Chemical Engineering June 2018 - 18

Newsfront
Simplifying Integration of
Modular Projects
Plug-and-produce concepts for automating modular skids may solve integration challenges
odular
M
construction -
both of facilities and process
skids - has gained
popularity due to its benefits,
including speed of delivery and
predictability of cost and schedule
(see Box 1 below and Chem. Eng.,
June 2017, pp. 44-50). However,
with the process industry embracing
big data, Industry 4.0 and the industrial
internet of things (IIoT), reliance
on automation is also growing, which
sometimes is at odds with modularity,
as the automation of modular
skids can, at times, be difficult to integrate
with higher-level, plant-wide
control systems. Fortunately, the automation
industry is making strides
to overcome these difficulties via the
development of modular automation
systems based on Lego-like and
plug-and-produce concepts.
The term
" modular " can apply
to anything from a simple, pre-assembled
process unit to larger skid
modules that form entire production
lines to multiple container modules
joined together to construct an enM
Jacobs
FIGURE
1. Lubrizol's highly reactive poly-isobutylene production unit from Jacobs' EPC project site in
Deer Park, Texas
tire facility. Modules can be simple,
off-the-shelf units or complex custom-engineered
solutions. But in all
of these scenarios, if the module is
not a stand-alone unit, it must be integrated
into the higher-level control
system of the plant, and this is where
things get tricky.
odular construction, whether it's a simple skid-mounted
filtration system, an entire process line containing mixers,
reactors, heat exchangers, pumps and the like, or a complete
facility, constructed of multiple process modules or containers
that are connected together at the user's location, provides a host of
benefits and cost savings when done correctly. The modular concept
means all the necessary components, both process and ancillary
equipment such as piping, instrumentation and electrical wiring, are
installed in a structural steel frame or mounted on a skid in a modular
shop. Everything is tested before delivery, the module is shipped via
truck or barge and, finally, installed on site. While there may be various
levels of modularization, all modules are pre-fabricated to the maximum
level of completion at a yard that is remotely located from the
customer's plant site. Modular yards are often indoors and operate on
an assembly-line-type premise, which provides many benefits.
" The objective of modular plants and process skids is to support
faster and easier commissioning during startup of a process plant and
during changes of production in the lifecycle of a process plant, " says
Tim-Peter Henrichs, marketing manager (chemical industry) at Yok18
Impact
on automation
Process module automation is commonly
accomplished in one of three
ways, according to Tim-Peter Henrichs,
marketing manager (chemical
industry), with Yokogawa Deutschland
GmbH (Ratingen, Germany;
www.yokogawa-blog.de/en):
THE MANY BENEFITS OF GOING MODULAR
ogawa Deutschland GmbH (Ratingen, Germany; www.yokogawablog.de/en).
" This is a significant prerequisite for flexible production,
which is a big trend in specialty chemicals, pharmaceuticals and life
science, as well as in LNG and marine markets. "
The biggest benefit, according to Jim Flake, director of module consulting
with Jacobs Engineering (Dallas, Texas; www.jacobs.com),
is mitigation of labor availability at the sites where large projects are
being installed. " Especially in the U.S. and the Gulf Coast area, there
is a strain on labor and we continue to see the available skilled craft
labor pool erode, " he says. " Being able to move work off site and
out of the area means you aren't competing for the same labor pool,
which is a huge benefit " (Figure 2).
The modular approach also provides schedule and cost certainty,
according to Jason Baron, power and controls group manager, with
EPIC Process Systems (St. Louis, Mo.; epicsysinc.com). " We are
building the system in our shop so contractors aren't on the facility
site. Not only can on-site construction be inconvenient, sometimes
it's impossible for a plant to operate during large-scale construction, "
he says (Figure 3).
(continued on p. 19)
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JUNE 2018

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Chemical Engineering June 2018

Table of Contents for the Digital Edition of Chemical Engineering June 2018