17 PAR Modules Manufactured by DL E&C
Transported and Installed for S-Oil's "Shahin Project"
Modules Measure 47m in Length and Weigh 10,000 Tons
Precise Construction Achieved with 3D Scanning and SWHU Welding
DL E&C announced on July 7 that it has completed the installation of the PAR (Pre-Assembled Pipe Rack) module, a large plant piping structure, at the construction site of S-Oil's "Shahin Project," which is the largest privately funded project in the history of the domestic petrochemical industry.
The PAR module is a key structure that supports the pipes transporting raw materials and finished products within the plant. The modules installed this time were manufactured by DL E&C in Mokpo, Jeollanam-do, and then transported 450 kilometers by sea and land to the Shahin Project site in the Onsan Industrial Complex in Ulsan. There are a total of 17 modules, weighing a combined 10,000 tons, with each module measuring 47 meters in length, 22 meters in width, and 36 meters in height, making them extremely large in scale.
To ensure precise construction, DL E&C adopted advanced 3D scanning technology. The actual topography and features of the site were digitally recreated and reproduced at the module fabrication yard. The modules were then manufactured to fit the specific site conditions, minimizing the margin of error to within 3 millimeters. The modules were also connected using the "SWHU (Single Weld Hook Up)" method, which reduced the amount of welding required by about half compared to conventional methods.
Transporting these massive structures by sea, with their constantly shifting centers of gravity, was also a significant challenge. DL E&C distributed the load according to the volume and center of gravity of each module, selected secure fixing points, and stably anchored the modules to the barge. This process was supported by sophisticated marine transport engineering.
After arriving at Ulsan New Port, the modules were transported to the site using a special transport device called a "Self-Propelled Modular Transporter (SPMT)." The overland transport was carried out at an extremely slow speed during late-night hours when the area was deserted, taking two hours to cover just two kilometers.
The modular construction method is gaining attention recently because it allows for better process management compared to traditional on-site construction methods, which are affected by variables such as weather and labor. DL E&C has accumulated modular construction expertise through projects such as the polyethylene plant in Texas, United States, and holds the domestic record for the heaviest single module (3,400 tons) at S-Oil's Residue Upgrading Complex (RUC).
Meanwhile, DL E&C is jointly executing "Package 1," the most critical of the three packages within the Shahin Project, together with Hyundai Engineering & Construction and Hyundai Engineering. The Shahin Project is progressing smoothly, aiming for completion in June next year.
Yoo Jaeho, Head of the Plant Business Division at DL E&C, stated, "The Shahin Project is significant as it marks our first entry into a new area of petrochemical plant construction," adding, "Thorough preparation, skilled personnel, and our previous modular construction experience have led to today's achievement."
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