Propane De-Hydrogenation Unit Integrated with Polypropylene Unit of Gas Authority of India Ltd At Ussar, Alibaug, Maharashtra
Installation of six (6) pass Superfrac Trays # 1 to Tray #208 for Product Splitter Column of Propane Dehydrogenation unit integrated with Polypropylene unit at Gas Authority of India Ltd. (GAIL), Ussar, Alibaug, Maharashtra.
GAIL (India) Limited is India’s principal Gas Transmission and Marketing Company under the Ministry of Petroleum and Natural Gas, Government of India. GAIL is also in the business of Gas Processing, Petrochemicals, LPG, Transmission and Telecommunications. The company has also extended its presence in Power, Liquefied Natural Gas regasification, City Gas Distribution and Exploration & Production through equity and joint ventures participations
Propane De-Hydrogenation Unit Integrated with Polypropylene Unit of Gas Authority of India Ltd At Ussar, Alibaug, Maharashtra
Objectives of the PDH-PP unit
- Meet India’s rising polypropylene demand: Polypropylene is a vital material used in industries like packaging, automobiles, construction, healthcare, and electronics. The project is designed to help fulfil the projected growth in demand.
- Enhance self-sufficiency: By creating India’s first propane dehydrogenation plant, GAIL will produce propylene “on-purpose,” reducing the country’s reliance on imports or by-product propylene from other processes.
- Utilize existing assets: The plant is strategically located at GAIL’s Usar site, utilizing land and infrastructure from a previous, now-shutdown, LPG recovery plant. This approach ensures optimal use of company assets.
- Diversify revenue streams: The project is part of GAIL’s strategy to diversify its petrochemical business and expand its downstream portfolio into new, high-growth areas.
Benefits of the PDH-PP unit
- Operational efficiency:The PDH-PP complex is a seamlessly integrated facility, with the propylene produced in the PDH unit directly fed to the polypropylene plant. This integration optimizes the production process.
- Adoption of advanced technology:GAIL is utilizing proprietary and highly efficient technologies, such as the CATOFIN process for PDH and UNIPOL for PP production, ensuring high yield and cost-effective operations.
- Engineering excellence:The project has already showcased advanced engineering capabilities with the successful on-site fabrication and erection of critical equipment like the reactor and the Product Purge Bin.
Challenge / Problem Statement:
- Lifting internal materials (tray panels, downcomer beams etc.) at 124 meters height without external platforms access.
- Monsoon conditions: high winds and heavy rainfall.
- Strict timeline for completion.
Our Approach / Solution:
- Tray Segregation: Marked and sequenced trays for efficient handling.
- Weather-Proof Storage: Corrugated sheet sheds near Scan Climber minimized exposure and handling time.
- Rain Protection: Tarpaulin covers, raincoats, and gumboots ensured dry and safe operations.
- Parallel Work Zones: Two Scan Climbers with dedicated crews enabled simultaneous tray installation.
- Modified Lifting Setup: Scan Climber customized for job-specific needs.
- Wind Safety: Ropes used to stabilize materials during lifting.
- Safety Compliance: Full adherence to safety protocols throughout adverse weather conditions.
Results / Outcome:
- Completed installation of 208 trays in 120 days
- Zero safety violations throughout the operation.
- Timely completion of the job as per project schedule.
Conclusion
The successful installation of 208 Superfrac trays in the Product Splitter Column of GAIL’s PDH-PP unit stands as a testament to our team’s engineering precision, operational resilience, and unwavering commitment to safety. Despite challenging monsoon conditions, high-altitude constraints, and a tight schedule, we delivered the project on time with zero safety violations—a reflection of our proactive planning, adaptive execution, and strict compliance with HSE standards.
This achievement not only supports GAIL’s strategic expansion into high-growth petrochemical segments but also showcases our capability to execute complex refinery operations under adverse conditions. It reinforces our reputation as a reliable partner in India’s energy infrastructure development.