Reformer Construction Sequence

REFORMER - ERECTION SEQUENCE
CONSTRUCTABILITY DEPARTMENT
HYDROGEN REFORMER
PETRONAS RAPID PROJECT
1
INDEX
I. PROPOSE……………………………………………………………………….……….… 3
II. REFORMER ERECTION SEQUENCE……………………………...………..... ...4
1. Foundation Works…………………………………………………………….5
2. Transfer Line and Process Gas Boiler Erection……………….…..7
3. Radiant Box Installation………………………………………………….…9
4. Catalyst Tubes Installation……………………………………………….23
5. Burner Erection…………….…………………………………………………26
6. Internal Refractory of Radiant Box…….…………………………….27
7. Crossover Duct Installation………………………………………………28
8. Internal Refractory of Cross Over Duct…………………………….30
9. Penthouse Structure Installation……………………………………..32
10. Piping Inlet System Installation………………………………………..35
11. Burner Piping Installation…………………………………………………37
12. Convection Section Modules Erection………………………………38
13. Air Pre-Heater Erections………………………………………………..…41
14. Combustion Air Duct Installation……………………………….…..…45
15. Structure and Steam Drum Erection…………………………….……47
16. Flue Gas Fan Erection…………………………………………………....…48
17. Stack Erection……………………………………………………………….…..50
18. Hot Flue Gas Duct Erection……………………………………….……….51
19. Combustion Air Fan and Air Intake Erection………………….…..52
III. ATTACHMENT 1 – Lifting Maneuvers responsibility……………………..54
2
PROPOSE
The propose of this document is to identify and establish the basic requirements and sequence of
operations necessary to the receiving, fabricating and assembling of the main elements that
constituting the Reformer;
Other aim is to have an overall idea of the field fabrication and lifting maneuvers in order to aid TR
and Subcontractor to predict with much accuracy the manpower and Cranes required;
This document does not overrule specific details or special installation instructions on TECHNIP
drawings and in specifications. Moreover, Vendor's installation specification and/or instructions must
always prevail and followed;
For detail instructions see TECHNIP drawings and Sub Vendors installation manuals;
WORK DESCRIPTION
The work consists of the construction of one Reformer at PETRONAS RAPID PROJECT.
The present Document has been prepared taking in consideration the Preliminary Schedule, TECHNIP
Construction Specification and available drawings;
3
REFORMER ERECTION
SEQUENCE
4
1. PERFORM FOUNDATIONS WORKS
Civil works should start the foundations on Radiant area and Air Pre-Heater;
Execution plan:
Transfer-Line Erection – 01-Aug. 16 to 11-Aug-16;

APH Structure Erection – 03-Aug. 16 to 13-Aug-16
Radiant Structure Erection – 16-Aug. 16 to 15-Set-16;
5
MAIN CHECK POINTS AFTER FOUNDATION COMPLETION
• Curing of Concrete - Shall be carried out in accordance with BS 8110-1, Clause 6.6 or CEB-FIB
Model Code, Appendix D 12;
• Formwork Stripping Inspection - The form work shall be removed in accordance with BS 8110-1,
clause 6.2.6.3 or CEB-FIB Model Code 1990;
• Control of Surface Finish - Shall be chipped and brushed to remove the weak upper layer of the
concrete;
• Bolts greased, nuts and washers properly protected and covered - PTS 34.19.20.31;
• Final Dimensional Control – In accordance with BS 8110-1, clause 6.2.8;
6
2. TRANSFER LINE AND PROCESS GAS BOILER Execution plan – 01-Aug. 16 to 31 Aug. 16
Transfer-Line is installed in two sections, connected by one field weld;
SECTION I SECTION II
FW to
Boiler
- Transfer Line
In case of a delayed delivery and the Transfer-Line arrives at Site after the Radiant Box Erection, the
Transfer-Line can be slide underneath the reformer and jacket up into the final position;
7
- Process Gas Boiler
Welding of outlet Transfer-Line:
Before welding of the refractory-lined transfer-line it shall be carefully checked that the alignment
of the process gas boiler and refractory lined transfer line has been performed in full accordance
with TECHNIP engineering documents;
In addition, a check shall be performed, that there is sufficient clearance for expansion, insulation,
supports and instruments in accordance with TECHNIP installation rules;
Just after final position of the Transfer-Line versus the Process Gas Boiler have been confirmed
can be fitted the Catalyst Sub-Header up to the Transfer-Line;
8
3. RADIANT BOX INSTALLATION Execution plan – 16-Aug. 16 to 02 Nov. 16
Approximately 7 weeks for:

+Unload and organize material;
+Pre-assemble and weld structure support and floor;
+Pre-assemble and weld x28 wall panels;
MAY JUNE JULY AUGUST SETEMBER OCTOBER NOVEMBER

MAY1 MAY2 MAY3 MAY4 JUN1 JUN2 JUN3 JUN4 JUL1 JUL2 JUL3 JUL4 AUG1 AUG2 AUG3 AUG4 SET1 SET2 SET3 SET4 OCT1 OCT2 OCT3 OCT4 NOV1 NOV2 NOV3 NOV4
FABRICATION & DELIVERY OF 1st REFORMER 01-05-16 10-08-16
TRANSPORTATION PACKAGE 24-05-16 21-06-16

(Includes Radiant Steel Material of 1st Reformer)
RADIANT BOX ERECTION 16-08-16 02-11-16 CRITICAL!
RADIANT WALL AND FLOOR PANELS INSTALLATION 16-08-16 15-09-16
SCAFFOLDING ERECTION INSIDE RADIANT BOX 15-09-16 05-10-16
RADIANT SECTION ARCH ERECTION 05-10-16 15-10-16
9
3.1 INSTALLATION OF STRUCTURE SUPPORT UNDER RADIANT FLOOR
10
3.1 INSTALLATION OF STRUCTURE SUPPORT UNDER RADIANT FLOOR
Structure elements are delivery in bulk material;
Structure elements are pre-assembled and welded at Site;
(Approximately 11.748 kg of steel)
RADIANT
BOX
STRUCTUTER
UNDER
RADIANT
FLOOR
CONCRETE
PEDESTALS
11
3.2 RADIANT FLOOR INSTALLATION
Structure elements are delivery in bulk material and connections are welded at Site;
The structure could be mainly pre-assembled and erected in 8 modules;
After erected and aligned the modules is welded the floor sheets and support beams to each module.
12
3.2 RADIANT FLOOR INSTALLATION
1 2 3 4 5 6 7 8
PRE-ASSEMBLE
MODULE
1 2 3 4 5 6 7 8 9
RADIANT FLOOR
SHEETS
CONNECTED TO
EACH MODULE
- Radiant Floor Plan
13
Characteristics of each module:
- Mainly formed by 2 main beams, 18 columns and 26 wall sheets;

- Pre-assembled and full welded at Site;
- Dimension 13200 x900mm.
Columns
Floor Sheet
Main Beams
Wall Sheet
14
3.3 RADIANT WALL INSTALLATION
WALL PANEL
RADIANT BOX 1 2 3 4 5 6 7 8 9
15

WARNING:
Structure elements are delivery in bulk material; The available information points to
the wall panels are full pre-assembled
Walls are pre-assembled and welded at Site in 28 panels; and welded at Site!
The Panels could be erected one by one or in groups of 2/3 panels;
Temporary supports should be used to fix the panels until the radiant box doesn’t
have self stability;
The Interior Seal Welding just starts after

the wall panels and arch been erected
and full aligned;
Field and seal welds should be painted

with a mastic paint from inside (3mm
thick);
Interior panel is painted with mastic paint;

External with Silicone Aluminum paint;
Both at workshop!
Characteristics of each panel:
- Formed by 2 main columns, 11 steel sheets and 24 reinforced beams;

- Pre-assembled and full welded at site;
- Dimension 13703 x 1807mm;
WALL SHEET
MAIN BEAMS
REINFORCED BEAMS
(Approximately 82.000 kg of steel all panels)
WALL SHEETS
17
MAIN CHECK POINTS DURING AND AFTER THE STRUCTURE EXECUTION
• Fit Up Inspection. Root gap, Edges preparation, Cleanness, Alignment, Bevels;
• Welding process monitoring. Travel speed, voltage and inter-pass cleaning.
• Visual Inspection of Welds;
• Non destructive testing (UT/RT/MT/PT). Check and review results;
• Weld repair. All repairs are carried out and re-examinated;
• Check levelling of anchor plate, shim plates, foundations, etc., before erection of columns;
• Preliminary Levelling and Plumbness;
• Final Tightness of Bolts (by torque wrench if required);
• Tightness of Anchor Bolts;
• Levelling and Plumbness Final Inspection;
18
3.4 SCAFFOLDING INSTALLATION INSIDE RADIANT BOX Execution plan – 15 Set. 16 to 05 Oct. 16
SCAFFOLDING INSTALLATION:
→ Shall be completely self-supporting and

must be distanced from the radiant wall to
avoid any interference with refractory
installation or the refractory be damaged
with scaffolding movements;
→ Shall be erected without close center

part of the chamber to allow the catalyst
installation;
- Scaffolding layout;
At yellow scaffolding area.
19
3.5 RADIANT ARCH INSTALLATION Execution plan – 05 Oct. 16 to 15 Oct. 16
Structure elements are delivery in bulk material.
The arch panel is mainly formed by 8 panels which support the burners and 8 panels
which support the catalyst tubes;
The 16 panels could be pre-assembled at Site and can be erected one by one or in groups
of panels;
The arch panel will be temporary supported by the scaffolding

erected inside the radiant box;
No Pre-Assembly drawings available!
20
3.5 RADIANT ARCH INSTALLATION
21
Execution plan:
3.6 ERECTION OF STAIR TOWER AND PLATFORMS UP TO ARCH LEVEL 13 Oct. 16 to 02 Nov. 16
The stair tower and around platforms form an integral part of the radiant box stability, therefore
should be assembled after the erection and alignment of radiant walls;
22
4. CATALYST TUBES INSTALLATION Execution plan –02 Nov. 16 to 12 Nov. 16
Catalyst tubes are delivery in modules with the Outlet Sub-Header included;
Total of 8 rows of catalysts to install;
Each row is formed by 5 modules;
MODULE 3
4 CAT. TUBES
(LOOSE DELIVERY)
F.W.
F.W. F.W. F.W.

F.W.
MODULE 1 MODULE 2 MODULE 4 MODULE 5
10 CAT. TUBES 9 CAT. TUBES 9 CAT. TUBES 10 CAT. TUBES
23
4. CATALYST TUBES INSTALLATION
- After the radiant box is installed, leveled, checked and seal welded,
the catalyst tubes should be inserted in radiant box;
- Under no circumstances special alloy catalyst tubes may come in

contact with painted structural steel or aluminum/ galvanizing
scaffolding, etc.;
- Special care has to be taken for temporary-supports and guides for

catalyst tube. (Wood or other non-metallic material shall be placed
between catalyst tube and support/guide);
24
4.1 FITUP AND WELDING LOOSE CATALYST TUBES Execution plan – 24 Nov. 16 to 13 Jan. 17
AND OUTLET SUBHEADER
After confirming correct installation of the transfer-line/Process Gas Boiler

the catalyst Sub-Headers can be fitted up to the Transfer-Line;
After all Catalyst Tube assemblies are correctly fitted up the Outlet
Headers (Module 3) can be welded and the supports installed in the trench
of the radiant floor.
When the correct position has been checked, the field welds to connect
the outlet Sub-Headers to the cone on top of the Transfer-Line can be
made;
25
5. BURNER ERECTION Execution plan – 13 Out. 16 to 16 Nov. 16
Reformer burners shall be carefully installed in reformer casing as

per TECHNIP/Vendor's instructions before commencement of
reformer roof refractory installation;
Erection of burner plate and refractory:
- Lay down on the platform the Burners Tile with muffle;

- Erection of burner plate in accordance with burner;
Take special attention for the burners delivery;

For complete the Arch Refractory works and remove the
scaffolding is mandatory the burners have been installed;
26
6. INTERNAL REFRACTORY OF RADIANT SECTION Execution plan – 02-Nov. 16 to 08 Apr. 17
Erection of refractory material in accordance to refractory supplier installation instruction and installation
lining instruction;
Before Starting Lining, check:

• Inside seal welds are completely and as well the application of 3mm of mastic paint on welding joints;
• Wall flatness. Should be avoid to have a gap between the wall plates and back layer of insulation;
- After completed and inspected the wall and Radiant Arch refractory remove the scaffolding and start with
the floor lining;
- Radiant Walls - Walls up to EL. +118.052 - Radiant Walls - Walls from EL. +118.052
Insulating Firebrick Class 23 178 mm Ceramic Fiber Module 1427/170 250 mm

Insulating Block 1100 50 mm Ceramic Fiber Blanket 1260/128 50 mm +
Insulating Block 1000 75 mm + 300mm
303 mm
- Radiant Floor - Radiant Arch
Castable Class III 74 mm Ceramic Fiber Module 1427/170 250 mm

IFB 23 76 mm Ceramic Fiber Blanket 1260/128 50 mm +
Insulating Block 1100 100 mm 300mm
Insulating Block 1000 75 mm +
325 mm
27
7. CROSS OVER DUCT INSTALLATION Execution plan – 13 Oct. 16 to 22 Dec. 16
28
7. CROSS OVER DUCT
Duct elements are delivery in bulk material;
The cross over duck shall be installed panel by panel,

starting from the floor, side walls and finally
the roof;
It shall be noted that the duct should not be

assembled on the ground and hoisted as
whole onto its place;
Temporary support of transition roof panels is required until

convection roof is in place.
29
8. INTERNAL REFRACTORY OF CROSS OVER DUCT Execution plan – 22.Dec.16 to 17.Mar.17
Transition duct refractory starts with the walls. First activity starts with checking of the anchors
(type/material specification/length);
For the refractory materials to be applied, the requirements of the supplied materials must
be adhered to, as walls will be cast in vertical position;
30
- Cross over duct floor - Cross over duct walls (Lower part, < El.+116.800)
Castable Class III 175 mm Castable Class III 150 mm

Insulating Block 1100 75 mm Insulating Block 1100 75 mm
Insulating Block 1000 75 mm + Insulating Block 1000 75 mm +
325 mm 300 mm
Special attention for the
castable curing time.
- Cross over roof (Lower part, < El.+116.800)
Castable Class III 125 mm

Insulating IB 1100 75 mm
Insulating IB 1000 75 mm +
275 mm
- Cross over duct walls and roof

(Upper part, > El.+116.800)
Ceramic Fiber Module 250 mm

Ceramic Fiber Blanket 50 mm
300 mm
For more details check V-02260-1511-F-201-0018
31
9. PENTHOUSE STRUCTURE INSTALLATION Execution plan – 13-Oct-16 to 29-Apr-17
After the installation of the radiant box the penthouse steel structure will begin;
Installation of the penthouse steel structure frames can be stick built in-situ or be pre-assembled in
one or more modules and hoisted in one or more sections onto the radiant;
32
9.1 PENTHOUSE CONSTRUCTION PROPOSALS – GANTRY SYSTEM

A proposed construction strategy is to pre-
assemble on the ground the main structure
gantries, erect it and finalize the secondary
frames at place;
Temporary bracings and purlins should be used

until the interconnection beams will be
installed and the structure stability is
guaranteed;
It is recommended that the roof- and parts of sidewall sheeting shall be installed as soon as the
penthouse structure is erected. Part of sidewall must be left un-sheeted to allow for inserting
combustion air ducts, piping and equipment;
33
9.2 PENTHOUSE CONSTRUCTION PROPOSALS – MODULAR
Construction sequence strategically and technically more challenging would be to pre-assembly the
upper part of the Penthouse on the ground with inlet pipes installed, including Pig Tails, Main and Sub-
Header and all spring hangers;
34
9.3 PENTHOUSE CONSTRUCTION PROPOSALS – STICK BY STICK
Considering a bigger number of liftings on a

construction sequence in stick by stick base and
the reduced laydown area is proposed use a Tower
Crane;
Benefits of Tower Crane:

- Small area required for stabilize;
45m 45m
45m
- Large area covered by the boom achieving the
pre-assembly areas;
- Superior lifting speed;
- Good load capacity;
90 m 90 m
35
9.1 RADIANT ARCH SUPPORTS
It is recommended that directly after the penthouse steel

structure is stable, the radiant arch be suspended (connecting the
tie rods with the radiant floor);
Only after the radiant arch is suspended, rest of work on radiant

arch may commence;
- Hanger support for arch panel
36
10. PIPING INLET SYSTEM INSTALLATION Execution plan – 21-Dec-16 to 26-Nov-17
37
10. PIPING INLET SYSTEM INSTALLATION
The inlet system of a reformer comprises of an inlet expansion loop, the inlet main header and
inlet sub-headers and pigtails.
It is preferred to commence installation of the inlet sub-headers on temporary supporting.
Thereafter the prefabricated pigtails shall be installed and after the correct position and the free
expansion of each pigtail, taking into account the insulation thickness, has been verified, the pigtail
can be welded to the catalyst tubes, as well as to the sub-header.
Installation of the inlet main header and expansion loop including supporting can be executed
thereafter.
Finally the connection pipes in between the main header and sub-header are to be fitted and
welded.
Pneumatic test should be performed;
38
10.1 PIPING INLET – PIG TAILS; Pig Tails:
The Pig tails are delivered in

loose items. Each item include:
- Pipe DN 32(1¼”) L=8610mm;

- Bended elbows;
- Two Field Welds;
Total Pig Tails F.W.:
2x8x42= 672 Field welds
39
10.2 PIPING INLET – SUB-HEADER;
Sub-Header: Total Sub-Header F.W.:

Sub-Header is delivery in spools. 5x8= 40 Field welds
Each sub-header is formed by:
- Pipe DN 150 (6”) and DN 200 (8”);

- Five Field Welds;
40
10.3 PIPING INLET – HEADER;
Header:
The Header is delivered in

spools and is formed by:
- Pipe DN 500;
- Five Field Welds;
41
10.4 PIPING INLET – INSULATION;
Insulation Requirements:
Material:
• First Layer – Ceramic Fiber Blanket (96kg/m3, 605°C);

• Second Layer – Mineral wool Pipe Sections (100kg/m3);
– Mineral wool Pipe Blanket (70kg/m3);
• Sheeting:
– Stainless Steel
Note:
All items use for securing in place of insulation, I.E.
mesh, strips, etc., to be of stainless steel material;
Insulation material is not supplied by Vendor
For more details check V-02260-1511-F-201-0137 - Pig Tail Insulation
42
11. BURNER PIPING INSTALLATION Execution plan – 24-Feb-17 to 04-Jun-17
Before the installation of burner piping, a pre-fabrication should be take place on the ground
with anticipation;
After welding and supports installed should be followed a hydraulic test;
43
12. CONVECTION SECTION MODULES Execution plan – 27-Dec-16 to 20-Jan-17
44
12. CONVECTION SECTION MODULES
The convection section is a steel box construction build-up

from prefabricated panels containing various convection tube
bundles;
It is formed by 2 individual modules with 145 and 195 tons

each;
After the modules been erected, installed the fiber glass

between them, checked the verticality, alignment, bolt
torqueing, then modules are seal welded;
A Heavy Lifting crane should be required for this erection;
TO CONFIRM:
If the seal weld is from inside or outside
45
12.1 STRUCTURE AROUND CONVECTION SECTION Execution plan – 03-Aug-16 to 11-Nov-16
After Convection erection could be installed the structure around the Convection, starting from
the North and South Towers and further with the structure under Combustion Duct;
Some structure elements could be pre-assembled on the ground;
46
13. AIR PRE-HEATER ERECTIONS Execution plan – 03-Aug-16 to 11-Nov-16
The Air Pre-Heater is mainly formed by four

equipment's:
- Hot APH (CE-262);

- Hot Boiler APH (CE-207);
- Cold Boiler APH (CE-207);
- Cold APH (CE-261);
TO CONFIRM:
If the seal weld is from inside or outside
After the convection section is installed, installation continues with the pre-assembled (seal
welded in situ) Air pre-heater coil banks;
During the installation the main topic is the checking of seal welding to avoid any mixing between
flue gas and air for burners, plus that no leakages thru to ambient;
47
13.1 Hot APH (CE-262) ERECTION
The Hot APH is formed by 6 modules. One Support Frame and five
Blocks with 8,300Kg each;
48
13.2 HOT AND COLD BOILER APH

(CE-207) ERECTION
The Hot and Cold Boiler are

individual blocks with 31 tons each;
- Hot Boiler - Cold Boiler

49
13.3 COLD APH ( CE-261) ERECTION
The Cold APH is formed by 15 blocks;
The weigh of each block ranges

between 15 tons and 24 tons;
The erection sequence should be

according the Erection Sequence
Plans;
- Erection sequence
- Gaskets types
50
14. COMBUSTION AIR DUCT Execution plan – 15-Dec-16 to 30-May-17
- Combustion Duct to APH - Main hot Header Duct
With the APH already installed is erected the duct to the APH;
The Main Hot Header is pre-assembled on the ground and erected after the structure above the
Convection have been installed;
51
14. COMBUSTION AIR DUCT
- Hot air distribution to Burners - By-Pass Duct between Cold & Hot air Duct
Following the Main Hot Header Duct above the Convection is installed the Hot Air Distribution to
Burners and later the By-Pass Duct between Cold & Hot air Duct;
On Hot Air Distribution Duct must to be given attention to the size of the elements to pre-
assemble due the lake of space for install it inside the Penthouse;
Accessories alike compensators, sliding pads shall be installed assembly as per TECHNIP/Vendor's
instructions;
52
15. STRUCTURE AND STEAM DRUM ERECTION Execution plan – 01-Jan-17 to 16-Feb-17
- Structure under Clean Steam Drum - Structure under Process Steam Drum
With Convection Section installed and the structure around assembled could start the Process
and Clean Steam Drum Structure assembling and equipment erection (V-741 and V-751);
53
16. FLUE GAS FAN ERECTION Execution plan – 01-Nov-16 to 23-Jan-17
The installation of the flue gas stack sections,

flue gas fan and the associated ducting and
structures can be separately installed from the
rest of the reformer;
The fan is delivery in separate elements. Base

frame, casing, rotor, fan shaft and motor have
to be mounted at Site;
To check the Installation Operating and

Maintenance Manual to detailed information;
54
Typical Fan mounting sequence:
1 - Place the metal base frame with the anchors on the concrete. 3 - Mount completely the casing of the fan. Check the centering of
The fan must be adjust on the foundations and must be axes.
tightened when all is of level and with a good height.
2 - Mount the rotor with the bellmouth in the fan. 4 - Mount the half coupling on the motor shaft. Put the motor on his frame.
Fix the bellmouth with the inferior part of the fan. Make the alignment of the coupling.
Make the final concrete (use non-shrink concrete) and fill the anchor holes.
55
17. STACK ERECTION Execution plan – 01-Mar-17 to 19-Apr-17
The Stack is delivery in 3 Modules;
Module 3 Each module has 15meters high and the

lower part has 30 tons and the other two
20 tons each;
Platforms and ladders should be pre-assembled

Module 2 with the modules in horizontal position and
after erected module by module;
WARNING:
Where is mentioned that refractory is
done in work shop?
Module 1
WARNING:
Reformer stack has to be colored marked for aircraft warnings;
Check if is considered on Vendor Contract;
56
17.1 HOT FLUE GAS DUCT
After installed and aligned the Flue Gas Fan and

Stack erected, is installed the Hot Flue Gas Duct
Between Fan and APH and between Fan and
Stack;
The Subcontractor shall install and align the flue gas stack sections, structures, flue gas fan(s),
including compensators, dampers, sliding gates and silences;
57
18. COMBUSTION AIR FAN AND AIR INTAKE ERECTION Execution plan – 01-Dec-16 to 06-Mar-17
The installation of the air inlet tower, fan with

associated ducting, dampers and structures to
air preheater can be separately installed from
the rest of the reformer;
The fan is delivery in separate elements.

Base frame, casing, rotor, fan shaft and
motor have to be mounted at Site;
To check the Installation Operating

and Maintenance Manual to detailed
information;
For smooth lifting maneuvers first is erected the Fan and later the Air Inlet
Tower;
58
After install the Cold Duct to APH and the Inlet Tower
Subcontractor shall install and align, structures,
combustion air fan(s), including compensators, dampers,
sliding gates and silences;
After grouting the motors and fans shall be final-aligned;
59
LIFTING MODULES & LIFTING MANUEVER RESPONSABILITY

Shipping Dimension
Total Total WT Lifting Manuever
Tag No. Q'ty Description Width Height Volume (KG) Supplier Remarks
Lengt Responsability
(m) (m) (m3)
h (m)
340.0000 Convection are 2 modules with 3 section of coils each
CE- 8.5 (3.8 Technical TR
2 Convection Modules 5,2 15,5 1) 145,000 Lifting maneuver bellow 20m height but > than 100 tons each
201/202/203/204/205 + 4.7) Reunidas Scope
2) 195,000 module
TR
E-301 1 Process gas boiler 14 2,8 2,6 105,20 62.610 Arvos Horizontal Equipment >50 tons
Scope
Mechanical Subcontractor
V-741 1 Steam Drum process 9 2 2 36,00 25.000 Furuise Horizontal equipment < than 50 tons
Scope
V-751 1 Steam Drum Clean Steam 12 2,5 2,5 75,00 50.000 Furuise Scope Horizontal equipment = 50 tons
K-202 1 Combustion Air Fan including motor 6,7 2,8 3,6 68,00 14.000 Boldrocchi Scope Its expected to install in 1 module with < 100 tons
Lifting Maneuver bellow 20m and <100 tons
K-201 1 Flue Gas Fan excluding motor 9,95 3 4 119,40 24.000 Boldrocchi Scope Its expected to install in 1 module with < 100 tons
8 rows. Each row is composed by 5 modules. The biggest module has
Schmidt & Mechanical Subcontractor 10 tubes and an outlet subheader with approximated weight of
F-201 8 Catalyst tubes assembly 1 thru 8 15,5 3 2,5 116,25 250.000
Clemens Scope 6.500kg
Lifting maneuver above 20m height but < than 50 tons each section
Mechanical Subcontractor Lifting Maneuver bellow 20m;
F-201 1 Refractory lined outlet header 20 1,2 2,2 52,80 30.000 LP Spa
Scope Horizontal equipment < than 50 tons;
Hot APH is installed in 6 modules
APH Benelux Mechanical Subcontractor
1 Airpreheater 12,35 5,15 1,85 117,66 40.000 Lifting Maneuver bellow 20m and <100 tons
1511-CE-262 Apex Scope
APH Benelux
1 Airpreheater 14,4 3,58 1,35 69,60 31.000 Scope Its expected to install in 1 module with < 100 tons
1511-CE-207 HOT Apex
APH Benelux
1 Airpreheater 14,4 3,58 1,35 69,60 31.000 Scope Its expected to install 1 module with < 100 tons
1511-CE-207 COLD Apex
Cold APH is installed in 15 modules.
Benelux Mechanical Subcontractor
APH 1511-CE-261 1 Airpreheater 13,2 5,2 5,6 384,38 279.000 Lifting Maneuver bellow 20m and <100 tons each module
Apex Scope
Penthouse structure is installed in modules.

F-201 1 Penthouse lower part 13,4 19,6 7,5 57.000 L&T Ningbo To define if is assembled in gantry system or other method.
Scope
Penthouse structure is installed in modules.
F-201 1 Penthouse upper part 13,4 19,6 6,5 115.000 L&T Ningbo To define if is assembled in gantry system or other section.
Scope
Cross over duct (Radiant box to Convection Mechanical Subcontractor Cross over duct is assembled stick by stick.
F-201 1 6,0 19,5 12,2 125.000 L&T Ningbo
Section) Scope Lifting maneuvers < than 50 tons
F-201 1 Stack (Bottom section) 15,0 5,00 30.000 L&T Ningbo Lifting maneuver bellow 20m height and < than 100 tons
Scope
F-201 1 Stack (Middle section) 15,0 3,00 20.000 L&T Ningbo Lifting maneuver bellow 20m height and < than 100 tons
Scope
F-201 1 Stack (Top section) 15,0 3,00 20.000 L&T Ningbo Lifting maneuver above 20meters but < 50 tons
Scope
F-201 1 Flue gas duct (APH to ID fan) 12,0 5,50 12,5 40.000 L&T Ningbo Scope
It is expected to install in 2 modules with < 100 tons each
Combustion Air duct (Manifold duct close to Its expected to install in 4 modules: Hot air above convection, Main
F-201 1 3,9 17,6 4,6 20.000 L&T Ningbo Scope
penthouse) hot air header, Hot air distribution duct to burners and By pass duct.
Lifting maneuver above 20meters but < 50 tons each
60

Reformer Construction Sequence

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Reformer Construction Sequence

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REFORMER - ERECTION SEQUENCE

1. PERFORM FOUNDATIONS WORKS

Transfer-Line Erection – 01-Aug. 16 to 11-Aug-16;

MAIN CHECK POINTS AFTER FOUNDATION COMPLETION

• Final Dimensional Control – In accordance with BS 8110-1, clause 6.2.8;

Transfer-Line is installed in two sections, connected by one field weld;

- Process Gas Boiler

Welding of outlet Transfer-Line:

3. RADIANT BOX INSTALLATION Execution plan – 16-Aug. 16 to 02 Nov. 16

Approximately 7 weeks for:

MAY JUNE JULY AUGUST SETEMBER OCTOBER NOVEMBER

TRANSPORTATION PACKAGE 24-05-16 21-06-16

3.1 INSTALLATION OF STRUCTURE SUPPORT UNDER RADIANT FLOOR

3.1 INSTALLATION OF STRUCTURE SUPPORT UNDER RADIANT FLOOR

Structure elements are delivery in bulk material;

Structure elements are pre-assembled and welded at Site;

(Approximately 11.748 kg of steel)

3.2 RADIANT FLOOR INSTALLATION

(Approximately 42.268 kg of steel)

The structure could be mainly pre-assembled and erected in 8 modules;

3.2 RADIANT FLOOR INSTALLATION

- Radiant Floor Plan

Characteristics of each module:

- Mainly formed by 2 main beams, 18 columns and 26 wall sheets;

3.3 RADIANT WALL INSTALLATION

3.3 RADIANT WALL INSTALLATION

The Panels could be erected one by one or in groups of 2/3 panels;

The Interior Seal Welding just starts after

Field and seal welds should be painted

Interior panel is painted with mastic paint;

3.3 RADIANT WALL INSTALLATION

Characteristics of each panel:

- Formed by 2 main columns, 11 steel sheets and 24 reinforced beams;

(Approximately 82.000 kg of steel all panels)

MAIN CHECK POINTS DURING AND AFTER THE STRUCTURE EXECUTION

• Fit Up Inspection. Root gap, Edges preparation, Cleanness, Alignment, Bevels;

• Welding process monitoring. Travel speed, voltage and inter-pass cleaning.

• Visual Inspection of Welds;

• Non destructive testing (UT/RT/MT/PT). Check and review results;

• Weld repair. All repairs are carried out and re-examinated;

• Preliminary Levelling and Plumbness;

• Final Tightness of Bolts (by torque wrench if required);

• Tightness of Anchor Bolts;

• Levelling and Plumbness Final Inspection;

→ Shall be completely self-supporting and

→ Shall be erected without close center

3.5 RADIANT ARCH INSTALLATION Execution plan – 05 Oct. 16 to 15 Oct. 16

Structure elements are delivery in bulk material.

The arch panel will be temporary supported by the scaffolding

(Approximately 32.625 kg of steel)

No Pre-Assembly drawings available!

3.5 RADIANT ARCH INSTALLATION

4. CATALYST TUBES INSTALLATION Execution plan –02 Nov. 16 to 12 Nov. 16

Total of 8 rows of catalysts to install;

Each row is formed by 5 modules;

F.W. F.W. F.W.

4. CATALYST TUBES INSTALLATION

- Under no circumstances special alloy catalyst tubes may come in

- Special care has to be taken for temporary-supports and guides for

After confirming correct installation of the transfer-line/Process Gas Boiler

5. BURNER ERECTION Execution plan – 13 Out. 16 to 16 Nov. 16

Reformer burners shall be carefully installed in reformer casing as

Erection of burner plate and refractory:

- Lay down on the platform the Burners Tile with muffle;