Modular fired heaters and pipe racks shop-built in Baddi (75m × 30m, ASME U+S, IBR, in-house refractory/painting/NDT) and Indrad (2,600 m²), then dispatched refractory-lined and dried-out for fast, low-risk site integration. EIL-enlisted for Modularization Packages (heaters + pipe racks).
Modular lifting
Shop-built assemblies aligned for field installation
Esteem is one of the pioneers in modular fired heater supply in India. Modularisation is incorporated from design through erection — engineering, fabrication, transport, lifting, and site work planned as a single strategy, not stitched together after the datasheet is locked.
Our Baddi shop (75m × 30m, ASME U-Stamp + S-Stamp, IBR certified, EOT cranes, in-house refractory lining, painting, and NDT) and our Indrad shop (2,600 m²) deliver refractory-lined and dried-out modules where project conditions support it. Complete heaters with platforms, burners, piping, ductwork, and instrumentation leave the gate as ready assemblies — cutting site exposure and protecting the critical path.
Esteem is EIL-enlisted for Modularization Packages — heaters and pipe racks — the Indian consulting authority's recognised vendor list for refinery project execution.
Modularization is most valuable when it is driven by engineering judgment, realistic transport studies, and clear battery-limit planning.
Off-site fabrication can proceed in parallel with civil and structural readiness, reducing exposure to field-driven delay.
Fewer field joints, smaller site crews, and more work in controlled shop conditions reduce congestion and coordination pressure.
Welding, refractory, and assembly in a controlled shop environment support repeatable inspection and stronger workmanship consistency.
Transport splits, lifting logic, and interface design are resolved earlier, improving field fit-up and handover discipline.
Module sizing, transport studies, and lifting plans vary by heater geometry. The right modular strategy preserves operability, maintainability, and field practicality after erection.
| Radiant Type | Typical Service | Modularisation Strategy |
|---|---|---|
| Horizontal | Steam reforming, Ammonia, Hydrogen, Methanol, Ethylene Cracking, Hydrocracker | For wall-mounted configuration, the entire radiant section can be sent as a single module. Alternatively, coils can be transported in hairpins. |
| Vertical | Catalytic Reforming, Aromatics, Crude | The entire radiant section can be dispatched in refractory-lined condition or in panels. Coils can be dispatched in pre-fabricated bundles ready for immediate field installation. |
| Arbor | Catalytic Reforming, Specific Aromatics | Coils can be supplied in complete arbors, pre-welded to manifolds for shipment and rapid site installation. |
| Vertical Cylindrical | Crude, Vacuum, Atmospheric, Hot Oil, Regeneration | Highly suited for modularisation. Can be dispatched as a complete radiant section, or in segmented "petals" of shell and coil assemblies. |
Representative projects where shop-built modules compressed schedules that would have blown up with stick-built field fabrication.
IOCL Bongaigaon
Delayed Coker Unit heater modular-fabricated at the Esteem shop and installed during a 35-day shutdown window, with thermal efficiency lifted +8%. Rebuilding a coker heater in situ is the kind of outage risk modularisation exists to eliminate.
IGL Kashipur
Vertical-cylindrical heater dispatched as three pre-assembled convection modules — built complete with platforms and instrumentation in Baddi, then stacked on site. Minimum field welding. Maximum predictability.
BPCL Mahul · HPCL Mumbai
Vacuum Distillation Unit convection modules replaced at one module per day, without removing the stack. The BPCL Mahul execution was recognised by BPCL as Best Turnaround Contractor (2017). Modular design is what made that schedule credible.
Crane lift
Engineered lifts coordinated with foundation readiness
Fabrication
Panel build-up prior to refractory lining and dry-out
Discuss transport splits, workshop capacity, and how modular delivery can align with your schedule and cost targets.