MODULARIZATION

Depending on the project’s needs, we can provide all levels of shop prefabrication, including the following:

• Conventional extent of fabrication
• Modularised extent of fabrication
• Fully dressed extent of fabrication.

The conventional extent of fabrication typically includes radiant panels and process coil sections to be assembled at the site. Radiant sections can be supplied in lined or unlined panels, with or without external casing’s painting.

The refractory material and anchors can be supplied loose for site installation.

Radiant coils can be supplied either in fully welded and tested sectors or banjos, while all other items are supplied loose for field installation.

Stack, ducts and breeching are supplied in prefabricated lined sections with the external casing’s prime painted.

Convection sections are always supplied in prefabricated modules, with the refractory already installed and the coils fully installed and tested.

The modularized extent of fabrication typically involves modular radiant sections supplied fully assembled, with refractory and coil.

The fully dressed extent of fabrication further reduces the required site works, as fired heaters (FHs) are assembled to already include cable trays, cabling to junction boxes, burners, utility piping, instruments, etc. Ladders and platforms can also be pre-mounted.

This degree of modularization adds significant costs and is usually only considered when required by projects with a short shut-down period or for extreme climates, or in case the availability of local labour is scarce or very expensive.

The modular approach can be suitable for tight schedules. It limits field works, improves safety, reduces overall costs, and can be a key factor in complex projects. However, it requires a complete rethinking of the project’s organizational process, starting from the very design phase.

To ensure accurate transportation of large and heavily modularized FHs, it is recommended the use of Self-Propelled Modular Trailers (SPMT), multi-axle trailers propelled by hydraulic drive motors with computer-controlled wheels, all individually controllable, to evenly distribute weight and properly steer.