American Oil and Gas Reporter - June 2024 - 71

Modular Facilities
To achieve more with every dollar
they invest, Duffy says many operators
are turning to Petrosmith's modular construction
services, which shorten field
work by building as much as possible on
skids in the factory. These skids are prefitted
at the company's production facility,
shipped to site and assembled in a fraction
of the customary time, he reports.
" The time savings vary based on how
big a facility is, but we have done 12well
facilities in 10 days that customers
told us would normally take 60-75 days
of field work, " he contrasts.
That speed comes from planning and
coordination, Duffy notes. " When an operator
wants a fully modular approach,
the skids house all the oil, water and gas
lines to take fluids from the well through
the vessel train to the tanks and out to
the LACT and the flare. This includes all
the interconnecting pipes that link skid
to skid, " he notes. " Before shipping any
skids to the field, we do test fits on each
one to ensure a proper alignment and fit,
which drives field efficiency. "
" The delivery and installation are coordinated, "
he adds. " Trucks arrive in a
defined sequence and crane moves are
planned so equipment can be offloaded,
connected and set up quickly. "
Such planning requires upfront engineering.
For a full production facility,
Duffy generally recommends allowing
12-14 weeks for engineers to discuss operators'
needs, design and optimize the
skids, and verify that they meet expectations.
He says this methodical design
process improves facility quality and
helps shrink overall material costs.
" When nearly everything needs to go
on a skid, the designers have to think
about how to bring fluid into the skid
and move that fluid where it needs to go
as efficiently as possible, " he says. " Compared
to stick-built designs, modular facilities
generally have less piping and
fewer elbows, Ts and bends. They reduce
overall facility costs not only by eliminating
costly field days, but also through
more efficient pipe routing and lower
material costs. "
Since most of the work is done in a
controlled environment, Duffy says modular
construction can keep costs predictable.
" Putting some of the more challenging
work in a shop, where we have
overhead cranes and capital equipment
to help with fabrication and construction,
can improve worker safety and minimize
potential incidents in the field, " he adds.
Given how much upfront engineering
it requires, the modular approach can be
a poor fit for small facilities with one or
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JUNE 2024 71
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American Oil and Gas Reporter - June 2024

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