The dismantling expert refineries and chemical plants trust
Decommissioning is a different discipline from construction. Aged equipment, residual product, fatigued steel and live-site interfaces all change the risk picture. HAIL has invested in dismantling-specific equipment, training and method statements so that one contractor can take responsibility for the entire shutdown — tanks, columns, exchangers, pipe racks, flare stacks and structural steel — under one HSSE plan.
We are the first Indian contractor to apply reverse jacking to an ammonia tank. The same method works on any large-diameter cylindrical tank: lift the shell with hydraulic jacks, cut at ground level, eliminate working-at-height. We currently apply it at Birla Copper Ltd., Dahej for Ostwal Phoschem (India) Ltd., dismantling a double-wall ammonia tank and a 55-metre flare stack.
What we dismantle
Storage tanks
API 650 fuel and chemical tanks, EFR/IFR/DDFR roofs, ammonia and cryogenic tanks, fire-water and DM-water tanks.
Pressure equipment
Reactors, columns, heat exchangers, condensers, boilers, deaerators, drums and ASME pressure vessels.
Flare stacks
Self-supporting and guyed flare stacks up to 60+ metres — engineered cut-down with controlled lowering.
Pipe racks & structures
Refinery pipe racks, equipment platforms, technological structures, silos and industrial buildings.
LPG bullets & spheres
Decommissioning of LPG mounded bullets and spherical vessels — purge, drain and sectional dismantle.
Full plant decommissioning
Aged refinery units, fertiliser and chemical plants — taken from running facility to cleared foundation.
Reverse jacking — the engineering edge
Conventional cutting needs full-tank scaffolding, top-down cutting and weeks of working at height. Reverse jacking lifts the shell on synchronised hydraulic jacks so each ring is cut and lifted off at ground level. Result: ~90% reduction in working-at-height, faster cycle, less scaffolding, and cleaner residue handling. We engineer the jack arrangement to the shell stiffness, residual loads and crane access so that the operation is completely controlled.
Safety and waste management
- Aged-plant safety study & HAZOP before mobilisation.
- Cold cutting (band saw, abrasive, magnetic drill) in vapour zones; hot work only after gas-free certification.
- Nitrogen purging, scrubber venting and continuous downwind monitoring for hazardous-residue tanks.
- Material segregation: ferrous, non-ferrous, insulation (perlite, foam-glass), refractory and hazardous waste.
- Waste manifests, weighbridge tickets and statutory disposal documentation.
- HSSE-trained workforce with cranes, man lifts, scissor lifts and certified scaffolding.
Reference projects
- Birla Copper Ltd., Dahej (Ongoing) — Reverse-jacking dismantle of double-wall ammonia tank + 55 m flare stack. Zero-incident execution for Ostwal Phoschem (India) Ltd.
- Refinery shutdowns & turnarounds — Multi-discipline support inside live IOCL facilities (Barauni, Gujarat) with full HSSE compliance.
- Plant clearing & equipment salvage — Aged tanks, columns and pipe racks dismantled, segregated and despatched under client manifests.
Why HAIL for dismantling
- India's first reverse-jacking ammonia tank dismantle — documented method, audited HSE.
- Single point of responsibility — engineering, dismantling, transport and disposal under one PO.
- Owned 200 MT, 100 MT, 50 MT and 20 MT cranes — no rental risk.
- Same workforce that builds tanks; we know exactly how to take them apart.
Frequently asked questions
What is reverse jacking in tank dismantling?
Hydraulic jacks lift the shell so each ring is cut and removed at ground level — instead of working at 25—30 m height with full external scaffolding.
What kinds of tanks and equipment do you dismantle?
Storage tanks, ammonia and cryogenic tanks, LPG bullets/spheres, columns, reactors, exchangers, boilers, flare stacks, pipe racks and entire plants.
Do you handle hazardous-residue tanks?
Yes — with HAZOP, drain-down, flushing, N— purging, scrubber venting and waste manifesting.
How fast is reverse-jacking dismantle?
Typically 30—40% faster than conventional top-down cutting on a 30 m diameter tank, depending on residue and insulation.
Do you provide aged-plant safety studies?
Yes — independent walk-down, structural fitness assessment, HAZOP and engineered dismantling procedure are issued before mobilisation.