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

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Modular construction of Fired Heaters can help in saving both time and cost. This presentation touches the topic from the Indian perspective and how it can also be helpful in revamps.
For any details, please visit us at https://www.esteemprojects.com.
Thanks,
Esteem Projects Pvt. Ltd.

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

  1. 1. MODULAR CONSTRUCTIVE SOLUTIONS REFINING INDIA 2015
  2. 2. 20 + Experience Serving the industry since 1994 Years CONSTRUCTIVE SOLUTIONS
  3. 3. Site Installation Design & Engineering Shop FabricationProcurement Tighter control Cost savings Shorter schedule One Stop Shop for all your Fired Heater related needs
  4. 4. World Class Quality ISO 9001:2008 Certified - Inspection report by major a Licensor “No major / minor 5laws in construction of Heater
  5. 5. !!!! !!!!!!!!! Safety First! OHSAS 18001:2007 Certified 5,000,000 *estimated * reportable-incident free man hours
  6. 6. Proud member of Esteem Projects LLC Esteem Projects Pvt. Ltd. Global Outlook
  7. 7. 100Projects +HEATERS REFORMERS CRACKERS NEW INSTALLATIONS REVAMPS + }
  8. 8. 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
  9. 9. 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?
  10. 10. Indian Scenario Lack of site fabrication space Congested existing plants Land transportation limitations Unfavourable conditions at certain sites
  11. 11. Congested plants
  12. 12. Road transportation
  13. 13. ~9m 5.45m 5.76m 81 MT Road transportation
  14. 14. ~9m 5.45m Near Limitation Road transportation 5.76m 81 MT
  15. 15. Suitable for Heater Size Heater Complexity Ease of Transportation Complete Heater in all respects Small - Mid Low - Moderate In modules All All In sub-modules Mid - Large All In panels and banjos Large - Very Large High Extent of modularisation
  16. 16. Suitable for Heater Size Heater Complexity Ease of Transportation Complete Heater in all respects Small - Mid Low - Moderate In modules All All In sub-modules Mid - Large All In panels and banjos Large - Very Large High Most favourable for India Extent of modularisation
  17. 17. Extent of modularisation Transportation, handling and erection efforts Incremental reduction in site activities Efforts Amount of modularisation/ Module size
  18. 18. Extent of modularisation Transportation, handling and erection efforts Incremental reduction in site activities Efforts Amount of modularisation/ Module size {Ideal in most situations
  19. 19. Extent of modularisation Transportation, handling and erection efforts Incremental reduction in site activities Efforts Impractical without port access Amount of modularisation/ Module size {Ideal in most situations
  20. 20. Export Scenario Sub-modules can be combined at or near port. Complete heater (with all coils, piping, instrumentation, etc.) can be loaded onto barge
  21. 21. 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, …
  22. 22. Site Installation Design & Engineering Shop Fabrication Procurement Needs to be incorporated design phase itself
  23. 23. 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
  24. 24. 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
  25. 25. 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
  26. 26. Cost Modular Stick built Increased
  27. 27. COST 0 25 50 75 100 Modular Stick-Built Engineering Procurement Transportation Indirect site exp Fabrication Erection Data for a typical Fired Heater Project
  28. 28. 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
  29. 29. 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
  30. 30. 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
  31. 31. 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
  32. 32. 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.
  33. 33. 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
  34. 34. 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
  35. 35. Schedule Engineering Procurement Fabrication Erection Stick Built Modular Data for a typical Fired Heater Project
  36. 36. Schedule Engineering Procurement Fabrication Erection Stick Built Modular SAVINGS Data for a typical Fired Heater Project
  37. 37. 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)
  38. 38. ! " #$ % & ' ( ) * + , -. Some case studies
  39. 39. Heat Duty: 5.37 MMkcal/hr Tonnage: 100MT Supplied as: Complete Modules Vertical Cylindrical Heater 120° Segments
  40. 40. Modularisation in Revamps
  41. 41. Small VC heater 14 days! Removal of old heater, and erection of complete new heater onto the foundation
  42. 42. 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
  43. 43. 40 days Complete
  44. 44. HeaterlookedlikethisRapid Revamp/ Reconstruction
  45. 45. We opened it up removed all tubes refractory casing… Rapid Revamp/ Reconstruction
  46. 46. removed all tubes refractory casing… We opened it up Rapid Revamp/ Reconstruction
  47. 47. and used pre-fabricated modules… Rapid Revamp/ Reconstruction
  48. 48. ' to complete the job within 30 days FLAT Rapid Revamp/ Reconstruction
  49. 49. 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
  50. 50. CONSTRUCTIVE SOLUTIONS Esteem Projects Pvt. Ltd. www.esteemprojects.com Thanks for your attention! epl@esteemprojects.com

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