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Operations

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Essar Projects has various advantages, which provides it with an ability to offer a comprehensive full-spectrum engineering, procurement, and construction capability to its clients

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Essar Projects is uniquely positioned among the Indian contracting fraternity with its integrated engineering, procurement, and construction (EPC) capability that includes both backward integration in steel and steel processing supply chain and forward integration of fabrication and modularization services. Apart from this we also have the advantages of incorporating operational experience of sister companies into the design and engineering phase of new projects.


We operate through these main businesses:

Hydrocarbon business unit
Essar Projects has executed a world-scale grass-roots refinery at Vadinar, Gujarat, with a capacity of 14 MMTPA, with the expansion phase leading to 20 MMTPA to be completed and commissioned shortly. This world-scale refinery has many complex process units. In addition, the utilities and infrastructure facilities built and commissioned include SBM for crude unloading, product jetty for refinery product export, a tank farm with total tankage of 3million cubic metres for crude, products and intermediate and 77 MW of captive power plant.

Steel business unit
Essar Projects enjoys a distinct advantage in the steel sector as it has created most of the assets for Essar Steel, which has an extremely high-level forward and backward integration. This has enabled Essar Projects to forge a significant presence in every stage of the steel manufacturing process, from iron ore to rolling out the end product. We are now regarded as a world leader in the delivery of beneficiation, slurry pipelines, pellet plant, jetty, integrated steel plant, and plate and pipe mill. Some of our completed projects include a 8 MMTPA beneficiation plant at Bailadila, Chhattisgarh; 8 MMTPA pellet plant at Vishakhapatnam, Andhra Pradesh; 4.6 MMTPA Integrated steel plant at Hazira, Gujarat; etc.

Power business unit
Essar Projects executes power plants across a diverse portfolio of gas-based, coal-fired and renewable energy sources. It was also the first private company to obtain a power transmission license in India. Some of its major completed projects include 515 MW combined cycle multi-fuel power plant, Hazira, Gujarat; 120 MW captive co-generation multi-fuel power plant at Vadinar, Gujarat; 500 MW gas-fired combined cycle power plant at Bhander, Gujarat; etc.

Offshore and subsea business unit
Essar Projects provides project management and engineering, procurement, construction, installation and commissioning services for marine construction projects in offshore and subsea. It also specialises in the development and construction of offshore terminals. It has been a pioneer in this business sector since two and a half decade and has executed several turnkey projects. Our total experience sums up to 350kms subsea pipelines, installation of 18 wellhead platforms and modification of 53 platforms. Some of our major completed projects are a complex revamp project worth $212 million at Mumbai High Field for ONGC, installation of SPM, PLEM and diffuser and laying of 48 inch concrete pipeline of 16 km for mooring 325,000 DWT tankers in the Gulf of Kutch for Vadinar Oil Terminal, laying of 28 inch subsea pipeline of 10.5km in the Gulf of Khambat for Bharuch Eco-Aqua Infra, etc.

Pipelines and terminals business unit
Essar Projects specializes in EPC services for cross-country, onshore and shallow water pipelines, and we have the capability to design, plan and execute complex pipeline projects in oil and gas, water, and slurry sectors. Some of our completed projects include the worlds second-longest iron ore slurry pipeline project of 267kms long Bailadila to Vizag, Ambatovy nickel ore slurry pipeline project at which is 100kms of 24 inch diameter nickel slurry pipeline at Madagascar, Vijaipur-Dadri gas pipeline project for of 330kms of 48 inch for GAIL, etc.

Ports and jetties business unit
Essar Projects has played an important part in the development of most major ports in India, and it has also contributed significantly to the growth of Essar Shipping, Ports, and Logistics, which is one of the largest owners and operators of ports in India. Some of its major projects include Nhava Development project for ONGC supply base, iron ore terminal for Goa Port Trust, Deepwater Port with 650m long berth and jetty at Kakinada in Andhra Pradesh, etc.

Civil and buildings business unit
Essar Projects specializes in buildings and townships, hydro power projects and all forms of infrastructure, including roads, bridges, railways, and airports. Some of our major completed projects include the development of 350 acres to build 1,597 residential units on a built up area of 2,500,000 sq ft for Hazira township and 60 acres developed to build 342 residential units on an area of 500,000sq ft for Vadinar township. Apart from these we have also rehabilitated and upgraded various national highways to four lanes such as 77kms of Chitradurga-Harihar and 56kms of Harihar-Haveri.

Heavy engineering services
State-of-the-art heavy engineering workshops, which has strategic waterfront access, facilitate Essar Projects to manufacture and fabricate a wide range of engineered-to-order heavy equipment, such as pressure vessels, reactors, vacuum vessels, cranes and steel plant equipments. During the last one year we have fabricated and delivered equipment totaling 15,000 MT of steel and fabricated pressure vessels of up to 250 MT and 140mm steel plates. These facilities are now being expanded to a capacity of 40,000 MTPA and will include the ability to construct offshore jackets and platforms in house.

Equipment bank
Essar Projects are owners of largest and latest equipment banks in the Indian EPC market space, that is constantly updated. This bank offers a competitive advantage and it allows the company to deliver the projects on fast-track basis. Our highly skilled operations and maintenance crew use preventive and condition-based maintenance to minimize downtime. Every stage of the project is closely monitored and managed on equipment tool management software, which helps manage over 3,000 items of equipment across multiple sites.

Engineering services
Essar Engineering Services has a pool of over 1,100 engineers with rich and varied experience in disciplines such as civil and structural, mechanical, electrical and electronics, piping, process, and instrumentation engineering, in addition to utilities and material handling, HVAC and FSPD projects. Our engineering team uses the latest design tools and collaboration processes to deliver end-to-end capability across all of the world’s time zones. Some of our major completed projects are 2 MMTPA refinery expansion project at Vadinar, 2 x 4.5 MMTPA steel pellet plant at Oman, marine facilities, jetty and offsite systems for 34 MMTPA port and terminal expansion project at Vadinar, 5 MMTPA integrated steel plant at Hazira, etc.

Procurement
Essar Projects follows a project-oriented procurement philosophy and relies on its global sourcing team to capture and add synergies to its supply chain. Our procurement team aims to build sustainable vendor relationships across business verticals in order to achieve and deliver cost efficiencies to the business, and thereby assist in creating competitive advantage for our clients. We have a strong registered global vendor base of over 26,000 vendors and our procurement systems are supported on Ariba platform.

Construction
Essar Projects has been in the construction industry for last four decades and has the ability to execute and deliver large and complex projects with a quick turnaround time. We are well placed to successfully execute projects of mega size and technical complexity with our experienced construction management manpower resource, technical and managerial expertise, fabrication facility, heavy-lifting capability, and extensive equipment bank. Across all our sites our operations teams accord highest priority to safety, quality, and environment protection principles. We optimize productivity and cost with the application of advanced construction and project management tools and information systems.

Technology
Essar Projects has a track record of working with technology partners across diverse and complex activities. We have recently negotiated and concluded an agreement with Foster Wheeler, the American engineering and construction company to license and manufacture CFB boilers from 150 MWe and potentially up to 800 MWe capacity. This will facilitate the entry of Essar Projects into the ever-growing utility power plant equipment space. The management sees this as the first step towards Essar Projects’ entry into design, manufacture and supply of power plant equipment, with further technology tie-ups for other equipments on the anvil. The philosophy being followed is “international technology and quality at Indian prices”.



 
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