MODULARIZATION OF PLANTS

INTRODUCTION

➢ Modularization was developed and adopted in the

offshore / onshore structures to facilitate large
volume of fabrication work to be carried out in shop
in a controlled environment.

➢ Modules are generally a set of preassembled

equipments and ancillaries such as piping, cable
trays, cables, insulation etc. Modules may vary in
size depending on design, installation, interfacing
and transportation constraints.

➢ Modularization facilitates re-usability, as module can

be developed, tested, modified and reused multiple
times reducing re-development time. Also, the
modularized plant can be relocated from one
location to another by dismantling.
WHAT IS MODULARIZATION?

❖ Modularization refers to the process and constructing equipment

off-site in a fabrication facility. The completed product can then
be delivered to the worksite and quickly installed and integrated
into field operations. This differs from on-site construction in
which the equipment or system is fully built at the worksite.

❖ Module is a set of separated parts from a complete unit or plant,

and is a transportable preassembly components of process plant
designed to minimise site installation and commissioning
activities and labour costs. Module Types are preassembled unit
(PAU), preassembled Rack (PAR), preassembled building (PAB),
and vendor assembled unit (VAU).

❖ Modular fabrication offers another set of very significant benefits

over field construction: efficiency, speed, safety, quality, economy,
and convenience.
WHY MODULARIZATION?

➢ Limited / strained labor force

➢ Limited workforce accommodation
➢ Limited equipment availability
➢ Harsh environment
➢ Limited plot plan area or greenfield
development
➢ Restricted geographic location
➢ Environmentally sensitive
➢ Limited time window
 HOW DOES MODULARIZATION SAVE TIME?

Modular Construction Schedule

Site Development
Permits & Installation of
Design Eng. & Commissioning Time Savings
Approvals Modules
Foundations
Simultaneously Site Development and
Fabrication of
Fabrication of Modules has Plants
Modules
open 30% to 50% sooner!

Stick-Built Construction Schedule

Permits & Site Development &

Design Eng. Construction at Site Commissioning
Approvals Foundations
 WHAT MUST BE CONSIDERED BEFORE WE START
TO DESIGN MODULES?

❖Where will the modules be fabricated?

❖Availability of suitable transportation

❖Incorporating transportation loads in the design of structural steel

❖What size of modules can be realistically moved?

❖Infrastructure limitations
EFFICIENCY:
One of the most important benefits of modular fabrication is that it is a very efficient process.
Since it takes place off-site in a specialize fabrication shop this allows the work environment to be fully optimized
to function in a way that is as time, quality, and cost efficient as possible. The equipment and materials needed to
do the fabrication will already be present at the fabrication shop and the work crew will be comfortable and
familiar with the working environment and process.

ECONOMY:
Another benefit of modular fabrication is that it is typically more economical than component-
based, site-built counterparts. Much of the reduced cost is related to the greater efficiency with which the
systems and equipment can be produced with modular fabrication. This also translates into fewer labor hours.
Additionally since the quality and safety can be closely monitored with modular fabrication costly accidents and
replacements can also be avoided.

CONVENIENCE:
One of the most beneficial things about modular fabrication, however, is the greater level of
convenience that it offers as compared to on-site construction.The added convenience takes many forms, but
four of the biggest aspects include.
KEY FACTORS INFLUENCING MODULARIZATION:
➢Modularization can be achieved by taking a “stick-build” design and divide into number of
modules. Modularization is dependent on a detailed assessment of the key project
parameters to determine the feasibility and the extent of modularization.

➢The key factors are generally labor, site conditions, site access, schedule and safety.
➢ First generation modularization such as pipe racks,
platforms etc.

➢ Second generation modularization such as

“customizing” equipment and other ancillaries
mounted on structural steel skids; and

➢ Third generation modularization such as

“standardizing” and not customizing of the modules
mounted with equipments and ancillaries.
 FIRST AND SECOND-GENERATION
MODULARIZATION
The following inputs will be required to carry out detail engineering
of various modules to be provided.

❖ The geographical details of site location, seismic zones,

wind/cyclone/ hurricane factor, soil bearing capacity,
groundwater table, soil resistivity, prevalent wind direction and
basic wind speed, rainfall, temperature, humidity, snow loads,
etc.
❖ Layout of the proposed plant
❖ Technological structure general arrangement layouts showing
tentative location of equipments.
❖ P & IDs for process and utilities.
❖ Customer’s design standards.
❖ Hazardous area classification.
❖ Data on industrial waste and wastewater treatment etc.
Continuation…..
❖ Customer’s philosophy on sourcing spares.
❖ Details on the new electric power distribution system, viz. system voltage levels, loads,
standby power supply etc.
❖ Master schedule for implementation of the plant, with scheduled deliveries for directly
sourced plant and equipment.
❖ Drawings, data sheets and foundation details for the equipment being sourced directly by
customer.
❖ Module sizes intended depending upon the transportation, constructability, operation and
maintenance requirements.
❖ Procedures for letter of intent, terms of payment, letter of credit,
liquidated damages, guarantees, efficiency demands, defects liability period etc.
❖ Knowledge of shipping and inland transportation constraints such as maximum dimension of
shipping consignment, maximum weight for the individual module, etc.
❖ Preliminary 3D model of the technology structure showing major equipments & piping, if
available.
CONCEPTUALISATION
The conceptualisation stage is considered to be very significant in any plant design. The key elements
of conceptualization are Process Optimization and Energy Optimization.
The following factors largely affect modular design:
➢ Process engineering;
➢ Equipment selection;
➢ Equipment layout and elevations;
➢ Piping and instrumentation;
➢ Size of modules;
➢ Interfacing of modules at site; and
➢ Availability of cranes in and around the site.

• Modular design takes advantage of both horizontal and vertical layouts to locate equipment in a
minimum space. A well-designed module can help to minimize space requirements, reduce piping
and cable lengths.
• Engineers or designers involved should possess multi-disciplinary capability to provide a design that
envelopes domain expertise in process, structural, mechanical, piping, instrumentation & electrical
design, procurement etc.
PROCESS ENGINEERING
Process involved in equipment layout, type
of equipments that are required and available in market,
various process alternatives, etc.

ENERGY OPTIMIZATION
Modular systems are best suited for energy
optimization because of the closed circuit of the process.
Process loop or circuit lengths are shorter in modules, which
increases the overall efficiency of the plant due to elimination
of the long lengths of piping. Shorter lengths of piping helps
in minimizing heat loss and condensation in the pipelines.
CIVIL & STRUCTURAL ENGINEERING
The design of modular fabrication shall have following Civil and Structural design
requirements:

➢ SIZE LIMITATION OF THE MODULE

• Each module shall be sized, based on the maximum transportable length, breadth and height in
consultation with process collaborator or technology supplier.
• The module size shall be selected as a self-standing structure for avoiding imbalance during
shipment.

➢ STRUCTURAL DESIGN
The structural members shall be designed to account for the forces acting during handling, lifting
and transportation.
Additional strengthening may be provided to resist critical forces or to avoid any deformity during
transportation
All site joints to be designed as bolted joints and all shop joints shall be welded joints.
➢ MATERIAL OF CONSTRUCTION

• Rolled steel members, Wide/parallel flange sections and plates from approved suppliers shall be
used as structural members.
• Special corrosion protection allowance or paints to be used to take care of transport and handling.

➢ CIVIL AND STRUCTURAL WORKS REQUIRED AT SITE

• Foundations.
• Installation of the modules as per the erection sequencing procedure.
• Grouting.
• Interconnection of the modules with prefabricated structural members either by bolting or welding.
• Installation of prefabricated pipe supports, minor equipment structures outside of the module.
MECHANICAL DESIGN
➢ Mechanical designs shall follow the relevant
standards, codes of practices such as ASTM,
ASME, TEMA, API, etc.

➢ Flexibility shall be one of the key components

of mechanical design. Bolted joints shall be
preferred over welded joints. Interfacing for
the pipes between two modules shall be with
spool pipe.

➢ Sizing of equipment, pipelines for process &

utility and selection & location of valves &
instruments shall be a part of detailed
engineering as per the Project/Plant Design
Manual, P & IDs, Data Sheets and relevant
codes and standards. Equipment layout shall
feature adequate space for O & M, aesthetics
and ergonomics, headroom clearances and
adherence to the local/ international safety
norms such as OSHA.
Conti……
➢ Preferably all the equipment, components,
instruments, valves, pipes, gaskets, fasteners, special
tools, consumable and capital spares etc., should be
sourced from indigenous reputed and ISO certified
manufacturers/sources.

➢ On the fabricated module, positioning of the equipment

shall be completed first. Placement of pipelines shall
be after alignment of majority of the equipment. Prior
to erection of the fabricated pipes onto the modules,
the inside surfaces shall undergo thorough mechanical
cleaning using a combination of sponge balls and
compressed air or other acceptable practices.

➢ Each module shall be identified with a distinct number.

Pipeline designation number and tag number for
equipment, valves, instruments etc. shall be prefixed
with the module identification number.
INSTRUMENTATION DESIGN

All the control room mounted equipment such as DCS/PLC/SCADA system packages shall be sourced
either locally or abroad as these require vendor’s assistance for enabling, commissioning and fine tuning as
per process requirements.
As part of the module, the following shall be housed:
➢ Field instruments, control valves, junction boxes and power supply distribution boards.

➢ Cabling between the field instruments, junction boxes and power distribution boards, which are contained
within the module.

➢ Cable trays and conduits for the cabling within the module.
ELECTRICAL DESIGN
➢ Electrical design shall comply with the relevant
codes, standards and practices such as NFPA,
ANSI/IEEE, UL/ CSA, IEC and EN.

➢ Modules shall house the local power distribution

board, control consoles, fire alarm panel etc. Cable
carrier system consisting of cable trays, tray supports
shall be included along with the pipe rack. The
module shall include poles, towers, & other supports
for mounting of lighting fixtures complete with wiring.

➢ For cables emanating & terminating within the

module, cable pulling and termination will be
executed as a part of the module. Cable pulling for
the cables joining one module to another will be
carried out on site.
SAFETY ASPECTS
Safety standards and codes as applicable to the industry and as required
by the concerned local authorities shall be adhered to while designing the
plant, equipment, layouts and utility services.

SPECIAL DESIGN CONSIDERATIONS

The plant shall be modeled in 3D environment. The model shall initially
show the following:

➢ Structural steel supporting frame work for individual module.

➢ Lifting points and guying points for the modules.
➢ Structural steel columns, beams, stairways, walkways/ leeways,
floor gratings, hand railing, toe plates, monorails etc.
➢ Plant and equipment.
➢ Pipelines, valves, and specialties.
➢ Cable trays.
➢ Monorails.
➢ Identify large/over-sized equipment such as
columns/reactors/vessels etc., which needs to be transported or
shipped and erected separately at the plant site.
MODULAR VS STICK-BUILT
➢ STICK-BUILT CONSTRUCTION:
Stick-built projects are designed
individually from scratch, each is designed to the
customer’s specifications in order to guarantee
desired product output and quantity. But
conventional construction requires more time and
money upfront to secure a large tract of real estate
and for engineering and design.

➢ MODULAR CONSTRUCTION:
Modular construction are
comprised of discrete pieces that are assembled off-
site. There’s less ramp-up time for construction
because workers at fabrication yards are generally
experienced at building the parts. Once modules are
delivered to the site, they are connected easily and
quickly; there’s little guesswork about the schedule
since prefabricated designs are known entities in
terms of assembly time.
MODULAR CONSTRUCTION BENEFITS
Modular construction involves prefabricating equipment and systems into modules offsite in a controlled
manufacturing facility. Once constructed, the modules are delivered to production site where they can be
installed and commissioned. This approach offers a number of advantages over traditional stick-built
methods of construction where the majority of work is performed onsite.

1. RELIABLE ACCESS TO SKILLED MANPOWER :

Modular construction offers access to the type of workers required to build large-scale facilities.
This is particularly critical in the oil and gas industry, where the pool of experienced tradespeople such
as welders and electricians can be limited. With a stick-built approach, securing skilled craft workers can
often inflate costs due to the need to provide travel allowances and /or housing accommodations. In
many instances, an offsite module fabrication facility can be selected in a region or country where the
labour supply and demand relationship is more balanced, allowing the operator to take advantage of
lower rates.
2. SHORTER DEVELOPMENT SCHEDULE:
Modularized construction can reduce a project’s development schedule, and it
does so in a number of different ways. First, by assembling modules using prefabricated parts offsite in a
designated facility, the chance of running into delays caused by weather or other environmentally-related
factors is minimized. Second, building offsite also affords operators the advantage of being able to
perform work on multiple areas of a facility simultaneously. This is not always possible when using the
traditional stick-built approach, particularly when it comes to offshore facilities, as the amount of
workable space onsite is often limited. Third, by performing work offsite, operators can remove certain
activities from the schedule’s critical path and reduce the chance of trickle-down delays.
• Modularization aims to reduce the number of interfaces, the total installed cost (TIC) and overall
schedule length of a project while optimizing the return on investment and allowing standardization of
future similar projects.

• Modularization offers many significant benefits including cost savings by reducing field erection;
higher quality and safety from having fabrication done in an offsite shop; decreased schedule (by up to
25–50%); increased efficiency; module mobility and re-usability; and less site construction complexity
due to fewer interface points for modules, reduced onsite logistics, etc. These advantages become
even more important at remote locations, and at any site contending with adverse weather/climate,
lack of skilled personnel onsite, and concerns about downtime on brownfield projects.
MODULARIZATION STRATEGY
Modularization or prefabrication requires significant planning before moving forward. Many facets must
be considered to make project execution effective. Sufficient time must be allocated to assess the various options, and to
bring all the elements of modularization together.

1. DRIVERS FOR MODULARIZATION

MODULARIZATION MAY BE CONSIDERED FOR MANY REASONS, INCLUDING:
•Limited availability of skilled and affordable labour
•Remote site access and severe site weather constraints
•Desire to minimize field time and reduce construction costs
•Reduction of site waste
•Improvement in quality due to controlled environment
•Extensive factory acceptance testing (FAT) required
•Repeatable construction that lends itself to duplication
•Equipment replacement at an operating plant where downtime is not possible.
2. TYPES AND SIZES OF MODULES CONSIDERED
Since a huge trade-off exists between module size and shipping costs, considerable thought must be given
to module size and configuration. If downtime at an operating facility cannot be tolerated, then the right
decision may be to use the largest shippable module possible.

• Mega-modules (over 500 t; require special shipping)

• Large and intermediate modules (require barge or rail)
• Truckable modules
• Pipe rack modules
• Skid-mounted equipment modules
• Hybrid modules (partially completed in the shop and fully assembled in the field).