Enereff Engineers Projects Undertaken

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Enereff has now broadened its engineering support services to beyond the Fired Heaters and now carries out all the engineering associated with the other interlinked disciplines. Accordingly, the repertoire of Enereff’s support encompasses the following fields of engineering:

Process Engineering
Thermal Engineering
Mechanical Engineering
Piping Engineering
Structural Engineering
Electrical Engineering
Instrumentation Engineering

This enables Enereff to support the end users, LSTK contractors, EPC agencies in providing a single stop centre of Engineering solutions and Project Management services for assignments related to its area of operation.

The list of Projects successfully brought to conclusion is quite detailed but a few of the recent Projects undertaken/ under execution by Enereff are mentioned below:

1.OHCU HEATERS/ APH SYSTEM, IOCL HALDIA

Enereff carried out design of 2 Nos. OHCU Heaters with a common Air-preheating system of overall heat duty of 42.4MMKcal/hr for IOCL Haldia Refinery. Scope included:

Preparation of Heater/ APH system P& IDs
Thermal/ Mechanical/ Structural design/ Refractory design
Preparation of engineering & fabrication drawings
Preparation of equipment data sheets/ MRs. Scope also included preparation of Operating & Maintenance manual as well as assistance during erection & system commissioning

2. HOT OIL SYSTEM ON NQ-RC OFFSHORE PLATFORM,
ONGC MUMBAI

Enereff undertook design & engineering of the Hot Oil system for the NQ-RC Platform, ONGC, Mumbai. Scope included design of a Hot Oil Trim Air Cooler, Crude Oil Heater, 4 Nos. Waste Heat Recovery Exchangers (with stacks and ducting) on Gas Turbines, exhaust, Hot Oil Expansion vessel, Catch pot and other associated equipment. The engineering support included:

Thermal/ Mechanical/ Structural Design, SACS design of the GT Stacks (2 Nos. up to 25 m from top of deck for each WHRE)
Review of vendor offers, TQ’s
Preparation of Engineering and Fabrication drawings for the critical equipment

3. NEW CONVECTION SECTION FOR CCR PLATFORMER,
ESSAR STANLOW REFINERY, U.K

Enereff undertook design and engineering of a new Convection Section system with ducting for a large Platformer for Essar’s Stanlow Refinery, U.K.
Scope included:

Thermal design
Mechanical/ structural design with engineering & fabrication drawings
Electrical/ instrumentation engineering
Preparation of equipment data sheets/ MRs/ Design documents
3D modelling
Modularisation engineering

Scope also included Transportation and erection engineering including lifting beams, transportation steel, erection procedures

4. STACK DAMPERS FOR HEATER REVAMP, TAKREER REFINERY, UAE

Enereff undertook design of 10 Nos. Stack Dampers for a project for revamp of Heaters for Takreer Refinery, UAE. Scope covered Damper design, pneumatic actuation system sizing, preparation of control schemes, release of engineering and fabrication drawings, control instrument data sheet preparation

5. TRIM CRUDE HEATER/ APH SYSTEM/ TRANSFER LINE, IOCL HALDIA

Enereff has been engaged by M/S IOCL Haldia for carrying out complete Process/ Thermal/ Mechanical/ Structural/ Civil/ Electrical/ Instrumentation/ Piping engineering for 1 No. Trim Crude Heater/ APH System of capacity 14.4 MMKcal/hr with Transfer line. Scope included:

Heater system sizing and detailed engineering of all associated disciplines
Scope also included complete cost estimation and preparation of various MRs for bought out items and a Site Tender, preparation of Operating & Maintenance manual

Enereff is also the Project Management Consultant (EPCM) to IOCL. Scope included Project Management/ Monitoring/ Techno-commercial analysis/ Tendering/ Site Supervision including commissioning assistance and material reconciliation.

6. 3 NOS. FURNACES/ APH, CDU & VDU UNITS, HMEL BATHINDA

Enereff undertook design & engineering for 3 Nos. Furnaces/ APH Systems for CDU/ VDU Units at HMEL Refinery, Bathinda. Crude Heater was of a ‘vertical tubes in box’ design while the Vacuum Heater was a twin cell cabin type. The Crude Heaters have a common APH system while the Vacuum Heater had an independent APH system. There was a common grade mounted 80m stack for the Heaters. The engineering support included:

Tender Document review for correctness
Preparation of Equipment data sheets/ MRs, Design Documents
STAAD Analysis, Engineering and Fabrication drawings, Trouble-shooting assistance at site etc

7. 2 NOS. FURNACES/ APH, DHDT UNIT, HMEL BATHINDA

Enereff carried out design & engineering for 2 Nos. Furnaces/ APH System with a common top mounted Stack for DHDT Unit at HMEL Refinery, Bathinda. The engineering support included:

Tender Document review for correctness
Preparation of Equipment data sheets/ MRs, Design Documents
STAAD Analysis, Engineering and Fabrication drawings
Trouble-shooting assistance at site etc

8. 5 NOS. FURNACES, NHT/ CCR UNITS, HMEL BATHINDA

Enereff was engaged for undertaking design & engineering for 5 Nos. Furnaces for NHT/ CCR Units at HMEL Refinery, Bathinda. The CCR Platformer is having 4 Arbor type Radiant Process Coils in a single casing with a common Convection Section used for BFW heating, steam generation/ steam superheating. The engineering support included:

Tender Document review for correctness
Preparation of Equipment data sheets/ MRs, Design Documents, IBR (Indian Boiler Regulation) Calculations, STAAD Analysis
Engineering and Fabrication Drawings, Trouble-shooting assistance at site etc

9. CRUDE AND VACUUM HEATERS/ APH SYSTEMS, IOCL PARADIP

Enereff is presently carrying out complete Process/ Thermal/ Mechanical/ Structural as well as Electrical/ Instrumentation and Piping Engineering for 2 Nos. Crude Heaters/ APH systems of capacity 66.42 MMKcal/hr each and 1 No. Vacuum Heater/ APH System of capacity 73.78 MMKcal/hr. Scope includes:

Preparation of P& IDs, Data sheets, Heater system sizing
Detailed Engineering of all associated disciplines
Preparation of various MRs (Material Requisitions) for bought out items
Preparation of Operating & Maintenance manual and also provide assistance in commissioning

Enereff is also carrying out 3D modeling of the Heaters with all Process/ Utility Piping Transfer line upto Heater battery limit.

10. NHT HEATER/ APH SYSTEM & CCR HEATERS, IOCL PARADIP

Enereff is currently engaged in carrying out complete Process/ Thermal/ Mechanical/ Structural/ Electrical/ Instrumentation as well as Piping engineering for 1 No. NHT Heater/ APH system of capacity 30.48 MMKcal/hr and CCR Heaters with the following description:

Charge Heater of capacity 70.55 MMKcal/hr
Inter Heater-1 of capacity 76.12 MMKcal/hr
Inter Heater-2 of capacity 51.23 MMKcal/hr
Inter Heater-3 of capacity 53.03 MMKcal/hr

Scope includes:

Preparation of P&IDs, Data sheets, Heater system sizing
Detailed Engineering of all associated disciplines
Preparation of various MRs (Material Requisitions) for bought out items
Preparation of Operating & Maintenance manuals and also provide assistance in commissioning

11. 4 NOS. FURNACES/ APH, HYDROCRACKING/ DHT UNITS,
BORL BINA

Enereff undertook design & engineering for 4 Nos. Furnaces/ APH Systems for HCU/DHT Units at BORL, Bina. Heaters are high pressure & temperature type and are of various configurations – dual cell cabin type or vertical cylindrical type. Outboard and onboard APH systems alongwith a grade mounted 100 m stack were also engineered. The engineering support included

Tender Document review
Preparation of equipment Data sheets/ MRs, Design Documents, STAAD Analysis, Engineering and Fabrication Drawings
Trouble-shooting assistance at site etc

12. DE-BOTTLENECKING STUDY FOR CRUDE PRE-HEAT TRAIN &
CDU/ VDU HEATERS/ APH SYSTEM FOR CAPACITY ENHANCEMENT, ESSAR OIL LTD.

Enereff had been engaged by Essar Oil Ltd., Jamnagar to undertake a comprehensive Study of upgrading the Crude/ Vacuum Unit capacities from 10.5MMTPA to 14 MMTPA. Scope included complete re-engineering of the Crude Exchanger Pre-heat Train and Crude/ Vacuum Heaters with their Airpreheating systems to cater to the upgraded refinery capacity with minimum changes.

13. LOBS HEATERS FOR BPCL MUMBAI

Enereff had provided Thermal & Mechanical design & detailing of 3 Nos. LOBS Heaters, BPCL Mumbai. Scope included:

Review of Heater/ APH system P&IDs
Thermal/ Mechanical/ Structural design, Refractory design, Preparation of engineering & fabrication drawings
Preparation of equipment data sheets/ MRs

Scope also included review of Operating & Maintenance manual as well as assistance during erection & commissioning

14. 30 MM KCAL/ HR HOT OIL HEATER/ APH SYSTEM, NIRMA

Enereff had been engaged by M/S Nirma for Thermal/ Mechanical design & Detailing of a new Hot Oil Heater of 30 MM Kcal/ hr alongwith an Outboard Airpreheating system. Scope included:

Process/ Thermal/ Mechanical design
Preparation of P& IDs, Instrumentation engineering, Furnace battery limit piping design
Refractory design, preparation of Engineering & Fabrication drawings & assistance at site and other execution support

15. ENGINEERING & PROJECT MANAGEMENT CONSULTANCY OF APH SYSTEM FOR VISBREAKER HEATERS, IOCL MATHURA

Enereff had been engaged by IOCL Mathura for carrying out the complete Process/ Thermal/ Mechanical/ Structural/ Civil/ Electrical/ Instrumentation/ Piping engineering of the complete Airpreheating system for 2 Nos. cabin type Visbreaker Heaters. Scope included:

Review of existing operating data
Simulation of vapour-enthalpy curves/ Physical properties of VBU feed, finalisation of revised VBU Heater duties
Simulation of existing Heaters with APH system, sizing of the APH system, and detailed engineering of all associated Instrumentation/ Electrical/ Civil & Piping disciplines for the system

Scope also included complete cost estimation and preparation of a composite Site Tender for execution of the scheme.

Enereff was also the Project Management Consultants to IOCL. Scope included Project management/ Monitoring/ Tendering/ Site supervision including commissioning assistance and material reconciliation.

16. STUDY FOR DE-BOTTLENECKING OF VISBREAKER HEATER,
IOCL BARODA

Enereff had been engaged by IOCL Baroda for carrying out a Study for trouble shooting of the existing Visbreaker Heater in the VBU Unit. The problem relating to over-pressurisation of Arch and under-performance was addressed including complete replacement of the Convection Section with a properly designed one. In-adequate ID fan operation was also to be resolved. The existing Heater operation was required to be improved by hardware changes so that the present Heater condition could be rectified and operation became safer.

The study included Data collection, Problem analysis, making recommendations for resolution of the operational anomalies.

Endeavour was also made to increase the Heater duty to the extent feasible under the given site limitations

17. HOT OIL HEATER/ APH SYSTEM, LAB PLANT, IOCL BARODA

Enereff had been engaged by M/S UHDE India Ltd for undertaking preparation of complete FEED Package for the 95 MM Kcal/ hr Hot Oil Heater/ APH System for the LAB Plant at IOCL Baroda. The scope included:

Undertaking of Thermal Design, P&IDs, Equipment Data sheets
Preparation of Engineering Drawings for the Heater, APH system Layout & grade mounted 80 m tall Stack
Foundation Loading Data had also being provided based on STAAD Design

The APH System was common to both the Pacol Heater & the Hot Oil Heater. Scope also included preparation of complete Bid Package for the Heater/ APH System and vendor document review.

18. MOUNDED LPG INTERIM STORAGE FACILITY, GAIL PATA

Enereff had been engaged by M/S L&T for Design & Detailing of the mounded LPG Interim Storage Facility at GAIL’s Pata site. This was a very typical design using 36” NB pipe fingers with headers to store LPG under a mound.

Scope included design, preparation of fabrication drawings, bill of material and assistance at site.

19. LINE BURNER MIXING CHAMBER, SRU REVAMP, IOCL PANIPAT

Enereff had been engaged by M/S L&T for design & detailing of Line Burner Mixing Chamber for the SRU Revamp at IOCL Panipat.

Scope included refractory design, mechanical design & preparation of fabrication drawings.

20. HEAT EXCHANGERS FOR BENZENE UNIT,
HALDIA PETROCHEMICALS

Enereff was engaged by M/S Lurgi India to carry out the Design & Preparation of drawings, fabrication drawings checking for 21 Nos. Heat Exchangers for the Benzene Extraction Unit of M/S HPL.

21. STACK DAMPER M/S HPCL, BOMBAY

M/S Thermax engaged Enereff to carry out the design of the Stack Damper for a Furnace at HPCL Bombay.

The scope included design, preparation of Damper drawings & data sheets for various control instruments.

22. FEASIBILITY STUDY FOR EFFICIENCY IMPROVEMENT OF
VBU / VDU FURNACES, IOCL BARODA

Enereff carried out a complete Feasibility Study for trouble shooting and Improvement of Efficiency of Visbreaker & Vacuum Furnaces at IOCL Baroda. The study included:

Data collection, Problem analysis
Making recommendations for good housekeeping and new APH system, Cost estimation and Techno–economic viability analysis
Study also included analysis of problem of overpressurisation of VBU Furnace arch and performance of existing ID Fans

23. STEAM GENERATION SYSTEM FOR 5 FURNACES OF IOCL, HALDIA

Enereff carried out design of Outboard Steam Generation System common to 5 Furnaces in the CRU Unit of IOCL Haldia for heat recovery from flue gases. Scope included:

Process Design, Preparation of PFDs/ P&IDs, Instrument Data Sheets
Thermal design Utilities summary, Preparation of Arrangement drawings, MRs, Site Tender for the total system
Enereff also undertook HAZOP study, Preparation of control logics and interlocks etc. for the complete system. Enereff also carried out the structure design and complete review of IBR & non-IBR piping

24. STEAM AIR HEATING SYSTEM TPS BOILER, IOCL HALDIA

Enereff undertook complete Thermal/ Mechanical design of Steam Air Heater along with its associated upstream/ downstream Piping, Instrumentation, development of P&ID for steam control and condensate removal scheme, preparation of Piping Drawings, MRs/ PRs for bought outs/ Instrumentation & Preparation of Fabrication/ Structural Drawings. The system was under IBR inspection.

The job was engineered for a dimensionally limiting location and a unique design was developed for ease of operation/ maintenance. The unique feature of this scheme was that the entire air preheating was achieved by steam heating only. The instrumentation was microprocessor based and engineered for hooking up to the DCS system.

25. DAMPERS FOR BOILER, ATIC INDUSTRIES

12 Nos. of high sealing Dampers were designed & engineered for M/S ISGEC John Thompson, Calcutta for installation in a Boiler at ATIC Industries, Gujarat. These Dampers were catering to high temperature gases. The Dampers were designed with Pneumatic/ Electrical actuation system and some Control Dampers with control characteristics were also engineered. Sealing efficiencies achieved were over 99.95% on area.

Enereff is also undertaking 3D modeling of all battery limit piping with the Heaters/ APH system in this project. Having a fully integrated engineering team working together under one roof is the best of both worlds - as it eliminates communication problems between designers and contractors. This approach allows for “best field practices” to be incorporated into the design – thus making the process more time and resource efficient.

Partnership created between the Project owners and our professionals establishes a foundation for the successful, safe and timely execution of projects.

At Enereff, we believe that a good design begins with a thorough understanding of the client’s goals, expectations and requirements. It is a collaborative effort; a joining of minds to deliver the best possible solutions. Over the years, in diverse locations, Enereff has delivered, to private and public sector clients, a range of innovative designs and solutions encompassing a range of Heat Transfer Projects.

Clients

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