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Impact of Increased
Modularization New Orleans, 27 October 2011
Guus Stigter
Modularization
Objectives of Modularization
Construction of plants in a timely and cost effective way
to reduce overall cost of capital projects.
Old Manner: Stick build
Pros: Offsite controlled fabrication area
Availability of qualified labor
Enhanced Safety and Quality
Transport mode: Road - Waterway
History
• Modular transportation was first initiated 35 years ago.
• The Offshore industry uses the modular concept for years and served as an
example for other industries.
• Some of the first on-land plants were transported and installed in the Middle
East.
• The transport equipment used was a first generation of Modular
Transporters 6m wide and 2m high.
• In 1984 a Self Propelled Modular Transporter (SPMT) was designed and
manufactured in Germany.
• This trailer has a high capacity, is easy to assemble can be mobilized in a
cost effective way, compared to other transport equipment.
Transportation
SPMTs – Self-Propelled Modular Transporter
Motiva Refinery Expansion
Method of construction – Modular
Project Motiva Refinery Expansion
Location Port Arthur, TX
Dates 2007 to 2010
Scope of Work
Transport 306 modules
Set Pipe Rack Modules with SPMT’s
Erect 5 Reactors, 900 Ton and 1 Vacuum Column 1300 Ton
Rotate 1300 Vacuum Column with Skid System
Erect 400' Flare Stack
Jack and Slide Process Modules
Test Lifts (Reactor and vacuum column), 110% load test
Modules Transport
Pipe rack
transport on
SPMT
Modules Installation at Height
Installation with false work
Modules Installation at Height
Installation
with false
work
Woodside LNG Modules
Method of construction – Modular
Project Construction of Pluto LNG Plant and all utilities
Location Laem Chabang, Thailand, Karratha, West Australia
Dates 2008 - 2010
Scope of Work
Transportation and Installation of Modules, Columns and other items of Heavy Equipment on using Self Propelled Modular Transporters, and several Heavy Lift Cranes
Max Module weight 1750 Metric Ton
First Modularized LNG Plant , 77 modules
17,000 Metric Tons
Woodside LNG Modules
Marine Transport
on Heavy Lift
Vessel
Woodside LNG Modules
Self-unloading on Anchor Bolts
Roll off onto Dock
Installation by Crane
Woodside LNG Modules
Modularization Challenges
Structural Integrity of Module
Designed and fabricated to withstand transport accelerations
Operational Feasibility
Dock suitability
Roll on/off operations
Vessel / barge access
Plant / Route clearances, e.g. utility clearances, pipe racks
Plant / Route compaction, e.g. allowable ground baring, culverts
Sea fastening
Impact of Increased
Modularization
Limited know-how in industry about complex mega projects
Strategic decision making
Engineering
Management of transport modes
Increased multi-party interface
Coordination
Gaps in scope of work, responsibilities, etc.
Scarcity of qualified Self-propelled Modular Trailers operators for mega projects
….
