lloyds steel industries limited engineering · pdf fileiocl haldia column through punj lloyds...

HYDROCARBON SECTOR

Introduction • Lloyds Steels Industries Ltd is established on May 12, 1974 at

Andheri, Mumbai and subsequently shifted its shop and converted into heavy fabrication, machine building unit at Murbad, Thane Dist. Maharashtra.

• Designer and manufacturer of heavy equipment, machines for Hydro Carbon, Oil & Gas ,Steel Plants, Power Plants, Boilers and Turnkey Projects.

• Our workshop is accredited with ISO 9001:2008 certification by SGS, United Kingdom.

• Our workshop is approved / enlisted by international consultants like Uhde, Tecnimont ICB, Aker Kvaerner, Jacobs H & G, EIL, Lurgi, PDIL, MECON, Dastur & Company, Toyo, SMS Group etc.

• Regularly undertaking jobs with reputed Inspection agencies like Lloyds, ABS, BV, TUV, DNV, SGS, IRS, etc.

2

LLOYDS STEELS INDUSTRIES LTD. A Shop

• Address : A 6/3 MIDC Area, Murbad

• Excise registration No. AAACE9285CEM001

• Service Tax registration No. CST TIN NO AACE 9285CSD001

VAT TIN No 27541147064 V

• Area : Covered (2 Bays) 4600 Sq Meters

• : Open 200 Sq Meters

• : Office (Built-up) 315 Sq Meters

• Type of product : Fabrication & Stress Relieving work

SS Fabrication, Assembly of Hydraulic equipment

Stress Relieving Furnace : 6 M x 6 M x 14 M long, Capacity : 80 Tons

• No of Shifts : 2 ( each shift of 8 hours)

• Workers / Shift : 50 Nos.

• Cranes : Bay 1 - 1 x 15 Tons, 1 x 25 Tons EOT

Bay 2 – 1 x 20 T, 1 x 15 Tons EOT

• Max size of equipment manufactured & despatched : 4 M Dia. x 33 M Length 100 MT MOC- SS for IGL.

3

LLOYDS STEELS INDUSTRIES LTD

B & C Shop


• Excise registration No. AAACE 9285CEM002

• Service Tax registration No. CST TIN NO AAACE 9285CSD001

VAT TIN No 27541147064V

• Area : B Shop : Covered 2250 Sq Meters

• C Shop : Covered 3400 Sq Meters

• Open 4800 Sq Meters

• Type of product :

B Shop : Light Machine shop, Fabrication & Assy. of items, Dished end ,

Normalizing furnace , 1000 MT Hydraulic press.

C Shop : Heavy Machine shop, Fabrication , Assy. / Testing & Paint booth,

Heavy thickness Plate Bending machines, 2000 MT Hydraulic press.

• No of Shifts : 2 ( each shift of 8 hours)

• Workers / Shift : 130 – 150 Nos.

4


B & C Shop

• Cranes : B Shop - 1 x 25 ,1x10 T, 1 x 5 T, 1 x 15 T & 1 x 20 T EOT

C Shop - 2 x 50, 2x10 T, 1 x 25 T EOT

• Max size of Job manufactured :

4.5 M Dia x 18 M Long, 122 MT Condenser for IIPL Power Plant,

Wardha

5.0 M Dia x 25 M Long, 140 MT for Punj Lloyds Ltd., for BORL

Refinery, Bina, MP.

7 No’s base frames for Rotary shear, weight 80 MT each for

Welspun, Anjar, Gujarat.

5.8 M Dia x 45.2 M Long, 382 MT Depropanizer Column for BPCL

Refinery, Kochi.

5


D Shop


• Area : Existing land 8085 Sq Meters

: Covered 2000 Sq Meters

: Open 6085 Sq meters

Adjacent plot closed textile unit is taken in possession and shall be

used for various fabrication, Assembly activities.

6

PRODUCT BOUQUET

Lloyds Steels Industries

• Process Plant Equipment & Systems

• Turnkey Projects

• Power Plant Equipment & Systems

• Steel Plant Equipment & Systems

• Waste Heat Recovery Steam Boilers.

• Marine / Truck Loading/Unloading Arms

• Steering Gear & Stabilizer systems with Controls.

• Hydraulic systems for Steering Gear & Stabilizer servicing and up gradations.

• Air Pollution Solutions (FGD System, DeNox System Electrostatic Precipitator , Bag Filter)

• Solar Energy Solution

• Water Treatment Project

7

REGISTRATION WITH CONSULTANTS / INSPECTION AGENCIES

• Bureau Veritas ( BVIS)

• Chief Controller of Explosives (CCOE)/ PESO

• Chief Inspectorate of Boilers (IBR)

• CQAE (WE)/CQAE (MS)

• Det Norske Veritas ( DNV)

• DRDO

• Engineers India Ltd. (EIL)

• Indian Register of Shipping. (IRS)

• Jacobs H & G Ltd.

• Kvaerner Power Gas India Ltd.

• Lloyd’s Register Industrial Services (LRIS)

• MECON Ltd.

• M N Dastur & Company , Kolkata

• Nuclear Power Corporation of India Ltd. (NPCIL)

• Projects & Development India Ltd. (PDIL)

• Tata Consulting Engineers (TCE)

• Tecnimont ICB Pvt. Ltd. (TICB)

• Toyo Engineering India Pvt. Ltd. 8

PROCESS PLANT EQUIPMENT- Major Projects Executed

Equipment Customer

---------------------------------------------------------------------------------------------------------------------

• Barge Mounted Ammonia Storage Tanks Alcock Ashdown & Co. /FACT,

Udyogamandal

• Deoxy Tower with Glass Flake Lining ONGC, Gandhar, Gujarat

• Fermentors SPIC Pharma, Cuddalore

• Heat Exchangers, Columns & Urea IFFCO, Aonla & NFL, Vijaipur

Hydrolyser

• High Pressure Anechoic Tank and DRDO, Hyderabad /NPOL, Cochin

Low Frequency Tanks

• Hydro pneumatic Accumulator SMS DEMAG, New Delhi

• Liquid Nitrogen Storage Tank &High Reliance Industries Ltd., Hazira

Pressure Oxygen / Gas Bullets

• MDEA Columns Madras Fertilizers Ltd., Manali

• Pelletron Accelerator Tanks TIFR / BARC, Mumbai

Nuclear Science Centre, New Delhi

• Rocket Engine Testing Vacuum Chamber ISRO, Mahendragiri

---------------------------------------------------------------------------------------------------------------------

9

PROCESS PLANT EQUIPMENT-

Major Projects Executed … Cont.

Equipment Customer ----------------------------------------------------------------------------------------------------------------------------------------

• S.S. Tubular Reactor Hindustan Organic Chemicals Ltd, Rasayani

• RB Heavy Water Vapour Nuclear Power Corporation of India Ltd.

Recovery System for TAPP 3 & 4 Tarapur

• High Pressure Reactor Steam India Glycols Ltd.Kashipur

Drum 90 mm thk x 80 MT under IBR

& Jacobs H & G inspection.

• SS Clad Columns IOCL, Digboi

• High Pressure Equipment Nirma, Baroda

(Adsorbers and Separators)

• Pressure Vessels & Scrubbers ISRO, Sriharikota / MECON, Ranchi

for N204 / UDMH,DM Water Tanker

& TEA Solution Tank & GS2/PS2

• 16” x 70’ Marine Unloading Arm HPCL, OSTT, Vizag

• SS 304 Contactor Column –100 MT India Glycols Ltd., Kashipur

• Main Loop Heater & Cooler. Design GTRE Bangalore

Pressure 200 bar, Test Pressure

300 bar.

• Helium Vacuum Test. BARC, Anushakti Nagar, Mumbai

----------------------------------------------------------------------------------------------------------------------------------------

This list is a representative list and not exhaustive.

10

LIST OF MAJOR CUSTOMERS

• Bhabha Atomic Research Centre. (BARC)

• Bharat Petroleum Corporation Ltd. (BPCL)

• Chennai Petroleum Corporation Ltd. (CPCL)

• Defence Research Development Organisation (DRDO)

• Elf Gas India Ltd.

• Garden Reach Shipbuilders & Engineers Ltd. ( GRSE)

• Gas Authority of India Ltd. ( GAIL)

• Hindustan Petroleum Corporation Ltd. (HPCL)

• Indian Farmers Fertilizers Co-op. Ltd. (IFFCO)

• Indian Oil Corporation Ltd. (IOC)

• Indian Space Research Organisation (ISRO)

• GTRE, Bangalore

• Indo Jordan Chemicals Co., Jordan

• Ispat Industries Limited

• Kandla Port Trust

• Kochi Refineries Ltd.

11

LIST OF MAJOR CUSTOMERS

• Welspun Power & Steel Pvt.Ltd. Anjar

• Welspun Gujarat Sthal Rohrun Ltd, Anjar

• Nuclear Power Corporation of India Ltd. (NPCIL)

• Kuwait National Petroleum Co. Kuwait

• Madras Fertilizers Ltd.

• MECON Ltd.

• Mumbai Port Trust

• National Fertilizers Ltd.

• Numaligarh Refinery Ltd.

• Oil & Natural Gas Corporation Ltd. (ONGC)

• Punj Lloyd Ltd.

• Reliance Ind. Ltd.

• SMS Demag, New Delhi

• Southern Petrochemical Industries Corporation Ltd. (SPIC)

• Tata Institute of Fundamental Research. (TIFR)

• VAI Engineering & Automation Ltd.

12

DEVELOPMENT JOBS FOR DEFENCE, SPACE & NUCLEAR PROJECTS

• Steering Gear for Naval Vessels

• Fin Stabilizer for Naval Vessels

• Large Space Simulation Chamber for testing of Satellites for ISRO

• Vacuum Chamber for testing of Rocket Engines for ISRO

• Anechoic Tank for Naval Research for DRDO

• Pelletron Accelerator for Nuclear Research -BARC / TIFR, Mumbai

-Nuclear Research Centre, New Delhi

• Heavy Water Vapour Recovery System for Dhruva Reactor of BARC, Mumbai.

• Main Loop Coolers and Heat Exchangers for Light Water Reactor, BARC, Mumbai

• Butadiene Tanker for ISRO

• Test facility for Environmental Control System for Light Combat Aircraft at GTRE, Bangalore.

• Heavy Water Vapour Recovery System for NPCIL, TAPP 3 & 4.

13

ISO 9001-2008 Certificate

14

MAXIMUM PARAMETERS ACHIEVED FOR EQUIPMENT FABRICATED

AT MURBAD WORKSHOP / SITE

AA) HEAT EXCHANGERS

Sr No Parameter Magnitude Reference

1. Largest Tube sheet 190 mm IFFCO, Aonla / NFL, Vijaipur / Thickness PDIL

145 + 120 mm BARC, Mumbai

(Lip Type) (Main Loop Cooler for Light Water Reactor)

2 Highest Heat 1950 M2 Kanoria Chemicals, Renukoot

transfer Area

3. Highest Design 200 bar (g) BARC, Mumbai (Main Loop

pressure Cooler for Light Water Reactor)

4. Highest Temperature 6800 C Gas Turbine Research Establishment, Bangalore

5. Max No. of Tubes 11878 Nos. Hindustan Organic Chem Ltd. / Uhde / Perstopp

6. Heaviest Heat 104 MT (Stacked Unit) IFFCO, Aonla & NFL, exchanger Vijaipur / PDIL

15

MAXIMUM PARAMETERS ACHIEVED FOR EQUIPMENT FABRICATED

AT MURBAD WORKSHOP / SITE

BB. PRESSURE VESSELS

Sr No Parameter Magnitude Reference

1. Highest Shell Thickness

a) Carbon Steel 100 mm(HR) Lloydsteel, Wardha

b) Stainless Steel 110 mm DRDO, Secunderabad / NPOL, Kochi

c) Clad Steel 65 + 3 mm Nirma, Baroda / Uhde / UOP

d) Carbon steel 90 mm CR, Kashipur / IBR and JH&G

SA 516 Grade 70

2. Highest Test Pressure 318 kg/cm2 Lloydsteel, Wardha

3. Highest Design Pressure 220 bar Accumulator for SAIL, Bhilai (SMS Demag)

4. Tallest Column

Site Fabricated 60230 mm IOCL, Digboi / EIL

Shop Fabricated 64275 mm IOCL, Baroda / LRIS (Shipped in 3 pieces)

5 Heaviest Equipment 330 MT Column (Clad Steel) (Shipped in 3 pieces)

Shop Fabricated. 465 MT Column HIC+ NACE A 516 GR 70

(Shipped in 4 pieces)

130 MT Madras Fertilizers Ltd. /Bureau Veritas

Site Fabricated 350 MT (SS 304L) ISRO, Bangalore

6. Largest Diameter

Site Fabricated 50 metres ONGC, Gandhar / EIL Floating Roof Tank

Shop Fabricated 6 metres BARC / TIFR, Mumbai

(Single Piece)

16

NOTES

Diverse range of materials of construction handled including :

• Sandvik grade materials 2 RE69 / 2RE10 for fertilizer plants

• SA 203 GRF – 3-1/2% nickel steel for Barge Mounted Ammonia Storage Tanks (ABS inspection)

• Low Alloy Steel, Low Ferrite Content Steel.

• Non-ferrous including Titanium tubes, Cupro-Nickel, Copper, Admiralty Brass, Naval Bronze, Monel, Aluminium Bronze.

• Clad Satinless Steel, Clad Monel

• Glass flake lining for Deoxy Tower for ONGC, Gandhar.

17

Hydro Carbon Sector, Boilers &

Power Plant

• Pressure Vessels

• Heat Exchangers

• Columns

• WHR Boilers, FBC Boilers

• Steam Drums

• Surface condenser

18

PRESSURE VESSELS

19

AMINE FLASH DRUM FOR BINA REFINERY

.

20

MOCK UP TANK

• SATISH DHAVAN

SPACE RESEARCH

CENTRE

ISRO, SHAR

SHRIHARIKOTA

MOC SS 316 L

21

STEAM REACTOR DRUM 2 Nos. FOR IGL, KASHIPUR

90 mm Shell thickness x 80 MT weight

22

PRESSURE VESSEL

FOR OPAL DAHEJ PROJECT THROUGH BOC KOLKATTA.

Shell Thickness 63 mm x 123 MT Weight

23

VESSEL FOR SMS INDIA FOR BHUSHAN

STEELS.

24

Digester Vessel for Utkal Alumina

25

8 NOS DIGESTOR

VESSELS

ERECTED AT SITE

UTKAL ALUMINA,

RAIGADA, ORISSA

26

PROPYELENE REACTOR

FOR OPAL DAHESJ PROJECT THROUGH

TECNIMONT ICB

27

COLUMNS

28

COLUMN FOR IOCL- PANIPAT

.

29

COLUMN FOR BINA REFINERY

.

30

IOCL HALDIA COLUMN

THROUGH PUNJ LLOYDS LTD.UNDER ERECTION

32

ERECTION OF COLUMN AT IOCL-HALDIA

.

33

COLUMN

FOR BRAMHAPUTRA CRACKERS - ASSAM

34

COLUMN FOR BRAHMAPUTRA CRACKERS- ASSAM

.

35

COLUMN FOR IOCL PARADIP REFINERY

PROJECT

36

LIST OF COLUMNS FOR BPCL KOCHI UNDER EXECUTION WITH SITE WORK AND ERECTION

Sr No Item description Inside dia of Stack /Overall

length (mm)

Materials of construction

Transported in single piece

Fabricated Weight in

MT

Inspn.

1 Regeneration Column IDL-V-102

1930 MM X 17920 MM long

SA 516 Gr 60 Single Pc 26 MT EIL

2 Naptha Splitter IF-V-303

3200 mm x 35920 mm long

SA 516 Gr 70 2 sections 95 MT EIL

3 LP Hot separator IG-V-117

3600 mm x 20650 mm long

SA 387 Gr 11 cl 2 Single Pc 108 MT EIL

4 Stripper IF-V-206

4.9 mtr Dia x 58 Meters long

SA 516 Gr 70 + HIC + NACE

4 Sections 465 MT EIL

5 Debutanizer IF-V-302

5.1 Mtr Dia x 49.6 meters long


6 Depropanizer IF-V-501

5.8mtrs dia x 45.30 meters long


39

CLIENT : BPCL – KOCHI- LSI – JOB NO 1199

(IF-V-501) DEPROPANIZER -4600/5800/6100 IDx45200 HT

COLUMN ASSEMBLY & ALIGNMENT DEMONSTRATION TO EIL AT UVSL, WORKS

CLIENT : BPCL - INTEGRATED REFINERY EXPANSION PROJECT, KOCHI

EQUIPMENT :PROCESS STRIPPER (IF-V-206) & UVSL JOB NO : 1199

DIMENSION : 58 MTR LG X 4.9 MTR ID x 50/48 MM THK

WEIGHT : 465 MT (SHIPPED IN 4 SECTIONS)

MOC : SA 516 GR 60 HIC + NACE

INSPECTION : ENGINEERS INDIA LIMITED

42

ODC MOVEMENT FROM UVSL, MURBAD - JNPT - KOCHI PORT - BPCL-IREP, KOCHI

CLIENT : BPCL - INTEGRATED REFINERY EXPANSION PROJECT, KOCHI EQUIPMENT : PROCESS STRIPPER (IF-V-206) - BOTTOM SECTION (UVSL JOB NO 1199)

DIMENSION : 10.2 MTR LG X 4.9 MTR ID x 50 MM THK

WEIGHT : 99 MT

INSPECTION BY : ENGINEERS INDIA LIMITED

43

MULTIMODAL SHIPMENT VIA BARGE FROM JNPT TO KOCHI PORT

PROJECT : BPCL - INTEGRATED REFINERY EXPANSION PROJECT, KOCHI

COLUMN SECTIONS OF DEBUTANIZER (WT – 293 MT) & DEPROPANIZER (WT – 359 MT)

UVSL JOB NO : 1199

44

MULTIMODAL SHIPMENT VIA BARGE FROM JNPT TO KOCHI PORT

PROJECT : BPCL - INTEGRATED REFINERY EXPANSION PROJECT, KOCHI

COLUMN SECTIONS OF DEBUTANIZER (WT – 293 MT) & DEPROPANIZER (WT – 359 MT)

UVSL JOB NO : 1199 45

IF-V-501

CLIENT : BPCL – KOCHI- FCCU UNIT LSI – JOB NO 1199

(IF-V-302) DEBUTANIZER -5 MTR DIA X 50 MTR HT -SA 516 GR 70- WT -313 MT

(IF-V-501) DEPROPANIZER-7MTR DIA X45.3 MTR HT-SA 516 GR 70- WT-382 MT

(IF-V-206) STRIPPER-4.9 MTR DIA X58 MTR HT – SA 516 GR70+ HIC +NACE- WT 465 MT

IF-V-302

IF-V-206

Client : BPCL- Kochi

Project : Sulphur Recovery Unit ( WHB

Package)

Vent Stack : Qty 2 Nos.

Size Dia mm : 6350/4180/2150

Height : 85 Meters

MOC : IS 2062 E250 BR

Lining ::

Internal : Refractory 75 mm thk 50%

Al2O3 Dense Castable

External : 50mm thk Insulation with

Alumina Cladding

Weight including Refractory : 415 MT

ERECTION -VENT STACK

HEAT EXCHANGER

49

Surface condenser for Power Plant.

◄ Surface condensers 2 nos.for 2 x 40 MW Steam Turbine for IIPL Wardha No of tubes: 7300

Tube size 7/8” OD x 1.2 Thick x 8500 Long. Wt – 120 MT

Material – SA 249 TP 304 , Tube sheet size 3150 Dia x 90 Thick

50

U-TUBE BUNDLE FOR IFFCO ANOLA PROJECT

51

U- TUBE BUNDLE (Other View)

52

SS 316 L CONDENSER FOR BARC

.

53

HEAT EXCHANGER FOR AURA MINERAL

54

AIR/LIQUID /GAS DRYER PLANT

55

AIR DRYING PLANT FOR IOCL- PARADEEP

56

AIR DRYING PLANT FOR IOCL- PARADEEP

57

Air ,Liquid and Gas Dryer Plants

Dryers Supplied to

BOC ( MRPL), NPCIL

(TAPP,KAIGA, RAPP),

Technip France (OPAL),

IOCL Paradip

58

BOILERS

59

WHR and FBC BOILERS ◄ 4 x 12 TPH WHR Boilers at Gopani Tadali.

Lloyds Steel signed an Licensee agreement with ERK Germany for Boilers based on Waste heat, coal , biomass etc. They have license agreements with more than twenty reputed boiler manufacturers covering around fifteen countries.

ERK has designed more than 5500 boilers in last fifty years and are working satisfactory.

This is a natural circulation boiler, They distinguish themselves by a robust and clear design best fitted for the demands of power stations or industrial applications.

The pressurized body is made of a Stable down comers, headers and tube walls are welded together to a gas-tight tube cage.

This tube cage is self supported by down comers in all four corners of the boiler. The total load is on 4 legs of down comer which reduces foundation cost and easier to construct.

There is no lower drum. It has not to take care of thermal stresses in the lower drum.

Boilers references

55 TPH – 1 No For LMEL Ghugus Chandrapur

40 TPH – 1 No For Mid India Engg. Ltd. Gandhidham

12 TPH – 8 Nos For Gopani Iron & Power,Tadali & LMEL Ghugus, Chandrapur.

◄ 4 x 12 TPH WHR Boilers at LMEL Ghugus, Chandrapur. 60

FIRST PASS ASSEMBLY OF 12TPH WHR

BOILER FOR GOPANI IRON & POWER

61

62 Client : Tecnicas Reunidas /BPCL – Kochi

Project : Waste Heat Boiler (39 TPH) Package ,Erection at SRU Unit under EIL Delhi

Client :Tecnicas Reunidas /Talara Refinery - Peru

Equipment : Heater & Steam Super Heaters - Mock up assembled

Turn KEY PROJECT

64

STEEL PLANT –TURNKEY PROJECTS

1.20 MTPA PELLET PLANT AT BARBIL ORISSA

• Lloyds Steels Industries Ltd. received work order from Tecnicas Reunidas

Bangalore for Supply of Vent Stacks with Refractory Lining , Structure Platforms,

Steam Piping Spools, Pipe Racks , Support Structure and Erection/ installation of

complete Waste Heat Boiler Package equipment at Sulphur recovery unit of BPCL

Kochi.

• Erection package

• The package consists of 2 trains of the identical equipment, each train having the

Thermal incinerator, Waste Heat Boiler and Vent Stack, Structural / Technological

Platforms, Pipe Racks, Steam Piping Spools, Bellows, Damper, Interconnecting

ducting etc. Brief specifications of major equipment is as given below,

• Thermal Incinerator - Overall length of 20700 mm, having fabricated weight of

70 MT, Design Temp 343 Deg Cent. MOC - SA 516 Grade 70

• Waste Heat Boiler - 43 TPH, Design temp.285 Deg Cent, Design Pressure 24 Kg /

Cm2, Weight of 110 MT. 67

Two Trains of WHRS Boilers Package with Incinerator, Vent Stacks and Associated

Steam Piping, Piping Racks for Sulphur Recovery Unit of BPCL-Kochi Refinery

through Tecnicas Reunidas - Bangalore

• Vent Stack - 86 meters height, with max dia 6500 mm at bottom and min dia

at top 2150 mm with refractory Lining and external Insulation.

• Fabricated Weight of each Vent Stack 233 MT and with refractory 420 MT.

MOC IS 2062 Grade E250B

• IBR Piping Spools – Total of 30 Pre- fabricated Spools for each Train

fabricated under IBR with piping size from 2” to 12“ NB, with additionally 19

lines of Small bore < 2” size . Erection and Assembly with Testing at Site

•

• Structure Platforms for Vent Stacks, Incinerator and Boiler, total tonnage of

approx. 70 MT. each

•

• Total order value for Supply of equipment, Erection and Installation of

equipment is Rs 21.00 Crores.

68

Two Trains of WHRS Boilers Package with Incinerator, Vent Stacks and

Associated Steam Piping, Piping Racks for Sulphur Recovery Unit of BPCL-

Kochi Refinery through Tecnicas Reunidas - Bangalore

CERTIFICATIONS

CONTACT US

Marketing office

Kamala city, Trade World

‘C’ Wing, 16th Floor,

Senapati Bapat Marg,

Lower Parel,

Mumbai 400 013

Maharashtra

India.

Tel: 91-22-30418111,

Fax: 91-22-30418260

E-Mail : [email protected]

: [email protected],

: [email protected]

Factory:

A 6/3 &5/5 MIDC Area,

Murbad Taluka

Dist: Thane 421401

Maharashtra

Tel : 91-252422271/9270901141

Fax : 91-2524222273

lloyds steel industries limited engineering · pdf fileiocl haldia column through punj lloyds...

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