modular fired heaters - a presentation by esteem projects at refining india 2015 conference
TRANSCRIPT
MODULAR
CONSTRUCTIVE SOLUTIONS REFINING INDIA 2015
20+
Experience
Serving the industry since 1994
Years
CONSTRUCTIVE SOLUTIONS
Site InstallationDesign &
EngineeringShop FabricationProcurement
Tighter control
Cost savings
Shorter schedule
One Stop Shop for all your
Fired Heater related needs
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QualityISO 9001:2008
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inconstructionofHeater
!!!! !!!!!!!!!
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Certified
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*estimated
*
reportable-incident free man hours
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Modularization
modularize [moj-uh-luh-rahyz]
verb (used with object), modularized, modularizing.
1. to form or organize into modules, as for flexibility.
“
Nature Architecture Software Industry
?Modularization
✓ Shop fabrication delivers better quality
✓ Faster construction
✓ Suitable for congested plants
✓ Shop fabrication requires lesser permits
✓ Minimal site interruption
✓ Minimal impact of weather
✓ Cost savings
Why?
Indian Scenario
Lack of site fabrication space
Congested existing plants
Land transportation limitations
Unfavourable conditions at certain sites
Congested plants
Road transportation
~9m
5.45m
5.76m
81 MT
Road transportation
~9m
5.45m Near
Limitation
Road transportation
5.76m
81 MT
Suitable for
Heater Size Heater ComplexityEase of
Transportation
Complete Heater in
all respectsSmall - Mid Low - Moderate
In modules All All
In sub-modules Mid - Large All
In panels and
banjosLarge - Very Large High
Extent of modularisation
Suitable for
Heater Size Heater ComplexityEase of
Transportation
Complete Heater in
all respectsSmall - Mid Low - Moderate
In modules All All
In sub-modules Mid - Large All
In panels and
banjosLarge - Very Large High
Most
favourable
for India
Extent of modularisation
Extent of modularisation
Transportation, handling and erection effortsIncremental reduction in site activities
Eff
ort
s
Amount of modularisation/ Module size
Extent of modularisation
Transportation, handling and erection effortsIncremental reduction in site activities
Eff
ort
s
Amount of modularisation/ Module size{Ideal in most situations
Extent of modularisation
Transportation, handling and erection effortsIncremental reduction in site activities
Eff
ort
s
Impractical without
port access
Amount of modularisation/ Module size{Ideal in most situations
Export
ScenarioSub-modules can
be combined at or
near port.
Complete heater
(with all coils, piping,
instrumentation,
etc.) can be loaded
onto barge
Module - arization
Fabricate and ship from shop in transportable modules
assemble near site or at port
move complete heater to siteplace on
foundation using jacks, crane, axels, …
Site
Installation
Design &
Engineering
Shop
Fabrication
Procurement
Needs to be incorporated
design phase itself
Design considerations✓ Module size and weights
✓ Steel to Steel interface
✓ Refractory to refractory interface
✓ Splice design
✓ Site sealing
✓ Lifting lugs, spreader beams, erection plans
✓ Structural stiffening
✓ Stability during transportation by road/ sea
✓ Wind loads
Refractory
Insulating Castable Ceramic Fibre
Products
Insulating Bricks
✓ Suitable for
Modularisation
✓ Good Strength
✓May need dry-out
✓ Interface is easy
✓ Suitable for
Modularisation
✓ Low strength - Needs
care during
transportation
✓ Does not need dry-out
✓ Interface is easy
✓ Not recommended
✓May remain loose even
with fixing systems or
tongue and groove
✓ Difficult interface
Cost
From the internet >>
Credit is due to whoever wrote that
✓ may not be a true
measure of effort
involved
✓ not always = value
✓ means different things
to different people,
societies and
geographies
✓ depends on a
multitude of factors
CostModular Stick built
Increased
COST
0
25
50
75
100
Modular Stick-Built
Engineering
Procurement
Transportation
Indirect site exp
Fabrication
Erection
Data for a typical Fired Heater Project
COST
0
25
50
75
100
Modular Stick-Built
Engineering
Procurement
Transportation
Indirect site exp
Fabrication
Erection
SAVINGS
Data for a typical Fired Heater Project
COST
0
25
50
75
100
Modular Stick-Built
Engineering
Procurement
Transportation
Indirect site exp
Fabrication
Erection
Moderate increase in
engineering costs
Data for a typical Fired Heater Project
COST
0
25
50
75
100
Modular Stick-Built
Engineering
Procurement
Transportation
Indirect site exp
Fabrication
Erection
Marginal increase in
Procurement costs
Data for a typical Fired Heater Project
COST
0
25
50
75
100
Modular Stick-Built
Engineering
Procurement
Transportation
Indirect site exp
Fabrication
Erection
Substantial increase
in transportation
costs
Data for a typical Fired Heater Project
COST
0
25
50
75
100
Modular Stick-Built
Engineering
Procurement
Transportation
Indirect site exp
Fabrication
Erection
Data for a typical Fired Heater Project
Substantial decrease
in indirect costs like
site management,
site office,
mobilisation,
lodging, etc.
COST
0
25
50
75
100
Modular Stick-Built
Engineering
Procurement
Transportation
Indirect site exp
Fabrication
Erection
Data for a typical Fired Heater Project
Negligible change in
fabrication cost
Productivity Work qty
COST
0
25
50
75
100
Modular Stick-Built
Engineering
Procurement
Transportation
Indirect site exp
Fabrication
Erection
Data for a typical Fired Heater Project
Substantial decrease
in erection costs
ScheduleEngineering
Procurement
Fabrication
Erection
Stick Built ModularData for a typical Fired Heater Project
ScheduleEngineering
Procurement
Fabrication
Erection
Stick Built Modular
SAVINGS
Data for a typical Fired Heater Project
Safety and
Environment✓ Reduced site duration = Reduced chances of un-safe
operations
✓ Shop environment = Better control over safety
✓ Reduced Wastage
✓ Less energy load at site during construction (Resource
efficient)
!
"
#$%
&
'
(
)*
+,
-.
Some case
studies
Heat Duty: 5.37 MMkcal/hr
Tonnage: 100MT
Supplied as: Complete Modules
Vertical Cylindrical Heater
120° Segments
Modularisation in Revamps
Small VC heater
14 days!
Removal of
old heater, and
erection of
complete new
heater onto
the foundation
Heat Duty: 27 MMkcal/hr
Tonnage: 230 MT
Supplied as: 4 nos. complete convection
modules (13m long) were
supplied from our Baddi
works
Ducting supplied in pre-
fabricated form
Cabin Heater
Entire heater
permanently lifted by
1000mm
40 days
Complete
Heate
r lo
oke
d li
ke this
Rapid Revamp/ Reconstruction
We opened it up
removed
all
tubes
refractory
casing…
Rapid Revamp/ Reconstruction
removed
all
tubes
refractory
casing…
We opened it up
Rapid Revamp/ Reconstruction
and
used
pre-fabricated
modules…
Rapid Revamp/ Reconstruction
'
to complete
the job
within
30 days
FLAT
Rapid Revamp/ Reconstruction
CONSTRUCTIVE SOLUTIONS
Critical Success Factors
✓ Experienced and proven team
✓ Detailed understanding of the parameters
and their impact on the project
✓ Freezing of the requirements
✓ Single point responsibility
CONSTRUCTIVE SOLUTIONS
Esteem Projects Pvt. Ltd.
www.esteemprojects.com
Thanks for your attention!