Damian Vujchich, Fluor, Case Study: Modularisation for Iron Ore Plant in Western Australia

Geography

1 SEA TRANSPORT ROAD TRANSPORT

CHINA (Fabrication)

PORT FACILITIES, WESTERN AUSTRALIA

Project Site

4000 NAUTICAL

MILES

PORT FACILITIES, WESTERN AUSTRALIA

Steelwork Totals

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STEELWORK TOTALS - 19 000 T of STEELWORK

15 000 T FABRICATED OFF SHORE (CHINA) {136 MODULES + ADDITIONAL LOOSE STEEL AND BREAK BULK ITEMS}

4 000 T FABRICATED IN AUSTRALIA

Steelwork Totals

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STEELWORK TOTALS - 19 000 T of STEELWORK

15 000 T FABRICATED OFF SHORE (CHINA) {136 MODULES + ADDITIONAL LOOSE STEEL AND BREAK BULK ITEMS}

4 000 T FABRICATED IN AUSTRALIA

ADDITIONAL 1500 TONNES OF SHIPPING STEEL DUE TO OFF SHORE FABRICATION – ROUGHLY 10% ADDITIONAL STEEL

Movement of Modules – Off-shore Fabrication

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FABRICATE MODULE IN YARD

DELIVER MODULE TO WHARF

LOAD ONTO SHIP SHIP TO SITE

UNLOAD ONTO ROAD TRANSPORT

TEMPORARY STORAGE AT PORT LAYDOWN

YARD

ROAD TRANSPORT TO SITE BY CONVOY

UNLOAD ONTO LAYDOWN AREA

INSTALL INTO FINAL POSITION

1 2 3 4

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6 7

8

9

NUMBERED STAGES


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YARD




1 2 3 4

5

6 7

8

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FABRICATION CONTRACTOR

INTERNATIONAL SHIPPING

CONTRACTOR

ROAD TRANSPORT CONTRACTOR

SMP INSTALLATION CONTRACTOR

TRANSPORT MANAGEMENT CONTRACTOR

MARINE WARRANTY SURVEYOR

CONTRACTOR RESPONSIBILITIES


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YARD




1 2 3 4

5

6 7

8

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FABRICATION CONTRACTOR

INTERNATIONAL SHIPPING

CONTRACTOR

ROAD TRANSPORT CONTRACTOR

SMP INSTALLATION CONTRACTOR

TRANSPORT MANAGEMENT CONTRACTOR

MARINE WARRANTY SURVEYOR

Constructability & Transportation Requirements

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♦  Each phase / stage will have restrictions on what type of module they can handle, lift, rotate, move, fit, approve, insure, transport and install.

♦  These size restrictions & transport loads need to be compiled into envelopes and guidelines for the design & construction team before detailed design taking place.

♦  This approach, which has been built up from experience on several projects, requires input and close collaboration between engineering, fabrication and construction teams for successful project delivery.

♦  Strong and clear guidelines minimises the potential for issues, delays and rework along the detailed engineering, fabrication, transportation & construction processes.

Fabrication Requirements

Fabricator’s capability ideally should include: ♦ Crane capabilities – lifting and rotation. ♦ All weather work areas – size can limit module work. ♦  Load out capabilities – are wharves wide & deep enough

for Heavy Lift Vessels? ♦ Paint shop and ventilated blasting yards – large enough to

handle long modules. ♦ Transportation of modules around yard via vehicles. ♦ Capabilities to perform pre-assembly, trial fitting and match

drilling of large inter connected modules.

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Fabricator’s capability ideally should include: ♦ Weighing facilities for modules larger than 50T. Weight

reports must be provided to engineering and shipping contractor prior to load out.

♦  Internal teams to handle Quality Assurance including certification of materials, welding, welders, tolerance and trial assembly sequences.

♦ Capabilities for support and shadowing services by EPCM and client representatives for QA, planning, scheduling and engineering.

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Crane Capacity

Covered Paint Sheds / Ventilated Blasting Sheds

All Weather Workshops

Outdoor Work Areas


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Wharf Capacity – Length and Depth

Issues

Wharf Capacity – Access for Movement

of Modules


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MODULE WEIGHING

THREE TESTS DONE TO GET

ACCURATE RESULTS

FABRICATOR TO PROVIDE WEIGHT

REPORT FOR EACH MODULE OVER 50T

PROJECT WIDE WEIGHT CONTROL IS IMPORTANT FOR BOTH HANDLING OF

MODULES AND TRACKING OF QUANTITIES FOR INVOICING


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TRIAL ASSEMBLY AND MATCH

DRILLING OF A MODULED TAKE UP

TOWER

CRITICAL CONNECTION

AT SITE – WORKING AT

HEIGHTS


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TRIAL ASSEMBLY MATCH DRILLING

ASSEMBLE MODULES TOGETHER TO CHECK FABRICATION – ANY ERRORS TO

BE CORRECTED PRIOR TO MODULE LEAVING FABRICATION YARD

MATCH DRILL CONNECTION TOGETHER TO ENSURE CORRECT

FIT UP AT SITE


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END PRODUCT – MODULE INSTALLED AT SITE WITH CORRECT FIT UP USING

ONE LIFT ONLY – EFFICENT AND AVOIDS WORKING AT

HEIGHTS ISSUES.

Marine Warranty Surveyor

♦ The MWS acts on behalf on the underwriters providing third party reviews for high value transportation projects.

♦ MWS have requirements for lifting on and off the vessels and these must be followed.

♦ Design team must understand MWS requirements for transport & submit calculations prior for review. The MWS reviews transportation calculations as well as the structural design to assess suitability for transportation.

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Marine Warranty Surveyor

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Surveyor Present at Lifts > 50T – Providing Approval of Rigging prior to each Lift

Provides Sailaway Certificates of Insurance of Seafastening

Prior to Vessel Departures

Transport & Logistics Management

♦ Responsible for customs and employment of international shipping & road transport. This could be done by EPCM if experienced personal are within the project team or alternatively by a external contractor.

♦ Fabricators must be able to provide clean modules with wash down facilities wharf side (including EWP for access). Module must be clean to be accepted by local quarantine agencies. Transport management conducts inspections of wharf side cleaning and washing down of modules prior to loading onto vessel.

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♦ Consideration for wash down & access about modules responsibility of the engineering design team. Temporary handrail can provide safe access about modules and seal plates around difficult access areas can provide for an easy wash down process.

♦ Additional responsibility with co-ordination role with local road authorities for acceptable road transport procedures. These include but are not limited to:

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o Bridge width and strength o Permitted turning circles

o Road widths and height limits o Clashes with power lines


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Transport Management Contractor Supervises and

approves Module wash down for AQUIS approval at Local Port.

International Shipping Requirements

♦ Responsible for the transport from off-shore wharves to local ports.

♦ Has restrictions with respect to lifting arrangements and to module sizes transported (ships have dimensional constraints).

♦ Must work with port’s local stevedores to rig and release module loadings.

♦ Responsible for sea fastening of modules to boat deck. ♦ Responsible for providing actual sea force accelerations

for review, inclusion in design and approval by the MWS.

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STOWAGE PLANS Document Provided For Each Voyage. Must be approved by Engineering and

MWS. Outlines Lifting, Stowage & Seafastening Procedures.

METHOD STATEMENT DOCUMENT

Voyage’s Method Statement Outlines Actual Sea-Forces.

Restraint Provide on Boat Deck.


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Module By Module Lifting Plans with each piece of

equipment detailed.

Overall Height critical for clearance over Ships Rails.


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LIFTING - DUAL CRANE SEAFASTENING

240T

MODULE TRANSPORTER

MODULE

GRILLAGE

STOPPER (RESISTS SLIDING)

CLIPS (RESISTS SLIDING & UPLIFT

Road Transport Requirements

♦ Responsible for the transport of the modules from the local wharf to the construction site lay down yard.

♦ Has dimensional and tie down restrictions which govern grillage design with respect to placement of stiffeners.

♦ Provides road transport accelerations for review by Engineering. ♦ Details convoy movements for clearance by local authorities,

including the arrangement of police escorts, road blocks, temporary road houses, mechanics and road side pull overs.

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EXAMPLE OF ARRANGEMENT OF ROAD TRANSPORT

4 FILE TRAILER PROVIDES WIDER BASE FOR BETTER SUPPORT AND STABILITY

8 AXLES 4 FILE TRAILER

TRESTLES


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SAFELY DELIVERED TO SITE

4 FLOOR PIECES LIFTING LUGS

GRILLAGE

TRAILERS CAN BE LOWERED – MODULE STORED ON CONCRETE

BLOCKS – NO NEED FOR CRANAGE

Installation Requirements

♦ Design team to provide lay-down area for modules with sufficient bearing capacity for module storage.

♦  Installation contractors to be aware of special crane requirements and construction procedures for module construction.

♦ Must be prepared for free issued pre-module inspection & time requirements for bolting, unbolting, rotating and rigging of modules.

♦ Engineering to assist by providing safe access around lifting lugs for rigging teams.

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Installation Requirements

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Long Lead Item – 750T Crawler Crane – rented by EPCM for

use by SMP

Prior to the design team commencing work, a set of project guidelines needs to be formed to control the properties of the

modules.

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Formation of Project Guidelines

♦ Module Envelope

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IMPORTANT INFORMATION. MODULE DIMENSIONS PROVIDED TO ALL ENGINEERS AND DESIGNERS IN EASY TO REFERENCE FORMAT.


♦ Shipping Loads

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Referenced from “Simplified Motion Criteria” – DNV – “Rules for Planning

& Executing Marine Operations”

IMPORTANT CRITERIA FOR STRUCTURAL DESIGN TEAM


♦ Road Transport Loads

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DISTANCE BETWEEN TRAILER HARD POINTS IS CRITICAL FOR DESIGN TEAM

Overall Module Stability during Road Transport is the

responsibility of the Road Contractor.

IMPORTANT CRITERIA FOR STRUCTURAL DESIGN TEAM

Using these guidelines, the engineering team is able to arrange module split lines.

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Designs were developed for all off-shore fabricated structures.

Resulted in four different “types” of

modules.

Type 1: Flat Pack Stacks (Floors & Trestles)

♦ Used for flat pack floors and trestles. ♦ Dimensions & connection locations needs to be similar ♦ Efficiency of transport is achieved as module does not have a

high percentage of transported air. ♦ SMP will be required to unbolt module to install each floor item. ♦ Requires detail consideration to how SMP will “lift & drop” into

place. Temporary support must be considered.

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FLAT PACKED FLOORS TRESTLES TRANSPORT & GRILLAGE DRAWINGS PROVIDE

CONTRACTORS (AND OTHER MEMBERS OF EPCM TEAM) INFORMATION REGARDING MODULES

GRILLAGE

LIFTING POINT INFORMATION


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SAFELY DELIVERED TO SITE

LIFTING LUGS

GRILLAGE

TRAILERS CAN BE LOWERED – MODULE STORED ON CONCRETE

BLOCKS – NO NEED FOR CRANAGE

LAYDOWN STORAGE INFORMATION

ROAD TRANSPORT CONFIGURATION


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INSTALLATION OF TRESTLES

TEMPORARY STABILITY OF TRESTLES BY SMP

CONTRACTOR

TEMPORARY SUPPORTS ALLOW SMP TO LIFT & DROP MODULE – MINIMISES MEN WORKING AT HIGH NEAR

RIGGED LOADS

Type 2: Rotated Tower Structures

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♦ Used for stair towers as well as Take Up Towers for conveyors. Can not be transported standing up as would be outside of the module envelopes.

♦ Requires two sets of four lifting lugs such that the module can be rotated in the fabrication yard and the site by SMP. Extra analysis required by structural engineers.

♦ Often requires horizontal braces to aid stability during transport. ♦  Lands directly onto concrete pedestals. ♦ Can be have internal stairs fully installed as to provide instant

access for construction.

Type 2: Rotated Tower Structures

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LIFT 1: SUCCESSFUL LIFTING ONTO

VESSEL

GRILLAGE

LIFTING POINT INFORMATION

TRANSPORT & GRILLAGE DRAWINGS PROVIDE CONTRACTORS (AND

OTHER MEMBERS OF EPCM TEAM) INFORMATION REGARDING MODULES

ROTATION DETAILS PROVIDED TO CONTRACTORS BY ENGINEERING SHOWED LIFTING ASSUMPTIONS (EQUALISING SHEAVES) USED BY DESIGN TEAM FOR INSTALLATION.

Type 3: Large Modules with Mechanical Components

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♦ Used for trusses, large screens, bins & hoppers. ♦ Shipped with handrail, grating, mechanical chute work and all

liners. Typical weight is between 150 T and 250 T. ♦ Modules can be installed onto of other modules and tolerances

can be provided to ease installation. ♦  Large Modules can be provided with 85T lifting lugs or

alternatively, lifting trunnions to minimise work at height on site.


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USE OF TRUNNIONS ALLOWS FOR RIGGING & RELEASING FROM GROUND LEVEL. THIS MINIMISES WORK AT HEIGHT

AND REDUCES RISK. HOWEVER THIS COMES AT A LARGE

FABRICATION COST.

LIFT ONTO SHIP


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UTILISATION OF LARGE CRANE FOR

MODULE INSTALLATION

MODULE INSTALLED INTO BUILDING WITH VENDOR SUPPLYIED

GATES ALREADY INSTALLED

Type 4: Large Modules with Vendor Items, Electrical Cabling and Piping – known as Smart Modules

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♦ EPCM delivered to site commissioned, with gates installed as well as electrics and piping.

♦ Module could be dropped onto concrete pedestals and connected to services, minimising commissioning time on-site.

Type 4: Large Modules with Vendor Items, Electrical Cabling and Piping – known as Smart Modules

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FABRICATION AT AMC

HENDERSON.

TRANSPORTED BY HEAVY LIFT VESSEL TO PORT HEDLAND.

INSTALLED & TRANSPORTED WITH

AUSTRALIAN VENDOR SUPPLYIED

COMPONENTS. POTENTIAL FOR

COMMISSIONING PRIOR TO ARRIVAL ON SITE.

VENDOR SUPPLIED

EQUIPMENT ALREADY INSTALLED

Summary – Part 1

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♦ Complete logistics study prior to setting module split lines. ♦ Award all contracts early so that inputs can be made to the

design engineering effort. This results in less rework and more efficient grillage.

♦ Contractors to work with EPCM to establish criteria for transport forces, tie down methods and trailer configurations.

♦ Early information provides opportunity to build shipping grillage & temporary braces into the structures, minimising rework and resulting in cost savings for the client.

♦ The planning and creation of schedules needs to be realistic to the tasks performed with allowances for trial fitting and unforeseen transport delays.

Summary – Part 2

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♦  Location of offshore fabrication is critical to successful project delivery and the providing of early information to the engineering design team. Issues include:

♦ Steel Material Grade ♦ Section Size & Availability ♦ Bolt and Weld Quality ♦ Paint Availability ♦ Providing this information to the design team early in the project

lifecycle avoids rework and delays for: ♦ Engineering ♦ Shop Detailing

♦ Fabrication ♦ On-site Construction

♦  Language Issues ♦ Cultural Issues ♦ Approach to Safety ♦ Efficient Transport Routes

Questions

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