Projects Flagship Case Study

Installation, Commissioning & O&M
of an Ethylene Plant

A safety-critical petrochemical project delivered with disciplined execution, process integrity, and sustained operational reliability.

Sector: Petrochemical Scope: Install & O&M Focus: Safety Critical

The Challenge

The client planned to install a complete ethylene production plant. Handling hazardous materials meant there was zero margin for error in installation or commissioning.

  • Handling of flammable and hazardous materials.
  • Precise mechanical installation and alignment required.
  • Strict compliance with safety and operational procedures.
  • Need for continuous maintenance support after start-up.
"This project required discipline, process understanding, and a deep safety culture—not just installation skills."

Project Objectives

To execute a flawless installation and commissioning process, transitioning smoothly into stable, long-term operation.

Safety Compliance

Install in full compliance with stringent process safety requirements.

Smooth Commissioning

Achieve incident-free start-up and stabilization.

Operational Stability

Provide reliable maintenance support to sustain performance.

Comprehensive Service

Scope & Responsibility

Mechanical Install

Reactors, vessels & rotating machinery.

  • Equipment setting
  • Precision alignment
  • Support structures

Piping & Utilities

Fabrication & installation of process lines.

  • Process piping
  • Valves & fittings
  • Utility integration

E & I

Power & signal integrity.

  • Cable routing
  • Field instruments
  • Loop checking

Commissioning

Support during critical start-up phases.

  • Pre-commissioning checks
  • Cold & Hot start-up
  • Production runs

O&M Support

Long-term operational care.

  • Preventive planning
  • Corrective maintenance
  • Optimization

Safety & Technical Challenges

Challenge 1

Hazardous Environment

Ethylene systems operate under strict safety conditions where sparks or leaks can be catastrophic.

Our Solution:

All activities were executed under strict permit-to-work systems, with rigorous adherence to safety procedures and method statements at every step.

Challenge 2

Precision Installation

Small errors in alignment or sealing can lead to leaks, vibration, or premature failure of high-value equipment.

Our Solution:

We implemented controlled installation procedures using calibrated tools and staged inspections to ensure absolute mechanical integrity.

Challenge 3

Commissioning Stability

Early operational instability during start-up can damage equipment and delay production.

Our Solution:

Close coordination with operations and control teams ensured a gradual, controlled ramp-up, monitoring critical parameters at every stage.

Execution Roadmap

1. Site Preparation

Mobilization & Safety

2. Mechanical Installation

Equipment Setting

3. Piping & Utilities

Integration

4. Electrical & Instrument.

Connectivity

5. Commissioning

Start-Up Support

6. O&M Support

Sustained Operations

Process discipline maintained at every stage.

Project Outcomes

Safety & Compliance

  • Incident-free installation
  • Full regulatory compliance
  • Strict adherence to permits

Operational

  • Stable plant start-up
  • Reliable early production
  • Minimized downtime

Long-Term Value

  • Extended equipment life
  • Maintenance practices set
  • Knowledge transfer to ops

Why This Is A Flagship Project

This project proves our capability to execute high-risk petrochemical installations. It demonstrates our ability to work safely in hazardous environments, integrate complex multi-discipline scopes, and act as a long-term technical partner beyond commissioning—positioning us for process plants and energy-sector projects.

Execute With Precision

If your project involves hazardous processes, complex commissioning, or ongoing operational support, this project demonstrates our capability to deliver safely and reliably.

Discuss Your Process Plant

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