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DL E&C installed large modules for Shaheen Project.
DATE 2025.07.07
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DL E&C installed large modules for Shaheen Project.
A barge carrying large modules for the Shaheen Project is docking at the Ulsan New Port.
- Precisely manufactured using ‘3D scanning’ technology; fabricated in Mokpo and transported to Ulsan by sea
- Moved 1km per hour on land; required years of knowhow, specialized equipment and skilled personnel
DL E&C announced on the 7th that it has installed PAR (Pre-Assembled Pipe Rack) modules at the construction site of S-OIL’s “Shaheen Project,” the largest-ever investment in Korea’s petrochemical industry. PAR modules are structural components that support the piping networks through which raw materials and products move within a plant.
The installed PAR modules were transported from DL E&C’s module fabrication yard in Mokpo to the Shaheen Project site, which builds a petrochemical facility in Ulsan’s Onsan Industrial Complex. DL E&C has transported the modules sequentially over 10 times since February. A total of 17 modules, including massive ones measuring 47 meters long, 22 meters wide, and 36 meters high, were transported. The combined weight of the modules reached 10,000 tons.
There are three major tasks required for module installation. First, the modules must be manufactured precisely, as even the slightest difference can cause anomalies. In particular, it is difficult to guarantee accuracy because there is a difference between the space where the module is manufactured and the actual physical environment where it is installed. To solve this problem, DL E&C introduced ‘3D scanning’. 3D scanning is a technology that calculates the time it takes for a laser to shoot and then return after hitting the target in order to identify the spatial structure. Based on this information, the Shaheen project site was perfectly realized in 3D at the Mokpo module fabrication yard, which enabled the tailored production that factored in topographic conditions. The gap between modules manufactured to the exact specifications was kept within 3mm. DL E&C was able to reduce the process and welding amount compared to the existing method of inserting pipes between modules to adjust misaligned parts. The SWHU (Single Weld Hook Up) method, which connects modules with a single weld, reduced the welding amount by about 50%.
DL E&C moves a large module at the Shaheen Project site using a Self-Propelled Modular Transporter (SPMT).
Next, the modules were loaded onto barges and transported 450km to Ulsan New Port, which was not an easy task. This is because the center of gravity can change frequently while transporting the modules, exposing them to the risk of damage or capsizing. In particular, long-distance maritime transport affected by waves, wind, and currents required more precise load distribution. DL E&C applied specialized maritime transport engineering techniques, such as selecting the lashing location for each module based on its volume and center of gravity, and packing it with specially manufactured supports and tie-down straps.
The final gateway to installing the modules is moving them onshore. A ‘module transporter’ (SPMT) was used to move the modules from Ulsan New Port to the Shaheen project site. SPMT (Self-Propelled Modular Transporter) is a specialized transportation equipment used to move large ships or large structures, mainly in shipyards. It has four wheels under a metal plate, and can be connected in train-like formations and move like a freight train. Considering the length of the modules, they were connected in two long lines with six units per line. The move took place at night, when there were fewer people around. It took two hours to move the modules two kilometers using “ultra-low-speed transport” to minimize vibration.
Modular construction method is one of the emerging areas in plant construction. Usually, plant construction is carried out on-site, which is highly influenced by on-site conditions such as climate and manpower. On the other hand, modular construction method enables pre-fabrication of key components, including machinery and piping, to minimize the possible problems. DL E&C is standing out in the area of the plant module. It is currently building the world's largest polyethylene plant in Orange County, Texas, using modular construction method. The S-Oil's Residue Upgrading Facility (RUC) constructed by DL E&C set a record for the heaviest weight (3400 tons) of a single module in Korea.
DL E&C is carrying out the core ‘Package 1’ of the Shaheen project, which was ordered in three packages, together with Hyundai Construction and Hyundai Engineering. The Shaheen project is progressing smoothly with the goal of completion in June next year.
Yoo Jae-ho, head of DL E&C’s Plant Business Division, said, “It is especially meaningful that we have entered a new field called the Shaheen Project among petrochemical plants,” and added, “We were able to successfully complete it thanks to our meticulous preparation, past knowhow on module manufacturing and transportation, and professional manpower.”
