Case Studies

Turning Ideas Into Measurable Results

Every project below is a real industrial mandate — the constraint we were handed, the method we executed, and the number the client could verify afterwards. Capability is measured by what changes once the work is finished.

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Featured Project — CRU PROJECT

CRU Project

Convection Module Replacement & Chimney Works

A major industrial execution project at the IOCL Gujarat Refinery involving the replacement of two convection modules, controlled chimney dismantling, structural repair, and final re-erection.

The Challenge

Execute critical heavy-lifting and dismantling activities safely, including removal of 60 MT and 45 MT convection modules and controlled chimney stack dismantling.

The Result

Integrated execution through stagewise scaffolding, certified heavy lifting, precision module installation, NDT-certified piping fabrication, and chimney repair and re-erection.

2Convection modules

105 MTCombined lift weight

500 MTCrane capacity

The Archive

Execution stories

Selected mandates across catalyst handling, mechanical restoration, decontamination and commissioning — each one reduced to the challenge, the method and the number.

Catalyst extraction from a PSA vessel under nitrogen

01 Catalyst Division

Oil & Gas IDLH Entry ATEX Rated

PSA Vessel Extraction

01 Catalyst Division

Challenge:A Pressure Swing Adsorption unit required a full catalyst changeout under a strict 100% IDLH nitrogen atmosphere.
Solution:ATEX-rated continuous pneumatic vacuum systems with continuous gas monitoring, minimising dust generation and carry-over.
Result:An unprecedented 96% yield recovery of the precious metal catalyst, with the vessel returned clean and certified.

96% Noble metal recovery

Precision retubing of a crude pre-heat exchanger bundle

02 Mechanical Division

Refining Heat Transfer Hydro-Test

Exchanger Retubing

02 Mechanical Division

Challenge:Fouling and tube degradation had cost a crude pre-heat train 40% of its thermal efficiency.
Solution:Extracted the 20-tonne bundle, removed every tube, then precision-rolled 1,200 new alloy tubes to specification.
Result:First-pass hydro-test clearance, with pressure drop restored from 2.8 bar to 0.4 bar.

1,200+ Alloy tubes rolled

Automated hydro-jetting inside a 50,000 MT crude storage tank

03 Environmental Services

Storage Pyrophoric Risk Zero-LEL

Tank Decontamination

03 Environmental Services

Challenge:A 50,000 MT crude storage tank presented heavy sludge compaction and active pyrophoric risk before entry could be authorised.
Solution:Automated 3D hydro-jetting paired with chemical oxidisers, run to a controlled sequence with continuous atmospheric monitoring.
Result:90% of the hydrocarbon content recovered and returned to process, with the tank certified to a zero-LEL environment.

90% Hydrocarbon recovery

Reformer duct bank installation and alignment

04 Commissioning

Fertiliser Flue Gas Alignment

Reformer Duct Bank Installation

04 Commissioning

Challenge:Flue gas duct banks had to be installed to tight alignment tolerances around a live reformer with restricted crane access.
Solution:Staged lifts to an engineered rigging plan, with laser alignment verified at every set-down before release.
Result:All duct banks set within tolerance at first attempt, with no rework and no impact on the commissioning sequence.

100% First-pass alignment

Fired heater overhaul during a plant shutdown

05 Shutdown Operations

Refining Confined Space 24/7 Shifts

Fired Heater Overhaul

05 Shutdown Operations

Challenge:Coil replacement and refractory repair inside a fired heater, scheduled against a fixed restart date with no float.
Solution:Round-the-clock shift rotation under a Primavera P6 schedule, with permit control and confined-space rescue cover maintained throughout.
Result:Heater returned to service on the planned restart date with all inspection hold points cleared first time.

0 Schedule slippage (days)

Results at a Glance

Measured after handover

Execution is judged by what changes once the crew has demobilised. These are the aggregate numbers across the mandates on this page.

50+ Projects Delivered

Critical-path turnarounds, emergency shutdowns and plant commissioning mandates executed since 1974.

25+ Industries Served

600+ Tradesmen Mobilised

96% Noble Metal Recovery

95% Client Retention

1,200+ Tubes Precision Rolled

Before → After

A 50,000 MT tank, transformed

Drag the handle to compare the tank as received against the same tank certified for entry.

Crude storage tank before decontamination, heavy sludge compaction

The same tank after decontamination, certified zero-LEL

Before After

Before

Compacted and unsafe

Heavy sludge compaction across the floor with active pyrophoric risk. Entry could not be authorised and the tank was out of service indefinitely.

Our Approach

Automated, then verified

Automated 3D hydro-jetting paired with chemical oxidisers, run to a controlled sequence with continuous atmospheric monitoring at every stage.

After

Certified and recovered

Zero-LEL environment certified for entry, with 90% of the hydrocarbon content recovered and returned to process rather than disposed of.

Our Services

Our Excellence

Catalyst Handling Project

Industrial Fabrication Project

Plant Mechanical Maintenance

Tank Cleaning & Sludge Processing

Chemical Decontamination Project

Industrial Plant Commissioning

Skilled Industrial Workforce

Industrial Equipment Rental

CASE STUDIES