Establish Acceptable Modular Design Methods

 In Modularization

The third key modularization method that will improve the capital efficiency of your project is to establish acceptable modular design methods.

Once the module envelope, weight and types are determined the project can determine which module configurations would be the most efficient to be used and must be considered at the beginning of the project. Different module configurations are discussed below:

  • Pre-Assembled Racks (PAR’s) – A Pre-Assembled Rack (PAR) typically support pipes, power cables and instrument cable trays in plants. They generally contain piping and electrical that transfers material between equipment and storage or utility areas.
  • Pre-Assembled Units (PAU’s) – A Pre-Assembled Unit (PAU) contains multiple pieces of equipment, piping, electrical and instrumentation for a partially or fully complete unit. Pipe racks can be incorporated into PAU’s depending on the module type and size chosen. Local electrical rooms can be located within the PAU.
  • Vendor Assembled Units (VAU’s) – A Vendor Assembled Unit (VAU) or Skid Mounted Module that contains separate pieces of common equipment on a common base frame or skid and is packaged as an item by a manufacturer. These are usually built by the equipment vendor or his subcontractor.

Technical constraints need to be established; which may limit the percentage of modularization. Modular designs can apply the following methods which may require deviations from owners’ current design specifications. These methods include:

  • Pumps on modules (blue sky)
  • Pumps within modules
  • Distributed electrical and control
    • Local electrical rooms on modules
    • Local electrical rooms declassified within classified areas

These design methods have been proven be successfully applied in a safe and operable situation. The Table 1 below shows the level of modularization per module configuration and can be used as a guideline. The percent modularization is defined as percentage of labour moved offsite.

DyCat Solutions has a proven table that shows the level of modularization per module configuration and type. This table can be used as a guideline for the % modularization a project can achieve.

Cost saving increases as the percentage of modularization increases. The TIC savings can be from 1% to 20% depending on the percentage of modularization.