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.

1. MODULAR
CONSTRUCTIVE SOLUTIONS REFINING INDIA 2015

2. 20
+
Experience
Serving the industry since 1994
Years
CONSTRUCTIVE SOLUTIONS

3. Site Installation
Design &
Engineering
Shop FabricationProcurement
Tighter control
Cost savings
Shorter schedule
One Stop Shop for all your
Fired Heater
related needs

4. World Class
Quality
ISO 9001:2008
Certified
- Inspection report by
major a Licensor
“No major / minor 5laws
in construction of Heater

5. !!!! !!!!!!!!!
Safety First!
OHSAS 18001:2007
Certified
5,000,000
*estimated
*
reportable-incident free man hours

6. Proud member of
Esteem Projects
LLC
Esteem Projects
Pvt. Ltd.
Global
Outlook

7. 100Projects
+HEATERS
REFORMERS
CRACKERS
NEW INSTALLATIONS
REVAMPS
+
}

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. 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. Indian Scenario
Lack of site fabrication space
Congested existing plants
Land transportation limitations
Unfavourable conditions at certain sites

11. Congested plants

12. Road transportation

13. ~9m
5.45m
5.76m
81 MT
Road transportation

14. ~9m
5.45m Near
Limitation
Road transportation
5.76m
81 MT

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. 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. Extent of modularisation
Transportation, handling and erection efforts
Incremental reduction in site activities
Efforts
Amount of modularisation/ Module size

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. 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. 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. 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. Site
Installation
Design &
Engineering
Shop
Fabrication
Procurement
Needs to be incorporated
design phase itself

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. 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. 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. Cost
Modular Stick built
Increased

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. 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. 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. 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. 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. 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. 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. 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. Schedule
Engineering
Procurement
Fabrication
Erection
Stick Built Modular
Data for a typical Fired Heater Project

36. Schedule
Engineering
Procurement
Fabrication
Erection
Stick Built Modular
SAVINGS
Data for a typical Fired Heater Project

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. !
"
#$
%
&
'
(
)
*
+
,
-.
Some case
studies

39. Heat Duty: 5.37 MMkcal/hr
Tonnage: 100MT
Supplied as: Complete Modules
Vertical Cylindrical Heater
120° Segments

42. Modularisation in Revamps

43. Small VC heater
14 days!
Removal of
old heater, and
erection of
complete new
heater onto
the foundation

44. 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

46. 40 days
Complete

47. HeaterlookedlikethisRapid Revamp/ Reconstruction

48. We opened it up
removed
all
tubes
refractory
casing…
Rapid Revamp/ Reconstruction

49. removed
all
tubes
refractory
casing…
We opened it up
Rapid Revamp/ Reconstruction

50. and
used
pre-fabricated
modules…
Rapid Revamp/ Reconstruction

51. '
to complete
the job
within
30 days
FLAT
Rapid Revamp/ Reconstruction

52. 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

53. CONSTRUCTIVE SOLUTIONS
Esteem Projects Pvt. Ltd.
www.esteemprojects.com
Thanks for your attention!
epl@esteemprojects.com