!! Modular Construction of Catalyst-Regen Unit Saves Time, Costs PDF

1/18/2019 Modular construction of catalyst-regen unit saves time, costs - Oil & Gas Journal
Modular construction of catalyst-regen unit

saves time, costs
06/19/2000
By Tracy Galvin
As part of the work associated with its 540,000 b/d Jamnagar,

Gurajarat, India refinery, completed in 1999, Reliance Industries
Ltd. (RIL) installed the catalyst-regeneration section of its
reforming unit in prebuilt modules.
Early in the development of the project, UOP presented the advantages of modular construction for the 85-
m tall catalyst-regeneration section to RIL and Bechtel Corp.'s office in London. RIL and Bechtel agreed that
this approach was the best way to shorten the schedule and reduce costs while maintaining quality.
The three companies also agreed that the off site fabrication of the modules should be carried out in India,
as proximity would yield efficiencies in cost and quality. UOP chose Larsen & Toubro Ltd. (L&T), Mumbai, as
the fabricator based on its experience in large projects.
This was the largest module-approach project undertaken by UOP to date. RIL and its contractors
completed the module installation at the construction site without any major issues.
Construction challenges
The reforming unit of the Jamnagar refinery uses UOP's Platforming process. The catalyst-regeneration
section, which uses a UOP technology called Cyclemax CCR (continuous catalyst regeneration), has a
catalyst-circulation capacity of 4,500 lb/hr.
Click here to enlarge image
The catalyst-regeneration section of
the Platforming unit is the world's
largest Cyclemax CCR application,
towering 85 m above grade (Fig. 1).
The nature of the process requires

the equipment to be positioned in
series and in a "flow-down" fashion,
resulting in a relatively narrow,
"high-rise" process unit. The unit
required more than 400
instruments, special metallurgy for
piping and vessels, and operating
temperatures greater than 500° C.
These combined issues posed
many obstacles to conventional
construction techniques.
https://www.ogj.com/articles/print/volume-98/issue-25/processing/modular-construction-of-catalyst-regen-unit-saves-time-costs.html 1/9
Whether the CCR section was
modularly or conventionally built,
several inherent challenges
included:
A large height-to-width ratio of the

structure.
A large number of high temperature
and stress-critical process piping
loops and equipment.
Stringent layout requirements of
piping, equipment, and instruments
for process reasons.
The need to have a user-friendly
layout at lower decks, where
equipment, piping, and instrument
density is high.
Construction planning for the

Jamnagar refinery project also had
to consider a potential shortage of
skilled labor for complex units.
Plans for modular approach

In third quarter 1996, senior
executives of RIL visited UOP to
discuss various aspects of the
project implementation. The
construction method for the "high-
rise" CCR section was discussed at length.
Several key issues led to the choice of modular construction:
The modular approach minimizes the number and sizes of required cranes. It also shortens the
erection time from several months to several days.
Module assembly at grade allows simultaneous access to all parts of the CCR section for construction
and inspection activities. The conventional approach requires all its activities to be carried out in a
"from the ground up, piece-by-piece" fashion.
Conventional construction activities at high elevation can affect the quality of fabrication and
nondestructive tests, such as radiography of pipe welding.
Pressure testing in the shop virtually eliminates any field-pressure testing.
It is easier to perform inspection and rectify deficiencies at the assembly site than at the construction
site.
In optimizing module dimensions, UOP considered the capacity and reach of available cranes and the
strength of the module's structural frame for lifting and safety in handling.
1/18/2019 Modular construction ofClick here to
catalyst-regen unitenlarge
saves time, costs - Oil & Gas Journal
image The modular CCR section consists

of twin towers of equal height. Each
tower has three modules,
designated A, B, C or D, E, F. One
side module, G, bridges the two
towers. Fig. 2 depicts this
arrangement.
In one of the two towers, a stairwell

provides access for both the CCR
and the reactor section. Running
parallel to the stairway and
supported laterally by the towers is
a lift with step-outs at various levels
to the CCR structure.
The largest and heaviest modules,

A and D, at grade level, weigh more
than 200 tonnes each and have a
length of approximately 31 m. All
except module G have an overall
cross-sectional dimension of
approximately 6.5 m wide by 7.3 m
high. The lightest are top level
modules C and F, each weighing
about 70 tonnes. The total weight of
the CCR modules exceeds 900
tonnes.
Local contractor
Prior to actual award of the project, RIL requested that UOP carry out a feasibility study for fabrication of the
modules in India. RIL had several chief considerations in mind: reducing transportation costs, minimizing
risks and damage to the modules, and better after-delivery service by the local module fabricator.
With the help of UOP's worldwide subcontracting and procurement database and logistical support by
UOP's liaison office in New Delhi, the proposal team engaged in review and inspection activities to qualify
Indian companies for the project.
UOP teamed up with L&T, one of the largest engineering, procurement, and construction (EPC) companies
in India. The chemical plants and systems, group II, division of L&T has had extensive experience in
petrochemical and refining projects in India. They have also executed various projects for RIL in India.
L&T's world-class fabrication facility was of particular importance for this project. It had a waterfront and jetty
for sea-going vessels, which could accommodate the number, size, and weight of the modules.
Detailed design
Based on its experience in designing and fabricating modular CCR units, UOP prepared a front-end
engineering design (FEED) package for the detailed designer. This package gives the EPC contractor a
good starting point for the design. It contained:
Mechanical flow diagrams.

General arrangement of equipment and major piping circuits.
Various design, fabrication, and construction-related specifications.
A framework of project-specific inspection and testing plan.
Other design instructions necessary for a given project.
For example, UOP provided front-end structural design and piping flexibility analyses for critical piping loops
in the FEED for this project because of the complexities as a result of the size of this particular CCR section.
For a smooth transformation of the FEED package into a detailed engineering package, UOP and L&T
design teams worked closely together. UOP maintained a resident team at L&T offices. Additionally,
specialists from UOP's main office in Des Plaines, Ill., were dispatched periodically to L&T offices for specific
discussions and reviews.
The two companies discussed and reviewed the equipment arrangement and piping layout in depth. L&T
reanalyzed the stress-critical piping loops to finalize routing. The front-end structural design package
enabled L&T to complete the structural analysis and design of the main skeletal members early, which in
turn, enabled timely procurement of long-lead structural members by UOP outside of India.
Use of up-to-date design software ensured a high level of accuracy and timely completion of detailed
engineering.
Chief among them were PDS (by Intergraph) for modeling equipment, piping, and structural steel; STADD III
for structural design; and CAESAR II for pipe stress analysis.
UOP and L&T also used the ANSYS package for finite element analysis of the baseplate assemblies and
the X-Steel package for automatic steel-fabrication drawings.
UOP and L&T jointly analyzed the PDS model to ensure compliance with various design, operational,
maintenance access, and safety requirements.
Procurement strategy
UOP has developed relationships with certain equipment manufacturers specifically for critical equipment
employed in the CCR section. These manufacturers have a good understanding of the equipment
requirements stipulated in UOP's basic process design package.
UOP and L&T split the procurement of all equipment and instruments to optimize UOP's relationships with
CCR equipment suppliers and L&T's relationships with local suppliers.
UOP supplied the regeneration tower, electric heaters, regeneration blower, dust collector, and all critical
instruments. It also supplied structural steel sections for major skeletal members not available in India. It is
worth mentioning that all heavy W14 wide flange sections used as columns were rolled to design lengths,
thus avoiding the cumbersome splicing.
L&T supplied the remaining equipment and bulk materials that were available locally. These included the
remaining fabricated pressure vessels, blowers, and pumps, as well as all electrical and instrumentation
(E&I) equipment, insulation, and piping raw materials.
To ensure the uniform quality of equipment and materials purchased both locally by L&T and internationally
by UOP, the two companies jointly developed technical and quality assurance and quality control (QA/QC)
requirements in the form of technical requisitions and inspection test plans (ITP).
Fabrication and QC
Workers fabricated the The CCR section was fabricated

catalyst-regeneration horizontally, or 90 degrees off from
section of the the normal erected position, as a
reforming unit in one
piece at the Larsen & single structure with predetermined
Toubro fabrication module breaks (Fig. 3). Workers
yard. Trestles, the routed all piping circuits through the
temporary frames
shown between the modules and connected them to the
structure and the equipment and vessels.
ground, supported the
modules during
The result was a completely
assembly and
transportation. Photo assembled CCR section in the
courtesy of UOP (Fig. horizontal position. This approach
3).
guaranteed exact fit of all pieces
Click here to enlarge
image upon disassembly of the structure
into individual modules.
Early planning and training of supervisors and workers helped overcome the perceived difficulties of this
unusual construction method. Training also identified the nuances of the CCR section as well as normal
construction considerations.
To this end, the UOP resident team and L&T design engineers formed a team and moved to the L&T
fabrication shop in Surat, Gujarat. This team had several major responsibilities:
Timely installation on modules of critical-path equipment and components manufactured and

fabricated elsewhere.
Fabrication and assembly of modules complete with structural framework, piping circuits and pipe
supports, lighting fixtures, electrical heat tracing, E&I cables, piping and equipment insulation, and
complete painting system.
Maintenance of precision in fabrication to ensure structural, piping, and E&I fit-ups at Jamnagar site.
Schedule control and development of recovery plan.
Implementation of inspection-test plan activities.
Compilation of manufacturers' record books for fabrication and testing-related documents.
When the horizontal assembly was complete, UOP Technical Services visited the module assembly site and
inspected the CCR for conformance with design. RIL also examined the unit for operating and maintenance
requirements prior to shipment to the site.
UOP and L&T generated detailed indices of the manufacturers' record books, covering all inspection and
testing requirements of equipment fabrication and module assembly. RIL and Bechtel approved these.
During the whole course of the project, these indices served as the road map for all QA/QC-related activities
from suppliers' shops to the module assembly site. Therefore, QA/QC-related documents such as test
procedures, welding procedure specifications and procedure qualification records (WPS/PQR), material test
certificates, and traceability records were secured and incorporated into the manufacturers' record books
with much ease.
These completed records allowed for a smooth sign-off of the ITP by UOP and L&T at the time of module
delivery to RIL.
Module shipment
Preparation to ship the modules consisted of three work items. First, workers had to separate the modules
and interconnecting components at the module breaks. Piping circuits were cut at the module breaks after
the completion of hydrotest.
Cable-tray splice pieces were removed as ship-loose items, and grounding jumpers were disconnected at
the module breaks. Cables that cross the module breaks were disconnected from the users, coiled, and
fastened for shipment.
Lacing angles, connecting the neighboring modules at both vertical and horizontal planes, were removed
and tagged for shipment. Finally, structural bolts at module breaks connecting the cap plates of the columns
from the higher and lower modules were removed, allowing the structural framework of the module to be
separated.
In parallel to the separation operation, workers added temporary supports to ensure safety during
transportation and lifting. Fragile components such as stainless steel surfaces, transmitters, and gauges
were protected against potential attack by seawater.
The third preparation component was the safety check. Before hydraulic trailers started moving the module
from the assembly site, safety engineers rechecked all new and existing temporary supports for tightness
and effectiveness, considering not just the horizontal shipping position but also the tilting from horizontal to
vertical position during lifting.
All modules were checked for and cleared of any loose, foreign objects such as tools, which might fall and
cause injury during transportation and lifting.
Hydraulic trailers transported the modules from the fabrication site to the shipping dock. Trestles, temporary
frames along the length of the structure, supported the modules during fabrication and transportation. The
trestles resulted in a flawless transportation of the modules from the L&T module assembly site to the
construction site in Jamnagar.
Transportation consisted of an overland movement on 16-axle hydraulic trailers and a sea journey on a
barge deck. At Jamnagar, another 16-axle hydraulic trailer helped roll the modules off the barge one at a
time.
Again, trestles supported the modules for the 12 km journey from the jetty to the construction site. Prior to
erection, they were also used for temporary storage of modules.
Field work
One of the biggest challenges in modular construction is the execution of field work because it is often
carried out by a party other than the module fabricator.
Based on experience from previous projects, UOP uses two important sets of documents, the master ship-
loose list and the field-erection construction package, which are further developed by the detailed designer
and module fabricator for eventual use by the field contractor.
The conceptual master ship-loose list in UOP's FEED package served as the basis for L&T's development
of a detailed and project-specific master ship-loose list. L&T gave a unique computer sequence number
system for each ship-loose component. All ship-loose components were tagged with this computer
sequence number identification in addition to a drawing number and a part description.
This tagging system, coupled with good preparation and packing for shipment, ensured that no damage
occurred during transportation. It was also instrumental in increasing the efficiency of the field work with its
comprehensive, easy-to-use data and its links to crucial documents, such as the field-erection construction
package.
Again, UOP provided basic input to L&T for generation of a comprehensive field-erection construction
package for use by field contractors. This package contained instructions and drawings for defining the
scope and recommending sequence of field activities. Drawings and instructions were either existing
documents with markups for field work (as in the case of E&I) or prepared specifically for ship-loose
components and parts (as in the case of piping and structural work).
All applicable WPS/PQR and NDE procedures and the ship-loose master list were also part of the package.
Wherever required, sequential activities and all necessary precautions were covered in great detail in the
form of step-by-step instructions. These features facilitated quick and efficient execution of field work.
UOP dispatched its resident team leader, who had been covering this project since its inception, to assist in
the field erection. He served as an indispensable link between what had been done at the module assembly
site and what was yet to be done at the construction site. This approach has proven to be beneficial to the
execution of field work.
Field erection
A foundation-loading diagram, generated during the design, showed the reaction forces for all site conditions
and prescribed the anchor bolt requirements (number, arrangement, size, grade, and projection length) for
the foundation design engineer. Foundation templates also aided the proper and accurate installation of
anchor bolts.
RIL used a 1,000-tonne capacity lead crane with a counterbalance and a boom height of 110 m from
Skyhorse. It also used a tail crane of 450-tonne capacity.
Considering the lifting equipment and associated devices that were available at the construction site, RIL
asked UOP and L&T to design a rectangular lifting frame to lift the modules. The frame was fabricated at the
RIL fabrication yard. This lifting frame bolted to the top caps of the module. The design called for the
installation of slings with shackles between the frame and the hook of the lead crane.
A simpler spread bar along with shackles and slings was used to lift the lower end of the module off the
ground. It bore the weight of the module during the tilting of the module from the horizontal to vertical
position.
The project team assembled the catalyst-regeneration section

horizontally and installed it module-by-module in the vertical position.
Photo courtesy of UOP (Fig. 4).
When the module was in a vertical position, the workers removed the lower lifting assembly, and the lead
crane lifted the module to the top of the foundation or to the already installed lower module (Fig. 4).
Since the entire CCR section had been horizontally constructed in one single piece prior to disassembly for
shipping, the maintenance team found very minimal fit-up problems. Only limited adjustments by shimming
were necessary to align the modules in the vertical erected position.
A small number of ship-loose items had been fabricated with provisions for field adjustment, such as the
catalyst-transfer lines between the reactor and CCR sections. Safety checks, conscientiously carried out on
temporary supports and loose objects at module assembly site, resulted in no incidents during the entire
journey to Jamnagar site as well as during the lifting operation.
The modules sit vertically in their final Fig. 5 shows all seven modules in
erected position. Photo courtesy UOP (Fig. their erected vertical position.
5).
As a result of good design and
planning, stacking up all seven 8/9
https://www.ogj.com/articles/print/volume-98/issue-25/processing/modular-construction-of-catalyst-regen-unit-saves-time-costs.html
modules to a height of 85 m took
only 2 working weeks. Installation of
all ship-loose items took 7
additional working weeks. Ship-
loose items included grating panels
bridging the two towers, pipe
segments at module breaks, home-
run electrical and instrument cables,
light tubes, motors, and delicate
instruments.
Acknowledgments
The authors thank the project teams
of RIL, Bechtel, UOP, and L&T for
their teamwork, which made the
modular approach for the world's
largest Cyclemax CCR section a success. The authors also thank A. B. Shah, RIL project manager, for his
active participation in the project execution and Youg Ganju, business executive at UOP, New Delhi, for his
tireless effort in working with RIL and Bechtel.

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1/18/2019 Modular construction of catalyst-regen unit saves time, costs - Oil & Gas Journal

Modular construction of catalyst-regen unit

As part of the work associated with its 540,000 b/d Jamnagar,

The nature of the process requires

A large height-to-width ratio of the

Construction planning for the

Plans for modular approach

Several key issues led to the choice of modular construction:

image The modular CCR section consists

In one of the two towers, a stairwell

The largest and heaviest modules,

Mechanical flow diagrams.

Workers fabricated the The CCR section was fabricated

Timely installation on modules of critical-path equipment and components manufactured and

The project team assembled the catalyst-regeneration section

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