Modularisation and Prefabrication
BIH has the in-house capability to design and deliver all levels of prefabrication from panellised designs through to fully dressed modules.
BIH can offer advice and guidance on project specific logistical considerations to make the decision on whether to modularise a unit.
Factors evaluated in the decision-making process include:
- Transport limitations on/off site (including public highway restrictions)
- Availability of modularisation yard local to job site
- Modularisation requires more complex engineering and adds to structural material costs
- Shipping costs versus site costs associated with large modules
- Cost and availability of specialist module installation equipment (e.g. self-jacking trailers, large heavy-lift cranes)
- Site labour availability and cost
BIH can offer panellised sections which reduce shipping costs. We collaborate with our clients to ensure we provide the most cost-effective solution for a smooth onsite erection. Some of the options we consider are:
- Radiant section supplied in lined or unlined panels with external casing painted
- Radiant coils supplied in fully welded and tested banjos, or with the banjos shipped loose
- All other items would be supplied loose for site installation
- Stack, ducts and breeching supplied in prefabricated lined sections with the external casing painted
- Convection section supplied in prefabricated modules with all refractory installed and coils fully welded, tested and installed with the external casing prime painted
BIH have the capability to offer greatly increased levels of off-site modularisation to reduce the installation time on site. This can be advantageous for sites where skilled labour is limited or working conditions are restrictive (extreme climatic conditions or installation into a live plant for example).
The level of modularisation possible for fired heaters is almost unlimited and the options can range from assembly of the radiant section into a single module, through to the installation of convection section, stack sections and dressing of the heater with ladders and platforms, burner piping and instrumentation.
Modules may be installed onto a permanent base frame so that they can be designed to be jacked-up and driven on and off a ship and onto the heater foundations using Self Propelled Modular Transport (SPMTs) or they can be designed for lifting from carrier to foundation as required by the project. BIH can tailor the level of modularisation and transportation method to suit the requirements of your project.
Very large box type heater transported from heater fabrication shop to dock side using SPMTs
Heater lifted on to ship using ship’s crane. Temporary steel base frame (in yellow and red below) can be seen.
Box heater leaving heater fabrication shop on SPMTs
Box heater lifted on to ship using ship’s crane.
heavy lift crane. Temporary steel base
frame has been removed.
The site work involved can be further reduced by ‘dressing’ the radiant module. Some or all of the following items can be installed on the module:
- Ladders and platforms
- Heater mounted instruments including cable trays, cabling to junction boxes etc
- Utility piping (fuel, steam, instrument air etc)
This very high degree of modularisation becomes attractive for projects with very high site labour costs or when the heater has to be installed on a live plant within a very short shut-down period.
Direct Fired Heaters