modular fired heaters - a presentation by esteem projects at refining india 2015 conference

53
MODULAR CONSTRUCTIVE SOLUTIONS REFINING INDIA 2015

Upload: tanveer-singh

Post on 08-Jan-2017

1.061 views

Category:

Business


2 download

TRANSCRIPT

Page 1: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

MODULAR

CONSTRUCTIVE SOLUTIONS REFINING INDIA 2015

Page 2: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

20+

Experience

Serving the industry since 1994

Years

CONSTRUCTIVE SOLUTIONS

Page 3: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Site InstallationDesign &

EngineeringShop FabricationProcurement

Tighter control

Cost savings

Shorter schedule

One Stop Shop for all your

Fired Heater related needs

Page 4: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

World Class

QualityISO 9001:2008

Certified-Inspectionreportby

majoraLicensor

“Nomajor/minor5laws

inconstructionofHeater

Page 5: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

!!!! !!!!!!!!!

Safety First!

OHSAS 18001:2007

Certified

5,000,000

*estimated

*

reportable-incident free man hours

Page 6: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Proud member of

Esteem Projects

LLC

Esteem Projects

Pvt. Ltd.

Global

Outlook

Page 7: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

100Projects

+H

EA

TE

RS

RE

FO

RM

ER

S

CR

AC

KE

RS

NEW INSTALLATIONS

REVAMPS

+ }

Page 8: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 9: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

?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?

Page 10: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Indian Scenario

Lack of site fabrication space

Congested existing plants

Land transportation limitations

Unfavourable conditions at certain sites

Page 11: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Congested plants

Page 12: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Road transportation

Page 13: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

~9m

5.45m

5.76m

81 MT

Road transportation

Page 14: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

~9m

5.45m Near

Limitation

Road transportation

5.76m

81 MT

Page 15: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 16: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 17: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Extent of modularisation

Transportation, handling and erection effortsIncremental reduction in site activities

Eff

ort

s

Amount of modularisation/ Module size

Page 18: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Extent of modularisation

Transportation, handling and erection effortsIncremental reduction in site activities

Eff

ort

s

Amount of modularisation/ Module size{Ideal in most situations

Page 19: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 20: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Export

ScenarioSub-modules can

be combined at or

near port.

Complete heater

(with all coils, piping,

instrumentation,

etc.) can be loaded

onto barge

Page 21: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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, …

Page 22: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Site

Installation

Design &

Engineering

Shop

Fabrication

Procurement

Needs to be incorporated

design phase itself

Page 23: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 24: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 25: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 26: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

CostModular Stick built

Increased

Page 27: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

COST

0

25

50

75

100

Modular Stick-Built

Engineering

Procurement

Transportation

Indirect site exp

Fabrication

Erection

Data for a typical Fired Heater Project

Page 28: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 29: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 30: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 31: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 32: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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.

Page 33: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 34: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 35: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

ScheduleEngineering

Procurement

Fabrication

Erection

Stick Built ModularData for a typical Fired Heater Project

Page 36: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

ScheduleEngineering

Procurement

Fabrication

Erection

Stick Built Modular

SAVINGS

Data for a typical Fired Heater Project

Page 37: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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)

Page 38: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

!

"

#$%

&

'

(

)*

+,

-.

Some case

studies

Page 39: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Heat Duty: 5.37 MMkcal/hr

Tonnage: 100MT

Supplied as: Complete Modules

Vertical Cylindrical Heater

120° Segments

Page 40: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference
Page 41: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference
Page 42: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Modularisation in Revamps

Page 43: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Small VC heater

14 days!

Removal of

old heater, and

erection of

complete new

heater onto

the foundation

Page 44: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 45: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference
Page 46: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

40 days

Complete

Page 47: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

Heate

r lo

oke

d li

ke this

Rapid Revamp/ Reconstruction

Page 48: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

We opened it up

removed

all

tubes

refractory

casing…

Rapid Revamp/ Reconstruction

Page 49: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

removed

all

tubes

refractory

casing…

We opened it up

Rapid Revamp/ Reconstruction

Page 50: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

and

used

pre-fabricated

modules…

Rapid Revamp/ Reconstruction

Page 51: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

'

to complete

the job

within

30 days

FLAT

Rapid Revamp/ Reconstruction

Page 52: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

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

Page 53: Modular fired heaters -  A presentation by Esteem Projects at Refining India 2015 Conference

CONSTRUCTIVE SOLUTIONS

Esteem Projects Pvt. Ltd.

www.esteemprojects.com

Thanks for your attention!

[email protected]