation pre-assembled and tested.
- Compressor packages — Compressor, motor, lube oil system, inter-coolers on a single skid.
- Electrolyser support frames — Structural modules with pre-installed piping and electrical conduits.
- BESS container racks — Structural steel frames for battery containers with integrated bus-bar routing.
- Water treatment modules — DM water, RO, and EDI packages for electrolyser feed water.
Why HAIL for green hydrogen EPC
- Twelve disciplines under one contract — same single-point EPC model proven on 300+ projects.
- ASME B31.12 hydrogen piping capability — SS 316L and duplex welding with orbital welding for critical joints.
- Ammonia expertise — cryogenic ammonia storage, handling, and decommissioning experience directly applicable to green ammonia plants.
- Owned 200 MT crane fleet — heavy-lift for electrolyser modules, reactor vessels, and absorber columns.
- Gujarat location — 100-300 km from India's primary green hydrogen corridor (Kutch, Mundra, Jamnagar, Dahej).
- Workshop fabrication — modular skids, piping spools, and structural assemblies at our Vadodara facility.
- RINA Consulting consortium — third-party design assurance for hydrogen and ammonia plant engineering.
- International reach — tendering in UAE, Oman, and the Middle East where green hydrogen/ammonia export projects are scaling.
Frequently asked questions
What is green hydrogen and why does India need it?
Green hydrogen is H2 produced by electrolysing water using renewable electricity. India's National Green Hydrogen Mission targets 5 MTPA by 2030 to replace grey hydrogen in refineries, fertiliser plants, and steel mills — cutting carbon emissions while creating energy security.
What is the difference between green hydrogen and green ammonia?
Green hydrogen is the base molecule (H2) from renewable electrolysis. Green ammonia combines green H2 with nitrogen from air separation via Haber-Bosch. Ammonia is easier to store and transport than hydrogen, making it the preferred carrier for international hydrogen trade.
What EPC scope does HAIL deliver for green hydrogen?
Balance-of-plant EPC — foundations, structural steel, hydrogen piping (ASME B31.12), electrical, instrumentation, storage vessels, modular skid fabrication, and commissioning support. We handle 60-70% of plant CAPEX while electrolyser OEMs supply the technology module.
Does HAIL build BESS facilities?
Yes — civil foundations, structural steel for battery racks, electrical bus-bar, DC cabling, fire suppression piping, HVAC supports, and balance-of-plant. Battery modules come from OEMs; HAIL builds everything around them.
What is CCUS and does HAIL do it?
CCUS (Carbon Capture, Utilisation and Storage) captures CO2 from industrial flue gas. HAIL provides EPC for the mechanical infrastructure — absorber columns, amine regeneration, CO2 compression and piping, structural platforms, and civil works.
Where are green hydrogen projects in India?
Gujarat (Kutch, Mundra, Jamnagar, Dahej), Rajasthan, Andhra Pradesh (NTPC Pudimadaka), Tamil Nadu, and Odisha. Gujarat alone targets 3 MTPA by 2030. HAIL's Vadodara base is 100-300 km from Gujarat's hydrogen corridor.
What codes apply to hydrogen piping?
ASME B31.12 (hydrogen piping), NFPA 2 (hydrogen safety), ISO 19880 (fuelling stations), CGA G-5.4, and IS 15916. Hydrogen embrittlement requires SS 316L or duplex stainless steel for high-pressure service.
Can HAIL fabricate modular skids for hydrogen plants?
Yes — our 33,000 sq.ft. Vadodara workshop builds hydrogen purification skids, compressor packages, electrolyser support frames, BESS container racks, and water treatment modules for rapid site installation.