Hydrocarbon Processing - November 2021 - 37

Engineering and
Construction
S. SARDANA and M. SINHA, Fluor Daniel India
Pvt. Ltd., Gurgaon, Haryana, India
Installation of magnetic level gauges
in modularization projects
In today's competitive world, new ways
of more efficiently executing a project are
being developed every day: one of these is
modular construction. Modularized facilities
allow a project to be completed more
quickly, with lower capital cost and better
material control. Module yards, or fabrication
yards, are built at a remote location.
Once construction is completed, the
module is transported to the site via road
or water, based on its size and destination.
In the construction of most modular
units, mechanical equipment (piping,
steel, cabling, instruments, etc.) are all
assembled in the module to save work at
the site. Therefore, it is essential that all
disciplines-piping, civil, mechanical, instrument
and electrical-work collaboratively
from the initial design phase to the
completion of engineering. Plant 3D software
is used for modelling all equipment,
piping, steelworks, cable trays, junction
boxes and instruments with accurate dimensions
to correctly assess, identify and
utilize the space available.
Instrumentation has a significant
amount of interface with vendors to ensure
accurate dimensions. Most vendors
do not submit the certified dimensions
until the purchase order is placed. Modelling
the instruments (especially non-standard
ones) with preliminary dimensions
may lead to rework at a later stage if the
received certified dimensions are not inline
with preliminary dimensions.
One such instrument is the magnetic
level gauge, which is not a factory-standard
product offered by a manufacturer
and must be designed based on project requirements.
Getting the certified dimensions
on time is challenging; however,
many factors can be addressed during early
engineering stages and the bid evaluation
process to save a considerable amount of
rework later. This article describes the factors
to be considered to finalize the correct
installation of magnetic level gauges
for modularized projects in the absence of
certified vendor data-the research here
was conducted at a large, modularized
project in real time. Many factors can be
missed during detailed engineering, so determining
all such points beforehand and
remaining aware of their significance can
save time, cost and schedule.
Modular construction. In this process,
a plant is divided into various modules
(e.g., process, utilities, power generation)
and their sub-modules, which are constructed
offsite, under controlled plant
conditions, using the same materials and
designing to the same codes and standards
as conventionally built facilities.1
In the authors' company's terminology,
modularization is divided into three parts:
* 1st-generation modularization:
° Prefabricated pipe racks
are sent to the site
* 2nd-generation modularization:
° 60%-70% of steel and
piping are modularized
° Pipe rack equipment
are pre-installed
° 20% of electrical and
instruments are moved under
the scope of the modules
* 3rd-generation modularization:
° Process blocks are modularized
° 95% of steel and piping are
assembled in the module
° 85% of electrical and
95% of instruments are
assembled in the module
FIG. 1. Module assembly. Source: KOMARINE.
Hydrocarbon Processing | NOVEMBER 2021 37
° Most cabling, wiring and testing
are done in the module yard
FIG. 1 shows a typical module assembly.
With 3rd-generation modularization,
it becomes imperative for instrumentation
to be designed at the right time so
that
accurately designed
reach the module yard well before the
module is shipped to the site.
Benefits of modularization. Modularization
has many benefits, including:
* Space: Modularized projects save
space, as an optimum area is used
building the large modules.
* Cost: Due to harsh weather
conditions in some geographical
locations, labor costs can be high.
By moving the construction
under favorable conditions, labor
costs decrease drastically.
* Time: Due to the structured
tracking and controlled
environment conditions at
a module yard, significant
time is saved.
* Large modules are divided into
small work packages to enable
easy identification and precise
tracking of all materials.
instruments

Hydrocarbon Processing - November 2021

Table of Contents for the Digital Edition of Hydrocarbon Processing - November 2021

Contents
Hydrocarbon Processing - November 2021 - Intro
Hydrocarbon Processing - November 2021 - Cover1
Hydrocarbon Processing - November 2021 - Cover2
Hydrocarbon Processing - November 2021 - Contents
Hydrocarbon Processing - November 2021 - 4
Hydrocarbon Processing - November 2021 - 5
Hydrocarbon Processing - November 2021 - 6
Hydrocarbon Processing - November 2021 - 7
Hydrocarbon Processing - November 2021 - 8
Hydrocarbon Processing - November 2021 - 9
Hydrocarbon Processing - November 2021 - 10
Hydrocarbon Processing - November 2021 - 11
Hydrocarbon Processing - November 2021 - 12
Hydrocarbon Processing - November 2021 - 13
Hydrocarbon Processing - November 2021 - 14
Hydrocarbon Processing - November 2021 - 15
Hydrocarbon Processing - November 2021 - 16
Hydrocarbon Processing - November 2021 - 17
Hydrocarbon Processing - November 2021 - 18
Hydrocarbon Processing - November 2021 - 19
Hydrocarbon Processing - November 2021 - 20
Hydrocarbon Processing - November 2021 - 21
Hydrocarbon Processing - November 2021 - 22
Hydrocarbon Processing - November 2021 - 23
Hydrocarbon Processing - November 2021 - 24
Hydrocarbon Processing - November 2021 - 25
Hydrocarbon Processing - November 2021 - 26
Hydrocarbon Processing - November 2021 - 27
Hydrocarbon Processing - November 2021 - 28
Hydrocarbon Processing - November 2021 - 29
Hydrocarbon Processing - November 2021 - 30
Hydrocarbon Processing - November 2021 - 31
Hydrocarbon Processing - November 2021 - 32
Hydrocarbon Processing - November 2021 - 33
Hydrocarbon Processing - November 2021 - 34
Hydrocarbon Processing - November 2021 - 35
Hydrocarbon Processing - November 2021 - 36
Hydrocarbon Processing - November 2021 - 37
Hydrocarbon Processing - November 2021 - 38
Hydrocarbon Processing - November 2021 - 39
Hydrocarbon Processing - November 2021 - 40
Hydrocarbon Processing - November 2021 - 41
Hydrocarbon Processing - November 2021 - 42
Hydrocarbon Processing - November 2021 - 43
Hydrocarbon Processing - November 2021 - 44
Hydrocarbon Processing - November 2021 - 45
Hydrocarbon Processing - November 2021 - 46
Hydrocarbon Processing - November 2021 - 47
Hydrocarbon Processing - November 2021 - 48
Hydrocarbon Processing - November 2021 - 49
Hydrocarbon Processing - November 2021 - 50
Hydrocarbon Processing - November 2021 - 51
Hydrocarbon Processing - November 2021 - 52
Hydrocarbon Processing - November 2021 - 53
Hydrocarbon Processing - November 2021 - 54
Hydrocarbon Processing - November 2021 - 55
Hydrocarbon Processing - November 2021 - 56
Hydrocarbon Processing - November 2021 - 57
Hydrocarbon Processing - November 2021 - 58
Hydrocarbon Processing - November 2021 - 59
Hydrocarbon Processing - November 2021 - 60
Hydrocarbon Processing - November 2021 - 61
Hydrocarbon Processing - November 2021 - 62
Hydrocarbon Processing - November 2021 - 63
Hydrocarbon Processing - November 2021 - 64
Hydrocarbon Processing - November 2021 - 65
Hydrocarbon Processing - November 2021 - 66
Hydrocarbon Processing - November 2021 - 67
Hydrocarbon Processing - November 2021 - 68
Hydrocarbon Processing - November 2021 - 69
Hydrocarbon Processing - November 2021 - 70
Hydrocarbon Processing - November 2021 - 71
Hydrocarbon Processing - November 2021 - 72
Hydrocarbon Processing - November 2021 - 73
Hydrocarbon Processing - November 2021 - 74
Hydrocarbon Processing - November 2021 - 75
Hydrocarbon Processing - November 2021 - 76
Hydrocarbon Processing - November 2021 - 77
Hydrocarbon Processing - November 2021 - 78
Hydrocarbon Processing - November 2021 - 79
Hydrocarbon Processing - November 2021 - 80
Hydrocarbon Processing - November 2021 - 81
Hydrocarbon Processing - November 2021 - 82
Hydrocarbon Processing - November 2021 - 83
Hydrocarbon Processing - November 2021 - 84
Hydrocarbon Processing - November 2021 - 85
Hydrocarbon Processing - November 2021 - 86
Hydrocarbon Processing - November 2021 - 87
Hydrocarbon Processing - November 2021 - 88
Hydrocarbon Processing - November 2021 - 89
Hydrocarbon Processing - November 2021 - 90
Hydrocarbon Processing - November 2021 - Cover3
Hydrocarbon Processing - November 2021 - Cover4
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201901
https://www.nxtbook.com/nxtbooks/gulfpub/petrochemical_2018_v2
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https://www.nxtbook.com/nxtbooks/gulfpub/hp_201812
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019_v2
https://www.nxtbook.com/nxtbooks/gulfpub/hpimarket_2019
https://www.nxtbook.com/nxtbooks/gulfpub/hp_201811
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