Hydrocarbon Processing - April 2021 - 51

Engineering
and Construction
M. VILLEGAS, Koch Modular Process Systems,
Paramus, New Jersey

Modular construction: Always considered,
now COVID-necessary
The COVID-19 pandemic created a sequence of changes
across all industries, and the chemical sector has not been immune to the impact of this global health crisis. What used to be
a " nice to have " feature in project execution has evolved into a
" must-have " component. Although modular construction is not
a new concept, it may become a necessity in current times.
Modularization is described as the process of shifting as
much labor-intensive field construction activities from the field
to an offsite fabrication facility to mitigate or reduce inherent
risks associated with field construction.
Typically, a modular system includes complete process units
that are fabricated remotely from the project's destination plant
site. The systems are built in a controlled indoor environment, assembly-line fashion horizontally as opposed to vertically, which
helps minimize the amount of work and resources needed vs. field
construction. The systems include all necessary components and
equipment that are placed within a structural steel frame required
to deliver a complete process system. These frames serve as support during shipment and provide access to the equipment for
operation and maintenance after installation at the plant site.
The project's process design, specifications, engineering
standards and guidelines are all taken into consideration and followed to ensure that the executed project meets all expectations
and requirements.
Key advantages of modular construction. Considering
the importance of operator safety and social distancing during
COVID-19, the following are five key advantages of modular
construction:
1. Reduced risk of community spread. When dealing
with on-site construction, depending on the project size,
fabrication may require over 1,000 craft workers to be
performing different tasks simultaneously. In many cases,
these are transient workers who will be newcomers to
the community. Adding more people to an area can
increase the risk of human-human exposure or could
promote the spread of COVID-19 to other areas as the
transient workers return home due to crew rotations.
2. Reduced risk of exposure to the labor force. Modular
assembly typically follows a preset sequence of activities
that inherently require a smaller local workforce. This
allows for social distancing during work activities,

while still being able to adhere to Occupational Safety
and Health Administration's (OSHA's) recommended
guidelines related to the prevention of workplace
exposures to COVID-19. It also brings an advantage
from the logistics perspective, as a small local workforce
is easier to manage vs. a field-built project, while
reducing the likelihood of exposure.
3. Reduced cost and schedule risk. Traditionally,
customers could see a 25%-30% cost reduction
with modular construction when compared to field
construction. The project can be quoted as a firm lump
sum bid vs. time and materials (T&M) and fabricated
to within 90% completion, with items such as piping
components, field instrumentation, lighting, electrical
wiring and others installed within a steel frame. All of
this is done offsite, reducing the amount of onsite work
required during installation. Furthermore, in parallel,
the customer can proceed to apply for work permits as
the construction of the modules have already begun
at an offsite shop, while minimizing plant-site
interruptions due to construction.
During a COVID-19 environment, with fabrication
occurring offsite, the ability to continue module
fabrication when field construction sites would otherwise
be shut down or materially impacted by COVID-19,
reduces the potential for extended schedule and increased
costs associated with delays. Furthermore, minimal plant
site interruptions allow the customer to proceed with
their normal operations, adjust to the new requirements
and create a set of preventive procedures that can be later
shared with the module installation workforce.
4. Increased productivity. Building a full system in a
controlled environment brings many benefits, including
increased productivity. For example, the workforce is
not subject to weather-related delays and benefit from
inherent efficiencies when working in a purpose-built
fabrication facility. Considering COVID-19, fabrication
shops are not experiencing the same level of productivity
hits being taken in the field during construction. In the
field, construction teams are implementing preventative
measures such as daily pre-work health checks, staggered
lunch schedules, breaks and re-checks when the
Hydrocarbon Processing | APRIL 2021

Hydrocarbon Processing - April 2021

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