Modular Pilot Plant Construction

 Published on January 31, 2016

Richard Palluzi
Pilot Plant and Laboratory Engineering, Safety, and Design Consultant at Richard P Palluzi LLC
85 articles Following

Modular Construction Advantages

 Modular construction is not a new idea; it has been utilized for decades through the
petrochemical industry. However, it is often felt to be most advantageous in locations where on
site construction faces daunting challenges such as inhospitable or inaccessible locations or areas
whose infrastructure would have difficulty in adequately supporting on site construction. (One
could not imagine trying to build an offshore platform in the middle of the North Sea!) While an
advantageous option in these cases - if not almost the only practical option - this approach has
many benefits for projects that do not suffer from these obvious handicaps.

 Modular construction is based on building units in sections which can be readily transported by
road, rail or sea depending on the final destination. Road transportation is the most common and
also the most restrictive. Larger modules are possible but become significantly costlier and
impose more restrictions on the routes available.  Standard road transportable sizes are more than
adequate for most pilot plants, even small scale demonstration units. One simply designs the
modules to be smaller or to come apart for shipment.

 Modular construction allows most pilot plants to be fabricated in a controlled environment;

typically, a shop specialized for modular or pilot plant and laboratory unit construction. Shop
construction is always more efficient than field construction as many of the inefficiencies and
variables affecting productivity can be eliminated or at least minimized. The work area is usually
enclosed and protected from the weather. The room around the construction area is usually more
open for access from all sides and commonly organized for greater efficiency. Large work tables
can be available for section fabrication, layout and assembly. Larger components can be
surrounded with scaffolding or rolling platforms to reduce inefficient ladder use. Cranes and
hoists - permanent or temporary - can be available to move and place larger equipment. Welding
equipment or outlets are readily available. Temporary construction power is easier to provide and
usually already distributed conveniently around the work area. Materials storage can normally be
arranged conveniently close to hand. Specialty tools can be justified due to repeated use and
result in significant cost savings. Stock rooms, equipment bins and similar materials storage can
be set up nearby in a convenient location. Operating restrictions such as permits, black out times,
access restrictions are eliminated. This includes time spent obtaining permits and clearances,
accommodating operational needs, keeping traffic corridors open, relocating tools or equipment
as operations require and a host of similar issues. All these features also contribute to safety by
allowing a more organized and efficient approach to construction. It helps eliminate potentially
unsafe field expedients and short cuts.

 Shop construction also promotes a steady craft crew size. Field construction often involves
obtaining new craft workers, training them in one's procedures and practices and releasing them
at the end of a project, losing all accrued orientation and experience. Shop construction can often
be scheduled to keep the crews for longer periods therefore eliminating repeated training and
learning curves.

 Modular Design and Construction

 For modular construction to be effective, the design it is important to embrace modular
construction as a standard practice. All new construction, regardless of unit size, should be on
pallets or frames. These pallets are designed to allow transportation of the unit without damage
and may range from simple strut to complex steel structures. Palletizing all units also allows
initial construction in another, more favorable location,

 My experience indicates that specialized shop construction is 20-50% more efficient than
similar field construction. This is particularly true for cramped spaces, such as laboratory hoods,
or exterior locations, exposed to weather. In addition to these efficiencies, shop construction
provides increased safety. The more open access typical of shop construction reduces ergonomic
related injuries as bending, stretching and contorted positions can be avoided through proper unit
placement in the shop. The lack of hazardous materials reduces the potential for worker
exposure, fires, explosions or spills. Quality is also increased as the shop conditions promote
better work. Climate control ensures components are not assembled in high humidity or bad
weather resulting in internal corrosion or water or dirt damage. The proximity of specialty
equipment allows better quality construction. Inspections are usually easier and more routine.

 Given these advantages why is there resistance to modular construction?

 First there is a perception that units constructed off site will not fit. It always seems that horror
stories abound although many, upon investigation appear to be more urban legends - or at least
classic examples of lack of adequate planning - than true relevant examples. Modular
construction does require more upfront design. One needs to determine how the unit can be
moved into place not just how to build it in place. This often creates problems as low beams,
intruding piping or wiring, undersized doors and a host of similar problems often arise. Yet, as
anyone who has ever moved into a house knows, these issues almost always have viable
solutions. Modules can be made in sections and easily reassembled in place. Doors can be
temporarily removed or permanently enlarged. Walls can often be opened by removing panels or
even removing and replacing masonry. Modules can be made to rig through roofs or upper walls.
Piping and wiring can - with planning and advance notice - often be economically rerouted or
temporarily removed and replaced. All of these can add to the cost but are usually offset by the
savings modular construction can deliver mentioned above.

 Second, there is a sense that the unit cannot be economically and safely shipped any long
distance. Anyone who has ever seen some of the process units shipped over highways will
understand how even incredibly large items can be moved. Of course, as they get larger, the
routes available get more limited, the preparations grow more involved, the permits and escorts
required more extensive and the costs higher. However, most modules can be shipped with
minimal problems if limited in a few key sizes. Most US interstate highways are limited to a 15
ft clearance. Low boy air ride trucks as low as 18 inches are available leaving one with a tight
but realistic 13 foot high module height. Widths and lengths are more flexible but, in general,
holding lengths to 20 feet and widths to 10 feet are not a problem. Expansion to 40 feet and 15
feet, while costlier, is usually an option. Recognize also that the module can sometimes be laid
on it's side for taller units or stood up for wider units to meet these dimensions. Modules do need
to be structurally strong enough to endure the lifting and transport. This does not mean, as some
fear, that they must always be enclosed with massive, and expensive steel frames. In many cases
proper bracing or temporary supports add more than enough stiffness and strength. Other options
include crating for smaller modules or shipping skeletons that are applied over the module but
removed upon installation. While an added cost these can often be reused or at least fabricated
more crudely to reduce their cost. In many cases, standard strut pallets and frames can move
across the continent with only minimal extra bracing if properly designed and constructed.
Simple tricks like double nutting threaded rods, tack welding joints and clips can greatly increase
vibration resistance. Temporary packing measures, ranging from bracing, lashing, stuffing,
wrapping to temporary wooden or metal supports can also work incredibly effectively to reduce
the risk of vibration damage. Removal of a minimal number of key components (such as
glassware or high sensitivity instruments) is also a viable option if not carried to extremes. Air
ride trucks are readily available in almost any shape or size which reduce the vibration on
modules to realistically controllable limits.

Third, there is a nagging concern that what is fabricated off site will not be what the organization
wants/needs. This is a valid concern as many organizations having decided to have something
(large or small) fabricated off site often basically abrogate all responsibility and leave it to the
fabricator's best judgment.  When contracting anything off site, the organization needs to be sure
to convey all the required information to the contractor. This includes not only a detailed design
or design specification but also adequate information on in house safety rules (both formal and
informal) and information on equipment, operating and installation standards. Installation
practices and "standards", many of which are widely accepted at a given site but poorly if ever
documented, also need to be conveyed. While some organizations seize on this effort as a reason
for not considering modular construction, the savings possible almost always allow for these to
be addressed effectively. More so, once addressed the next effort reaps additional savings as the
effort does not have to be repeated.

 Guidelines for Effective Modular Construction

 Select the contractor carefully. In addition to all the normal issues (technical skill,
professionalism, quality, cost, etc.) the contractor has to have adequate familiarity with the
modular concept. Building a unit in a shop is not hard but making sure it can be safely shipped
and installed does require some significant training and experience.

 Be willing to address the problems that arise with an open mind. Spending some time and effort
to reroute a line, widen a doorway, open a wall of accept a few days of scheduled downtime can
go a long way towards reducing costs and improving the final product.

 Learn from other's experience. Discuss problems and issues that have arisen with those
experienced in this approach. Shamelessly question the contractor, the transportation company,
the rigger and anyone else you can find for potential problems, past practices and horror and
success stories and apply the results to your efforts.

 Plan, plan and plan some more! No project ever suffered from too much advance planning.
Modular projects, in particular are very poor at trying to address issues in the field as opposed to
up front. Recognize that you may have to do a higher level of design, layout and review than you
normally are accustomed to. You will probably find, however, that this extra effort pays high
rewards not just in the modular component but in the rest of the project as well.

 Conclusions

 Modular construction is a viable option for pilot plants. It can reduce costs, alleviate on site
restrictions and produce a high quality cost effective product if done properly.