Phil Millette 27 Oct 2016 MODULAR CONSTRUCTION: A NEW TREND ACROSS INDUSTRIES

Transcription

1 Phil Millette 27 Oct 2016 MODULAR CONSTRUCTION: A NEW TREND ACROSS INDUSTRIES

2 Topics for today 1 1 Modularity 2 Examples of modularization 3 A Case Study : E-House / EICT Concept 4 Summary

3 Modularity - definition 2 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

4 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

5 Start Modularity Value chain view In-House or Fab shop 4 Finish Define Design Manuf FAT Package & check-out Shipping Logistics Config Test Binding At Site or Shipyard Goods Receipt & Check-in Install Test Position to destination Test Commission Mount Integrate Connect Flange Weld

6 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 5 Physical shipped modules Logically pre-integrated modules

7 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 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

8 7 Example of multiple systems supply: ICSS on Floating and Fixed Platforms

9 Honeywell Holistic Solution for FPSO Advanced Applications Production Optimizers Power Management Optimizers Gas Lift Optimization Training (Dynamic) Simulator Prod n guidance Simulator Remote control Remote engineering / maintenance Well/Reservoir Monitoring & Control Production Well Monitoring & Choke Control Gas Lift Control Gas/Water Injection Well Monitor & Choke Control Down-hole Monitoring Business and Other Applications Well Test Accounting Production Accounting and reconc. Data Warehousing Equipment Health Management Operator Training Integration with ERP Marine Systems Loading Computer Cargo & Ballast Control Moorings monitor Other Systems Personnel Address Drilling Communications Power Applications Power management Load Shedding Turbo Generator Control 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

10 Topics for today 9 1 Modularity 2 Examples of modularization 3 A Case Study : E-House / EICT Concept 4 Summary

11 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

12 Offering GAS NGL CONTENT (GPM 2 ) Segment 11 UOP Packaged Gas Processing facilities Nat Gas Conditioning NGL Recovery NGL Upgrading Dehydration Mol Sieve Adsorption Glycol (TEG, DEG) Absorption Acid Gas Removal Amine Units (200, 400, 700, & 1000 gpm 1 sizes) Rich Gas Conditioner Mechanical Refrigeration (1000, 2000, 3000, 4500 HP sizes) Cryogenic Turboexpander (60mm, 120mm, & 200mmscfd sizes) Fractionation Deethanizer, Depropanizer, Debutanizer 1 gpm = gallons of amine per minute 2 GPM = gallons of NGL per thousand scfd of natural gas Packaged Sour Gas Processing & HC Management UOP 7116Q-11

13 Modularized Gas Processing 12 LPG Recovery Unit Inlet Filter Skids Mol Siv Dehydration Switching Valve Skid LPG Recovery Process Skids UOP 7116Q-12

14 Modular work HPS with UOP Factory built - not site built. Better quality pre-tested from instrument to IO modules. Minimizes site work and rework important for remote, in-hospitable locations. Fiber optic IO cabinet cables are run directly to the controller cabinet Inlet Gas without intermediate marshalling saves time and cost with no re-work to accommodate late changes. AmineReduces wiring from JBs all Treater MOLSIV TM around plant to marshalling cabinet in control (saturated room feed) Refrig Loop 13 Preconfigured displays, alarms and procedures based on ASM reduces engineering, Residue Gas enables rapid time to first production and full capacity HMO System Cryo Plant Depropanizer Propane Debutanizer Butane Gasoline OSBL HART Devices On device connection, Experion detects, interrogates, configures, enables and documents for automatic device commissioning HPS has greater presence in many remote regions around the globe to help with installation and startup Prefabricated Modular Control Room with Reduced footprint leading to lower cost of blast proof area

15 Fiscal metering - Integrated Skids & Prepackaged Solutions.wherever gas needs to be measured, controlled or stored 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 14

16 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

17 Topics for today 16 1 Modularity 2 Examples of modularization 3 A Case Study : E-House / EICT Concept 4 Summary

18 Modular Construction for Offshore Projects 17

19 Modular Construction in Offshore Projects 18 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

20 Case Study: Te Giac Trang Field E-House 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 Proven capability for full EIT/EICT

21 E-House TGT WHP : Project scope 20

22 E-House Package : TGT WHP 21 E-House 2 Floor Steel Structure Diesel Engine Driven Generator Set Micro-Turbine Generator Set LV Switchboard UPS/DC System Frequency Converters HVAC

23 E-House TGT WHP : E-House Layout 22

24 E-House TGT WHP : Process Skids 23 Wellhead Control Panel

25 E-House TGT WHP : Process Skids 24 Chemical Injection Skid

26 TGT E-House Project : Generators 25 Micro-Turbine (Fuel Gas)

27 TGT E-House Project : Generators 26 Emergency Diesel Generator

28 Success Story

29 Awarded Shorter Schedule l

30 Awarded Completed March 2015

31 TGT E-House Project: Offshore Assets & Onshore Integration 30

32 TGT E-House Project: Offshore Assets & Onshore Integration 31

33 Topics for today 32 1 Modularity 2 Examples of modularization 3 A Case Study : E-House / EICT Concept 4 Summary

34 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, preconstructed 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