Chemical Engineering June 2017 - 50

Cover Story
to open, including the completion of all module
interconnections and terminations, and
commencement of construction testing and
pre-commissioning. Advances in module
lifting and setting technology have enabled
the use of advanced rigging systems that
can be adjusted rapidly to accommodate
various module sizes and configurations.
Use of these systems increases the setting
pace of modules, thus increasing work-front
availability. Work fronts encompass available
space for construction and work. For example,
only after a module is set into place can
further work take place to finish it, connect
it and test and energize it. With advances in
module lifting and technology, modules can
be set faster and work fronts opened more
quickly. This provides the onsite construction
workforce with more available areas
for work and the ability to finish the project
faster. Investments in this new technology
can benefit the schedule immensely.
The construction group will be the recipient
of the modules and the modular
design. The continued interface with the
construction group during all stages of the
project will enable a successful moduledelivery
plan.
Pre- and site commissioning
Opportunities to improve project value continue
into pre-commissioning and site commissioning.
At the module yard, modules
should have, to the maximum extent possible,
completed testing, pre-commissioning
and preservation prior to shipment to the
site. When testing and pre-commissioning
activities are maximized in the module yard,
the project achieves a reduction in the site
commissioning efforts. This approach requires
alignment in the early stages of the
project to assist with the planning. The
stakeholders, including construction, commissioning
and operations and maintenance
teams, must provide input during the design
phase. This input provides an avenue for the
most efficient design incorporating the experience
these teams bring to the overall safe
operability of the end product.
This input must continue to be an iterative
process through formal reviews, or by
identifying and addressing issues during
design development.
As module walkdowns are completed, areas
such as pressure testing, electrical and equipment
testing and pre-commissioning can be
incorporated into the turnover strategy from
the fabrication or assembly company to the
jobsite. By incorporating these activities into
50
the turnover strategy, testing and pre-commissioning
can be completed in the controlled
environment of the module-assembly yard.
The quality assurance of the work is monitored
to ensure all modules are fabricated
in accordance with specifications and standards
prior to loading for transportation to
the site. The systems-turnover documentation
must also be completed for immediate
retrieval at the site.
Transporting a tested and pre-commissioned
component of an overall site minimizes
startup timing after module delivery,
as well as site installation and commissioning
costs and schedule.
Closing thoughts
The practical solutions discussed here provide
an overview of modular design and
execution fundamentals, and offer some
recommendations on how to overcome the
challenges that advanced modular execution
brings. Modular execution is an integrated
approach to project management,
and affects every aspect of implementation,
including engineering, logistics, supply
chain, construction and commissioning.
The design of a module provides additional
complexities that need to be effectively
addressed. This approach will challenge
many traditional design and execution
methods. Overcoming these challenges will
help all stakeholders to deliver success and
overall improved project results.
■
Edited by Suzanne Shelley
Susan Halford is in project management at
Fluor Corp. (55 Sunpark Plaza SE, Calgary,
Alberta, Canada, T2X 3R4; Email: susan.
halford@fluor.com). A certified project management
professional, she has been with
Fluor for 10 years, and has 18 years of experience
with engineering, procurement and
construction (EPC) and construction companies
within the oil-and-gas and mining industries.
Halford's professional experience focuses
on project management, module coordination, offshore
fabrication management, engineering coordination, project controls,
materials management, IT project management and infrastructure
design, with a keen focus on project team environments to manage
projects and lead teams effectively to achieve project objectives.
Tony Kretzschmar is a project director at
Fluor Corp. (55 Sunpark Plaza SE, Calgary,
Alberta, Canada, T2X 3R4; Email: tony.
kretzschmar@fluor.com). A registered professional
engineer, he has been with Fluor
for more than 28 years, with experience in
engineering, operations, materials management
and project management across Fluor's
business lines. For much of his career,
Kretzschmar has led and supported projects
implementing modular execution. This work has taken him from
his native Canada to working overseas in India, China and Mongolia
for more than half of his career. He is also a member of Fluor's
Business Transformation & Innovation team leading various innovation
initiatives.
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Chemical Engineering June 2017

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