chemical plant design and construction

Modularization of LNG
liquefaction plants
the transition to a mainstream project strategy
by Richard Brookeld, Director, Global LNG & Midstream,
Foster Wheeler, and Jeremy Cooke, Project Operations
Manager, Business Solutions Group, Foster Wheeler
Richard Brookeld Jeremy Cooke
in order to reduce the work required at the main construc-
tion site by use of one or more pre-fabrication and pre-
assembly sites in other locations. Pre-fabricated and pre-
assembled modules are then transported usually by ship
and then by land transportation to the main construction
site where they are installed, connected and completed.
Modules are complete pre-assemblies of equipment,
bulk materials and components which are fabricated in
an offsite facility into a steel structure which can be trans-
ported and installed at the main construction site. Mod-
ules will vary in size, typically ranging from a few tonnes
up to several thousand tonnes depending on design and
installation constraints.
At its most simplistic level, modularization
can be achieved by taking a stick-build
design and splitting it into modules.
Alternatively, and more effectively,
modularization is based on a

M
thorough assessment of the project
odularization is a construction strategy that was drivers to determine the optimum
originally developed in the offshore oil industry extent of modularization and
to enable large amounts of fabrication work specic modular designs for
to be carried out on land in a safer environment and at the project, taking account
considerable cost saving. Modular strategies for onshore of all relevant drivers and
projects have subsequently emerged, particularly since constraints.
the mid-1980s, made possible by developments in heavy
lift craneage and other specialist land transportation
equipment.
The application of a modularization strategy to an
onshore LNG liquefaction plant is very recent the North
West Shelf Venture Phase V LNG Expansion in Western
Australia, completed in 2008, was the rst LNG plant to
be designed and constructed on a multiple module ba-
sis where the process train was divided into a number
of separate, pre-fabricated modules. Subsequently,
several other onshore LNG developments planned
in Australia and other locations have also adopted
similar modular strategies and modularization has
now become a key consideration for many prospec-
tive LNG plant projects worldwide.

The modular
approach to plant construction
The traditional approach to construction of
process plants is to stick-build the facilities
entirely at the main construction site using
basic materials and a large construction labour
workforce. Where this is not desirable or not
feasible, a modular approach may be adopted

Chemical Technology October 2011 7

 chemical plant design and construction
Drivers for modularization
There are many aspects of a project that may drive a
modularization strategy and typical considerations are
summarized in Table 1 on page 9. The main positive
drivers are generally labour (differential rates, availability
and productivity) and site attributes (climate and remote-
ness). Schedule, safety and environmental issues may
also inuence modularization decisions.
Scarcity of resources, particularly skilled labour, is a
key driver which leads to higher construction costs and
increases the risk of delay. This may be the case in areas
of signicant construction activity, where there is a high
demand for labour, as well as remote locations where in-
sufcient local labour is available or where it is expensive
to bring labour to the site.
The attributes of the main construction site are also
key drivers, particularly for sites in remote locations and
where climatic conditions are extreme and will constrain
construction works. These factors will have potentially
signicant impacts on cost and feasibility of stick-build
construction.
Degree of modularization
and module size
One of the key decisions to be made in the early stages
of design is the degree of modularization that is
appropriate for the project based on a detailed
assessment of the various factors and drivers as
summarized in Table 1. For many projects, some
modularization will be desirable and in some
cases it will be advantageous to maximize the
amount of work that can be transferred from the
main construction site. However, it is not
possible to achieve total modularization
as there will always be work at the main
construction site such as site prepara-
tion, excavation, tank erection and nal
installation of the modules themselves.
Modules are complete pre-assemblies of equipment,
bulk materials and components that are fabricated
offsite into a steel structure that can be transported
and installed at another location. Image: Courtesy of
Woodside Energy. Source: Foster Wheeler
8 Chemical Technology October 2011
Another key factor for every modular project is the
maximum module size that can be fabricated, shipped
and transported to the main construction site. Onshore
modules typically range up to 5 000 tonnes although the
maximum practicable size and weight will vary from proj-
ect to project, often depending on the physical limitations
of the transportation route to the main site location.
Module fabrication is generally carried out in low-cost
locations where labour rates and productivity levels are
favourable in comparison to the main construction site.
However, an increased degree of modularization will not
necessarily translate into overall cost savings as these
will be offset to some extent against the cost of addition-
al steelwork, shipping and specialist land transportation.
Implications for project execution
Adopting a high degree of modularization has implica-
tions for all aspects of project execution. The use of
large-scale module fabrication yards introduces multiple
construction locations for the project and consequently
increases the complexity of execution planning and the
requirement for experienced management resources to
achieve safe and successful outcomes.
Constructability issues for modular projects are com-
plex and need to be considered from the outset as they
will inuence early strategic decisions taken
during feasibility and conceptual
phases. Modularization decisions
made during later project phases
can result in considerable re-
work, and potentially, signi-
cant impacts on schedule. A
key consideration is the plant
layout which should be cong-
ured from the outset to suit
the degree of modulariza-
tion, site location and
constraints, opera-
tional and mainte-
nance requirements
and the strategy for
module installation
and sequencing.

Modularization can give added schedule security by
moving work away from a constrained construction site,
but will not usually shorten schedule due to the addi-
tional logistical steps required. Logistics are particularly
relevant for projects where signicant land transportation
of modules is required to reach the construction site.
Future opportunities
for LNG modularization
Modularization is a complex strategy with many variables
to consider and specic drivers will be different for each
individual project. It is not a silver bullet and, in many
cases, may not be an appropriate solution. However, in
some circumstances, modularization offers signicant
benets and these can be maximized by early decisions
to embed the execution strategy throughout all project
phases.
The successful design and execution of the rst
modular LNG plants has prompted a signicant number
of further LNG liquefaction projects to adopt modulariza-
tion strategies. Many of these projects are being planned
for construction in Australia where scarce and high cost
labour resources are key drivers for modularization. Other
international LNG projects planned for remote and ex-
treme environment locations are also following modular
strategies which have become an established alternative
to traditional stick-build construction techniques.
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chemical plant design and construction
Table 1: Summary of main considerations for modularization
Main considerations for modularization
Labour Is there a lack of labour available at the project site, or local
area, or is there a restriction on site labour due to access and/or
available land?
What are the relative labour rates and productivities for site and
potential module yards?
Site How do the site climatic conditions impact the construction logistic
Attributes requirements of the site?
For example, cyclonic conditions, weather windows for shipping,
cold climate, warm climate, hours of daylight, wind loading, snow
and ice loading, etc.
Site Do the available routes and lifting paths allow use of modules with
Access the dimensions set by road, rail or sea transportation?
Schedule Are there any significant constraints or requirements for the
project schedule which would benefit from a modular approach?
Is construction constrained by weather windows or periods of
restricted site access?
Safety Are there existing facility operations on the site, unusual site
hazards, site risk contours and regulatory requirements?
What is the expected safety performance for stick-build
construction compared to work in module yards?
Local Are there any requirements for local content for the project?
Content May reduce or eliminate any potential benefit of modularization.
Chemical Technology October 2011 9