MODULARIZATION

DESIGN

ASPECTS

Presented by : Partha Parthasarathi, P.Eng.,

September 24, 2012

24-Sep-12

Modularization Guideline

G 907-0003

http://knowledge.worleyparsons.com/ws/default.aspx
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24-Sep-12

Modularization
TOPICS COVERED TODAY

24-Sep-12

WHAT IS A MODULE ?

WHY MODULARIZATION ?

MODULE TYPES

MODULE CONTRACT SCOPES

TRANSPORTATION

LIFTING

ENGINEERING AND DESIGN

LESSONS LEARNED

QUESTIONS -

ANY TIME

What is a Module ??

Module is a Structural Unit

assembled with the following:

EQUIPMENT
STEEL
PIPING
ELECTRICAL
INSTRUMENTATION
FIRE PROOFING
INSULATION

Assembled at a location away

from the project site.
(Edmonton, Texas, China,
Korea etc.)

Transported by Road, Rail,

Waterways, Air or in
combination to project site.
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Module Example 1

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Module Example 2

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Module Example 3

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Module Example 4

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Module Example 5

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Module Example 6

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Stick - Build Construction

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WHY Modularization

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REDUCED COST

REDUCED SCHEDULE

REDUCED RESOURCES

BETTER QUALITY

MORE

SAFETY

COST Reductions
HOW TO REDUCE COST ??
MOVE LABOR AWAY FROM SITE
WHAT ARE THE ADVANTAGES?
Reduces cost of housing (CAMP) personnel at site
Reduces number of construction personnel at site
(Cost of Travel, Local Transportation, Meal,
Recreation etc.)
Reduces number of vehicles and other equipment
at site (Vehicles, Cranes, etc.)
Cost of field labor is higher
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COST Increases

COST OF ENGINEERING

Requires additional engineering hours to design

modules for Lifting, Transportation conditions, Extra
design drawings, 3D-Model splits, CWPs.

STEEL MATERIAL
Modular construction will increase the quantity of
steel by 10 to 25% (of stick Build) and hence
higher steel cost

TRANSPORTATION AND HEAVY LIFT

Additional costs are involved for transportation
(Road, Rail, Waterway etc., and also the cost of
Heavy Lift Cranes.

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Overall Cost Benefits

The cost increases stated earlier are off-set by the

reduced cost of assembly, painting, piping, Electrical,
Insulation and other works performed in the Fabrication
Facility instead of in the Field
The transportation cost of a larger module is usually
competitive with the combined cost of shipping of individual
items

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Quality
Higher Quality of work is easier
to achieve at Module Yard
Productivity will be higher

No constraint on weather conditions

Accessibility to the Module Yard

is easier

Efficient work due to

controlled working conditions
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Quality (Continued)
Availability of skilled craftsmen in certain
jobsites is a major problem. The off-site
fabrication location is usually away from
the Project site, where skilled personnel
are more easily available
Control of incoming material / issuing
material (Inventory) is better controlled in
a shop than in the field.

There will be fewer fitting errors and rework in the field, as most components are
pre-assembled in the Modules.

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Schedule Reduction
STICK BUILD PROJECT SCHEDULE
Civil works

Fabrication Piping, Structural,

Mechanical, Electrical, Instr.

Field Installation
Commissioning

MODULAR PROJECT SCHEDULE

Civil works

Fabrication Piping, Structural,

Mechanical, Electrical, Instr.

Modular Yard assembly

Field Installation
Commissioning

CONSTRUCTION TIME IN THE FIELD IS REDUCED,

and hence the cost is also reduced
Reduced schedule enables earlier Plant START-UP and
adds great value to the Project
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Increased SAFETY

The number of personnel working in the field is reduced

and hence, the incidents are reduced. Safety is increased.

The number of components to assemble in the

field is extensively reduced. Safety is increased.

Field personnel are not required to work at much

higher elevations. Safety is increased.

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Module Types
Type 1: Pipe rack / Process Modules

Assembled at Modular
Yard and transported to
project site

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Module Types
Type 2: Pre - Assemblies

It is also a Module Larger

in size and Heavier in
weight than a typical
Module

1
2

Modules assembled within

Project site are known as
Pre-Assemblies.

Public road restrictions do

not apply

Transported / Lifted within

Project site

Example: Delayed Coker derrick structure

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(Continued)

Module Types
TYPE 3 : Vendor assembled Modular / Package Units

Example: Equipment
skids, vessels with
platforms, Compressors,
Pumps etc.,

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(Continued)

Site Fabricated Equipment

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Shop Fabricated Tank

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Module Types

(Continued)

Type 4: Modular Buildings

Example : Instrument Buildings, Electrical Sub-stations, MCC, Deluge

Buildings, Chemical buildings etc.,
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Module Types
Type 4: Modular Buildings

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(Continued)

Module Types

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(Continued)

Module Contracts

Typical Modular construction involves

several contracts
Steel fabrication
Pipe Spool Fabrication
Equipment vendors (Mechanical, Electrical & Instrument)
Module Assembly in Module Yard
Transportation of Modules to site
Installation of Modules at site
Note: Some of the above contracts may be combined

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Module Contracts
Contract Scope Details
1.

Steel Fabrication :
Material supply, fabrication, painting,
fire-proofing and transport fabricated
steel to Module yard or to the project
site.

2.

Pipe spool Fabrication :

Fabricate pipe spools and transport
to Module Yard

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Module Contracts

3a. Mechanical Equipment (Pump, compressor,

etc.) purchased from vendors and shipped to Module
Yard

3b. Electrical Equipment (MCC, VFD, Cable

Trays etc.) purchased from vendors and shipped to
Module Yard

3c. Instruments (control valves, flow meters etc.)

purchased from vendors and shipped to Module Yard

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Module Contracts
4a.

Module Yard (Indoor):

Assemble equipment, pipes, electrical, Instruments, structural
steel, fire-proofing, Insulation etc.,

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Module Contracts
4b.

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Module Yard (Outdoor):

Module Contracts
5. Typical Transportation contracts:
Road, Rail or Waterway carriers
All of these transportation modes require
Permits / Regulatory approvals
Logistics provide weight limits, route study,
bridge capacity verification, etc.,

What is Logistics:
Logistics is a department in WP that
will organize all types of transportation
requirements, Storage, Heavy Lift,
perform route studies, economics,
schedule for the Module transportation
from the module yard locations to the
project site
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Module Contracts
6. Mechanical contract at Project site:

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Unload modules from trucks and install them on foundations /structures.

Fasten/secure the modules properly and join pipes, structural, cables
Supply appropriate cranes for field installation of modules.

Transportation
Method of Transport

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ROAD

AIR

RAIL

WATER WAYS

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Road Transportation

Limitations on Module Dimensions due to:

Bridge Height Clearances
Available road widths
Regulatory requirements (vary with each Province)

Note:
Always consult Logistics on Dimensional and Load Guidelines
for Transportation
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ROAD Transportation (Continued)

Limitations on the Weight of Modules due to:

Load carrying capacity of Bridges along the route

Pay Load capacity of Trucks

Road Conditions (Pay Load Capacity of Trucks vary with season)

Maximum load is allowed during Winter

Table 2: Trailer Pay Load Capacity (Single width Trailer 10 Axle)

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Season

Pay Load

Spring

75 Tonnes

Summer

105 Tonnes

Fall

120 Tonnes

Winter

135 Tonnes

Road Transportation (Continued)

MODULE WEIGHT SHALL BE LIMITED TO 90%
OF PAYLOAD CAPACITY OF TRUCKS TO PREVENT
AXLES FROM OVERLOADING LOCALLY

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Road Transportation (Continued)

Table 1: Limitations on Modules (in Alberta)

TYPE

WIDTH

HEIGHT **

LENGTH

WEIGHT

REMARKS

8- 6 14- 0

17- 0

80- 0

< 62 kips

-STAIRS, PLATFORMS, VESSELS

- LOW COST PERMIT

8- 6 14- 0

17- 0

120- 0

62 kips - 130
kips

- EXPERTISE REQD FOR BLOCKING AND

BRACING
-LARGE VESSELS, HEAVY EXCHANGERS

14-0 24-0

29- 6

120- 0

130 kips 200 kips

- EXPERTISE REQUIRED FOR CRANE

RIGGING, LOADING, BLOCKING, BRCG
- LARGE HEAVY VESSELS
- SMALL MODULES

14-0 24-0

29- 6

120- 0

200 kips 300/319 kips

(300 for CalgaryEdmonton)

> 24-0

> 29-6

>120-0

300 / 319 kips

(300 for CalgaryEdmonton)

SUPER LOAD
ENGG EXPERTISE REQD FROM
TRUCKING FIRM (PLTFM TRAILOR /
PRIME MOVER)
LARGE VESSELS, MODULES

- FOR NON-DIVISIBLE LOADS

- TECHNICAL JUSTIFICATION REQD
- SPECIAL PERMISSION REQUIRED FROM
ALBERTA INFRASTRUCTURE
- ENGG EXPERTISE REQD FROM TRUCKING
FIRM (PLTFM TRAILOR / PRIME MOVER)

Height ** measured from the road surface Typical truck bed height 4-3
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Road Transportation (Continued)

Table 3: Limitations on Modules (Other Provinces and USA)

LOCATION

WIDTH

HEIGHT **

LENGTH

WEIGHT

BRITISH
COLUMBIA

14- 6

14- 0

98- 6

Subject to approval of local

transportation authority

SASKATCHEWAN

24- 0

20- 7

99- 0

Subject to approval of local

transportation authority

MANITOBA

16- 4

20- 7

99- 0

Subject to approval of local

transportation authority

ONTARIO

16- 4

20- 7

120- 0

Subject to approval of local

transportation authority

QUEBEC

16- 4

20- 7

88-0

Subject to approval of local

transportation authority

UNITED STATES
OF AMERICA

18-0 20-0

18-3
20-3

40-0
80-0

Subject to approval of local

transportation authority

Height ** measured from the road surface Typical truck bed height 4-3
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Road Transportation (Continued)

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SCHEUERLE TRAILERS ARE COMMONLY USED BY

THE TRANSPORTERS

TRAILERS ARE COMPLETELY MODULAR. THEY CAN

BE COUPLED TOGETHER, END TO END OR SIDE BY
SIDE TO CREATE MANY CONFIGURATION OF
LENGTH AND WIDTH

Road Transportation (Continued)

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Road Transportation (Continued)

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Road Transportation (Continued)

Two File (Single width) Trailer

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Four File (Double width) Trailer

Road Transportation (Continued)

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Trailer bed heights are hydraulically adjustable up to

1-0 (300 mm)

This feature facilitates loading the module directly on

the truck bed, by driving the truck bed under the
Module and raising the bed to pick up the module

Road Transportation (Continued)

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Modules will be fastened to the Trailer bed by cables or

chains. The stability of the Module shall be ensured by the
Transporter

SPMT Self Propelled Modular Transporter

SPMT.flv

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SPMT Self Propelled Modular Transporter

Maximum Payload - SPMT

Speed

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6 Axle

12 Axle

0.5km/hr

206 Tonnes

419 Tonnes

1.0 km/hr

182 Tonnes

371 Tonnes

6.0 km/hr

146 Tonnes

299 Tonnes

SCHEUERLE PLATFORM TRAILER

Schuerele Trailer.flv

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Road Transportation (Continued)

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Road Transportation (Continued)

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Road Transportation (Continued)

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Road Transportation (Continued)

MODULE TRANSPORT BY ROAD TRAILER

TYPE 4 TRANSPORT (DOUBLE WIDTH ARRANGEMENT)
* FOR MAXIMUM HEIGHT AND WIDTH REFER TO TABLE 1 AND 3
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Road Transportation (Continued)

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Rail Transportation

Table 4: Limitations on the Modules

REGION

WIDTH

HEIGHT **

LENGTH

WEIGHT

WESTERN CANADA

12- 3

14- 0

80- 0

346,000 lb

EASTERN CANADA

13- 10

18- 2

80- 0

346,000 lb

WESTERN USA

13- 0

18- 3

80- 0

346,000 lb

EASTERN USA

12- 10

18- 6

80- 0

346,000 lb

Note 1: ** Module Height excluding the rail car bed height

Note 2: Always consult Logistics for Dimensional and Load guidelines for transportation

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Air Transportation

Table 5: Limitations on Modules

AIRCRAFT TYPE

LENGTH

WIDTH

HEIGHT

WEIGHT

PASSENGER AIRCRAFT

10- 0

7- 6

5- 4

~ 9,000 lb

CARGO AIRCRAFT

10- 0

7- 6

8- 0

~ 10,000 lb

HEAVY LIFT CARGO

AIRCRAFT
(ANTONOV AN-124-100)

120- 0

21- 0

14- 6

~ 264,000 lb

Note 1: Heavy lift Cargo Aircraft is very expensive

(>$500,000) and will be considered only for special cases
Note 2: Ft McMurray Airport cannot handle Antonov
aircraft
Note 3: Always consult Logistics on dimensional and
Load Guidelines for Transportation
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Water Way Transportation

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Water Way Transportation (continued)

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Water Way Transportation (continued)

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Suitable for overseas fabricated Modules

Loads up to 10,000 Tonnes can be carried by ships and barges

Typical deck space for Barges is about 400 ft x 100 ft

Lead time to acquire Barges is over 12 months

Module size may be limited due to road/rail restrictions

4 Major routes to Alberta are possible: West/East/Gulf coasts of USA

and Northern (Canadian) route

Northern (Canadian) route has many risks like frozen waters, need
for ice breakers to move the ships, dredging the McKenzie river at
certain locations, Dock installations, impact on Aboriginal people, low
water levels in Athabasca river etc.

Water Way Transportation (continued)

SUITABLE FOR OVERSEAS
FABRICATED MODULES

4 Possible routes to Alberta:

WEST COAST PORTS (USA)
COMBINED WITH ROAD/RAIL
TRANSPORT
EAST COAST PORTS (USA)
COMBINED WITH ROAD/RAIL
TRANSPORT
GULF COAST PORTS (USA)
COMBINED WITH ROAD/RAIL
TRANSPORT
NORTHERN (CANADA)
THROUGH BERING STRAIT
NWT - THROUGH McKENZIE /
ATHABASCA RIVERS
NOTE: ALWAYS CONSULT LOGISTICS ON DIMENSIONAL AND LOAD GUIDELINES FOR
TRANSPORTATION
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Module Lifting

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Module Lifting

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Module Lifting

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Lifting Arrangements
Type 1 VERTICAL Lifts

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It is recommended to use 4 or 8 point lift

instead of 6, 10 or 12 points

Module Lifting

8 point lift
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Lifting Arrangements
Type 1 VERTICAL Lifts

6 OR 10 POINT LIFTING NOT PREFERRED

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Lifting Arrangements

10 point lift

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Lifting Arrangements
Type 2 INCLINED Lifts

Certain situations in the field may require lifting of Modules with inclined
CABLE , as shown due to overhead obstructions (Reduced crane height)
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Lifting Arrangements
Type 3 Upending

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Example : Stair Tower Module, Tall vessels

Lifting Arrangements
Type 3 Upending

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Example : Stair Tower Module, Tall vessels

Jack & Roll

Jack & Roll:
Lifting and moving heavy loads (<50 Tonnes) without
using cranes
Ideal in Remote locations
Cost effective
Place hydraulic jacks under the module at predetermined locations (Jacks connected to central
Jacking pump) and lift the module.
Unified jacking pumps apply simultaneous pressure to all
the jacks to ensure an even and level lift.
Place a rail system with rollers under the jacked up
module.
Roll the module from the trailer onto the foundation/pile,
using winch trucks.
Module is lowered via the hydraulic jacks
Require large space around the module.
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Jack & Roll

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Jack & Roll

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Hydra-slide
Hydra-slide: Lifting and moving very heavy loads
(> 50 Tonnes) without using cranes

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Similar to Jack & Roll

Used for very heavy loads
Hydra-slide system with shoes installed inside the rail
system for precise movement
Shoes attached to Hydraulic rams and rams connected to
pumps
Hydraulic pumps are controlled by the operator for precise
movement of load (can slide, stop or go without concern)
Winch trucks are not required.
Require less space around the module

Hydra-Slide

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Hydra-Slide

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Super Modules

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Super Modules

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Super Modules

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Super Modules

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Super Modules

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Engineering

ENGINEERING
&
DESIGN

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Engineering

Over-land transportation
1) Road Trailer

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2) Rail

Module structural framework shall be designed for module loads and

impact loads, super-elevation, acceleration, deceleration forces
induced during transportation

In addition, wind load shall also be considered during transportation

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Engineering
Over-land transportation Impact Loads

Road Trailer:
Vertical Impact
Longitudinal Impact
Transverse Impact

Iv = 0.5 g
IL = 0.25 g
IT = 0.25 g

Rail:
Vertical Impact
Longitudinal Impact
Transverse Impact

Iv = 1.0 g
IL = 3.0 g
IT = 1.0 g

Note :
1) Above values can be used unless project specific data is
provided by Client Specs or Logistics or Module Transport
Contractor
2) Impact loads include acceleration or deceleration
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Engineering

Impact Forces during Road Transportation

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Engineering
Over-land transportation Loads & Load Combs

Loads:
Dead Load of Module
Wind Load
Horizontal Load

=D
=W
= H (super-elevation based on 1:10)

Load Combinations for Limit State Design (2005 NBC):

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1.4D
1.25D + 1.5 IV + (1.5 IT + 1.5 HT + 0.4W T) or (1.5 IL + 1.5HL + 0.4W L)
1.25D + 0.5 IV + (0.5 IT + 0.5 HT + 1.4W T) or (0.5 IL + 0.5HL + 1.4W L)
0.9 D + 1.5 IV + (1.5 IT + 1.5 HT + 0.4W T) or (1.5 IL + 1.5HL + 0.4W L)
0.9 D + 0.5 IV + (0.5 IT + 0.5 HT + 1.4W T) or (0.5 IL + 0.5HL + 1.4W L)

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Engineering
Waterway Transportation - Vessel Motion

VH

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BARGE

Engineering
Waterway Transportation
Terminology
Wave Induced Forces
Deck Flexing (Sag/Hog)
Fatigue
Sea Fastening
Head Sea
Beam Sea
Port / Starboard
Bow / Stern
Draft

Data required from Naval

Architect (Shipping Agency)
Roll angle
Pitch angle
Roll period
Pitch period
Heave period
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=
=
= TR
= TP
= TH

Engineering
Water Transportation
Typically Naval architect /Shipping contractor will provide the
design criteria. In the absence of this information, the following
forces may be used for the preliminary design.
Longitudinal force
Transverse force
Vertical force

= 0.25 D to 0.4 D
= 0.5 D
= 0.3 D

D = Total weight of module

In addition to the above wave forces, wind load should be

considered in the design. The following load combinations should
be included in the design calculations:
Heave + Roll + Wind
Heave + Pitch + Wind
Heave, Roll and Pitch forces shall be considered as live loads.
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Engineering
Air Transportation

Logistics to provide the design loading in consultation

with the Cargo Airliner

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Engineering

LIFTING OF MODULES

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Engineering
LIFTING OF MODULES

Modules will be lifted using cranes for placement on transport equipment

or final placement at the site
Vertical Impact (Rigging) Factors should be considered in the analysis
for Module Lifting due to variation between actual and theoretical CG
of module and also due to sudden load application
Vertical Impact Factor
Vertical Impact Factor
Horizontal Impact Factor

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= 0.33 for 4 point lift

= 0.25 for 8 point lift
= 0.02 for all cases

Engineering
LIFT LUG & SHACKLE

Alberta Occupational Health and Safety Code specifies the

requirement of a Factor of Safety = 5 on the Ultimate Strength of
Lugs
ANSI / ASME B30.20 specifies the requirement of a Factor of Safety
= 3 on the Yield Strength of Lugs

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Shackles
Crosby G-209 or G-2130 Shackles are commonly used
(to be confirmed by Lifting contractor assigned to the Project )
The weight of Shackles can be heavy
Do not specify heavy shackles for Light loads
unless standardized by the Lifting Contractor
The Shackle (Crosby) manufacturer provides
Safe Working Load only. Meets Factors of Safety
specified by Alberta OHS and ANSI/ASME
Design drawings should specify Shackle
Model Number and Capacity
The same Shackle type should be specified for all
of the lift points in a module
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Lift Lugs

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Lift Lug materials shall be specified as Notch Tough steel (WT) to allow
for erection during cold temperature conditions

Lift Lug welds shall be 100% UT tested

Critical design checks for Lift Lug are as shown below

Lift Lugs
TYPE 1
Used for very heavy lifts
Require installation and
removal every time (extra time
+ labor cost)
Lugs can be reused
New set of bolts suggested for
every lift

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Lift Lugs
TYPE 2
Lift holes reinforced with
doubler-plates
Limited lifting capacity
Can be used for top modules
only
Future extension of modules
will require modification

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Lift Lugs

TYPE 3
Double function lug Lifting
and splicing achieved
Lower splice plate shaped to
receive the shackle
Allows splicing of modules
without Type 1 Lift Lug
Lift holes reinforced with
doubler-plates
Limited lifting capacity for Lug
and splice connection

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Lift Lugs

TYPE 4
Used for special applications
like Building skids, Piperack
units

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Inter-Connection of Modules Pipe Welding

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Temporary Steel

Temporary steel may be required during transportation or

lifting the module
It is suggested to paint the temporary steel in Fluorescent
orange or other color for easy identification for removal at
site
Temporary steel shall be identified in a separate color in the 3-D
model for clash check purposes
It should be very clearly stated on the design drawings, when
and what stage the temporary bracings should be removed and
at what sequence

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MODULE DESIGN Responsibility

Defining Modules (dimensions/splits) is the combined responsibility

of Piping Layout, Structural, Electrical/Instrument Disciplines.
Logistics shall provide details on the transportation strategy,
methods, limitations on weights, sizes etc., based on feasibility and
economics studies.
Module construction contractor, Module erection (Lifting)
contractor, Procurement dept., Steel Fabricator, the
Construction Manager and the Client shall be involved from the
early stages of engineering to optimize the Modularization Process.

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Lessons Learned
There are several lessons learned on Modularization from each
project in

Engineering
Design
Fabrication
Construction
Transportation
Site Installation

Consult with the Client and other database for the lessons
relevant to the type of project
Some lessons are presented in the following slides
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Lessons Learned

All these piping had to be

removed after installation
due to overweight

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Lessons Learned

Pipes, cables, steel members

located outside module limits

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Lessons Learned
No clearance between Fire-proofing
and the Instrument

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Lessons Learned
Kick-plate was not modeled

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Lessons Learned
Kick-plate was not modeled

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Lessons Learned

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Lessons Learned
Block-out Fire proofing on the module bottom beam
or provide steel stub below for seating on the transport truck

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Lessons Learned
Gusset plates sticking outside
module width

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Module Steel Drawing EXAMPLE

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Module Steel Drawing EXAMPLE

Support Conditions at Module Yard

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MODULARIZATION

QUESTIONS ? ?

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