PROJECTS
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Modular Plant Construction
Sara Industry, as a trusted special project execution company, secured a prestigious contract in 2022 from a renowned chemical manufacturing company to construct a full-scale chemical plant to be commissioned in the USA. The innovative approach of the client involved designing and assembling the entire plant in Tamil Nadu, India, as modular units, which would then be shipped to the USA for final installation and commissioning.
PROJECT OVERVIEW:
| Category | Details |
|---|---|
| Client | Leading Chemical Manufacturer |
| Location | Tamil Nadu, India |
| Plant Capacity | 130,000 metric tons per year |
| Project Value | ₹40 Crores |
| Project Duration | 24 months |
| Total Structure Weight | 4,000 tons |
| Total Pipe Length | 1,20,000 inch-meters |
| Pressure Vessels Manufactured | 39 units (300 to 175,000 liters capacity) |
| Limpet Coil Tanks Manufactured | 10 units (400 to 75000 liters capacity) |
| Tanks with Full Coils Manufactured | 4 units (3000 to 175,000 liters capacity) |
| Air Preheater Manufactured | 1 unit with 2 Bundles consisting of 432 Nos finned tubes |
| Steam Drum Manufactured | 1 unit (18,000 liters capacity) |
| Pipe Size Range | 1/4 inch to 36 inch |
| Material Types Used | SS-304, SS 316, SS 316L, Carbon Steel, Titanium |
| Modular Units Erected | 71 units (5x5 meters; 54 Units – 20 meters & 17 units - 40 meters height) |
| Skilled Workers Involved | 160 |
| Semi-Skilled Workers Involved | 80 |
| Tools and Tackles Used | Yes |
| Erection Method | Modular Erection with Full Mock-Up Assembly |
| Final Execution | Dismantled, QC Checked, Loaded in Trucks |
Project Highlights
The contract involved the construction of 71 modular units, each measuring 5 meters in length and width, with heights ranging from 20 to 40 meters. These units housed a variety of essential equipment, including pressure vessels, limpet coil pressure vessels, centrifugal pumps with motors, fans, and other vital components specific to chemical plant operations.
Scope of Work
Sara Industry was tasked with the manufacturing of critical equipment's, pressure vessels and assembly of the complete plant in India including all equipment and structures.
Some of key equipment manufactured by SARA under this contract are as follows:
- Pressure Vessels: 39 high-capacity units, ranging from 300 to 175000 liters, were manufactured with precision and U Stamp certification to meet the stringent operational requirements.
- Limpet Coil and Full coil Tanks: 10 tanks designed with limpet in shell and dish and 4 tanks designed with full coils in shell, each with a capacity between 400 and 75000 liters, were fabricated to the highest standards.
- Air Preheater: Single pass Air preheater designed with circular shell consisting of 2 rectangular bundles with 432 Nos Finned tubes was designed, fabricated, stamped and supplied.
- Steam Drum: A robust 18,000-liter steam drum with U stamp certification, with dimensions of 2.0 meters in diameter and 7.3 meters in length, was designed and manufactured. The steam drum was designed for a design pressure of 720psi and was tested for a hydrotest pressure of 1020 psi.
- After Cooler: Critical Heat exchanger consisting of 5000 Nos of Finned tubes with dimensions of 2.5 meter in diameter and 11.5meter overall length was manufactured with U stamp certification. The equipment was designed, manufactured, tested and insulated at our factory and shipped directly to USA.
Structural and Piping Work
Structural Engineering: The project involved the erection of 4,000 tons of steel structures, forming the backbone of the modular units.
Piping System: An extensive network of 1,20,000 inch-meters of piping was installed, covering sizes from 1/4 inch to 36 inches in diameter. Materials used included SS-304, SS 316, SS 316 L, carbon steel and Titanium, ensuring durability and efficiency.
Modular Construction and Execution:
The project was executed using cutting-edge modular construction techniques. This approach allowed for the rapid assembly and disassembly of the plant's components, ensuring seamless transportation and installation at the final site in the USA. Key aspects of the modular construction process included:
- Modular Units: 71 units, each measuring 5x5 meters and with heights of 20 or 40 meters, were meticulously assembled, mock-tested, dismantled, and prepared for shipment.
- Quality Control: Rigorous quality checks were conducted throughout the process, including fit-up, welding, weld visual inspection, radiographic testing (RT), alignment verification and hydrotesting of all lines.
- Skilled Workforce: A dedicated team of 160 skilled workers and 80 semi-skilled workers were involved in the project, ensuring every detail was executed to perfection.
Final Execution
Upon successful mock-up assembly and quality control, the units were carefully dismantled, thoroughly inspected, and loaded onto trucks for transport to the shipyard. This meticulous approach ensured that the entire chemical plant could be reassembled seamlessly at its final destination in the USA.
Conclusion
This project stands as a milestone achievement for Sara Industry, demonstrating our capability to deliver complex and large-scale modular construction projects with precision and efficiency. The successful completion of this project has further solidified our reputation as a leading provider of industrial solutions on a global scale.