MODULARIZATION DESIGN
ASPECTS
Presented by : Partha Parthasarathi, P.Eng., September 24, 2012
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Modularization Guideline
G – 907-0003
http://knowledge.worleyparsons.com/ws/default.aspx 2
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Modularization TOPICS COVERED TODAY
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Ø
WHAT IS A MODULE ?
Ø
WHY MODULARIZATION ?
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MODULE TYPES
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MODULE CONTRACT SCOPES
Ø
TRANSPORTATION
Ø
LIFTING
Ø
ENGINEERING AND DESIGN
Ø
LESSONS LEARNED
Ø
QUESTIONS -
ANY TIME
What is a Module ?? Ø
Module is a “Structural Unit” assembled with the following: Ø Ø Ø Ø Ø Ø Ø
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EQUIPMENT STEEL PIPING ELECTRICAL INSTRUMENTATION FIRE PROOFING INSULATION
Ø
Assembled at a location away from the project site. (Edmonton, Texas, China, Korea etc.)
Ø
Transported by Road, Rail, Waterways, Air or in combination to project site. 24-Sep-12
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 Ø
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REDUCED COST
Ø
REDUCED SCHEDULE
Ø
REDUCED RESOURCES
Ø
BETTER QUALITY
Ø
MORE
SAFETY
COST Reductions HOW TO REDUCE COST ?? MOVE LABOR AWAY FROM SITE WHAT ARE THE ADVANTAGES? Ø Reduces cost of housing (CAMP) personnel at site Ø Reduces number of construction personnel at site (Cost of Travel, Local Transportation, Meal, Recreation etc.) Ø Reduces number of vehicles and other equipment at site (Vehicles, Cranes, etc.) Ø Cost of field labor is higher 13
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COST “Increases”
COST OF ENGINEERING
Ø
Requires additional engineering hours to design modules for Lifting, Transportation conditions, Extra design drawings, 3D-Model splits, CWPs. Ø
STEEL MATERIAL Modular construction will increase the quantity of steel by 10 to 25% (of stick Build) and hence higher steel cost
Ø
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
Ø 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 Ø The transportation cost of a larger module is usually competitive with the combined cost of shipping of individual items
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Quality Ø Higher Quality of work is easier to achieve at Module Yard Ø Productivity will be higher
Ø No constraint on weather conditions
Ø Accessibility to the Module Yard is easier
Ø Efficient work due to controlled working conditions 16
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Quality (Continued) Ø 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 Ø Control of incoming material / issuing material (Inventory) is better controlled in a shop than in the field.
Ø There will be fewer fitting errors and rework in the field, as most components are pre-assembled in the Modules.
Ø
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Ø
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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
Ø CONSTRUCTION TIME IN THE FIELD IS REDUCED, and hence the cost is also reduced Ø Reduced schedule enables earlier Plant START-UP and adds great value to the Project 18
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Increased SAFETY
Ø The number of personnel working in the field is reduced and hence, the incidents are reduced. Safety is increased.
Ø The number of components to assemble in the field is extensively reduced. Safety is increased.
Ø 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
Ø Assembled at Modular Yard and transported to project site
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Module Types Type 2: Pre - Assemblies Ø
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.
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Ø
Public road restrictions do not apply
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Ø
Transported / Lifted within Project site
Ø
Example: Delayed Coker derrick structure 21
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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., 25
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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 Ø Steel fabrication Ø Pipe Spool Fabrication Ø Equipment vendors (Mechanical, Electrical & Instrument) Ø Module Assembly in Module Yard Ø Transportation of Modules to site Ø 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: Ø Road, Rail or Waterway carriers Ø All of these transportation modes require Permits / Regulatory approvals Ø Logistics provide weight limits, route study, bridge capacity verification, etc.,
Ø 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 33
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Module Contracts 6. Mechanical contract at Project site: Ø Ø Ø
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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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Ø
ROAD
Ø
AIR
Ø
RAIL
Ø
WATER WAYS
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Road Transportation
Limitations on Module Dimensions due to: Ø Bridge Height Clearances Ø Available road widths Ø Regulatory requirements (vary with each Province)
Note: Always consult Logistics on “Dimensional and Load Guidelines” for Transportation 36
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ROAD Transportation (Continued) Limitations on the Weight of Modules due to: Ø
Load carrying capacity of Bridges along the route
Ø
Pay Load capacity of Trucks
Ø
Road Conditions (Pay Load Capacity of Trucks vary with season)
Ø
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
1
8’- 6” – 14’- 0”
17’- 0”
80’- 0”
< 62 kips
-STAIRS, PLATFORMS, VESSELS - LOW COST PERMIT
2
8’- 6” – 14’- 0”
17’- 0”
120’- 0”
62 kips - 130 kips
- EXPERTISE REQ’D FOR BLOCKING AND BRACING -LARGE VESSELS, HEAVY EXCHANGERS
3
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
4
14’-0” – 24’-0”
29’- 6”
120’- 0”
200 kips 300/319 kips
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(300 for CalgaryEdmonton)
5
> 24’-0”
> 29’-6”
>120’-0”
300 / 319 kips (300 for CalgaryEdmonton)
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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” 39
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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” 40
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Road Transportation (Continued)
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Ø
SCHEUERLE TRAILERS ARE COMMONLY USED BY THE TRANSPORTERS
Ø
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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Ø
Trailer bed heights are hydraulically adjustable up to ± 1’-0” (300 mm)
Ø
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) Ø
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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 53
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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 56
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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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Ø
Suitable for overseas fabricated Modules
Ø
Loads up to 10,000 Tonnes can be carried by ships and barges
Ø
Typical deck space for Barges is about 400 ft x 100 ft
Ø
Lead time to acquire Barges is over 12 months
Ø
Module size may be limited due to road/rail restrictions
Ø
4 Major routes to Alberta are possible: West/East/Gulf coasts of USA and Northern (Canadian) route
Ø
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: Ø WEST COAST PORTS (USA) COMBINED WITH ROAD/RAIL TRANSPORT Ø EAST COAST PORTS (USA) COMBINED WITH ROAD/RAIL TRANSPORT Ø GULF COAST PORTS (USA) COMBINED WITH ROAD/RAIL TRANSPORT Ø NORTHERN (CANADA) THROUGH BERING STRAIT – NWT - THROUGH McKENZIE / ATHABASCA RIVERS NOTE: ALWAYS CONSULT LOGISTICS ON “DIMENSIONAL AND LOAD GUIDELINES” FOR TRANSPORTATION 60
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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 65
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Lifting Arrangements Type 1 – VERTICAL Lifts
6 OR 10 POINT LIFTING – NOT PREFERRED 66
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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) 68
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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: Ø Lifting and moving heavy loads (<50 Tonnes) without using cranes Ø Ideal in Remote locations Ø Cost effective Ø Place hydraulic jacks under the module at predetermined locations (Jacks connected to central Jacking pump) and lift the module. Ø Unified jacking pumps apply simultaneous pressure to all the jacks to ensure an even and level lift. Ø Place a rail system with rollers under the jacked up module. Ø Roll the module from the trailer onto the foundation/pile, using winch trucks. Ø Module is lowered via the hydraulic jacks Ø Require large space around the module. 71
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Jack & Roll
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Jack & Roll
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Hydra-slide Ø Hydra-slide: Lifting and moving very heavy loads (> 50 Tonnes) without using cranes Ø Ø Ø
Ø
Ø
Ø Ø
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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
Ø
Module structural framework shall be designed for module loads and impact loads, super-elevation, acceleration, deceleration forces induced during transportation
Ø
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 84
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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): Ø Ø Ø Ø Ø
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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 88
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=θ =Ф = 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. 89
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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
Ø Modules will be lifted using cranes for placement on transport equipment or final placement at the site Ø 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
Ø Alberta Occupational Health and Safety Code specifies the requirement of a Factor of Safety = 5 on the Ultimate Strength of Lugs Ø 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 ) Ø The weight of Shackles can be heavy Ø Do not specify heavy shackles for Light loads unless standardized by the Lifting Contractor Ø The Shackle (Crosby) manufacturer provides Safe Working Load only. Meets Factors of Safety specified by Alberta OHS and ANSI/ASME Ø Design drawings should specify Shackle Model Number and Capacity Ø The same Shackle type should be specified for all of the lift points in a module 94
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Lift Lugs
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Ø
Lift Lug materials shall be specified as Notch Tough steel (WT) to allow for erection during cold temperature conditions
Ø
Lift Lug welds shall be 100% UT tested
Ø
Critical design checks for Lift Lug are as shown below
Lift Lugs TYPE 1 Ø Used for very heavy lifts Ø Require installation and removal every time (extra time + labor cost) Ø Lugs can be reused Ø New set of bolts suggested for every lift
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Lift Lugs TYPE 2 Ø Lift holes reinforced with doubler-plates Ø Limited lifting capacity Ø Can be used for top modules only Ø Future extension of modules will require modification
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Lift Lugs
TYPE 3 Ø Double function lug – Lifting and splicing achieved Ø Lower splice plate shaped to receive the shackle Ø Allows splicing of modules without Type 1 Lift Lug Ø Lift holes reinforced with doubler-plates Ø Limited lifting capacity for Lug and splice connection
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Lift Lugs
TYPE 4 Ø 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
Ø Temporary steel may be required during transportation or lifting the module Ø It is suggested to paint the temporary steel in Fluorescent orange or other color for easy identification for removal at site Ø Temporary steel shall be identified in a separate color in the 3-D model for clash check purposes Ø 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
Ø Defining Modules (dimensions/splits) is the combined responsibility of Piping Layout, Structural, Electrical/Instrument Disciplines. Ø Logistics shall provide details on the transportation strategy, methods, limitations on weights, sizes etc., based on feasibility and economics studies. Ø 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 Ø There are several lessons learned on Modularization from each project in Ø Ø Ø Ø Ø Ø
Engineering Design Fabrication Construction Transportation Site Installation
Ø Consult with the Client and other database for the lessons relevant to the type of project Ø Some lessons are presented in the following slides 103
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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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