Hydrocarbon Processing - July 2021 - 26

Plant Design, Engineering and Construction
ning leads to better space utilization. This
is a huge benefit from an owner's point of
view because the extra spaces saved can be
used to install more facilities to improve
future productivity.
Minimize the need for construction
labor onsite. Modularization showcases
the perfect solution for onsite labor shortage,
which has long been a bottleneck in
modern construction projects. By modularizing
most of the process-related systems
and equipment for preassembling and testing
in the module yards, construction work
hours can be significantly reduced. Such
simplified site infrastructure configuration
results in lower resource requirements for
onsite labor and machinery, thus creating
a more spacious work environment. This
not only enhances safety and quality, but
Engineering
Procurement
Engineering and
procurement-driven schedule
Nozzle handover to piping
FRD/CRD
Place order
Drawing issue
Manufacture
Transportation
Piping, instrumentation
and electrical
Transportation
Equipment installation
Fabrication and
construction-driven schedule
also helps improve work sequences and resource
allocations throughout the project.
High level of adaptability to various
environmental conditions. Modularization
projects are less susceptible to
unfavorable climate or geographical conditions
since the process is performed in
independent module yards. In addition,
they are highly adaptable to changes, allowing
adjustments or modifications to
module engineering designs, such as for
size and weight, structural reinforcement
and fixation, module layout, heat insulation,
and anti-corrosive or anti-rust coating
treatments as required on job sites.
MEGA-MODULE PROJECT
EXECUTION: EXPERIENCE
AND STRATEGIES
Module fabrication
Steel structure
Erection and hook-up
Construction
Handover
The mega-module project that will be
discussed here is the world's largest inland
petrochemical refinery plant in Texas. It is
owned by a JV of two international oil and
gas companies that are looking to capitalize
on domestic shale gas resources and
supply. Once the plant begins operations,
it is expected to produce millions of tons
per year of mono-ethylene glycol (MEG),
along with thousands of local job opportunities.
The following will elaborate on
the execution features of this mega-module
project from three aspects:
1. Project control and
schedule planning
2. Procurement and material
management
3. Key highlights of module
fabrication.
Project control and schedule planning.
Successfully planning a modularization
project depends on proper integration
of work packages with engineering,
procurement, fabrication and construction.
To achieve this goal, project control
aims to manage the following tasks:
* The engineering team supports the
construction sequence and schedule
* Vendor-supplied equipment
remains on schedule
* Materials are purchased and
delivered to support construction
FIG. 2. The FRD and CRD are the most important dates in a project schedule.
Level
TABLE 1. Schedule level of detail
Engineering
Level 1
Milestone-Overall
Model review
Major drawing
* Communication of specific work
tasks is improved throughout the
workforce-from the superintendent
level through the craft ranks
Procurement
LLE
Critical materials
Level 2 Master project schedule-Discipline
Primary steel
Secondary steel
ISO drawing IFC
Static equipment
Rotary equipment
Package equipment
Electrical and instrumentation
(E&I) equipment
E&I bulk material
Level 3 EPC CPM network-Module and area
Module discipline
Area discipline
Level 4 Work package
Engineering document index
26 JULY 2021 | HydrocarbonProcessing.com
Equipment and material item
Fabrication work package/deck Construction work package
Requisitions
Module discipline
Area discipline
Fabrication
First cut
Sail away
Steel fabrication and assembly
Piping fabrication and erection
E&I installation
Construction
Air permit(s)
MC Level 1
Foundation erection
Piping fabrication and erection
Module erection and hook-up
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Hydrocarbon Processing - July 2021

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