Chemical Engineering June 2018 - 19

(continued from p. 18)
In addition, site prep work, such as preparing foundations and getting
ready for the modules to arrive, can be done in tandem with the
module's construction, greatly accelerating the project timeline. Also,
says Baron, building within a controlled-environment modular yard
provides a cost savings when compared to having contractors onsite,
where they may be subject to weather and permitting delays, which
can increase labor and project costs.
" Also helping to speed up schedule and delivery is the fact that when
building the whole system modularly in-house, we can fully test the
system before it gets to the site, " says Baron. " That reduces time
spent with on-site startup and troubleshooting because the system is
already tested and ready to go. "
Other benefits of going modular include increased safety and quality,
says Preston Wendel, global director of fabrication, with Fluor Corp.
(Irving, Texas; www.fluor.com). " Usually there are multiple levels to a
plant and a lot of critical activities for a project include working at
heights, but when we modularize a job, we can take some of that
work and bring it down to grade which removes many of the hazards
associated with working at heights, " he says. " There's also safety im*
The module has no automation
system and control is accomplished
via the plant's automation
system, which is common with
simple modules. In this scenario,
wiring must be run from the plant's
automation system to the module's
field devices via hardwiring or
a multiplexing system.
* The plant's existing automation
system connects to the module's
I/O (input/output) via a digital connection,
common with more complex
modules. This approach allows
the module builder to prewire
all I/O to field devices, so the
plant's automation system only
needs to connect to the I/O via a
digital data link.
* The module has its own automation
controller, which is linked to
the plant's automation system via
a digital connection, common with
more complex modules, allowing
the module builder to test module
and automation system operation
prior to shipment. The module's
automation system may not be
familiar to plant personnel. Plants
can specify the type of automation
system, but this may drive up
costs and delivery time.
" Often, the mechanical exchange
of a process module requires less
time than the integration of the module
and plant automation systems, "
provements due to the repeatability of work performed in the same
location using the same standards. "
This repeatability also yields quality improvements, says Wendel.
" Moving from a stick-built environment, where everything is new, to
a manufactured modular approach, where there is repeatability, provides
increased quality. We see better rejection rates on welding and
overall better quality coming out of modular yards compared to what
we see on stick-built jobs " (Figure 4).
Modular construction, especially process skids, can also provide
flexibility, says Craig Correia, director of process industries for North
America, with Festo (Islandia, N.Y.; www.festo.com).
" Modularity allows processors to be more flexible with production
because modules can be moved or placed in series. They can scale
up certain sections of the plant if they need to fix a bottleneck or increase
production without having to duplicate or redesign, " he says.
" Ten or fifteen years ago, the plant was designed for a particular purpose
and if a change was necessary, you had to interrupt the process
to expand equipment that was currently in use. Modules are designed
to be used in series and moved around as capacities increase or the
product changes. "
❑
says Henrichs. Common problems
include difficulties in establishing digital
connection, incompatibilities between
the plant's automation system
and the module's I/O, lack of plant
personnel's familiarity with the module's
automation system and different
naming conventions for tag names,
alarms, events and commands.
Modular automation allows module
vendors to include and protect their
intellectual property and also helps
their end users by reducing the costs
and time required to build and operate
flexible production plants.
Integration
problems
magnify
when there are multiple skids manufactured
and delivered by different
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Chemical Engineering June 2018

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