INGENIEUR
CHALLENGES OF MODULARISATION
1 . Fabrication Yard ( Shipyard ) and Site Location ( Countries ) Globally , LNG Industry Players are in transition to the modular construction concept with remarkable project achievements in the US , Canada , Europe , Australia and Russia where the success of modular fabrication in terms of a controlled environment at a shipyard provides advantages such as improvement in productivity , project cost ( fabrication part ), fabrication schedule in control with shipyard facilities , technology and skilled manpower to expedite the modular fabrication activities and is able to deliver good products and quality of process modules . This can potentially bring 5 % to 10 % savings in construction cost via productivity improvement , through shipyard lean work processes , standardisation and systematic automation .
2 . Statement of Purpose ( SOP ) Approach : “ Begin with Construction In Mind …” A breakthough modular concept for LNG Plant Land – Based Construction within Asia Pacific Region such as Malaysia , Singapore , Indonesia , Vietnam , Thailand , Brunei will be a challenge when compared with the US , Canada , Europe , Australia and Russia or the Balkan Region in terms of the interconnected ecosystems including : site preparation ; site constructability ; resources and facilities availability during the site integration ; site engineering support ; economic benefit to the local community ; and political and public interests . A fit-for-purpose approach to fabricating modules outside the site location will provide a better control and less site environmental disturbance . The modular fabrication concept focuses on an In-Side Battery Limit ( ISBL ) Process Plant Area by applying the proven modular fabrication driven-schedule while the site location plot plan preparatory activities such as building the modular foundation base , setting up a temporary site access road for multiaxle trailers to manoeuvre heavier modules to the plant site , and assembling site cranes with the relevant capacity , are essential to assist the modules ’ erection and installation during the Integration Phase .
3 . The Right Modular Weight and Dimension ; “ To start with …” To start with a smaller module of an LNG Process Plant in the range of 1 to 1.5 MTPA or 1.5 MTPA to 3.5 MTPA capacity could be the best catalyst in Asia Pacific Region Land-Based Construction Approach . This requires a simplifed and proven LNG Process Technology in which the module weighs approximately around 1,000 to 1,500 tons with the module dimension size of 40 metres x 20 metres x 20 metres . The estimated site process plot plan area will be approximately 350 metres by 80 metres excluding a temporary access road and laydown area , crane movement , site emergency escape route .
4 . Modular Portion versus On-Site Construction Portion : “ Hybrid Construction Contract …” The construction Contract Strategy involves a Project Overall Contract Strategy ( OCS ) framing and development as early as possible to determine the Modular Fabrication Contract and On-Site Construction Contract by focusing on project cost optimisation especially construction cost benefits with the right ratio of modularisation against on-site construction work scoping e . g . 60 % -70 % : 30 % -40 %. For example , comparing the cost of LNG process modules such as pretreatment , liquefaction utilities , versus the costs of on-site stick-built scopes such as module foundation , storage tanks , temporary facilities and accessibility , heavy lift , erection and integration , pre-commissioning and commissioning .
5 . Enabling Construction Technology : “ Marine and Onshore Constructability …” An advancement in construction technology through marine and onshore constructability facilitates the Land-Based Modularisation Concept as follows :
● Availability of heavy lift ship or marine barge vessel or floating crane to cater for the module weight for marine transportation delivery including the open sea route study , towing study , port of shelter .
● Availability of multi-axle modular trailer both at shipyard fabrication and site location to manoeuvre the module and delivery e . g . transport the module inside the heavy lift
76 VOL 84 OCTOBER-DECEMBER 2020