A gas-to-gas heat exchanger for UHDE’s
The Godrej Process
ll big ideas start simply. And one such simple
beginning in 1976, which saw the birth of the Process Equipment Division (PED),
today holds out the promise of being another big idea in the basket of big
ideas that Godrej has floated since 1897.
Starting with the manufacture of trays in 1976, PED today designs and
manufactures a range of process equipment in diverse metallurgies, ranging
from plain carbon steels to alloy steels, duplex and super duplex stainless
steels, nickel alloys and other non-ferrous metallurgies ranging from copper
to aluminium and titanium.
Starting with a not-so-big plant of Indian Petrochemicals Corporation
Limited (IPCL) in India, PED today has its equipment installed and
commissioned on every continent. Dehydrogen desulphurisation (DHDS)/ultra
low-sulphur diesel (ULSD) reactors, secondary reformers, polypropylene
reactors, high-pressure vessels and exchangers —for the uninitiated, these
are only names, but for process plant engineers, anyone who can make these
has well and truly arrived. PED can count itself among the global few.
PED discovered the global market in the late 1990s when capital investment
in India saw a downturn, and the start-up of new projects was consequently
put on the back burner. Not to be defeated by circumstances, the people in
PED set their sights across national boundaries and, in doing so,
transcended the self-imposed barriers of myths such as "We cannot be
competitive", "Too far away" and "Nobody wants 'Made in India'". Today the
question in PED is not "Argentina where?" It is "Argentina when?"
A few small orders and then came the big break in 2001. More than 100 pieces
of equipment out of a possible 250 for a fertilizer plant in Qatar ?QAFCO-IV
?confirmed global engineering major UHDE's confidence in PED's
capabilities. From then on there was no looking back.
A degassing vessel for Nanhai Petrochemical
Some of PED's major achievements in recent
UHDE Germany ordered close to 50 pieces of
critical equipment for a fertilizer project in Turkmenistan.
Godrej won a major replacement order from
Qatar Fertilizer Co. (Qatar) for supplying a critical high-pressure heat
exchanger ?a synthesis boiler feed water heater.
Technip (France) and Snamprogetti (Italy)
ordered equipment for another major fertilizer plant in Oman.
PED received an order from Aker Kvaerner
(the Netherlands) for supplying stainless steel columns to EVAL, a
petrochemical plant in Belgium. This was PED's first opportunity to
supply equipment to a European plant.
Bechtel (Houston) ordered stainless steel
vessels for a liquefied natural gas (LNG) plant in Darwin, northern
Tecnimont (Italy) ordered a degassing
vessel for Nanhai
Petrochemical Complex in China.
PED won an order from Technip (Italy) for
supplying a critical high-pressure reactor for a desulphurisation project in
a refinery in Chile.
Bechtel (Houston) ordered stainless steel and
clad vessels for an LNG project in Equatorial Guinea, west Africa.
BASF (USA) ordered three large and heavy heat
exchangers for their petrochemical plant in Port Arthur, Texas.
Hitachi Zosen (Japan) ordered DHDS reactor
internals for a low-sulphur diesel project in Bahrain.
PED broke through into the top of the line and
most coveted segment of the market ?DHDS reactors. It bagged the largest
single order worth U.S. $14 million for three such high-pressure,
thick-walled reactors from Valero Refinery in Louisiana, USA. The heaviest
reactor weighs 665 metric tons and the base material of the reactors is
heat-resistant alloy steel, of 153 mm, 132 mm and 124 mm thickness
respectively, and will be cladded from the inside with a 3.2 mm deposit of
Stainless Steel 347 (SS 347) ?using the electro slag strip cladding
process. Along with the reactors, PED will also fabricate and supply the
trays and internals, which will be installed in the reactors before despatch.
This highlights PED's unique strength of being the only international
fabricator with contrasting capabilities required to supply reactors as well
as reactor internals/trays.
PED's relentless efforts to get a share of the
replacement market comprising major end users in the Middle East paid off,
when Kuwait National Petroleum Company placed a major order for 25 heat
A CD hydro column for Jacobs / Conoco
Today PED's capabilities have been endorsed by
the biggest international names in the process licensing and engineering and
contracting business ?UHDE, Aker Kvaerner, Bechtel, Jacobs, Conoco
Phillips, Valero, Japan Gas Corporation, Stone & Webster, Technip,
Snamprogetti, Haldor Topsoe, Universal Oil Products, Tecnimont?The list is
not endless, but it is growing rapidly.
Getting them is not as difficult as keeping them. For that, PED's mantra has
been to perform consistently well on each of the critical success factors
for international projects —Total Quality, Logistics, Schedule, Safety and
Aesthetics. This has been achieved thanks to consistent and sustained
efforts towards augmenting infrastructure, upgrading quality systems,
regular progress monitoring and review, and implementing better shop
practices. At the same time, region-specific marketing approaches have been
evolved to ensure optimum focus and better overall coverage.
A CD hydro column for Jacobs / Conoco
weighing 480 MT and 71m tall.
However, the biggest catalyst for PED's
progress has been its "can do, will do" attitude, high level of self-belief,
commitment and transparency coupled with the doggedness to hang in there.
The indefatigable desire to excel and to contribute is shared by all members
of the PED team; there have been innumerable occasions where workmen have
taken the initiative to perform a task in a better way ?be it mechanisation
or fixturing. It is this pooling of ideas and the collective determination
to succeed that makes PED tick.
PED won its first order for physical exports
to Saudi Arabia, when UHDE, Germany, ordered critical equipment such as
secondary reformer and high-pressure exchangers and vessels for a fertilizer
project, SAFCO-IV. For the third consecutive year, UHDE ordered a major
project from PED, signifying the high level of confidence and trust they had
in PED's capabilities.
SNC Lavalin (Perth, Australia) ordered alloy
steel reactors for a fertilizer plant in Karratha, western Australia.
PED received an order from Metax (Singapore)
for supplying the world's largest butterfly valves to the Changi Water
Treatment Project, Singapore.
PED received an order from Jacobs (USA) for
fabrication and supply of two large towers to Alliance Refinery of Conoco
Phillips, Louisiana, USA. These towers were the cornerstones of the low-sulphur
gasoline project being implemented at the refinery. This was a significant
landmark in PED's progress, being PED's first opportunity to physically
export to the USA. It also brought with it a huge challenge for the PED
team, as the order comprised the heaviest and tallest columns to have ever
gone out of not just PED, but also from the city of Mumbai. The city's civic
and port infrastructure had never been tested to this extent and hence was
unproven. The PED team took up this as well as the other challenges, which
are part and parcel of a complex and high-magnitude project such as this.
The path to successful project execution was fraught with numerous hurdles
and unknown devils. PED's resolve and unwavering focus saw it through and
the columns were delivered to Mumbai’s high seas almost 10 days ahead of the
contractual delivery date (19 November, 2004). This performance left the
customer completely satisfied ?in fact overwhelmed ?with the commitment
shown by PED.
That PED has firmly established itself as an
international manufacturer of high-end equipment is evident from the fact
that PED's international sales constitute about 65 per cent of the annual
The PED team looks ahead to explore more uncharted territories, to reach out
to newer horizons in the future. PED also strives to realise its dream of
being a leading global fabricator of high-end critical process equipment
counting every major process plant in the world among its satisfied
The PED Team