In the field of industrial design (chemical, petrochemical, mining, energy) DCRPROGETTI is able to provide the design and analysis of MODULARIZED STRUCTURES, including verification in the various construction and installation phases.
Each project can be followed from the feasibility study to the detail, analyzing every aspect related to construction and handling.
DCRPROGETTI offers targeted advice on all design aspects:
- feasibility studies: analysis of the different construction types, depending on the type of industrial process inserted in the plant, the weather-climatic conditions of the installation site and the preparation or cost of local labor; all conditions that generally represent one of the reasons for a “Modular” choice of structures. In this phase, based on the distance between the construction site and the installation site, the transport methods are defined and consequently the dimensions of the Modules themselves or of the support Skids are established;
- analysis of the assembly phases: DCRPROGETTI is also able to follow the entire construction phase in the workshop, developing, in addition to the design of the primary structures, also all the auxiliary structures necessary during the assembly phases of the Modules. In this phase, the consultancy concerns the engineering, 3D modeling and drawings;
- analysis in operational conditions: verification of the structures at the final installation sites. DCRPROGETTI is able to verify the structures in the operating conditions in accordance with national (NTC2008) and international (Eurocodes, B.S., ASCE, ACI, AISC, DNV, API, AS, NZ) codes. The modular typology also requires the design of an adequate system of ground restraints, capable of solving the problems associated with the installation phase. The "industrial" use of the Modules also requires the analysis of structural behavior under specific conditions:
- occasional "impact" conditions (drop-check): verification of primary and secondary structures against impact loads, possible during the installation, operating or maintenance phases;
- the exceptional conditions of "explosion" (blast-check): analysis and verification of the structural behavior of the system subjected to explosive loads INTERNAL and / or EXTERNAL to the structure (ASCE 2010);
- analysis in handling conditions: they represent the most important and often dimensioning part of a modular structure. The term "handling" actually collects all the steps necessary to bring the Macro-Modules from the construction site to the final site. DCRPROGETTI in this field has decades of experience able to tackle any transport and installation aspects:
- verification of land transport conditions ("road-transport"): land transport is the most used method in the event that the structure can be broken down into modules of limited size and weight. In this configuration, the distances traveled can also be considerable and the displacement speeds can determine the most severe conditions for the structure under examination. The analyzes, in accordance with the field codes (Noble Denton (NB)), verify the Modules against transport accelerations, simulating the possible road configurations due to longitudinal and / or transverse slopes.
- verification of the conditions of "load-out" or "loading": it is generally linked to a movement that involves a subsequent sea transport of the structures. It represents the first phase of displacement of the Module from the construction site (yard) to the deck of the barge, on relatively short stretches and with very low speeds, due to the required positioning accuracy. The methodologies can be traced back, depending on the weight and site conditions, to the use of SPMT (Self Propelled Modular Transporters) trolleys or to a "skid system" using hydraulic jacks (strand jacks). The analyzes concern the optimization of the Modules and auxiliary structures that are necessary for their transport.
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- verification of sea-transport conditions: the sea-trasport (or river) phase is necessary in the presence of heavy loads or big dimensions, or when reaching the final installation sites requires path that are too long or too bumpy (traffic, bridges, lack of adequate road structures). In these cases the verification requires:
- the analysis of the behavior of the modules against the inertial actions due to wave motion, in accordance with the most stringent international standards and codes (Noble Denton (ND), API, DNV).
- the design and the verification of the constraint systems of the Modules according to their weight and/or size. The analysis aims to identify the best technological solution between "rigid" systems formed by the combination of grillage and sea-fastening beams, or "flexible" systems made using preloaded sling systems (lashing-system);
- the verification of the resistance of the deck of the means of transport (barge or Ro.Ro. system). In these cases, the load limits of the anchor points are checked and any necessary reinforcements for the loading bridge are designed;
- analisi condizioni di installazione: rappresentano l’ultima fase del percorso dei Moduli dal sito di fabbricazione al sito di produzione. Le numerose tipologie strutturali modulabili, le diverse condizioni di sito e le diverse disponibilità di mezzi per l’installazione richiedono un’analisi dedicata per ogni singolo progetto. In particolare la precisione richiesta e l’ingombro dei mezzi di sollevamento (martinetti, SPMT…) influiscono nella geometria dei Moduli e di conseguenza influiscono sulle successive analisi in condizioni operative. DCR negli anni ha sviluppato numerose esperienze individuando le soluzioni ottimali di installazione per ciascun progetto affrontato, sviluppando:
- analisi in fase di sollevamento (lifting): in genere corrisponde alla fase finale di assemblaggio dei Moduli di una struttura. In fase progettuale particolare attenzione andrà riservata alla corretta geometria del sistema di funi e ai dettagli di aggancio tra queste e la struttura stessa (golfari).Le verifiche sono sviluppate in accordo alle specifiche normative internazionali (API, Noble Denton (NB), DNV).
- analisi di installazione tramite “skidding system”: la soluzione tramite skid system è la più indicata in caso di strutture molto pesanti e/o in caso di terreni con limitate capacità portanti. In questo caso la struttura, tramite martinetti idraulici (strand jacks), viene fatta “slittare” direttamente, o tramite “skid shoes”, su un sistema di “binari” (beam-rail).DCR è in grado di progettare l’intero sistema considerando anche le strutture ausiliarie e il dispositivo di fondazioni necessarie durante le fasi di tiro.
- la fase di installazione: “jack-down”: rappresenta la soluzione di posizionamento più semplice ed economica, la più indicata in presenza di limitati “spazi di manovra” (in genere in progetti di “revamping”), nel caso di Moduli particolarmente alti o in siti difficili da raggiungere anche per i mezzi di installazione.
RAFINERY THAI OIL CLEAN FUEL PROJECT - Shiracha - Thailandia - 2019-2020.
UTE PORTO DE SERGIPE - Power Plant - Brasil, 2017 - 2018.
ARU - JURRASSIC PRODUCTION FACILITY (JPF) - Sabriya - Kwait - 2017.
TERMINAL FOR PRODUCTION AND LOADING OF LNG - STAGE III - Port Vysotsk - Russia - 2017.
EPC SURFACE FACILITIES - PHASE III - AL DABB'IYA - U.A.E. - 2016.
NGL TRAIN 1 PROJECT - Basrah - Iraq - 2014.
KASHAGAN FIELD DEVELOPMENT “EXPERIMENTAL PROGRAM CLUSTER" (EPC) - Kazakhstan - 2013-2016.
Mamba Project - Mozambico - 2012.
SOUTHERN SWAMP ASSOCIATED GAS SOLUTION (SSAGS) PROJECT - PRODUCTION FACILITIES EPC - Tunu - Nigeria - 2012-2014.
STAATSOLIE REFINERY EXPANSION PROJECT - Suriname - 2011-2012.
OLT – FSRU Project Livorno - Adriatic Sea - Italy - 2008-2010.
BROWSE PROJECT-DOWNSTREAM ENGINEERING SERVICE - Australia - 2011-2012.
KASHAGAN FIELD DEVELOPMENT “EXPERIMENTAL PROGRAM CLUSTER" (OFFSHORE COMPLEX D) - Kazakhstan - 2009.
SEMISUBMERSIBLE GAS AND CONDENSATE PROCESSING PLTF - ASGARD B PROJECT - Kverner Statoil - Norwey - 1998-1999.