Mechanical EPC for petrochemical complexes
Petrochemical plants demand tight tolerances, exotic metallurgies, and flawless safety execution inside high-hazard zones. As a specialist petrochemical EPC contractor, HAIL brings the same discipline we apply in refinery EPC to every petrochemical plant construction project — ASME, API, and PESO compliant petrochemical fabrication, erection, and commissioning. Our integrated approach eliminates the interface gaps that plague multi-vendor petrochemical construction, providing single-point accountability from engineering through mechanical completion.
Petrochemical services we deliver
Storage tanks
API 650 atmospheric tanks for methanol, ethanol, aromatics, naphtha, and petrochemical intermediates. Cone roof, EFR, and IFR configurations up to 110m diameter.
Pressure vessels & reactors
ASME U-stamp heat exchangers, process reactors, distillation columns, condensers, reboilers, and separators in SS, duplex, and exotic alloys for petrochemical service.
Process piping
High-pressure process piping, offsite piping, underground piping with 3LPE coating, and cross-country pipelines for petrochemical feedstock and product transfer.
Column erection
Heavy lift erection of distillation columns, fractionators, absorbers, and stripper towers using owned crane fleet (200MT, 100MT, 50MT). 40+ critical erections completed.
Structural steel
Pipe racks, equipment platforms, cable trays, access walkways, and structural foundations for petrochemical process units and utilities.
Shutdown & revamps
Brownfield revamps and turnaround maintenance inside operating petrochemical plants. Full PTW compliance and zero-incident execution in live plant environments.
Petrochemical industries we serve
Olefins & polymers
Ethylene crackers, polyethylene, polypropylene, PVC, and polymer processing plants. Process equipment, tankage, and piping for olefin downstream units.
Aromatics
Benzene, toluene, xylene (BTX) extraction and purification units. Reformer off-gas processing and aromatics recovery equipment.
Methanol & derivatives
Methanol, formaldehyde, acetic acid, and methanol-to-olefins (MTO) plants. Storage, handling, and process equipment fabrication.
Petrochemical intermediates
Butadiene, propylene, ethylene oxide, ethylene glycol, and other petrochemical intermediate processing and storage facilities.
Codes & standards
Vessel & tank codes
ASME Section VIII (U-stamp), API 650, API 620, IS 2825, TEMA R/C/B for heat exchangers, PESO SMPV(U) for mounded bullets.
Piping & safety
ASME B31.3 process piping, OISD 244 safety standards, NACE MR0175 sour service, IBR for steam piping.
Types of petrochemical projects
India's petrochemical industry spans a wide range of process technologies, from naphtha crackers to downstream polymer plants. HAIL's petrochemical engineering India capability covers mechanical, piping, and EPC scope across the following project types:
Ethylene and propylene plants
Naphtha and gas crackers producing ethylene and propylene as base feedstocks. HAIL's scope covers reactor systems, quench towers, fractionation columns, cryogenic separation equipment, and associated piping in CS, LTCS, SS, and 9% nickel for ethylene cold-box temperatures.
Polyethylene and polypropylene plants
Downstream polymer production units — HDPE, LDPE, LLDPE, and PP. Equipment includes loop reactors, flash drums, extruder feed systems, pelletiser support structures, and product storage silos with associated piping and utility systems.
PTA and PET plants
Purified terephthalic acid (PTA) and polyethylene terephthalate (PET) production facilities. HAIL fabricates and erects oxidation reactors, crystallisers, centrifuge supports, high-pressure process piping in SS 316/316L, and atmospheric storage tanks for paraxylene and acetic acid.
MEG and EO/EG plants
Mono ethylene glycol (MEG) and ethylene oxide/ethylene glycol production. Scope includes EO reactor internals support, glycol distillation columns, reboilers, condensers, and process piping in carbon steel and stainless steel with full PWHT and radiography.
Aromatics recovery and BTX
Benzene, toluene, xylene extraction and recovery units. Reformer off-gas processing, aromatic extraction columns, and product tankage for BTX storage and handling.
Methanol and derivatives
Methanol synthesis, formaldehyde, acetic acid, and methanol-to-olefins (MTO) facilities. Storage tanks, reactor systems, distillation equipment, and process piping for methanol plant mechanical infrastructure.
Green hydrogen & carbon capture
Petrochemical plants are adopting green hydrogen as feedstock and carbon capture (CCUS) for decarbonisation. HAIL provides EPC for hydrogen piping (ASME B31.12), electrolyser BOP, CO2 absorber column erection, and BESS infrastructure supporting petrochemical plant energy transition.
HAIL's scope in petrochemical projects
As a petrochemical EPC contractor with in-house petrochemical fabrication at our 33,000 sq.ft. Kalol workshop, HAIL delivers the following scope items for petrochemical complexes:
- Static equipment: Pressure vessels (ASME U-stamp), heat exchangers (TEMA R/C/B), reactors, columns, drums, and separators. Materials range from carbon steel through duplex, Inconel, and Hastelloy depending on process duty.
- Storage tanks: API 650 atmospheric tanks for feedstock and product — methanol, ethanol, naphtha, aromatics, and petrochemical intermediates. Cone roof, external floating roof (EFR), and internal floating roof (IFR) configurations.
- Process piping: High-pressure process piping per ASME B31.3 in CS, SS, alloy steel, LTCS, and lined piping. Shop spool fabrication at Kalol with field erection, NDT, and hydrotest.
- Structural steel: Pipe racks, equipment platforms, access walkways, cable tray supports, and structural foundations. Design, fabrication, surface treatment, and erection under single scope.
- Column erection and heavy lifts: Erection of distillation columns, reactors, and heavy vessels using owned crane fleet (200MT, 100MT, 50MT). 40+ critical erections completed with engineered lift studies.
- Electrical and instrumentation: Cable tray installation, cable pulling, termination, earthing, lighting, instrument installation, loop checking, and DCS interface support as part of multi-discipline EPC scope.
- Painting and insulation: Protective coatings (epoxy, polyurethane, zinc-rich primers), thermal insulation (mineral wool, calcium silicate, PIR), and fireproofing for structural steel and equipment.
- Pre-commissioning and commissioning support: System-by-system pre-commissioning — flushing, leak testing, rotation checks, interlock verification, loop checks, and safety system validation through to mechanical completion certificate.
Typical deliverables
For every petrochemical plant construction project, HAIL's engineering and project management teams produce the following deliverables as part of the execution scope:
- Fabrication drawings and shop detail drawings per ASME, API, and client specifications.
- Welding procedure specifications (WPS) and procedure qualification records (PQR) to ASME Section IX for each material-thickness combination.
- Non-destructive testing reports — radiography, UT, MT, DPT, PMI — with full traceability to weld joint numbers.
- Hydrotest reports with calibrated chart recorder data for every test package.
- Material test certificates (MTC) with third-party verification for all pressure-retaining materials.
- Post-weld heat treatment (PWHT) records with thermocouple charts for alloy and thick-wall fabrication.
- Erection survey reports — plumb, level, alignment, and orientation verification for all erected equipment.
- Pre-commissioning and mechanical completion dossiers per client turnover package requirements.
- As-built drawings reflecting all field changes and modifications during construction.
Major petrochemical hubs in India
HAIL's petrochemical engineering India operations are concentrated in the country's major petrochemical corridors, where proximity to clients reduces mobilisation time and logistics cost:
- Jamnagar, Gujarat: Home to Reliance Industries' integrated refinery-petrochemical complex — one of the world's largest. HAIL serves mechanical and EPC requirements for units within this corridor.
- Dahej, Gujarat: The Dahej Petroleum, Chemicals and Petrochemicals Investment Region (PCPIR) hosts multiple petrochemical producers. HAIL has active project history at Dahej including the Birla Copper facility.
- Hazira, Gujarat: Major industrial zone with ONGC, L&T, Shell, and petrochemical processing facilities. HAIL's Vadodara base provides fast mobilisation to Hazira projects.
- Vadodara, Gujarat: HAIL's headquarters and primary operations base. IOCL Gujarat Refinery at Koyali (adjacent to Vadodara) is a key client location where HAIL has delivered multiple projects including the N-Butanol unit for Thyssenkrupp.
- Haldia, West Bengal: IOCL Haldia Refinery and Haldia Petrochemicals — eastern India's primary petrochemical hub.
- Nagothane and Mumbai, Maharashtra: BPCL, RIL, and HPCL petrochemical facilities in Maharashtra's Konkan industrial corridor.
Reference projects
N-Butanol Project — IOCL Gujarat Refinery
Executed for Thyssenkrupp Industrial Solutions — process piping fabrication and erection, industrial coatings, and complete pre-commissioning inside a live refinery environment.
Multi-Discipline Revamp — IOCL Barauni
Rs 105 Crore EPCC for Coker-B unit — piping, painting, electrical, cathodic protection, heavy equipment erection, civil, instrumentation, and pre-commissioning.
Why HAIL for petrochemical projects
Single-point accountability
Mechanical + civil + piping + E&I under one contract. No interface gaps between disciplines that cause schedule slips in multi-vendor petrochemical projects.
Exotic metallurgy expertise
In-house fabrication capability for SS 304/316/321, duplex 2205/2507, Inconel, Hastelloy, and clad materials required for aggressive petrochemical service.
Live plant experience
Proven track record inside operating IOCL refineries and petrochemical complexes. PTW-compliant crews with zero major incident history.
Own workshop & cranes
33,000 sq.ft. fabrication workshop at Kalol. Owned crane fleet up to 200MT. Self-performed fabrication, erection, and testing without sub-contractor dependency.
What petrochemical plant services does HAIL provide?
HAIL provides complete mechanical and EPC services for petrochemical plants including storage tank construction (API 650), pressure vessel fabrication (ASME U-stamp), process piping, column erection, structural steel, and plant dismantling. We handle methanol, ethanol, butadiene, propylene, ethylene, aromatics, and downstream petrochemical units.
Which petrochemical plants has HAIL worked at?
HAIL has executed mechanical and EPC works at petrochemical complexes in Jamnagar, Dahej, Hazira, and Vadodara for clients including Reliance Industries, IOCL, BPCL, and Thyssenkrupp Industrial Solutions.
Does HAIL work inside operating petrochemical plants?
Yes. HAIL specialises in brownfield revamps and shutdown maintenance inside live petrochemical plants with stringent PTW protocols and HSSE systems.
What materials does HAIL fabricate for petrochemical service?
Carbon steel, stainless steel (SS 304, 316, 321), duplex (2205, 2507), super duplex, Inconel, Hastelloy, Monel, and clad plates — all per ASME Section VIII with full PMI traceability.