The Modularization Option
Ichthys Project Onshore LNG Facilities – image courtesy of INPEX
A pioneer in the field of module solutions
The Modularization Case Weighing the factors on module versus stick build or a hybrid solution takes the right partner with an in-depth understanding of the design, logistics and construction challenges. With KBR, you work with an expert that has successfully completed more modular studies, pre-FEEDs, FEEDs, and Detailed Designs than anyone in the industry.
Why KBR ■■
■■
The modular decision requires careful assessment of all variables including location, laydown, labor, logistics, safety, availability of materials and quality. KBR is a neutral partner with extensive constructability experience that can help you find the right solution that is best for your project’s unique challenges, to help you achieve on-time, safe and cost-effective execution.
■■
■■
In both offshore and onshore environments, greenfield and brownfield sites for hydrocarbon fluids, we have the experience and capabilities to conceive an effective modularization plan. ■■
Dedicated, Highly Experienced Modularization Teams: Our module experts have designed and procured over 1.5 million tons of modules since 2000 alone, acquiring the right experience and capabilities to help our clients ensure timely project completion. In-depth Global Fabrication Expertise: We have worked with and provided project supervision for nearly all the Tier 1, 2 & 3 fabricators worldwide, keeping critical path modules on schedule. Proven Tools & Systems: We have the customized systems for modules: 3D CAD, 4D and Materials Management in addition to our suite of engineering, procurement and cost and schedule project controls tools, to help our clients ensure project success and on-time delivery. Logistics Approach and Focus: Our logistics teams since 2000 have transported 20 million tons of material over 8 million miles, mitigating risks and focusing on delivery of equipment and materials, including heavy lift modules, anywhere, anytime, helping our clients maximize project return. Commissioning & Startup: Our system-based approach begins with the end in mind, starting this planning in the engineering and procurement phases of FEED and Detailed Design in order to effectively maximize the hook-up and pre-commissioning activities in the fabrication yard, minimize carry over work to site and deliver an easy efficient start-up.
“
Modularization has recently become a bit of a buzz word within the industry. While it can be very advantageous, it must not be assumed to be a ‘one size fits all’ solution. KBR has successfully worked with clients at all phases of a project’s execution to confirm the correct project specific input is analyzed early enough to consider the entire breadth of modularization possibilities. Michael Kluck Sr. Project Manager – Engineering, Project Execution
2
” 3
Types of Modules
Modularization in construction has been around for well over one hundred years, but increased in popularity during the early 20th century. From 1910 to 1940, Sears Roebuck sold more than 500,000 pre-fabricated homes in the U.S. alone. As Gas Monetization became more commercially viable, modularization of gas treatment facilities steadily increased. Currently, with newer technologies, greater transportation options, increased lifting capabilities and an increased demand for products and services, modularization continues to provide economic options to owners.
In both Offshore and Onshore environments, greenfield and brownfield sites, for hydrocarbon fluids, KBR has forged a dominant global role in assisting owners to develop their assets commercially. When assessing constructability of a planned facility, KBR has the experience and capabilities to conceive an effective modularization plan. When it comes to modularization, at KBR, We Deliver.
KBR is considered a pioneer in the field of modular construction – we built the first modular offshore platform in the North Sea over 40 years ago. Having been at the forefront of study and design enhancements in modular construction for over 50 years, KBR has proven itself as a world-class modularization contractor.
SKIDS ■■
■■
■■
■■
■■
4
Specialty technical equipment is supplied on skids Associated ancillary equipment, access platforms, ladders, etc. are attached to the package unit
Preassembled racks (PARs) ■■
■■
Usually built by equipment vendor or his subcontractor Weight and size is limited by existing mechanical handling facilities at supplier shop facilities and nearest port, restrictions on route from port to site and cranage at site Large amount of hook-up required on site
Complete modularized sections of a process unit or offsite pipe rack Typically contains piping, valves, instrumentation and electrical hardware
Preassembled units (PAUs) ■■
■■
Specialist fabricator required Requires quay facilities at fabrication yard
■■
Can be fabricated by a large range of fabrication facilities
■■
■■
Loaded out by trailers or lifted by crane
■■
■■
Sizes limited by the length capable of being transported and set at site
Multiple pieces of equipment are packaged together on a single rigid frame designed to resist the forces experienced during transit and installation
■■
Usually single level with weight seldom exceeding 2,000 tons Partial hook-up and commissioning at the fabrication yard
Large modules ■■
■■
■■
■■
■■
Larger than PAUs and generally contain whole/several systems Specialist fabricator required: most piping & instrumentation and electrical is installed Major piperacks can be part of the module or may be standalone modules Requires large quay to receive transportation barge Modules of up to 15,000 tons have been installed on offshore platforms
5
Related Success Offshore or onshore, greenfield or brownfield sites, when project economics favor a modular solution, KBR delivers. Our rich history of module solutions backed by our long standing relationships with module fabricators around the world and strengthened by our commitment to safety, quality, structural integrity and on-time delivery make us the right partner for your module project. 1995: NLNG
2007: Skikda
NLNG Train 3 Bonny Island, Nigeria Malaysia LNG Dua Bintulu, Malaysia
NLNG Trains 1 & 2 Bonny Island, Nigeria
1990: Woodside LNG
QatarGas LNG Trains 1 & 2 Doha, Qatar Malaysia LNG Dua Bintulu, Malaysia
NLNG Train 6 Bonny Island, Nigeria
Pertamina LNG “H” Kalimantan, Indonesia
Woodside LNG Train 4 Karratha, Australia
Tangguh LNG Papua, Indonesia
SEGAS LNG Train 1 Damietta, Egypt
Yemen LNG Bal Haf, Yemen
Woodside LNG Train 3 Karratha, Australia
1990
NLNG Trains 4 & 5 Bonny Island, Nigeria
1995
2000
Gas Monetization EPC Gas Monetization EPC: Modular Offshore Oil & Gas EPC: Modular Offshore Projects
BP Block 18 FPSO Angola
2012: INPEX - operated Ichthys LNG Project
Kitimat LNG BC, Canada INPEX - operated Ichthys LNG Project Darwin, Australia Statoil Karstø Upgrade Processing Plant Norway
Skikda New Train LNG Skikda, Algeria
2010
Chevron Agbami FPSO Nigeria
Magnolia LNG (MLNG) Louisiana, USA
2015
Total Pazflor FPSO Angola
ConocoPhillips Belanak FPSO Indonesia
Petrobras Barracuda/ Carratinga FPSO Brazil
BP Glen Lyon FPSO North Sea
PEMEX EPC-1 Mexico
Chevron Benguela-Belize Angola
Total CLOV FPSO Angola
Shell EA FPSO Nigeria
2000: Shell EA FPSO
Statoil Karstø Expansion Processing Plant Norway
2005
Shell Malampaya Phillipines
6
Chevron GTL Escavros, Nigeria
Chevron Tombua-Landana Angola
2008: BP Glen Lyon FPSO
2004: Petrobras Barracuda/Carratinga FPSO
7
KBR Delivers Module Solutions Global Reach KBR’s global network of offices and execution centers provide the ability to deploy the best resources to a project while minimizing travel and relocation costs.
With over 1.5 million tons of modules designed, fabricated and installed (or in progress), KBR is a world leading module contractor
8
Best in Class, Tools, Systems & Processes KBR uses proven industry leading best practice tools, systems and processes on every project. Total security enabled transparency, anywhere, any place, any time.
Modularization Achievements ■■
■■
First modularized GTL facility in Africa (Nigeria) >1.5 million tons of modules designed and fabricated
Resources
Vast Project Experience
KBR employs over 22,000 of the world’s most talented and experienced people. We staff major projects worldwide. Over 30% of our global team has modular experience.
KBR has led many of the world’s large and mega-projects over the past 20 years. In remote locations requiring flexible solutions, KBR consistently helps our clients deliver projects on time and on budget.
Lessons Learned
Proven Performance
KBR has well developed Lessons Learned databases established over many years and projects. These valuable assets are used on every project to ensure success.
KBR offers tried, tested and proven performance over many years, in all locations, in various project scenarios meeting our customers’ expectations…We Deliver.
Fabrication Yard Relationships KBR has worked with most of the world’s fabricators: Tier 1, 2 & 3. These long standing relationships assist us to deliver modular solutions on time and minimizes on-site hook-up & commissioning.
9
The Modularization Path A typical modularization path follows a familiar project progression.
Influence is high in the early phases and drops off dramatically as decisions are made and costs are committed. Project success and maximum ROI requires experienced inputs at the outset. KBR has successfully completed more modular studies, pre-FEEDs and FEEDs than most contractors. On modular design, We Deliver.
INFLUENCE
MODULE CONSTRUCTION / HOOK-UP
long-lead items
procurement
COST
This plan is also subject to the same project relationship between influence and cost.
TIC systems-based start-up
logistics & transportation
detailed design
INFLUENCE
A successful module plan works through the recognized project phases: Conceptual ➔ FEED ➔ Detailed Design & Procurement ➔ Fabrication ➔ Construction ➔ Turn-Over & Start-Up.
FID
management buy-in & support Essential to have complete client buy-in.
DEVELOP module team Composed of competent personnel from previous projects, the right people for the job. Apply lessons learned.
early module definition Define module envelope. Develop scope for hydraulics, pipe stress, dimensions, maintenance access, transport, weight management.
economic analysis Perform analysis on engineering, bulk materials, shipping, logistics, camp, all of the relevant factors.
constructability Assess laydown area, materials, cost analysis, schedule, path of construction, fabrication yards, delivery. Safety in design.
project concept Evaluate site, labor market, community, housing, access, ROI...
S Conceptual
10
T
U
D
Y Feasibility
F
E
E
Definition
D
E Detailed Design & Procurement
P
C
Fabrication & Construction
Commissioning & Start-up
11
We Deliver. KBR works alongside clients worldwide to deliver any project, any time, any place—making us a leader in the engineering, construction and services industries. KBR, Inc. is a global technology, engineering, procurement and construction company serving the hydrocarbons and government services industries, employing over 22,000 people worldwide with customers in more than 80 countries and operations in 40 countries. We are proud to work with our customers across the globe to provide technology, value-added consulting services and integrated EPC skills to help ensure consistent project delivery with predictable results.
KBR Headquarters 601 Jefferson Street Houston, Texas 77002, USA +1 713 753-2000
www.kbr.com © 2015 KBR. All Rights Reserved. K15002
