Page 102 - Industrial Plants

territory of the refining Complex in the District of Yamal- Module 2 (6050x6000x4800 mm): The reactor recycle
Nenets Autonomous Region, for this reason, the pump module is used to provide the recirculation of
Licensor obtained permission from the U.S. Department diesel coming from the reactors and include two
of Commerce to export its own materials to the canned vertical pumps (licensed equipment) with two
Russian Federation. reciprocating pumps (licensed equipment) with
APS team designed 8 (eight) modules of a dimension maintenance sites and piping system components.
compatible with railway and truck transportation. All The lubrification system of recycle pump is provided by
modules have been totally prefabricated, in the Module 7 (3750x2000x5141 mm) through the
collaboration with Gruppo Antonini. gasoil produced by DHU itself. (figures 5-6)
Of particular importance for its complexity and
dimensions are: The design stage has great significance for the Modular
Module 8 (13900x6300x6250 mm): The make-up construction process. The use of advanced 3D
hydrogen compressor unit is intended for maintaining Modelling software is among the main factors
permanent hydrogen concentration and circulation in contributing to an accurate review of accessibility for
the reactor unit, as in the process of the diesel fuel maintenance, operation and safety. Moreover, it is
hydrotreatment a part of hydrogen undergoes various necessary to include design allowance in order to avoid
reactions and is removed together with hydrocarbon any misalignment of components during the assembly.
gases. All unit components are connected with each Once modelling is sufficiently progressed, the software
other by the pipes. The Hydrogen from module 8 will allows a “walk-through review” of the modules
be mixed with gasoil coming from the Atmospheric simulating exactly the future configuration of the plant.
distillation unit and feeding to reactors system. (figures The 3D modelling, (figure 2) skillfully used by APS
3-4) Team, has allowed to solve, in design phase, any type
of clash or physical inconsistencies thus avoiding
costly and time consuming modifications during
construction phase.

Modular plant solution

The economics of the downstream industries are under
pressure due to the low cost of oil and natural gas and
uncertainties regarding their future as the world
economic situation is changing rapidly. Major capital
projects are being re-evaluated in a market where
supply, demand and pricing have suddenly become
uncertain. In addition, developing countries are quickly
building new plants and infrastructure to support a
rapidly growing middle class that demands all the
benefits of modern industrial production.
Modular construction is widely used in many fields and
approaching this solution could help also the EPC
Fig. 3 – Assembly of Module 8 sector to use it as a standard successful approach that
can generate a lot of benefits. This highly efficient
process may be a solution for projects located in
remote regions where skilled labor is difficult to secure.
It gives the possibility to reduce schedule and cost
uncertainty and may help achieve a faster start-up
(figure 7).
Modularization has become particularly prominent in
the offshore oil and gas industry [1]. By fabricating key
components in a controlled environment, it is possible
to minimize risk, improve quality and increase overall
safety. Units derived from fabrication workshops can
be preassembled for shipping anywhere around the
world and modular construction can be more easily
executed with available on-site skills [2].
Fig.4 – Module 8 Nevertheless, there is still low awareness level of both

IndustrIal Plants - May 2017
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