Modularised utility packages for the largest refinery in Africa
Apart from setting a record in manufacturing the largest packaged plug-and-play utility boilers in India to date, Thermax also achieved a benchmark in the concept of modularisation. During the year, the company completed the supply of its largest export so far comprising four utility boilers, eight heat recovery steam generators, two flue gas steam generators and a hot oil heater for the largest refinery and petrochemical project in Nigeria, West Africa.
The sub-assemblies were manufactured at Thermax facilities in Shirwal, Savli, and Chinchwad as per global quality norms. The final assembly was then completed at Mundra. Speaking of numbers, 1,300 people, including third parties, worked on the project, deployed 5.1 million man-hours, to build equipment weighing over 21,000 tonnes, without a single reportable accident. The largest module weighed 1,450 tonnes and the tallest one was higher than an eight-storey building.
The other critical aspect of the project, managed skilfully, was transporting these massive structures to the port and rolling them on to special ro-ro vessels. The modules were sea-fastened to ensure that they would sail smoothly between continents, enduring strong winds and rolling seas. With increasing complexities involved in setting up greenfield process plants, these modularisation solutions can help customers de-risk their construction work and accelerate completion time, evident from the fact that the first package was installed in a record time of 21 hours, which would have taken six months to complete had it been built at site.
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