phil millette modular construction: 27 oct 2016 a · pdf filea new trend across industries ......

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

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Topics for today

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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

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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

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Modularity – Value chain view

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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


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

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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

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Example of multiple systems supply:

ICSS on Floating and Fixed Platforms


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


Summary


Modularity


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Topics for today

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UOP Modular Refinery units

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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


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

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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)

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3

Se

gm

en

tO

ffe

rin

g

UOP Packaged Gas Processing facilities

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Packaged Sour Gas Processing & HC Management UOP 7116Q-11


Modularized Gas Processing

LPG Recovery Unit Inlet Filter Skids

UOP 7116Q-12

Mol Siv Dehydration Switching

Valve Skid

LPG Recovery

Process Skids

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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


….wherever gas

needs to be

measured,

controlled or

stored

Fiscal metering - Integrated Skids & Prepackaged

Solutions

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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

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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

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Main Modell MTCS.pdf

Main Modell MTCS.pdf


Summary


Modularity


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Topics for today

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Modular Construction for Offshore Projects

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• 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

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Modular Construction in Offshore Projects


Case Study: Te Giac Trang Field – E-House

Proven capability for full EIT/EICT

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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


E-House TGT WHP : Project scope

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• 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

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E-House TGT WHP : E-House Layout

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E-House TGT WHP : Process Skids

Wellhead

Control Panel

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E-House TGT WHP : Process Skids

Chemical

Injection Skid

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TGT E-House Project : Generators

Micro-Turbine

(Fuel Gas)

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TGT E-House Project : Generators

Emergency

Diesel Generator

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Success Story 2009

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Awarded 2011

-- Shorter Schedule

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Awarded 2014

Completed March 2015

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TGT E-House Project: Offshore Assets &

Onshore Integration

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TGT E-House Project: Offshore Assets &

Onshore Integration

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Summary


Modularity


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Topics for today

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Summary

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• 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

phil millette modular construction: 27 oct 2016 a · pdf filea new trend across industries ......

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