Projects Sustainability Insights:

Strategies for Effective

Project Delivery and
Modularization Excellence
 Table of
Content
INTRODUCTION 4
UNDERSTANDING THE CHALLENGES 5
IDENTIFYING THE MODULAR SYSTEM CLASSIFICATIONS 7
ASSESSING MODULARIZATION FEASIBILITY: STEP-BY-STEP 8
TRANSPORTATION AND THE TRANSPORT ENVELOPE 12
SUCCESS STORIES OF MODULARIZED PROJECTS IN SAUDI ARABIA 13
CONCLUSION 14
INTRODUCTION

Modularization in oil and gas refers to the offsite fabrication and

assembly of process units and utility systems into standardized modules
that are later transported and installed at the project site. These
include Pre-Assembled Units (PAUs), Pre-Assembled Racks (PARs), and
Pre-Assembled Structures (PAS). This approach shifts construction from
site to controlled environments, improving safety, quality, and project
predictability.
The most critical advantage modularization brings is schedule
assurance. By executing civil works onsite while modules are built in
parallel offsite, projects compress timelines significantly. This is
particularly crucial for remote or brownfield facilities where site
congestion, access, and HSE risks can delay stick-built construction.
Global chemical and process giants like SABIC, ExxonMobil, Shell, and
Dow have embedded modular strategies into their delivery models.
Notable examples include:
• SABIC’s Corpus Christi facility on the U.S. Gulf Coast, where
large-scale modularization enabled cost control and fast commissioning.
• Motiva Enterprises in Texas (a Saudi JV), using modular units to expand
refinery capabilities with minimized site impact.
• Modular refineries in Asia and petrochemical complexes in Europe that
rely on PAS, PARs, and PAUs for schedule and safety optimization.
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UNDERSTANDING THE CHALLENGES
While modularization offers significant benefits, its adoption; especially
in the context of Saudi Arabia comes with several challenges. However,
these should be seen as opportunities to strengthen the ecosystem.
• Transportation and Logistics Constraints
Transporting large, heavy modules across kingdom poses practical
challenges, particularly in regions with limited road width, bridge
capacity, or urban congestion. Modules that exceed standard transport
envelopes may require special permits, escorts, or even modification of
infrastructure. Onshore (shoreline) projects with port access have an
advantage, but inland (far from shoreline) projects demand early and
detailed logistics planning with authorities.
• Design Freeze and Early Engineering
Modularization requires early locking of design packages. This can
conflict with traditional project workflows, where design flexibility is
preserved longer through many phases. Teams must be prepared to
front-load decisions and ensure that process, electrical, and civil design
disciplines are tightly coordinated in early project stages to assure early
issued for Construction for any scope related to Modularization.
• Integration Complexity
Modules are only as successful as their ability to integrate smoothly
on-site. Misaligned piping tie-ins, mismatched cable lengths, or
instrumentation conflicts can cause major delays. To overcome this,
laser scanning, and rigorous 3D modeling must be enforced across
vendors and contractors.
• Supply Chain Gaps
Although Saudi Arabia’s industrial base is growing, some modular
components like specific instrumentation, control panels, or specialized
valves are still sourced internationally. This creates risks in delivery
timelines, especially when global supply chains are under pressure.
Strengthening local content and qualifying new suppliers will help close
this gap.
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• Fabrication Yard Standardization and Capacity
Not all local yards are currently equipped with standardized
modularization workflows or experienced supervisory teams. Variability
in quality and productivity may exist. Establishing best practices,
workforce training, and unified inspection protocols across yards is
essential to ensuring repeatability and scalability.
• Cultural and Institutional Familiarity
Some project teams, EPCs, or proponent may still prefer traditional
stick-built methods due to comfort with long-established practices.
Shifting to modularization requires a cultural shift in mindset toward
front-end planning, offsite control, and digital execution. Executive
buy-in and structured onboarding help drive this transformation.
• Regulatory and Permitting Process
Modules that involve pressure vessels, lifting operations, or import of
foreign-built components must navigate regulatory approvals (e.g.,
SASO, customs, civil defense). Early engagement with government
entities and clear documentation help prevent delays in module delivery
and site installation.
• Interfacing with Brownfield Constraints
In existing facilities, space limitations, tie-in restrictions, and
simultaneous operations (SIMOPS) increase the complexity of
modularization. Planning crane access, ensuring utility connections, and
coordinating shutdowns with operations teams can be intensive
especially in congested zones with old infrastructure.

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IDENTIFYING THE MODULAR SYSTEM
CLASSIFICATIONS
Typical modular systems include:
• PAU (Pre-Assembled Unit): Large, standalone modules containing full
process systems compressors, vessels, pumps, and control systems.
• PAR (Pre-Assembled Rack): Multi-service pipe racks with electrical and
instrumentation cable trays, built offsite and installed as full racks.
• PAS (Pre-Assembled Structure): Structural modules such as
substations, shelters, or elevated platforms fabricated and tested in
controlled yards.
These units are integrated through standardized tie-in points and often
undergo FAT and pre-commissioning before delivery

ASSESSING MODULARIZATION FEASIBILITY:

STEP-BY-STEP
GENERAL FRAMEWORK
The Kingdom’s ambitious industrial growth has placed process
modularization at the forefront of project execution strategies. To
ensure efficiency, cost-effectiveness, and timely delivery, project teams
must adopt a structured approach to modularization. Best practices
emphasize a systematic process to integrate modularization into
complex projects effectively.

1. Conducting a Feasibility Study

A thorough feasibility study assesses the viability of modularization
within the Kingdom’s industrial landscape. This step involves analyzing
project scope, supply chain limitations, workforce availability, and
regional logistical constraints key factors influencing modular execution.

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2. Defining Modular Scope
Successful modularization begins with a well-defined scope. Project
teams must determine which process components can be
prefabricated off-site while ensuring seamless integration with existing
infrastructure. This early assessment optimizes design efficiency and
reduces site-related risks.

3. Establishing Transport Envelope Early

The Kingdom’s vast geography requires careful logistics planning.
Transport constraints including road accessibility, module dimensions,
and weight limitations must be identified early. This proactive approach
prevents costly delays and ensures smooth module delivery.

4. Integrating 3D Design for the module index

Advanced 3D modeling and interface management streamline modular
coordination. Digital tools allow teams to simulate installations,
minimizing spatial conflicts. This strategy enhances stakeholder
collaboration, reducing rework and improving design accuracy.

5. Engaging with Local Fabricators and Logistics Early

A strong partnership with Saudi fabricators and logistics providers is
critical in the Kingdom’s modular projects. Early engagement helps
synchronize module fabrication and transport logistics, ensuring
efficient production and on-time delivery.

6. Aligning Site Civil Works with Module Fabrication

Modularization demands seamless coordination between on-site civil
works and off-site module production. Proper sequencing avoids
bottlenecks, ensuring foundational readiness for incoming modules. Early
alignment enhances project execution speed and minimizes downtime.

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7. Applying Digital Tools and QA/QC Standards
Leveraging digital twin technology and QA/QC protocols guarantees
consistency across modular units. The Kingdom’s projects benefit from
stringent quality assurance measures, ensuring compliance with safety
standards and performance benchmarks.
Process modularization in the Kingdom is transforming project delivery
by reducing costs, enhancing efficiency, and mitigating risks. PMI
methodologies emphasize early planning, stakeholder engagement, and
digital integration to ensure successful modular execution. By following
these structured steps, organizations can achieve operational
excellence in modular projects.

MODULARIZATION WITHIN FACILITIES

(Brownfield and Live Facilities)
Modularization inside existing facilities (brownfield or live operating
environments) focuses on upgrading or adding systems with minimal
disruption. Common examples include pump skids, chemical injection
units, instrumentation shelters, utility bridges, water treatment
modules, and substations.
Why it matters
• Safety: Reduces hot work and working in congested, hazardous areas.
• Schedule Assurance: Allows offsite fabrication while the plant remains
online.
• Access: Enables installation in tight, restricted spaces.
• Standardization: Reuse of modular designs across similar units or sites.

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Execution considerations
• Tie-ins: Minimized and standardized for speed and safety.
• Crane access: Requires 3D scans and rigging feasibility in tight plant
spaces.
• Internal transport: Modules must fit through gates and around
equipment.
• Compact footprint: Often designed vertically to fit limited space.
• SIMOPS: Must plan carefully around live operations and utilities.
Challenges include
• Lifting under overhead structures
• Vibration sensitivity to rotating equipment; may trigger VMS alarms.
• Complex permitting (permit issuance) in operating zones or life
facilities
• Interface
Best integration with old systems
practices
• Lifting under overhead structures
• Vibration sensitivity to rotating equipment; may trigger VMS alarms.
• Complex permitting (permit issuance) in operating zones or life
facilities
• Interface integration with old systems
Intra-plant modularization enhances safety, efficiency, and execution
certainty especially in shutdown-constrained environments.

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MODULARIZATION IN NEW PROCESS FACILITIES (Greenfield Projects)
In greenfield (grassroots) projects, where a new facility is built from
scratch modularization serves as a cornerstone for accelerating
delivery and managing mega-scale complexity.
Greenfield modularization is typically used in large oil and gas complexes,
or utilities infrastructure. It involves modularizing major systems such
• Process trains (PAUs)
• Pipe racks and electrical systems (PARs)
• Substations, shelters, and MCC buildings (PAS)
• Utility skids and early production facilities
Advantages in new facilities modularization `
• Faster execution by parallelizing module fabrication and site
development.
• Cleaner site conditions: reduced field congestion, lower manpower,
better logistics.
• Schedule Assurance: reduced weather impact and workforce
limitations.
Strategic Considerations
Greenfield modularization is crucial for remote or high-safety-risks
environments, such as remote locations or offshore platforms. By
locking design early and managing execution in parallel workstreams,
proponent achieve cost and schedule certainty essential for large
capex, fast-track facilities. In greenfield (grassroots) projects, where a
new facility is built from scratch modularization serves as a cornerstone
for accelerating delivery and managing mega-scale complexity.

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TRANSPORTATION AND THE TRANSPORT ENVELOPE
Transportation is a defining constraint in modular design. Projects
must define their transport envelope early this includes:

• Width, height, and weight limits for road or port access

• Turning radius and bridge load capacities
• Lifting points and structural integrity during moves

Kingdoms road infrastructure is strong in industrial zones, strict

permitting, clearance limits, and bridge load capacities can restrict
module size. Permits, escorts, and customs can take weeks if not
planned early.

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To overcome this:
• Some projects use near-site modular yards to build and move modules
within short distances.
• Heavy haul contractors with SPMTs and hydraulic trailers are engaged
during early design.
• The design team sets envelope limits (e.g., 5.5 m wide, 6.0 m tall, 200
tonnes max weight) to guide the entire 3D modeling process.
• Slice and dice the models in a way that is within your transport envelop
and assemble it near by the site.
• Try to be in touch with other projects that is located within the same
area of your project and utilize their logistics and heavy hauling studies;
this will save time of doing new study.

Failure to define the transport envelope upfront leads to rework,

late-stage redesign, or splitting of modules, which defeats the purpose
of modularization.
SUCCESS STORIES OF MODULARIZED PROJECTS IN SAUDI ARABIA
Modularization is no longer a conceptual strategy in Saudi Arabia; it has
been successfully implemented in several high-impact projects under
several portfolio. These cases demonstrate the feasibility, value, and
scalability of modular execution in the Kingdom's unique logistical and
regulatory environment; as below cases that are not limited to the
following:

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1. Hawiyah Unayzah Gas Reservoir Storage Project (HUGRS)
The HUGRS project marked Saudi Arabia’s entry into subsurface gas
storage. Modular components, including gas compression systems and
utility skids, enabled parallel fabrication and civil construction, helping
meet tight delivery windows while minimizing site congestion and HSE
exposure.
Source: Aramco Life – HUGRS Project
2. South Ghawar Gas Compression Project
Aramco’s Haradh and Hawiyah Compression Projects incorporated
modular substations and utility systems to accelerate installation
timelines. The modular approach supported early testing and
integration, while also enhancing construction safety in remote desert
zones.
Source: Aramco Life – Gas Compression Projects
3. Jazan Refinery and Terminal
This 400,000 bpd mega-refinery used modularized piperacks and offsite
substations to reduce congestion on-site and improve schedule
reliability. The approach enabled better logistics planning and safer
construction operations at a complex coastal location.
Source: [Link] – Jazan Complex
4. Fadhili Gas Plant
Fadhili is one of the Kingdom’s most advanced gas processing facilities. It
reached full design capacity of 2.5 BSCFD while utilizing pre-assembled
skids and modular sulfur recovery units. The modular strategy reduced
on-site work, helped maintain schedule, and supported early
commissioning.
Source: [Link] – Fadhili Gas Plant

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CONCLUSION
Modularization is more than a design choice; it’s a strategic delivery
model. When deployed properly, it enables:

Faster and more predictable project delivery

• Lower HSE and integration risk
• Early revenue generation
• High-quality fabrication and controlled installation
• Stronger alignment with Saudi Arabia’s localization goals

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