MODULARIZATION
DESIGN
ASPECTS
Presented by : Partha Parthasarathi, [Link].,
September 24, 2012
24-Sep-12
Modularization Guideline
G 907-0003
[Link]
2
24-Sep-12
Modularization
TOPICS COVERED TODAY
24-Sep-12
WHAT IS A MODULE ?
WHY MODULARIZATION ?
MODULE TYPES
MODULE CONTRACT SCOPES
TRANSPORTATION
LIFTING
ENGINEERING AND DESIGN
LESSONS LEARNED
QUESTIONS -
ANY TIME
What is a Module ??
Module is a Structural Unit
assembled with the following:
EQUIPMENT
STEEL
PIPING
ELECTRICAL
INSTRUMENTATION
FIRE PROOFING
INSULATION
Assembled at a location away
from the project site.
(Edmonton, Texas, China,
Korea etc.)
Transported by Road, Rail,
Waterways, Air or in
combination to project site.
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Module Example 1
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Module Example 2
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Module Example 3
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Module Example 4
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Module Example 5
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Module Example 6
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Stick - Build Construction
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WHY Modularization
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REDUCED COST
REDUCED SCHEDULE
REDUCED RESOURCES
BETTER QUALITY
MORE
SAFETY
COST Reductions
HOW TO REDUCE COST ??
MOVE LABOR AWAY FROM SITE
WHAT ARE THE ADVANTAGES?
Reduces cost of housing (CAMP) personnel at site
Reduces number of construction personnel at site
(Cost of Travel, Local Transportation, Meal,
Recreation etc.)
Reduces number of vehicles and other equipment
at site (Vehicles, Cranes, etc.)
Cost of field labor is higher
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COST Increases
COST OF ENGINEERING
Requires additional engineering hours to design
modules for Lifting, Transportation conditions, Extra
design drawings, 3D-Model splits, CWPs.
STEEL MATERIAL
Modular construction will increase the quantity of
steel by 10 to 25% (of stick Build) and hence
higher steel cost
TRANSPORTATION AND HEAVY LIFT
Additional costs are involved for transportation
(Road, Rail, Waterway etc., and also the cost of
Heavy Lift Cranes.
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Overall Cost Benefits
The cost increases stated earlier are off-set by the
reduced cost of assembly, painting, piping, Electrical,
Insulation and other works performed in the Fabrication
Facility instead of in the Field
The transportation cost of a larger module is usually
competitive with the combined cost of shipping of individual
items
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Quality
Higher Quality of work is easier
to achieve at Module Yard
Productivity will be higher
No constraint on weather conditions
Accessibility to the Module Yard
is easier
Efficient work due to
controlled working conditions
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Quality (Continued)
Availability of skilled craftsmen in certain
jobsites is a major problem. The off-site
fabrication location is usually away from
the Project site, where skilled personnel
are more easily available
Control of incoming material / issuing
material (Inventory) is better controlled in
a shop than in the field.
There will be fewer fitting errors and rework in the field, as most components are
pre-assembled in the Modules.
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Schedule Reduction
STICK BUILD PROJECT SCHEDULE
Civil works
Fabrication Piping, Structural,
Mechanical, Electrical, Instr.
Field Installation
Commissioning
MODULAR PROJECT SCHEDULE
Civil works
Fabrication Piping, Structural,
Mechanical, Electrical, Instr.
Modular Yard assembly
Field Installation
Commissioning
CONSTRUCTION TIME IN THE FIELD IS REDUCED,
and hence the cost is also reduced
Reduced schedule enables earlier Plant START-UP and
adds great value to the Project
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Increased SAFETY
The number of personnel working in the field is reduced
and hence, the incidents are reduced. Safety is increased.
The number of components to assemble in the
field is extensively reduced. Safety is increased.
Field personnel are not required to work at much
higher elevations. Safety is increased.
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Module Types
Type 1: Pipe rack / Process Modules
Assembled at Modular
Yard and transported to
project site
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Module Types
Type 2: Pre - Assemblies
It is also a Module Larger
in size and Heavier in
weight than a typical
Module
1
2
Modules assembled within
Project site are known as
Pre-Assemblies.
Public road restrictions do
not apply
Transported / Lifted within
Project site
Example: Delayed Coker derrick structure
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(Continued)
Module Types
TYPE 3 : Vendor assembled Modular / Package Units
Example: Equipment
skids, vessels with
platforms, Compressors,
Pumps etc.,
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(Continued)
Site Fabricated Equipment
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Shop Fabricated Tank
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Module Types
(Continued)
Type 4: Modular Buildings
Example : Instrument Buildings, Electrical Sub-stations, MCC, Deluge
Buildings, Chemical buildings etc.,
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Module Types
Type 4: Modular Buildings
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(Continued)
Module Types
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(Continued)
Module Contracts
Typical Modular construction involves
several contracts
Steel fabrication
Pipe Spool Fabrication
Equipment vendors (Mechanical, Electrical & Instrument)
Module Assembly in Module Yard
Transportation of Modules to site
Installation of Modules at site
Note: Some of the above contracts may be combined
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Module Contracts
Contract Scope Details
1.
Steel Fabrication :
Material supply, fabrication, painting,
fire-proofing and transport fabricated
steel to Module yard or to the project
site.
2.
Pipe spool Fabrication :
Fabricate pipe spools and transport
to Module Yard
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Module Contracts
3a. Mechanical Equipment (Pump, compressor,
etc.) purchased from vendors and shipped to Module
Yard
3b. Electrical Equipment (MCC, VFD, Cable
Trays etc.) purchased from vendors and shipped to
Module Yard
3c. Instruments (control valves, flow meters etc.)
purchased from vendors and shipped to Module Yard
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Module Contracts
4a.
Module Yard (Indoor):
Assemble equipment, pipes, electrical, Instruments, structural
steel, fire-proofing, Insulation etc.,
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Module Contracts
4b.
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Module Yard (Outdoor):
Module Contracts
5. Typical Transportation contracts:
Road, Rail or Waterway carriers
All of these transportation modes require
Permits / Regulatory approvals
Logistics provide weight limits, route study,
bridge capacity verification, etc.,
What is Logistics:
Logistics is a department in WP that
will organize all types of transportation
requirements, Storage, Heavy Lift,
perform route studies, economics,
schedule for the Module transportation
from the module yard locations to the
project site
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Module Contracts
6. Mechanical contract at Project site:
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Unload modules from trucks and install them on foundations /structures.
Fasten/secure the modules properly and join pipes, structural, cables
Supply appropriate cranes for field installation of modules.
Transportation
Method of Transport
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ROAD
AIR
RAIL
WATER WAYS
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Road Transportation
Limitations on Module Dimensions due to:
Bridge Height Clearances
Available road widths
Regulatory requirements (vary with each Province)
Note:
Always consult Logistics on Dimensional and Load Guidelines
for Transportation
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ROAD Transportation (Continued)
Limitations on the Weight of Modules due to:
Load carrying capacity of Bridges along the route
Pay Load capacity of Trucks
Road Conditions (Pay Load Capacity of Trucks vary with season)
Maximum load is allowed during Winter
Table 2: Trailer Pay Load Capacity (Single width Trailer 10 Axle)
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Season
Pay Load
Spring
75 Tonnes
Summer
105 Tonnes
Fall
120 Tonnes
Winter
135 Tonnes
Road Transportation (Continued)
MODULE WEIGHT SHALL BE LIMITED TO 90%
OF PAYLOAD CAPACITY OF TRUCKS TO PREVENT
AXLES FROM OVERLOADING LOCALLY
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Road Transportation (Continued)
Table 1: Limitations on Modules (in Alberta)
TYPE
WIDTH
HEIGHT **
LENGTH
WEIGHT
REMARKS
8- 6 14- 0
17- 0
80- 0
< 62 kips
-STAIRS, PLATFORMS, VESSELS
- LOW COST PERMIT
8- 6 14- 0
17- 0
120- 0
62 kips - 130
kips
- EXPERTISE REQD FOR BLOCKING AND
BRACING
-LARGE VESSELS, HEAVY EXCHANGERS
14-0 24-0
29- 6
120- 0
130 kips 200 kips
- EXPERTISE REQUIRED FOR CRANE
RIGGING, LOADING, BLOCKING, BRCG
- LARGE HEAVY VESSELS
- SMALL MODULES
14-0 24-0
29- 6
120- 0
200 kips 300/319 kips
(300 for CalgaryEdmonton)
> 24-0
> 29-6
>120-0
300 / 319 kips
(300 for CalgaryEdmonton)
SUPER LOAD
ENGG EXPERTISE REQD FROM
TRUCKING FIRM (PLTFM TRAILOR /
PRIME MOVER)
LARGE VESSELS, MODULES
- FOR NON-DIVISIBLE LOADS
- TECHNICAL JUSTIFICATION REQD
- SPECIAL PERMISSION REQUIRED FROM
ALBERTA INFRASTRUCTURE
- ENGG EXPERTISE REQD FROM TRUCKING
FIRM (PLTFM TRAILOR / PRIME MOVER)
Height ** measured from the road surface Typical truck bed height 4-3
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Road Transportation (Continued)
Table 3: Limitations on Modules (Other Provinces and USA)
LOCATION
WIDTH
HEIGHT **
LENGTH
WEIGHT
BRITISH
COLUMBIA
14- 6
14- 0
98- 6
Subject to approval of local
transportation authority
SASKATCHEWAN
24- 0
20- 7
99- 0
Subject to approval of local
transportation authority
MANITOBA
16- 4
20- 7
99- 0
Subject to approval of local
transportation authority
ONTARIO
16- 4
20- 7
120- 0
Subject to approval of local
transportation authority
QUEBEC
16- 4
20- 7
88-0
Subject to approval of local
transportation authority
UNITED STATES
OF AMERICA
18-0 20-0
18-3
20-3
40-0
80-0
Subject to approval of local
transportation authority
Height ** measured from the road surface Typical truck bed height 4-3
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Road Transportation (Continued)
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SCHEUERLE TRAILERS ARE COMMONLY USED BY
THE TRANSPORTERS
TRAILERS ARE COMPLETELY MODULAR. THEY CAN
BE COUPLED TOGETHER, END TO END OR SIDE BY
SIDE TO CREATE MANY CONFIGURATION OF
LENGTH AND WIDTH
Road Transportation (Continued)
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Road Transportation (Continued)
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Road Transportation (Continued)
Two File (Single width) Trailer
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Four File (Double width) Trailer
Road Transportation (Continued)
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Trailer bed heights are hydraulically adjustable up to
1-0 (300 mm)
This feature facilitates loading the module directly on
the truck bed, by driving the truck bed under the
Module and raising the bed to pick up the module
Road Transportation (Continued)
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Modules will be fastened to the Trailer bed by cables or
chains. The stability of the Module shall be ensured by the
Transporter
SPMT Self Propelled Modular Transporter
[Link]
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SPMT Self Propelled Modular Transporter
Maximum Payload - SPMT
Speed
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6 Axle
12 Axle
0.5km/hr
206 Tonnes
419 Tonnes
1.0 km/hr
182 Tonnes
371 Tonnes
6.0 km/hr
146 Tonnes
299 Tonnes
SCHEUERLE PLATFORM TRAILER
Schuerele [Link]
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Road Transportation (Continued)
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Road Transportation (Continued)
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Road Transportation (Continued)
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Road Transportation (Continued)
MODULE TRANSPORT BY ROAD TRAILER
TYPE 4 TRANSPORT (DOUBLE WIDTH ARRANGEMENT)
* FOR MAXIMUM HEIGHT AND WIDTH REFER TO TABLE 1 AND 3
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Road Transportation (Continued)
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Rail Transportation
Table 4: Limitations on the Modules
REGION
WIDTH
HEIGHT **
LENGTH
WEIGHT
WESTERN CANADA
12- 3
14- 0
80- 0
346,000 lb
EASTERN CANADA
13- 10
18- 2
80- 0
346,000 lb
WESTERN USA
13- 0
18- 3
80- 0
346,000 lb
EASTERN USA
12- 10
18- 6
80- 0
346,000 lb
Note 1: ** Module Height excluding the rail car bed height
Note 2: Always consult Logistics for Dimensional and Load guidelines for transportation
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Air Transportation
Table 5: Limitations on Modules
AIRCRAFT TYPE
LENGTH
WIDTH
HEIGHT
WEIGHT
PASSENGER AIRCRAFT
10- 0
7- 6
5- 4
~ 9,000 lb
CARGO AIRCRAFT
10- 0
7- 6
8- 0
~ 10,000 lb
HEAVY LIFT CARGO
AIRCRAFT
(ANTONOV AN-124-100)
120- 0
21- 0
14- 6
~ 264,000 lb
Note 1: Heavy lift Cargo Aircraft is very expensive
(>$500,000) and will be considered only for special cases
Note 2: Ft McMurray Airport cannot handle Antonov
aircraft
Note 3: Always consult Logistics on dimensional and
Load Guidelines for Transportation
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Water Way Transportation
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Water Way Transportation (continued)
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Water Way Transportation (continued)
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Suitable for overseas fabricated Modules
Loads up to 10,000 Tonnes can be carried by ships and barges
Typical deck space for Barges is about 400 ft x 100 ft
Lead time to acquire Barges is over 12 months
Module size may be limited due to road/rail restrictions
4 Major routes to Alberta are possible: West/East/Gulf coasts of USA
and Northern (Canadian) route
Northern (Canadian) route has many risks like frozen waters, need
for ice breakers to move the ships, dredging the McKenzie river at
certain locations, Dock installations, impact on Aboriginal people, low
water levels in Athabasca river etc.
Water Way Transportation (continued)
SUITABLE FOR OVERSEAS
FABRICATED MODULES
4 Possible routes to Alberta:
WEST COAST PORTS (USA)
COMBINED WITH ROAD/RAIL
TRANSPORT
EAST COAST PORTS (USA)
COMBINED WITH ROAD/RAIL
TRANSPORT
GULF COAST PORTS (USA)
COMBINED WITH ROAD/RAIL
TRANSPORT
NORTHERN (CANADA)
THROUGH BERING STRAIT
NWT - THROUGH McKENZIE /
ATHABASCA RIVERS
NOTE: ALWAYS CONSULT LOGISTICS ON DIMENSIONAL AND LOAD GUIDELINES FOR
TRANSPORTATION
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Module Lifting
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Module Lifting
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Module Lifting
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Lifting Arrangements
Type 1 VERTICAL Lifts
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It is recommended to use 4 or 8 point lift
instead of 6, 10 or 12 points
Module Lifting
8 point lift
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Lifting Arrangements
Type 1 VERTICAL Lifts
6 OR 10 POINT LIFTING NOT PREFERRED
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Lifting Arrangements
10 point lift
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Lifting Arrangements
Type 2 INCLINED Lifts
Certain situations in the field may require lifting of Modules with inclined
CABLE , as shown due to overhead obstructions (Reduced crane height)
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Lifting Arrangements
Type 3 Upending
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Example : Stair Tower Module, Tall vessels
Lifting Arrangements
Type 3 Upending
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Example : Stair Tower Module, Tall vessels
Jack & Roll
Jack & Roll:
Lifting and moving heavy loads (<50 Tonnes) without
using cranes
Ideal in Remote locations
Cost effective
Place hydraulic jacks under the module at predetermined locations (Jacks connected to central
Jacking pump) and lift the module.
Unified jacking pumps apply simultaneous pressure to all
the jacks to ensure an even and level lift.
Place a rail system with rollers under the jacked up
module.
Roll the module from the trailer onto the foundation/pile,
using winch trucks.
Module is lowered via the hydraulic jacks
Require large space around the module.
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Jack & Roll
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Jack & Roll
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Hydra-slide
Hydra-slide: Lifting and moving very heavy loads
(> 50 Tonnes) without using cranes
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Similar to Jack & Roll
Used for very heavy loads
Hydra-slide system with shoes installed inside the rail
system for precise movement
Shoes attached to Hydraulic rams and rams connected to
pumps
Hydraulic pumps are controlled by the operator for precise
movement of load (can slide, stop or go without concern)
Winch trucks are not required.
Require less space around the module
Hydra-Slide
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Hydra-Slide
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Super Modules
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Super Modules
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Super Modules
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Super Modules
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Super Modules
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Engineering
ENGINEERING
&
DESIGN
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Engineering
Over-land transportation
1) Road Trailer
83
2) Rail
Module structural framework shall be designed for module loads and
impact loads, super-elevation, acceleration, deceleration forces
induced during transportation
In addition, wind load shall also be considered during transportation
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Engineering
Over-land transportation Impact Loads
Road Trailer:
Vertical Impact
Longitudinal Impact
Transverse Impact
Iv = 0.5 g
IL = 0.25 g
IT = 0.25 g
Rail:
Vertical Impact
Longitudinal Impact
Transverse Impact
Iv = 1.0 g
IL = 3.0 g
IT = 1.0 g
Note :
1) Above values can be used unless project specific data is
provided by Client Specs or Logistics or Module Transport
Contractor
2) Impact loads include acceleration or deceleration
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Engineering
Impact Forces during Road Transportation
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Engineering
Over-land transportation Loads & Load Combs
Loads:
Dead Load of Module
Wind Load
Horizontal Load
=D
=W
= H (super-elevation based on 1:10)
Load Combinations for Limit State Design (2005 NBC):
86
1.4D
1.25D + 1.5 IV + (1.5 IT + 1.5 HT + 0.4W T) or (1.5 IL + 1.5HL + 0.4W L)
1.25D + 0.5 IV + (0.5 IT + 0.5 HT + 1.4W T) or (0.5 IL + 0.5HL + 1.4W L)
0.9 D + 1.5 IV + (1.5 IT + 1.5 HT + 0.4W T) or (1.5 IL + 1.5HL + 0.4W L)
0.9 D + 0.5 IV + (0.5 IT + 0.5 HT + 1.4W T) or (0.5 IL + 0.5HL + 1.4W L)
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Engineering
Waterway Transportation - Vessel Motion
VH
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BARGE
Engineering
Waterway Transportation
Terminology
Wave Induced Forces
Deck Flexing (Sag/Hog)
Fatigue
Sea Fastening
Head Sea
Beam Sea
Port / Starboard
Bow / Stern
Draft
Data required from Naval
Architect (Shipping Agency)
Roll angle
Pitch angle
Roll period
Pitch period
Heave period
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=
=
= TR
= TP
= TH
Engineering
Water Transportation
Typically Naval architect /Shipping contractor will provide the
design criteria. In the absence of this information, the following
forces may be used for the preliminary design.
Longitudinal force
Transverse force
Vertical force
= 0.25 D to 0.4 D
= 0.5 D
= 0.3 D
D = Total weight of module
In addition to the above wave forces, wind load should be
considered in the design. The following load combinations should
be included in the design calculations:
Heave + Roll + Wind
Heave + Pitch + Wind
Heave, Roll and Pitch forces shall be considered as live loads.
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Engineering
Air Transportation
Logistics to provide the design loading in consultation
with the Cargo Airliner
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Engineering
LIFTING OF MODULES
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Engineering
LIFTING OF MODULES
Modules will be lifted using cranes for placement on transport equipment
or final placement at the site
Vertical Impact (Rigging) Factors should be considered in the analysis
for Module Lifting due to variation between actual and theoretical CG
of module and also due to sudden load application
Vertical Impact Factor
Vertical Impact Factor
Horizontal Impact Factor
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= 0.33 for 4 point lift
= 0.25 for 8 point lift
= 0.02 for all cases
Engineering
LIFT LUG & SHACKLE
Alberta Occupational Health and Safety Code specifies the
requirement of a Factor of Safety = 5 on the Ultimate Strength of
Lugs
ANSI / ASME B30.20 specifies the requirement of a Factor of Safety
= 3 on the Yield Strength of Lugs
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Shackles
Crosby G-209 or G-2130 Shackles are commonly used
(to be confirmed by Lifting contractor assigned to the Project )
The weight of Shackles can be heavy
Do not specify heavy shackles for Light loads
unless standardized by the Lifting Contractor
The Shackle (Crosby) manufacturer provides
Safe Working Load only. Meets Factors of Safety
specified by Alberta OHS and ANSI/ASME
Design drawings should specify Shackle
Model Number and Capacity
The same Shackle type should be specified for all
of the lift points in a module
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Lift Lugs
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Lift Lug materials shall be specified as Notch Tough steel (WT) to allow
for erection during cold temperature conditions
Lift Lug welds shall be 100% UT tested
Critical design checks for Lift Lug are as shown below
Lift Lugs
TYPE 1
Used for very heavy lifts
Require installation and
removal every time (extra time
+ labor cost)
Lugs can be reused
New set of bolts suggested for
every lift
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Lift Lugs
TYPE 2
Lift holes reinforced with
doubler-plates
Limited lifting capacity
Can be used for top modules
only
Future extension of modules
will require modification
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Lift Lugs
TYPE 3
Double function lug Lifting
and splicing achieved
Lower splice plate shaped to
receive the shackle
Allows splicing of modules
without Type 1 Lift Lug
Lift holes reinforced with
doubler-plates
Limited lifting capacity for Lug
and splice connection
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Lift Lugs
TYPE 4
Used for special applications
like Building skids, Piperack
units
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Inter-Connection of Modules Pipe Welding
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Temporary Steel
Temporary steel may be required during transportation or
lifting the module
It is suggested to paint the temporary steel in Fluorescent
orange or other color for easy identification for removal at
site
Temporary steel shall be identified in a separate color in the 3-D
model for clash check purposes
It should be very clearly stated on the design drawings, when
and what stage the temporary bracings should be removed and
at what sequence
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MODULE DESIGN Responsibility
Defining Modules (dimensions/splits) is the combined responsibility
of Piping Layout, Structural, Electrical/Instrument Disciplines.
Logistics shall provide details on the transportation strategy,
methods, limitations on weights, sizes etc., based on feasibility and
economics studies.
Module construction contractor, Module erection (Lifting)
contractor, Procurement dept., Steel Fabricator, the
Construction Manager and the Client shall be involved from the
early stages of engineering to optimize the Modularization Process.
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Lessons Learned
There are several lessons learned on Modularization from each
project in
Engineering
Design
Fabrication
Construction
Transportation
Site Installation
Consult with the Client and other database for the lessons
relevant to the type of project
Some lessons are presented in the following slides
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Lessons Learned
All these piping had to be
removed after installation
due to overweight
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Lessons Learned
Pipes, cables, steel members
located outside module limits
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Lessons Learned
No clearance between Fire-proofing
and the Instrument
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Lessons Learned
Kick-plate was not modeled
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Lessons Learned
Kick-plate was not modeled
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Lessons Learned
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Lessons Learned
Block-out Fire proofing on the module bottom beam
or provide steel stub below for seating on the transport truck
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Lessons Learned
Gusset plates sticking outside
module width
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Module Steel Drawing EXAMPLE
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Module Steel Drawing EXAMPLE
Support Conditions at Module Yard
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MODULARIZATION
QUESTIONS ? ?
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