Knowledge Sharing on

Modularization

Owner: Jagdish Dhantole 1

What is Modularization?
A term used to describe the three levels of “off-site” or “on-site out of the hole”
fabrication of piping, equipment and structures.

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Aim of Modularization?
■ Maximum Shop work
- Better workmanship and monitoring
- Controlled & congenial work environment
- Parallel construction
(more than one module which will be finally seated one above other can be shop assembled
in parallel)

■ Minimum Field work

- Field work is costly
- Restriction for the Deployment of the workers at site
- Harsh environment
- Long winter, less time in a calendar year for field work

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Terminology –
■ Module
- Part of structure assembled in Module yard
- Volume as per Logistics requirement
- Including Piping, Equipment, Lighting fittings, Cable tray (without cables)
- Transportation by Trailer
- Lifting & Placing by Crane
■ Skid
- Single Tier Module supported on Beam; NO column below tier level
- Rest similar to Module
■ Stick Built
- Ship loose items which are NOT part of Module
- Attached to main structure at site or at Super module yard
■ Super Module
- Total structure assembled in Super module yard
- Including Module & Stick-built
- Assembly on Temporary Foundation or Directly on Trailer
- No volume limit
- Transportation by Trailer
- Placing over foundation at site by lowering down Trailer Bed
- Scaffolding arrangement need not to move from structure to structure for Stick
Built erection
- Heavy Cranes not required at Site for Module erection

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Modularization Construction Pros

 Modularization Allows construction activities to be done in parallel.

 Streamline field installation
 Reduces number and skills requirement
 Facilitates remote site locations
 Shortens/reduces multiple work fronts
 Reduces risk of site conditions/weather
 Breaks projects into manageable parts
 Improves safety, quality, and productivity performance
 Shortens duration of and reduces field staff
 Reduce on-site fabrication
 Reduce temporary facilities
 Reduce scaffolding
 Reduce small tools and consumables
 Reduce staff and craft
 Reduce amount of dimensional control
 Reduce number of field welds

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Modularization Construction Cons

 Committed execution sequence

 Committed module delivery schedule and routes
 Potential for design changes and rework
 Potential loss or damage during transport
 Heavier construction cranes
 More cranes earlier for large module assembly and outfitting
 More planning, communication, organization
 Less flexibility

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 Construction Phases –
Fabrication Yard Painting or Galvanizing Yard
Fabrication of Structural Member Corrosion Protection of Structural Member
(Welded Assembly) (Painting or Galvanization)

Module Yard Fire Proofing Yard

Formation of Module Fire Proofing of Structural Member
(Erection of Structural Member (Optional)
including Grating, Handrail etc.)
(Erection of Equipment) Trailer Transport
(Erection of Pipe) Lifting of Module
(Erection of Cable Trays) (Module Yard to Trailer)
(Erection of Lighting Fittings) Lifting of Module
(Trailer to Barge)
At Site
Lifting of Module Lifting of Modules Barge Transport
(Trailer to Temporary Foundation/ (Trailer to Foundation/
Super Module Trailer) Module) Trailer Transport

Erection of Stick Lifting of Module

Super Module Yard
(Barge to Trailer)
Formation of Super Module Built Items At Site
(Erection of Modules)
(Erection of Stick Built Items) Transport of Super Erection of Super
Module Module (on Foundation)
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Construction Phase – Operating Condition

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Construction Phase – Lifting Condition Lifting Holes in Column

Lifting with Spreader Bars (i.e.

Slings may be at 90 degree or with
Slope/Angle).

This may have Multiple Lifting

Points.

Lifting with Spreader Framing (i.e.

Slings will be truly Vertical at 90
degree).

Ease to limit number of lifting points

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Lifting Lugs
Construction Phase – Transportation Condition
• Road Transportation Condition
Lifting Lugs

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Construction Phase – Transportation Condition
• Sea Transportation Condition – N/A for Blue Jay

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Conceptualization – Pipe Rack Module Arrangement

Additional Tier, if
required

Module
Stick
Built

Men Alternative,
Height=2300
Or
Braced Frame
Maintenance
Height =……
Width =……
Grade/
HPP

Option 1
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 Gap

Option 1_Longitudinal Section of PR

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 Lifting Hole Detail_1

Module-2

Lifting Hole Detail_2

Additional Tier,
if required

Note: Until Lifting is done with

Columns directly, No use of
Lifting Lug. (This is
Module-1 recommended to avoid
additional expenses).
Stick
Built

Men
Alternative,
Height=2300 Braced Frame
Or
Maintenance
Height =……
Width =……
Grade/
HPP
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Option 2
 Gap

Additional Tier, if required

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Option 2_Longitudinal Section of PR,……Module over Module
 Lifting Arrangement – ➢ Lifting from All Column Points
(See Details – 1 to 3)
➢ All Lifting Points are at same level
➢ Without using Lifting Frame
➢ Without using Lifting Lugs

Equipment, if
any

Additional Tier,
if required

Module-1

Module Lifting Arrangement for Option 2

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➢ Lifting from All Column Points
➢ All Lifting Points are at same level
➢ Using Lifting Frame
➢ Using Lifting Lugs (See Detail – 4)
 In case of Lifting Lug, Module Height should be
calculated including lifting lug. Normal practice is
to fit the lifting lug at Module Yard and remove
after final Lift. Reasons are as follows:
a. Connecting bolts are torque tightened
b. Removal of bolts is NOT very easy
c. Once removed reuse of bolts is NOT permitted

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Lifting Hole Lifting Hole Lifting Hole Lifting Lug
Detail_1 Detail_2 Detail_3 Detail_4

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Transportation Arrangement – Module Envelope
4.3 m (4.3 x 4.65 x 27.4) m

Equipment, if
any

Additional Tier,
if required
4.65 m

Spreader Beam
Module-1

Road
Clearance

Trailer Bed Width

< Module Width
Timber
Support Pads
Module Transportation Arrangement for Option 2 19
Analysis & Design –
Structure – In plant condition
▪ Empty
▪ Operating
▪ Hydro-test
▪ Maintenance
▪ Fire

Module – Lifting condition

▪ with vertical impact
▪ with wind (=Zero)

Module – Transport condition

▪ with vertical impact
▪ with lateral impact
▪ with longitudinal impact
▪ with wind (As applicable)

Module – Centre of Gravity Calculation

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Design Need – or Care to be taken in Design
1) The Piping and E&I loads has to be applied very precisely under the point of
contact without any assumptions. This will directly impacts over the Lifting and
Transportation Design.

2) The Module weight has to be maintained as per the limiting Capacity of the Lifting
and Rigger Contractor.

3) The COG is the key factor while performing Lifting/ Transportation of the Modules.
This may leads to uneven distribution of loads carrying by slings which finally may
results in failure.

4) The angle of a rigging strap/ cable attachment in relation to the lifting point greatly
effects the vertical and horizontal forces placed on the anchor attachments as well
as the forces in the strap/cable.

5) The Calculation of the COG to be performed by the Fabricator.

6) The Choice of the SHACKLE’s has to be finalized in the beginning and the same to
be followed during the Lifting Lugs/Hole designs.

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Safety – Importance of Design & Execution

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