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MODULAR CONSTRUCTION:
A NEW TREND ACROSS INDUSTRIES
Phil Millette
27 Oct 2016
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Summary
A Case Study : E-House / EICT Concept
Modularity
Examples of modularization
1
2
3
1
Topics for today
4
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Modularity - definition
• Modularity is the degree to which a system's components may be
separated and recombined. The term modularity is widely used in
studies of technological and organizational systems. Product
systems are deemed “modular”, for example, when they can be
decomposed into a number of components that may be mixed and
matched in a variety of configurations.
• Key words:
- Decompose / Separate
- Recombine
- Key requirement is finding and drawing boundary where dependencies
are fewest, or are technically / commercially least penalizing
• Also achieve:
- Standardization – reusable components
- Miniaturization – as needed
2
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Modularity - why• Further reduce dependencies between project components
- over ALL of the value chain
• In order to
- reduce COST – pre-build, pre-integrate larger components, reduce
space footprint / energy requirements
- Reduce project / schedule risk
- Achieve better control of project complexity
- Overcome lack of facilities at destination
• Take advantage of
- Different cost profiles along the value chain
Engineering
Manufacturing, assembly
Fabrication yard
Ship Yard – if for Marine / offshore
- Shift the work where cost exposure is lower
3
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Modularity – Value chain view
4
Define Design Manuf
Start Finish
BindingConfig Test
Package & check-out
Shipping Logistics
Goods Receipt & Check-in Install
FAT
Mount
Integrate
Connect
Flange
Weld
Test CommissionPosition to destination Test
In-House or Fab shop
At Site or Shipyard
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Modularity - examples• Examples:
- Offshore Oil & Gas => equipment and control modules
Reducing onsite time and effort
- Pre-built control buildings, equipment rooms and enclosures
For remote sites, reducing at site time and effort
- Electrical package
- Modular process plants, such as
Gas processing
Modular refinery units
- Skid-mounted equipment – maximise in-house engineering and
construction prior to shipping to site
Fiscal metering
Well head panels
• Physical shipped modules
• Logically pre-integrated modules
5
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Modularity – how enabled• Project methodology
- Refer to LEAP
• Technology
- Definition and connections protocols that enable remote engineering
and easily tolerate late changes with low effort:
That allow a confident drawing of boundary of the modular effort
DSA, virtualisation, UIO, standard cabinets, OPC UA, EIP, IEC 61850
- Separate and recombine project pieces with low technical effect or
commercial effect on cost.
- More completeness of scope – combine access controls, security and
F&G, HVAC, such as for access to modular buildings
• In-house wider integration ability
- Including procurement required to supply whole module
- Engineering capacity and field experience – across different domains
• Project Management capability
- To manage larger single pieces of delivery
6
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
7
Example of multiple systems supply:
ICSS on Floating and Fixed Platforms
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Honeywell Holistic Solution
for FPSO
Topside Process Control
• Gas Processing Control
• Flow Control & Metering
• Compressor Control
• Gas/Oil Pipeline Monitor & Control
• Turbo Generator Control
• Gas/Oil/Water Separation Control
• Well Test Control
• Water Treatment Control
• Subsea and packaged equip. integration
Safety Systems
• Process Shutdown
• Security System
• Emergency Shutdown
• Fire and Gas
• Heating, Ventilation and Air
Conditioning
• Person on Board Systems
• Corrosion monitoring
Power Applications
• Power management
• Load Shedding
• Turbo Generator Control
Other Systems
• Personnel Address
• Drilling
• Communications
Advanced Applications
• Production Optimizers
• Power Management Optimizers
• Gas Lift Optimization
• Training (Dynamic) Simulator
• Prod’n guidance Simulator
• Remote control
• Remote engineering / maintenance
Marine Systems
• Loading Computer
• Cargo & Ballast Control
• Moorings monitorBusiness and Other Applications
• Well Test Accounting
• Production Accounting and reconc.
• Data Warehousing
• Equipment Health Management
• Operator Training
•Integration with ERP
Well/Reservoir Monitoring & Control
• Production Well Monitoring
& Choke Control
• Gas Lift Control
• Gas/Water Injection Well Monitor
& Choke Control
• Down-hole Monitoring
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Summary
A Case Study : E-House / EICT Concept
Modularity
Examples of modularization
1
2
3
9
Topics for today
4
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
UOP Modular Refinery units
10
Typical UOP Modular Refinery Flow Scheme/chart
UOP’s modular offering includes:
•Detailed engineering design
•Procurement of materials and equipment
•Shop fabrication of modules
•Site delivery coordination
•Field advisory services during onsite installation
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Nat Gas Conditioning
Dehydration
Mol Sieve Adsorption
Glycol (TEG, DEG)
Absorption
Acid Gas Removal
Amine Units (200, 400,
700, & 1000 gpm1 sizes)
Rich Gas
Conditioner FractionationDeethanizer, Depropanizer,
Debutanizer
2GPM = gallons of NGL per thousand scfd of natural gas1gpm = gallons of amine per minute
NGL Recovery NGL Upgrading
9
4
2
GA
S N
GL C
ON
TE
NT
(G
PM
2)
Mechanical
Refrigeration(1000, 2000, 3000,
4500 HP sizes)
Cryogenic
Turboexpander(60mm, 120mm, &
200mmscfd sizes)
6
3
Se
gm
en
tO
ffe
rin
g
UOP Packaged Gas Processing facilities
11
Packaged Sour Gas Processing & HC Management UOP 7116Q-11
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Modularized Gas Processing
LPG Recovery Unit Inlet Filter Skids
UOP 7116Q-12
Mol Siv Dehydration Switching
Valve Skid
LPG Recovery
Process Skids
12
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Modular work HPS with UOP13
Prefabricated Modular
Control Room with
Reduced footprint
leading to lower cost of
blast proof area
Fiber optic IO cabinet cables are
run directly to the controller cabinet
without intermediate marshalling
– saves time and cost with no
re-work to accommodate late
changes. Reduces wiring from JBs
all around plant to marshalling
cabinet in control room
HART Devices – On device connection,
Experion detects, interrogates, configures,
enables and documents for automatic
device commissioning
OSBL
Preconfigured displays, alarms
and procedures based on
ASM reduces engineering,
enables rapid time to first
production and full capacity
Factory built - not site built.
Better quality pre-tested from
instrument to IO modules.
Minimizes site work and re-
work– important for remote,
in-hospitable locations.
HPS has greater presence in many
remote regions around the globe to
help with installation and startup
Residue Gas
Gasoline
(saturated feed)
Cryo Plant
Refrig Loop
HMO System
Depropanizer Propane
ButaneDebutanizer
MOLSIVTM
Inlet Gas
Amine
Treater
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
….wherever gas
needs to be
measured,
controlled or
stored
Fiscal metering - Integrated Skids & Prepackaged
Solutions
14
We custom design and
manufacture modular
packages for the worldwide
Gas industry. Large scale
projects benefit from our
LEAP™ paradigm shift
keeping projects off the
critical path
Modular skid-mounted, pre-packaged solutions integrate with scalable
control systems and advanced meter data management to help
customers manage their gas supply
14
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Remote Instrument Enclosure / Local
Equipment Room supply• Pre-fab to needs
• Addresses Challenges
- Constrained Space
- Short time for integration,
testing, commissioning
- Environment controls as
needed
- Security, safety aspects
• Reduce needed size by use of
Universal IO
- Refer to UIO topics
15
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Summary
A Case Study : E-House / EICT Concept
Modularity
Examples of modularization
1
2
3
16
Topics for today
4
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Modular Construction for Offshore Projects
17
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
• EIT / E-House Projects
E : Electrical
I : Instrumentation & Control
T : Telecommunications
Case Study:
TGT WHP Project, Vietnam
> Responsibility with ICSS
manufacturer
> Faster start-up
> Smoother execution
18
Modular Construction in Offshore Projects
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Case Study: Te Giac Trang Field – E-House
Proven capability for full EIT/EICT
19
Honeywell completes 2 more EICT projects
• TGT or White Rhinoceros Field for HJLOC JV.
• New build normally unmanned WHP’s.
• Built and integrated in Singapore yards
• Honeywell Scope:– WHP-01 Award Feb 2010,
CompFeb 2011
– WHP-04 May 2011 to Mar 2012
– WHP-05 Award Jul 2014
– House (EICT) contract including ICSS, MV switchgear, UPS, PMS, DC Power, Frequency Converter, telecomms, F&G
– ICSS based on Experion PKS and SM
– Wellhead Control Panel.
– Chemical injection skids
– Micro Turbine Generator
– Diesel Emergency Generator
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
E-House TGT WHP : Project scope
20
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
• E-House – 2 Floor
Steel Structure
• Diesel Engine Driven
Generator Set
• Micro-Turbine
Generator Set
• LV Switchboard
• UPS/DC System
• Frequency Converters
• HVAC
E-House Package : TGT WHP
21
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
E-House TGT WHP : E-House Layout
22
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
E-House TGT WHP : Process Skids
Wellhead
Control Panel
23
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
E-House TGT WHP : Process Skids
Chemical
Injection Skid
24
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
TGT E-House Project : Generators
Micro-Turbine
(Fuel Gas)
25
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
TGT E-House Project : Generators
Emergency
Diesel Generator
26
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Success Story 2009
27
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Awarded 2011
-- Shorter Schedule
l
28
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Awarded 2014
Completed March 2015
29
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
TGT E-House Project: Offshore Assets &
Onshore Integration
30
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
TGT E-House Project: Offshore Assets &
Onshore Integration
31
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Summary
A Case Study : E-House / EICT Concept
Modularity
Examples of modularization
1
2
3
32
Topics for today
4
Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Summary
33
• Modularity brings benefits by isolating some risk and technical elements from delivery
• Modular supply is already part of Honeywell - HPS and UOP – activity
• Achieved in pre-assembled, pre-constructed or pre-integrated scope of supply
• Supply to destination or marine shipyards
• Includes beyond traditional ICSS scope for HPS
• Enabled by latest technology
• Offshore / marine activity:
• Project Methodology and delivery to meet ISO marine standards
• Alignment with shipowner expectations through many previous projects